ILAPack CARRERA 2000PC User Manual

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Carrera 2000 PC Touch

SALES AGENTS AND SERVICE ORGANISATIONS.........................................................1

SPARE PARTS ..........................................................................................................1

INTRODUCTION .........................................................................................................2

WARNINGS FOR USE OF THE INSTRUCTIONS............................................................2

PURPOSE AND LIMITS OF THE INSTRUCTION AND MAINTENANCE MANUAL .............2

KEEPING OF THE MANUAL.....................................................................................2

UPDATING OF THE MANUAL ..................................................................................2

COLLABORATION WITH THE USER.........................................................................2

MACHINE IDENTIFICATION DATA .............................................................................3

EC STAMPING AND SAFETY STANDARDS...................................................................... 4

SAFETY RULES.........................................................................................................5

CLOTHING...............................................................................................................7

ACCESS TO THE WORKING ZONE ..............................................................................7

MACHINE USE DESTINATION....................................................................................8

MACHINE APPLICATION ...........................................................................................8

VALUATION OF RISKS..............................................................................................9

RISKS LINKED TO THE INSTALLATION SITE OF THE MACHINE.................................9

RISKS LINKED TO THE FEATURES OF THE MACHINE...............................................9

RESIDUE RISKS ZONES AND OPERATIONS...............................................................10

WARNING SIGNS ...................................................................................................10

RESIDUE DANGERS................................................................................................11

WORKING AND CONTROL ZONES - SAFETY ZONES ..................................................

ENVIRONMENTAL USE CONDITIONS .......................................................................

NOISE LEVEL ......................................................................................................12

TEMPERATURE AND HUMIDITY............................................................................

OPERATIONAL SITE.............................................................................................

ILLUMINATION ...................................................................................................12

VIBRATIONS.......................................................................................................12

RESIDUE AND ENVIRONMENTAL CONTAMINATION ...............................................12

SAFETY DEVICES ...................................................................................................13

MACHINE INSTALLATION..........................................................................................14

INSTALLATION SITE REQUIREMENTS......................................................................14

EXTERNAL INSTALLATION REQUIREMENTS .............................................................14

UNPACKING...........................................................................................................

MACHINE UNPACKING AND POSITIONING...............................................................

LEVELLING ............................................................................................................17

ATTACHMENT OF INFEED CONVEYOR .....................................................................18

 Copyright ILAPAK Italia S.p.A. Ed 1 Rev 06 - June 2005 User manual –- 1

Carrera 2000 PC Touch

ELECTRICAL SYSTEM CONNECTION ........................................................................20

EARTHING.............................................................................................................20

PNEUMATIC SYSTEM (OPTIONAL)...........................................................................21

COOLANT INSTALLATION CONNECTION (OPTIONAL)...............................................21

CLEANING .............................................................................................................21

MACHINE DEMOLITION.............................................................................................22

MACHINE CONTROLS................................................................................................23

PUSH BUTTONS AND OTHER ELECTRO-MECHANICAL DEVICES.................................23

SIGNAL LAMPS.......................................................................................................25

USER INTERFACE......................................................................................................26

DISPLAY................................................................................................................26

OPERATIVE KEYS...................................................................................................28

MULTIFUNCTIONAL KEYBOARD...............................................................................29

RECALL KEYS.........................................................................................................30

HELP ON LINE .........................................................................................30

PRELIMINARY OPERATION........................................................................................31

LANGUAGE SELECTION...........................................................................................31

USER PASSWORD...................................................................................................33

ENTERING THE PASSWORD....................................................................................34

DEACTIVATION OF THE PASSWORD........................................................................

MODIFICATION OF PASSWORD “OPERATOR”...........................................................

OPERATION CYCLE START.........................................................................................39

BASE PAGE............................................................................................................

CREATION OF A NEW PRODUCT .............................................................................

CREATION OF A NEW DATABASE .........................................................................42

MECHANICAL MACHINE ADJUSTMENTS......................................................................45

DETERMINING THE STEP OF THE PRODUCT FEED LUGS...........................................45

INSERTING THE INFEED LUGS................................................................................46

FIXED FOLDING BOX...........................................................................................47

ADJUSTABLE FOLDING BOX (OPTIONAL)..............................................................48

ADJUSTING PRODUCT GUIDES.............................................................................

DETERMINING THE WIDTH OF THE REEL................................................................

MOUNTING FILM REELS .........................................................................................50

INSERTING FILM....................................................................................................

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ADJUSTING THE MECHANICAL ARM ........................................................................52

ADJUSTING THE FILM REEL BRAKE.........................................................................53

JAW HEIGHT ADJUSTMENT.....................................................................................54

VERSION “CARRERA 2000 PC 400” .......................................................................54

JAW HEIGHT SELECTION.....................................................................................54

VERSION “CARRERA 2000 PC 250” .......................................................................55

MOUNTING THE INTERCHANGEABLE PRODUCT SUPPORT ........................................56

ENTERING PRODUCT DIMENSIONS AND ADJUSTMENTS..............................................57

ENTERING THE OPERATING PARAMETERS OF THE MACHINE ....................................61

“TEMPERATURE” PAGES .........................................................................................62

“TEMPERATURES ACCORDING TO THE MACHINE SPEED ............................64

PAGE “PRODUCTION RELATED DATA”.....................................................................66

OFF SET PARAMETER ...........................................................................68

“ACCESSORIES” PAGE ............................................................................................69

DESCRIPTION OF PARAMETERS ....................70

ACCESSOIRES PAGE: PRINTER/GUSSET/CARDBOARD CUTTER...............................71

PRINTER ...........................................................................................71

GUSSET ............................................................................................71

CARDBOARD CUTTER

INDEPENDENT CUT

.....................................................................72

.........................................................................72

ACCESSOIRES PAGE: LABEL APPLICATOR/SPRAY...................................................73

LABEL APPLICATOR ............................................................................73

SPRAY ...............................................................................................73

VARIOUS ACCESSORY PAGES...............................................................................74

"USER CAMS" PAGE ....................................................................................75

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PAGE “FUNCTIONS” ....................................................................................78

