Cooper-Atkins 1075 Installation Manual

INSTRUCTION

MANUAL

Part # 702900

TITAN

1075 Rollbag

TM

1533 Crescent Dr • Carrollton, TX 75006 • Phone: [phone] • Fax: [phone] • www. audionautomation.com

“The Single source for all your packaging needs”

©2003

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TABLE OF CONTENTS

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HOW TO USE THIS MANUAL

NOTES

This users manual contains information important to the proper operation of the

1075 Rollbag

Packaging system.

SAFETY INFORMATION

This manual also contains very important information to protect both the operator and the machine.
Please pay special attention to the SAFETY WARNINGS that appear in the manual.

The STOP icon appearing in the margin alerts you to a safety warning on the subject it
accompanies.

A CAUTION icon alerts you to the possibility of an event that may affect the machine and
its operation. A full explanation of the safety caution accompanies the caution icon when it
is used.

READ MANUAL FIRST

Your new

TITAN 1075 Rollbag

packaging machine is safe and easy to use and maintain providing a

few simple procedures are followed.

IMPORTANT: PLEASE READ THIS MANUAL AND FAMILIARIZE YOURSELF WITH THE
EQUIPMENT BEFORE ATTEMPTING TO USE IT. THE MANUAL WILL SERVE AS A
VALUABLE AID TO UNDERSTANDING THE MACHINE, ITS OPERATION, AND THE
PACKAGING MATERIALS USED WITH IT.

As Audion Automation’s policy is one of continuous improvement and development of each line of
machinery that we make, this manual though up to date at the time of publication is subject to
change without notice.

Serial number ______________ and voltage marked on the ID plate _______VAC
Please enter the serial number of your machine in the space provided above. If it becomes neces-

sary to contact Audion Automation, please be prepared to furnish both the model number and serial
number.

1533 Crescent Dr • Carrollton, TX 75006 • Phone: [phone] • Fax: [phone] • www. audionautomation.com

SAFETY INFORMATION

FOLLOW LOCAL ELECTRICAL AND SAFETY CODES AS WELL AS THE NATIONAL
ELECTRICAL CODE (NEC) AND THE OCCUPATIONAL HEALTH AND SAFETY ACT
(OSHA).

POWER

The unit must be located at or near an appropriate electrical supply. Be certain that the power
source conforms to the requirements of the machine and that the proper gauge and type of wire is
used. Connections should be made using the shortest possible runs of wire. Long runs of wire can
result in reduced voltage.

Check the specifications on the Machine Identification Label, if the Machinery is rated at 120 volts
AC, it may be plugged directly into an appropriately grounded electrical supply. The use of
extension cords is not recommended. Units that are marked for voltages of 208 volt AC and above
should only be installed by a qualified electrician.

ALL WARRANTIES ARE VOID IF THE MACHINE IS USED WITH AN IMPROPER GROUND OR
IN AN UNGROUNDED CONDITION.

ONLY QUALIFIED SERVICE PERSONS SHOULD BE ALLOWED TO SERVICE THE
EQUIPMENT. THEY MUST BE EQUIPPED WITH PROPER TOOLS AND HAVE AN
ELECTRICAL SCHEMATIC OF THE UNIT.

There are live, high voltage components within the machine. Always disconnect the
machine from its power source and secure using approved LOCK OUT - TAG OUT
procedures as specified by OSHA before removing any access panels or attempting to
service the machine. On machines intended for 110-125 volt AC service disconnect the line
cord and secure the male plug in an approved LOCK OUT - TAG OUT device to prevent an
unexpected reapplication of electrical service. Machines marked for 208 volts AC and higher must
be disconnected from electrical service via removal of fuses at the supply, switching its disconnect to
the OFF position and locking the switch lever and tagging it so that there can not be an unexpected
reapplications of electrical service. Only a qualified electrician should perform these tasks.

DO NOT OPERATE THIS UNIT IN AN EXPLOSIVE ATMOSPHERE. DO NOT SUBJECT THE
MACHINE TO WET OR CORROSIVE ENVIRONMENTS. KEEP ALL FLAMMABLE AND CAUS­TIC SUBSTANCES AWAY FROM THE MACHINE AT ALL TIMES.

LOCATION

The unit must be located indoors only, in a nonexplosive atmosphere. Place the unit on a
level, sturdy table that as a minimum is able to support the weight of the machine and the
products that are to be packaged as well as those that have been packaged.

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INSTALLATION AND SETUP

1. Check shipping packaging for signs of damage. If there are any signs of
mishandling, it is a good idea to take pictures of the damaged container before
the machine is removed from it. Remove the machine and check it for damages.
You will need to immediately notify your shipping carrier if damages are found.