PRE-PRODUCTION....................................................................................................81

VERIFICATION OF SETTINGS AND ADJUSTMENTS....................................................81

ADDITIONAL TESTING PROCEDURES WITH REGISTERED PRINT ......................... 82

TEST RUN..............................................................................................................85

ADVANCED FUNCTIONS: MISPLACE - NO PRODUCT NO BAG .....................................87

PRODUCT SAFETY SYSTEM (MISPLACE) .....................................................87

INTRODUCTION OF THE FUNCTION “PRODUCT SAFETY”......................................88

ENTERING PARAMETERS .....................................................................................89

ACTIVATION OF THE FUNCTION “PRODUCT SAFETY” (MISPLACE)..........................91

“NO PRODUCT / NO BAG” .................................................................92

NOTES FOR THE CORRECT CALIBRATION OF THE PHOTOCELL..............................92

CONDITIONS FOR THE CORRECT FUNCTIONING................................................92

OPERATING RULES...........................................................................................92

ACTIVATING THE “NO PRODUCT / NO BAG” FUNCTION......................................93

AVAILABLE INSTRUMENTS................................................................................93

OPERATING .....................................................................................................94

DATA NEEDED FOR THE AUTOMATIC CALCULATION...........................................94

HOW TO CHANGE THE PRODUCT STOP POSITION..............................................96

USE OF THE FILM ADVANCE..............................................................................

FORCING OF THE FILM STOP CYCLE AT THE CUT-OFF........................................

SAVING PARAMETER VALUES

......................................................................98

96 97

PRODUCTION.........................................................................................................100

SIZE CHANGE

...........................................................................................102

STATISTICS ..............................................................................................104

PRODUCTS LIST MANAGEMENT...............................................................................105

DELETION OF A PRODUCT ........................................................................105

COPYING A PRODUCT ...............................................................................107

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CORRECTING/CHANGING A PRODUCT NAME .........................................................109

DIAGNOSTIC..........................................................................................................111

“DIAGNOSTIC” PAGE............................................................................................111

“INFEED AXIS” PAGE............................................................................................112

“FILM AXIS” PAGE................................................................................................113

“ROLLER AXIS” PAGE............................................................................................114

“JAW AXIS” PAGE.................................................................................................115

“DISCHARGE BELT” PAGE (OPTIONAL)..................................................................116

“AUTOMATIC FEEDER” (OPTIONAL) ......................................................................117

“TEMPERATURE” PAGE.........................................................................................118

“I/O STANDARD” PAGE.........................................................................................119

“DIGITAL INPUT” PAGE ........................................................................................120

“DIGITAL OUTPUT” PAGE .....................................................................................121

“ANALOG INPUT/OUTPUT” PAGE...........................................................................122

“ALARM LIST” PAGE .............................................................................................123

TROUBLESHOOTING...............................................................................................124

MACHINE MALFUNCTION DURING OPERATION......................................................124

ERROR MESSAGES ...............................................................................................139

MESSAGGE ..........................................................................................................139

PROBLABLE CAUSE / REMEDY............................................................................139

MAINTENANCE .......................................................................................................142

GENERAL.............................................................................................................142

SAFETY CONDITION.............................................................................................

PUTTING IN MAINTENANCE CONDITION...............................................................

142

143

PERIODICAL MAINTENANCE .................................................................................143

MACHINE.............................................................................................................

MACHINE MAINTENANCE......................................................................................

144

146

FRAME CLEANING AND MAIN COMPONENTS.......................................................146

INFEED CONVEYOR...........................................................................................146

MACHINE BODY ................................................................................................146

LONGITUDINAL SEALING AND PROPELLING ROLLERS .........................................147

JAWS................................................................................................................147

DISCHARGE CONVEYOR BELT ............................................................................147

JAW AND ROLLER HEATER ROTARY COLLECTORS...............................................147

LEVELLING CHECK.............................................................................................

MECHANICAL PARTS MAINTENANCE......................................................................

147

148

BOLTS AND NUTS TIGHTENING CHECK ..............................................................148

WEAR AND TEAR CHECK AND REEL BRAKE OPERATION: .....................................148

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LUBRICATION OF DRIVE CHAINS .......................................................................148

CHECK OF TRANSMISSION BELT TENSION..........................................................148

CHECK OF MOTOR BELT....................................................................................148

MAINTENANCE MOTOR – ADAPTORS – VARIATOR .................................................149

CHECK AND OIL REPLACEMENT..........................................................................149

MAINTENANCE OF SAFETY DEVICES .....................................................................150

EFFICIENCY CHECK OF THE EMERGENCY STOP BUTTON .....................................150

EFFICIENCY CHECK OF THE SAFETY SWITCHES..................................................150

ELECTRICAL INSTALLATION MAINTENANCE...........................................................151

CABLES FIXING CHECK......................................................................................151

MAINTENANCE PUSHBUTTONS, CONTROL SELECTORS AND INDICATORS.............151

PNEUMATIC INSTALLATION MAINTENANCE (OPTIONAL)........................................152

CONDENSATION DRAINAGE AND PRESSURE REGULATOR FILTER CLEANING ........152

LUBRICATING OIL LEVEL CHECK........................................................................152

EFFICIENCY CHECK OF THE PNEUMATIC INSTALLATION COMPONENTS................154

COOLANT INSTALLATION MAINTENANCE (OPTIONAL) ...........................................155

WATER CIRCULATION CHECK ............................................................................155

COOLANT CIRCUITS PIPING CHECK....................................................................155

AIR CLEANING FILTER REPLACEMENT...................................................................156

REPLACEMENT OF COMPONENTS..........................................................................157

REPLACEMENT OF UPPER JAW KNIFE.................................................................157

ADJUSTMENT OF UPPER JAW KNIFE...................................................................157

REPLACEMENT OF LOWER JAW ANVIL................................................................157

REPLACEMENT OF HEATING RESISTANCES CARBON BRUSHES.............................159

JAW HEATER..................................................................................................159

SEALING ROLLER HEATERS.............................................................................

REPLACEMENT OF HEATER RESISTANCES...........................................................

159

161

UPPER JAW HEATER.......................................................................................161

LOWER JAW HEATER......................................................................................

SEALING ROLLER HEATERS................................................................................

161

162

REPLACEMENT OF TEMPERATURE PROBES .........................................................162

UPPER AND LOWER JAW TEMPERATURE PROBE...............................................162

SEALING ROLLER TEMPERATURE PROBE ............................................................163

 Copyright ILAPAK Italia S.p.A. Ed 1 Rev 06 - June 2005 User manual –- 6

Carrera 2000 PC Touch

SALES AGENTS AND SERVICE ORGANISATIONS

The Sales Agent and Service Organisation in your area is:

TO BE FILLED IN BY THE AGENT OR AREA REPRESENTATI VE

The machine subject of this publication was designed by ILAPAK S.p.A. (Nova Milanese; Milano; Italy), which is a company of the ILAPAK group.

ILAPAK ITALIA S.p.A. puts its proper Assistance Service at disposition of the customers in order to solve whatever problem regarding the use and the maintenance of their machines.

The customers can signal their requests to the related commercial ILAPAK companies.

SPARE PARTS

It is recommended to use exclusively original spare parts.

The requests for spare parts should be made at the related commercial ILAPAK Company, observing the standards contained in the catalogue of the spare parts and nominating always the type and serial number of the machine.

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INTRODUCTION

WARNINGS FOR USE OF THE INSTRUCTIONS PURPOSE AND LIMITS OF THE INSTRUCTION AND MAINTENANCE

MANUAL

This manual is destined to all the operators in charge of the use, maintenance and surveillance of the machine during its working life. The purpose of the manual is to supply the information regarding:

- The technical features of the machine

- The preparation of the working site regarding the environmental characteristics and the feeding sources

- The accident prevention standards, use and calibration of the safety devices

- The use of the machine as provided in the project

- The ordinary and extraordinary maintenance

- The availability of the spare parts

The manual cannot replace the specific preparation, which the operators should have carried out previously on equal appliances or who will be accompanied on this machine by already skilled staff.

KEEPING OF THE MANUAL

The use and maintenance manual is considered integral part of the machine and should be kept for future reference till the final dismantling of the machine. The manual should always be available for consultation and should be kept with care; in case of damaging which compromises also partially the consultation, the user has to ask a new exemplar to the constructor.

UPDATING OF THE MANUAL

This manual has been prepared at the same time with the realization of the referred machine and cannot be considered inadequate only because successively updated (also for similar machines) according to new experiences. ILAPAK ITALIA S.p.A. has the right to modify together with its production also the related manuals, without the obligation to update the previous supplied ones. Possible integrations sent to the users, under the form of “UPDATING”, have to be kept together with the manual.

COLLABORATION WITH THE USER

ILAPAK ITALIA S.p.A. is at disposition of its customer to supply further information regarding the use and the maintenance of their machines as well as considering improving proposals for the manual in order to make them always more suitable to the requirements of the customers.

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MACHINE IDENTIFICATION DATA

The main identification data of the machine are printed on the proper plate with the EC marking installed outside the machine.

The plate notes the following data:

- Name of manufacturer and his address

- Type of machine

- Serial number

- Construction date

- Feeding voltage

- Absorbed power

- EC marking

Another plate, fixed inside the electrical panel, notes furthermore the values in relation to the electrical supply

- Serial number of the electrical panel

- Nominal voltage

- Frequency

- Number of phases

- Frequency

- Full load current

- Number of the wiring diagram

- Short-circuit interruption power

NOTE In case of a technical assistance request or an order of the spare parts, nominate

always the type and serial number of the machine a/o the data in relation to the electrical supply.

Machine identification

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EC STAMPING AND SAFETY STANDARDS

The machine bears the EC stamp indicating conformity with Directive 89/392/EEC, and subsequent modifications, of the European Community Council.