Damages will have to be accounted for by the carrier not Audion Automation!

2. Place the machine on a worktable. Level the machine by adjusting the four feet on
the bottom of the machine. All four feet must be touching the tabletop!

See figure 1.

3. Install the Roll Bag support brackets onto the backside of the machine.

See figures 4 & 7.

Back out the two screws enough to allow the slots in the brackets to
slide over the screws. Seat the bracket and securely tighten the screws. The left bracket
contains a filter regulator unit. Connect the air line to the bulkhead fitting on the backside
of the machine.

See figure 6.

4. Install the Power and Foot Switch cords into their corresponding receptacles on the
backside of the machine. Plug the power cord into a 120vac, 3-amp (min.) circuit.

See figure 6.

5. Connect a dry air supply of at least 80 psi to the regulator. Adjust the regulator for an

80-psi output. CAUTION: THE SEAL JAW WILL SWING OPEN.

See figure 1.

6. Turn the machine on. The On/Off switch is part of the Power Entry Module located on

the backside of the machine. (See figure 6). The display on the PLC will flash the seal
bar temperature set point value until the temperature is reached. The PLC will then put
the machine in "Manual Mode".

7. Reset Emergency Stop. Rotate red knob of switch clockwise.

See figure 1.

8. Place a roll of bags onto the support rod. Install a spring and a retainer on either side of

the roll. Place this unit on the support brackets making sure the flats on the rod are
securely seated in the bracket slots. Center the roll to the machine. Create a light anti­roll tension on the roll by slightly compressing the springs as you lock the retainers into
position.

See figures 4 & 5.

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9. Thread the bag stream into the machine. First open the Pinch Roller by moving its

toggle switch to the open position (to the left it you are at the back of the machine).

See figure 3.

The Pinch Roller will drop down creating a gap between itself and the Drive Roller. Lift

the Bag Perf Sensor (center black knob) and rotate it ¼ turn clockwise and then release it.

See figure 3.

It will now be setting on a ledge that will keep it suspended above the platen. Unwind
approximately two feet of bags from the roll and thread the bag stream between the
plate and Perf Sensor and then between the Drive and Pinch rollers. Pull the bag
stream down until a perforation line is near the top of the Stripper bracket.

See figure 2.

Now close the Pinch roller by moving the toggle switch back to the right. Reset the Bag Perf
Sensor by rotating it counterclockwise and allowing the spring pressure to push it down to the
platen. Ensure proper seating by lifting and releasing the sensor a few times.

10. The bag is opened at the end of the seal cycle by a high volume stream of air. After the

bag is opened the high volume air is turned off and a low volume air supply is turned
on. The low volume air will maintain the bag opening without wasting a lot of air. The
two air supplies are adjustable. The flow controls are located on the backside of the
machine. Adjust to suit your needs.

See figure 7.

11. The machine is now ready for operation. Read the "Machine Operation" section of this

manual before attempting to run the machine!

Fig. 1 Fig. 2

E-Stop

Levelling Foot

Seal Jaw

Stripper BRKT

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MACHINE SET - UP

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Fig. 3 Fig. 4

Fig. 6Fig. 5

Fig. 7

Pinch Roller
Toggle Shut Off

Support

Brackets

SpringRetainer

Bag Roll

Support Rod

On/Off Switch

Air Fitting

Power Foot Switch

Flow

Controls

Central

Bag Roll

Bag PKAF

Bag Roll

Support

BRKT

High

Volume

Constant Low

Volume

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MACHINE OPERATION

The 1075 Rollbag Packaging System automatically dispenses, opens for filling and seals pre­opened perforated bags on a roll. The basic machine operation requires product to be placed into
the opened bag upon which a seal cycle is initiated. The seal jaw closes, capturing the bag between
the seal pad and the seal bar. The temperature controlled constant heat seal bar welds the front and
back faces of the bag together. After the sealing process is completed, a parting blade is extended
to separate the sealed bag from the bag stream. As the seal jaw opens, the sealed bag drops out of
the way and a new bag is fed into the fill position. The bag is opened with a burst of high volume air
as it reaches the fill position. The bag opening is maintained by a supply of low volume air. The
machine is ready for the next seal cycle.

Note: For safety reasons, the jaw closes under a two-pressure system. The jaw closes
under low pressure until it is almost closed, less than ¼" travel left. At this point high pres­sure finishes the closing of the jaw. The jaw remains under high pressure throughout the
sealing process. The jaw opens under low pressure. For added safety the jaw close cycle is

timed. If the PLC does not receive the jaw close input within a specified time, the jaw is
immediately reversed.