NOTE: The stamp is affixed to the machine nameplate. The original copy of “EEC Statement of conformance” is handed over to the customer

at the time of machine delivery. This document shall be carefully kept by the Customer, and produced upon request by the concerned Authorities. The “EEC Statement of Conformance” is to be considered an integral part of the machine, and shall be transferred to the new owner whenever the machine is re-sold.

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SAFETY RULES

The following safety rules should be observed during installation, operation and maintenance of the machine. Lack of compliance with the following rules may result in impaired effectiveness of the machine safety features.

The staff in charge of the use, the maintenance and the surveillance of the machine should be instructed by the employer regarding the accident risks, the safety devices installed on the machine and the general accident prevention rules, provided by the international norms and the laws of the country where the machine is installed.

ILAPAK denies any liability for machine damage or injuries to the operator third parties arising from the lack of compliance with the safety rules listed hereafter.  MACHINE DISPLACEMENT DURING INSTALLATION MUST BE CARRIED OUT

ONLY BY SPECIALISED PERSONNEL, AND BY USE OF SUITABLE LIFTING AND TRANSPORTATION EQUIPMENT.

 MAKE SURE THAT ALL NECESSARY PRECAUTIONS ARE TAKEN DURING

LIFTING OR TRANSPORTATION OF THE MACHINE, AND THAT ALL THE INSTRUCTIONS CONTAINED IN THIS MANUAL ARE CAREFULLY ADHERED TO.



MACHINE CONNECTION TO THE ELECTRICAL POWER MEANS

SHALL BE CARRIED OUT ONLY BY SKILLED PERSONNEL.

 BEFORE CONNECTING MACHINE TO THE ELECTRICAL POWER

MAINS, MAKE SURE THAT THE MAINS ELECTRICAL CHARACTERISTICS CORRESPOND TO THOSE SPECIFIED ON THE MACHINE NAMEPLATE. ALSO, MAKE SURE THAT THE MAINS IS PROVIDE WITH A SUITABLE GROUND WIRE, AND THAT THE VOLTAGE MEASURED ON THE NEUTRAL WIRE IS ZERO.



THE WIRES OF THE ELECTRICAL CONNECTION CABLE SHALL HAVE

A MINIMUM CROSS-SECTION OF 4 SQUARE MM.

 THE MACHINE SHALL BE OPERATED ONLY BY SKILLED AND AUTHORISED

PERSONNEL.

 THE MACHINE OPERATOR SHALL MAKE SURE THAT ALL THE

INSTRUCTIONS GIVEN IN THIS MANUAL ARE CORRECTLY FOLLOWED.

 JAW MOTION REPRESENTS THE GREATEST DANGER FOR THE

OPERATOR WHEN THE MACHINE IS RUNNING. IN ORDER TO PROTECT THE OPERATOR, THE MACHINE IS PROVIDED WITH A SAFETY DEVICE THAT PERMITS MACHINE OPERATION ONLY WHEN THE PROTECTION GUARDING ARE CLOSED.

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 IN CASE OF MAINTENANCE OR REPAI R ACTIONS REQUIRING THAT

THE MACHINE OPERATES WITH PROTECTION GUARDING OPEN (SAFETY DEVICE CUT OUT), PROCEED WITH EXTREME CAUTION TO PREVENT HAZARDS OR INJURIES TO THE OPERATOR.

 IN CASE OF DANGER FOR THE OPERATOR, OR WHENEVER IT IS

NECESSARY TO IMMEDIATELY STOP THE MACHINE, PRESS THE RED EMERGENCY STOP PUSH-BUTTON. THIS BUTTON STOPS THE MACHINE AT ONCE IRRESPECTIVE OF THE KIND OF WORKING OPERATIONS IN PROGRESS.

 THE USER IS RESPONSIBLE FOR THE OPERATIONAL SAFETY OF ANY

AUXILIARY EQUIPMENT NOT SUPPLIED BY ILAPAK.

 ANY ACTION ON THE MACHINE WHICH MAY INTERFERE WITH THE SAFETY

DEVICES IS CARRIED OUT AT THE OPERATOR’S RISK.

 IN CASE OF MAINTENANCE OR REPAIR ACTIONS REQUIRING

OPENING OR DISABLING OF PROTECTIONS, PROCEED WITH THE UTMOST CARE AND IMPLEMENT ALL THE APPLICABLE SAFETY MEASURES. THESE ACTIONS SHALL BE CARRIED OUT ONLY BY AUTHORISED PERSONNEL.

 MAKE SURE THAT THE ELECTRICAL POWER SUPPLY IS

DISCONNECTED AND THE PNEUMATIC SYSTEM IS DISCHARGED BEFORE CARRYING OUT ANY ADJUSTMENT/CALIBRATION OF THE MACHINE.

 MAKE SURE THAT THE MACHINE IS DISCONNECTED FROM THE

ELECTRICAL POWER MAINS BEFORE CARRYING OUT ANY CLEANING OR LUBRICATION OPERATION. POSITIVELY AVOID DIRECTING WATER JETS ON THE MACHINE, INSIDE IT, ON THE CONTROL PANEL, AND ABOVE ALL INSIDE THE ELECTRICAL CABINET.

 DO NOT EMBODY MODIFICATIONS IN THE MACHINE WITHOUT PRIOR

AUTHORISATION BY ILAPAK.

 ANY MODIFICATION SHALL BE EMBODIED BY ILAPAK AUTHORISED

PERSONNEL ONLY, AND RECORDED IN THE APPLICABLE TECHNICAL DOCUMENTATION. ANY TAMPERING OF THE MACHINE, OR MODIFICATION PERFORMED BY THIRD PARTIES VOIDS ANY RESPONSIBILITY OF ILAPAK IN CASE OF MALFUNCTION OR INJURY TO THE OPERATOR.

 Copyright ILAPAK Italia S.p.a

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CLOTHING

The clothing of the operator or the person, who carries out maintenance on the machine should be according to the legal safety rules in the country of application. In general, the operator should wear accident prevention shoes, and it is forbidden to wear moccasins, clogs, slippers or any kind of footwear that could compromise the mobility of the person. Use proper thermo-protective fireproof gloves when working in areas, which are characterised by heat emission.

NOTE : When working on the machine, don’t wear bracelets, watches, rings or chains

which can dangle or hinder movements. Pay maximum attention, when working near moving parts of the machine, that the proper clothing is suitable and avoid hitching up with these devices (sleeves, shirt tails, hair, etc.)

ACCESS TO THE WORKING ZONE

The working area should never be occupied so that nothing interferes with the freely movement of the operator. The immediate access to the machine from the staff in charge should be guaranteed in emergency cases.

It is forbidden to have access to the working area to people who are not directly in charge with the operation of the machine. This should be signalled with proper signs.

ATTENTON During the maintenance operations , in particular way when you work with

protections or disconnected safety devices, it is necessary to pay the maximum attention that the working area is not accessible to people, who are not directly in charge with these operations. At the end of the maintenance interventions verify that no used tool remains inside the accident prevention guards or inside the working area.

 Copyright ILAPAK Italia S.p.a

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Carrera 2000 PC Touch

MACHINE USE DESTINATION

MACHINE APPLICATION

THE WRAPPING MACHINE MODEL CARRERA 2000 PC IS DESIGNED TO WRAP FOOD PRODUCTS AND INERT MATERIALS.

IT MAY NOT BE USED TO WRAP PRODUCTS WHICH MIGHT REPRESENT A SAFETY HAZARD FOR THE OPERATOR OR SEVERELY DAMAGE THE MACHINE

 POSITIVELY DO NOT WRAP GAS-CONTAINING BOTTLES,

CONTAINERS OR JELLIES OF THE FOLLOWING MATERIALS: GUN POWDER OR SIMILAR MATERIALS, FLAMMABLE FLUIDS, GLUES, SOLVENTS, ETHER, ALCOHOL, GASOLINE, CATALYST AND CORROSIVE ACIDS, ETC.

 POSITIVELY DO NOT WRAP ANY CHEMICALS OR OTHER

MATERIALS WHICH MAY REACT AT THE SEALING TEMPERATURES AND RELEASE POISONOUS, FLAMMABLE OR EXPLOSIVES GASES, ETC.

 WHEN THE OPERATION OF THE MOTORISED PRODUCT SUPPORT

DEVICE HAS BEEN ACTIVATED (FUNCTIONAL KEY ) AVOID THAT THE MAXIMUM PRODUCTION SPEED EXCEEDS 90 PIECES PER MINUTE.

THE MACHINE SHOULD BE USED FOR THE WRAPPING WITH EXACTLY DEFINED CHARACTERISTICS AND WITHIN THE LIMITS ESTABLISHED BY THE SUPPLYING CONTRACT, DRAWN BETWEEN THE PURCHASER AND THE CONSTRUCTOR. THE USE OF THE MACHINE TO OBTAIN HIGHER PRODUCTION VALUES OR DIFFERENT FROM THE ESTABLISHED ONE IS CONSIDERED AS AN IMPROPER USE AND THE CONSTRUCTOR DENIES EVERY LIABILITY FOR DAMAGES CAUSED TO THINGS OR PEOPLE AND DOESN’T ACCEPT ANY KIND OF GUARANTEE ON THE MACHINE.

ILAPAK DENIES ANY LIABILITY DERIVING FROM IMPROPER USE OF THE MACHINE.

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VALUATION OF RISKS Risks linked to the installation site of the machine

On the installation site of the machine there can be some risky situations, which could compromise the correct operation.

FLOOR

The surfaces where the machine is placed on should guarantee during time the correct placing and levelling; for example some asphalt floor under high temperatures condition and in presence of soluble liquids can present an accelerated wear and tear with possible formation of holes corresponding to the supporting points and therefore making the machine position unstable.

TEMPERATURE

The established environmental temperature should be guaranteed (from 2 to 35 °C); high temperature peaks could cause machine operation problems (for example cooling difficulty of the motors).

POLLUTING MATERIAL

The potential damage coming from the use in the working area with polluted material should be preventively valuated; for example:

 DUST which could accelerate the wear and tear of the seals;  PVC which thermal degradation, generating HCl, can cause aggressive emissions of

the metal surfaces without proper protections.

MAGNETIC FIELDS,

Determined by the passage of electrical power lines near the electronic appliances installed on the machine. They can cause disturbances and malfunctioning.

WARNING The user should assure the suitability of the installation place of the machine,

in order to save its integrity during time.