The machine has three modes of operation. These modes (Manual, Automatic, Auxiliary) determine
how the next seal cycle is initiated.

In Manual Mode the foot switch initiates the cycle. The operator depresses and then releases the
foot switch to run a single cycle. If the operator keeps the foot switch depressed, the machine will
keep running cycles. By releasing the foot switch the machine will stop after the present cycle is
completed.

In Automatic Mode the machine will run cycles based on an operator predetermined pace rate.
Depressing and releasing the foot switch will cause the automatic cycles to start processing. Cycles
will run at the predetermined rate until the foot switch is depressed again or the machine is put in
manual mode. The pace rate will depend on the time required for the operator to fill the bag. Pace
rate is adjustable through the operator panel on the PLC.

In Auxiliary Mode the machine is interfaced with external automatic filling and feeding equipment.
The machine is capable of sending and receiving electrical signals to control the external feeding
and delivery systems. The inputs from these devices will determine how cycles are run.

The 1075 Rollbag machine has adjustable parameters so one can fine-tune the operation of the
machine. Once the parameters have been defined for a particular type of bag or process they can
be saved as a program. The next time that particular setup is required all one has to do is call up
the program associated to it. Multiple programs can be stored on the PLC. The values of the param­eters are changed through the front panel of the PLC. The following list contains a brief description
of each adjustable parameter.

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MACHINE OPERATION (cont.)

Seal Time is the amount of time the seal jaw stays closed against the seal bar during a seal cycle.

The jaw close time will depend on the type of material the bag is made of and its thickness. In gen­eral, the thicker the bag the more time it takes to seal it.

Start Delay parameter determines the cycle pace rate when running in Automatic Mode. This time is
determined by the amount of time required by the operator to fill the bag. This parameter is also
used to delay cycle start when running off a photo eye system or an external cycle start system.

Bag Stop Position controls the length of time the bag feed motor runs after the PLC receives an
input from the Bag Perf Sensor. The run time determines where the top of the bag stops in relation
to the sea bar. To raise the bag one must decrease the value of the parameter.

Cycles to Run is a cycle counter. Its value will determine the number of cycles the machine will run
before it sets a warning flag. The PLC will display "Count Target" when the number of cycles ran
matches the preset value. The current cycle count is displayed on the PLC along side "Manual
Mode" or "Automatic Mode". Pressing the "zero" button on the PLC resets the current cycle count.
When in the chain/strip packaging mode the cycle counter considers the chain as a single cycle. If
the chain value is set for three, and six bags are sealed, the counter will show a count of two.

Bags Chain is the number of bags wanted in the chain. When the last bag of the chain is sealed,
the parting blade will advance and separate the chain from the roll of bags.

Program Number is the value of the program that is currently being used. Each program can con­tain a value for each of the adjustable parameters. All values can be different from one program to
the next. The operator will need to keep track of which program to run with a particular bag or
process.

B.Roll Qty parameter contains the number of bags on a new roll of bags. The operator enters this
value when he installs the roll of bags onto the machine. Each cycle will decrement this value. When
the bag remaining count reaches 30, the PLC will set a flag. "Bags Low" will be displayed on the
PLC.

Air On parameter determines when the high volume air is turned on. This airflow is used to open
the bag.

Air Off parameter determines when the high volume air is turned off. On difficult to open bags, the
air may need to stay on for a longer period of time.

Feed Delay parameter enables one to delay the bag feed start time from its normal setting. A
machine equipped with a printer may need to delay the start of the bag feed cycle.

Temp Set parameter is the set point value for the temperature of the seal bar. The heat required to
seal a bag will depend on the bag material and its thickness. Typically a thick bag will require a high­er temperature or a higher seal dwell time than a thin bag.

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MACHINE OPERATION (cont.)

Bag Support parameter controls the amount of time the bag support tray (optional) stays in the

rotated position. The tray rotates to dump the sealed bag.

Note: Seal bar temperature and seal dwell time will determine the quality of seals one can
achieve. Typically one will make adjustments to these two parameters on a trial and error
basis until an acceptable seal is accomplished. A good seal will have a milky appearance

its entire length and width. A poor seal can be recognized by complete melt thru in areas of
the seal zone or the bag is easily opened. Rule of Thumb- Thick (heavy gage) bags will
require a higher temperature and/or more seal time than thin (light gage) ones. A good
starting point would be to have the temperature set at 220 degrees Fahrenheit and the seal
time set at .6. These settings should be finalized before running production!

Note: Never attempt to heat seal through the printed area of a bag. The ink will transfer

onto the seal pad and seal bar causing seal quality problems on subsequent seals