RISKS LINKED TO THE FEATURES OF THE MACHINE

According to the EEC 89/392 standards, all the areas of the machine characterised by intrinsic with the working process or with the structure of the machine have been analysed. The most suitable measurements have been taken to reduce, as well as to eliminate possible risks to people in charge, equipping the machine with a series of standard protections, fixed and movable, which stop the access to the dangerous areas during the working. However, the best safeguarding for the operator’s safety is that the operator himself pays attention and has a good sense and that the greatest experience during time using the machine, can improve the safety margins during the operation.

 Copyright ILAPAK Italia S.p.a

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RESIDUE RISKS ZONES AND OPERATIONS

The areas of the machine or the procedures, which, even with suitable safety measurements present a high danger degree are defined residue risks, for example the presence of high voltage, high temperature or moving parts. All the areas with residue risks have been marked with proper name plates according to the ISO standards;

WARNING SIGNS

In compliance with the EC regulations, and in order to highlight the machine areas requiring special operator’s attention, or involving particular hazards for operator safety, the following warning signs are used.

LIVE LINE

HOT SPOT

CUT/SEVER HAND AND

FINGERS

MOVING GEARS

PUT TENSION OFF

BEFORE WORKING

INSIDE

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RESIDUE DANGERS

 INFEED CONVEYOR END

There is the danger that your hands may caught and crushed where product lugs return upward at the end of the infeed conveyor. Therefore, avoid working in this area, and pay much attention if working there cannot be avoided.

 ADJUSTMENT OF PRODUCT GUIDES

Adjustment of the product guides shall be such as there is a gap of less than 5 millimeters or of more than 25 millimeters between the guide and the pusher. If the product to be wrapped requires that the distance between the guide and the pusher is set a value between 5 and 25 mm, pay much attention as you run the risk that your hands are caught between the guide and the pusher.

 CONVEYOR AREA

Lug overturning creates a serious danger for your hands. They may be crushed. Pay much attention when working in this area.

 LOADING OF FILM REELS

The loading of reels weighing between 18 and 36 kg shall be made by two people. Load the heavier reels by use of a suitable equipment (not supplied with the machine).

WORKING AND CONTROL ZONES - SAFETY ZONES

The description of the working and control areas, is indicated in the layout included with the statement of conformance.

 Copyright ILAPAK Italia S.p.a

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ENVIRONMENTAL USE CONDITIONS NOISE LEVEL

The noise emitted by the wrapping machine during operation is 73 dB as resulting from the measurements carried out by using a sample machine.

TEMPERATURE AND HUMIDITY

The machine can be used in rooms with room temperature included between 2 and 35 °C and with a related humidity lower than 80 %.

OPERATIONAL SITE

The machine should be used protected against atmospheric conditions (rain, hail, snow, fog, etc.). Should the machine be used in corrosive sites, it is necessary to intervene on the modality and the maintenance periods, adapting it in order to avoid an excessive wear and tear of the components.

The use of the machine under explosive or partially explosive conditions isn’t provided, therefore it is forbidden to use it under these conditions.

ILLUMINATION

The room where the machine is placed should be illuminated in such a way to individuate easily the buttons and the devices for the control and the emergency stop. The illumination should allow carrying out under safety condition the ordinary maintenance operations; the user should carry out these interventions according to the legal rules regarding the modality of the illumination.

VIBRATIONS

Under normal use conditions, following the indications from this manual, the vibrations may not cause danger situations. In case of anomalous vibrations, stop immediately the machine and get in touch with the assistance service.

RESIDUE AND ENVIRONMENTAL CONTAMINATION

If the used material for the production is elaborated according to the recommendations of the constructor, there won’t be noxious substances, as regards the EN 626-1 standards. In case of using toxic or noxious plastic materials, the user has to install proper fume aspiration hoods and the training of the operators for a correct treatment of these materials. The user should observe the legal standards and community rules also for the treatment and the lubrications used on the machine.

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SAFETY DEVICES

The safety devices fitted to the machine are shown in the following picture. When the safety guards are opened while the machine is in operation, switches stops the main motor and cuts off the power supply. When pressed, emergency stop buttons interrupt machine operation and cut off the power supply. Isolator switch is a safety device that cuts off electrical power supply to all machine components when the door of the electrical cabinet is opened.

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MACHINE INSTALLATION

INSTALLATION SITE REQUIREMENTS

The machine should be installed on a supporting floor that can bear the weight of the machine on the several supporting points, without a decline during time; furthermore the floors should be on spirit level, non-slipping and shouldn’t present roughness The installation site should allow the operator to go around the machine without any hindrances and to carry out easily the normal working operations and service operations (maintenance and interventions on the machine). Furthermore it is extremely important, that the protection guards and the doors of the electrical power boards can be opened without hindrance and in a complete way. For this purpose the minimum distance according to the building walls or to a possible hindrance should be about 2 meters.

EXTERNAL INSTALLATION REQUIREMENTS

The installation site should be prepared for the connection of the electrical installation, the earthing, the pneumatic installation and possible coolant installation of the machine to the outside net. The electrical and earthing installation of the installation site should be realized according to the standards.

UNPACKING

The machine is shipped using packaging or proper protection means according to the used kind of transport; pay particular attention when unpacking in order to avoid damages to people or to the machine and to dismantle the packaging materials according to the legal rules in force in the country where the machine will be used. At receipt, control visually regarding possible damaging deriving from the shipment or missing parts. In case of damaging or missing part, get immediately in touch with the forwarding agent.

MACHINE UNPACKING AND POSITIONING

ATTENTION

he lifting operations of the parts composing the machine should be carried out by staff in char drivers, etc.) and with the assistance on the ground by a person in char with the signalling if the overall dimension of the load doesn’t allow a sufficient visibility; the staff should be equipped with the necessary individual accident prevention protections. The access to the area where the lifting operations are carried out is forbidden to the staff, who is not in charge with this operation, using the most proper means (barriers, signs, etc.). The capacity of the used lifting means should be suited to the mass to be moved; the movement should be carried out slowly under good illumination conditions and with sufficient free space to work under safety conditions. For no reason, the staff in charge with the operations is authorized to pass under the load or at its proximity. This is valid also for the staff in charge with the signalling on the ground.

e of these functions (crane operators, truck

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Carefully follow this procedure when unpacking and positioning the machine:

 Remove covers and protections, if any from the shipping crate  Remove the infeed conveyor.  By use of suitable equipment , lift the pallet to which the machine is

secured, taking care to operate from the back side in order to avoid any risk of machine overturning.

 Carry the pallet to the location where the machine is to be installed, and

lower it to the ground.

 Remove the screws (1) attaching the support channels (2) to the pallet.  Operating from the back of the machine, position the forklift under the base

plate, and lift the machine at a height sufficient to permit pallet removal.

 Remove the four bolts (3) that attach the support channels to the machine,

and replace them with the four adjustable feet (4).

 Lower the machine to the ground, remove the forklift, and carry out

machine levelling as described in the following paragraph

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TTENTION: ☺ SCRAP PACKING IN THE FIT DUMP

 DON'T LEAVE PACKING IN THE ENVIRONMENT !!

OPERATE FROM BACK SIDE

1. Attachment Screw,

2. Support channel to Pallet

3. Support Channel Attachment Bolt, Support Channel to Machine

4. Adjustable foot Machine unpacking and positioning

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WARNING The instructions supplied in this chapter are a synthesis of the procedures

established during the assembling of the machine and are destined to technical staff, already in possession of the necessary knowledge for this operation. However the staff should always be accompanied by specialised ILAPAK staff. The purpose of these instructions is to supply a general description of the methods, used for the connection of the main groups, composing the machine.

LEVELLING

The machine has to run in perfect horizontal direction and should transmit only a minor quantity of possible vibrations on the floor where it is installed; for this purpose, after having placed it on the operation site, proceed with the levelling acting on the proper supporting feet on the base and acting on the four adjustable feet, using as reference the counter plane. At the end of the procedure, block the four feet by means of the related lock nuts.

WARNING

he levelling of the machine should be carried out with exact precision in order to avoid torsion phenomenon, an incorrect parallelism of the planes and unexpected loads on the elements. The constructor declines each responsibility for damages or malfunctioning of the machine, deriving from an incorrect levelling or from a missing execution of the established periodical checks.

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ATTACHMENT OF INFEED CONVEYOR

Attach the infeed conveyor by following this procedure:  Place the infeed conveyor on its support casting on the machine body making

sure that it rests on the casting correctly.

 If necessary, level the infeed conveyor by adjusting the two suppor t feet.  Insert the two paper pins for infeed alignment (these pins are supplied with the

machine) then install the four attachment bolts with their washers

 Connect the infeed conveyor chain by following the follows procedure:  If necessary, slacken the chain using the two side tensors.  Join the chain ends on the sprocket by use of the special link and the relevant

retaining clips.

 Adjust the chain tension by use of the special side tensors, making sure that the

chain is not too tensioned, and that distance “X” measured between the end of the tensor and the sprocket shaft is the same for both tensors.

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CAUTION. A too tensioned chain may result in bending of the sprocket shaft and

damage to the infeed conveyor.

 Plug the electrical connector of the auxiliary control panel of the infeed conveyor

into socket on the left (or right) side of the machine

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ELECTRICAL SYSTEM CONNECTION

CAUTION:

1. Make sure that the mains power characteristics correspond to those of the machine.

2. Open the electrical cabinet and connect the power supply wires to the terminal board by referring to the applicable interconnection diagrams shown in Section wiring diagrams of this manual.

3. Connect the end of the power supply cable to a mains circuit breaker (thermal or magnetic) according to the machine connection sequence.

Connection of the machine to the electrical mains power is carried out by the user under his/her full and sole responsibility,

and in compliance with the following instructions:

EARTHING

The machine should be earthed by means of a centralised line, available on the installation site. The main earthing joint with the outer line is realized inside the electrical board.

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PNEUMATIC SYSTEM (OPTIONAL)

The machine pneumatic system is designed to the closing of sealing – propelling rollers In addition to other optional devices such as:

 Air gusseting  Air Ejector  Automatic reel splicer  Quality Control

The system is fed directly from the air supply line available at the machine installation location, through the filter-pressure regulator that is normally set at a pressure of 6-7 bars. The system is fully controlled by selector valves whose closing and opening is electronically commanded according to the operating parameters set by the operator. Each selector valve is also fitted with a pressure regulator that regulates the compressed air discharge pressure.

COOLANT INSTALLATION CONNECTION (OPTIONAL)

The machine can be equipped with a coolant installation, provided with a specific water input and output; Check that the water inlet and outlet pipe on the machine are correctly connected from the distribution block to the users.

CLEANING

Carry out an accurate cleaning of the machine at the end of the installation; remove the dust and the present residues with particular care to the sliding surfaces. Furthermore check that there aren’t any oil remnants near the tank of the lubrication installation. Use a compressed air blowing device and a dry cloth for the cleaning in order to remove the dust and also a non-aggressive solvent.

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MACHINE DEMOLITION

The machine demolition should be performed by staff specialised in the electric and mechanic field. The standards in force concerning these operations are often different in the various Countries, so it is recommended to analyse and apply all the provisions stated by laws at the moment the machine is to be dismissed. The machine has been realised using non-dangerous materials, (steel, plastics, rubber), which won’t give any problems for recycling or disposal at the end of the service; anyway, it is necessary to have a deep knowledge of the machine construction features and great technical skills to disassemble the machine, besides the specific tools. It is strongly recommended to contact ILAPAK assistance service, in order to obtain the maximum safety conditions in carrying out this job.

WARNING It is necessary to provide for the oil recovery and its differentiated disposal

according to the antipollution standards.

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MACHINE CONTROLS

PUSH BUTTONS AND OTHER ELECTRO-MECHANICAL DEVICES

Push buttons and switches are located on the console except for the mains isolator switch on the door of the electrical cabinet on the rear of the machine.

Green push button POWER UP /

With the mains isolator on, powers the machine up or resets power after one of the following events:

 use of the EMERGENCY STOP push button  opening of an interlocked guarding during operation of the machine  mains cut-off

Sets the machine in motion after powering up; in specific conditions executes also the following functions:

 reset an alarm or error message on the display screen  initialises co-ordination (synchronisation) of the “axes” (separate drive motors of

carriage, jaws, product infeed, sealing-propelling rollers and film unwinding roller), when in a non-synchronised condition.

START

(3)

NOTE: Synchronising of the axes will take place automatically upon pushing

the START button, each time the axes are not any more in their "normal" positions, in particular after:

 turning on the mains;  a mains cut-off;  a size change;  operating one single axis separately;  a film rupture;  operation of the “electronic safety clutch”, i.e. when a product has got caught in the

sealing jaws.

 co-ordinated start of all motors (under normal operating conditions); the machine

will accelerate continuously up to the speed set on the speed control potentiometer.

Red push button

makes the machine come to a halt in a pre-defined position with open sealing jaws (so that the film will not be burnt). Normally, after pushing this button the machine will reduce speed and approach the correct position at lower speed.

POSITIONAL STOP

(1)

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Emergency stop button

Stops the machine with IMMEDIATE effect independent of its momentary position; In agreement with EC- and other international regulations the operation of the emergency stop push button has the following effects:

 Power off the complete machine;  cut all outputs from the electronic control system;  release compressed air from all pneumatic systems under pressure.  In order to return to working conditions after operating the EMERGENCY STOP button,

it is necessary to unlock it by rotating it in the direction of the arrow.

EMERGENCY STOP

(2)

NOTE: The emergency stop button must not be used other than in case of

real danger or any other emergency situation necessitating an

immediate machine stop. Using the emergency stop button for “normal” machine stoppages violates the safety regulations and may lead to damage on the machine and/or the products to be wrapped.

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SIGNAL LAMPS

The signal lamps are located on top of the machine in the form of a “light column” and are intended to signal different machine conditions which are detailed below:

– red

continuous EMERGENCY STOP button pushed or guarding opened during machine operation. Red light remains on until the relative message on the display has been reset.

– orange

flashing For machines with automatic product indexer: machine in standby mode, i.e. machine will start automatically upon arrival of products.

– green

continuous START button pushed, machine in operation and/or drive motors under current.

– orange + green

alternate flashing Axes not synchronised either after operating one of them alone (operative keys

or JOG keys) or after an operation

of the electronic safety clutch.

– white

continuous Mains on, i.e. machine under tension.

Red Light Orange Light

Green Light White Light

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USER INTERFACE

DISPLAY

The display screen is divided into the following main areas:

1. Area of machine denomination, selected menu page title and messages

The name of the machine will be indicated under normal operating conditions when the “Home page” is displayed; the heading of current page will be reported when other pages of the operating program are displayed, instead.

In the upper area, area delimited by a yellow background, is the actual machine condition displayed; example: “Delayed start”, Current re-timing”, etc.

NOTE: The interface messages with the user are displayed in this area. If the

message indicates the operation of the EMERGENCY STOP button the cause of the anomaly that caused the use of the emergency stop should be attended to first; only then unlock the EMERGENCY STOP button by pulling it out and reset the supply by pushing the related button for the electrical line introduction.

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2. Area of “recall buttons”

3. Area of multifunctional keyboard

4. Area of adjustments and data display

This area displays selected menu page with the parameters and their “values” (i.e. settings); when a parameter is selected, a green flashing LED appears.

5. Area of operative buttons with permanently allocated functions; buttons visible at

all times, which are placed on the left of the interface.

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OPERATIVE KEYS

Deactivated Activated Description

(Optional) Manual opening/closing of pulling roller pair;

activated only while machine is stationary and deactivated while in operation.

Selection of operating mode (“Manual” or “AUTOMATIC”); (only in combination with an OPTIONAL automatic product indexer). No-product / no-bag: enables and disables the function which prevents the machine from producing empty bags if one or more products are missing from the infeed.

(Optional) Its activation makes intervening the by-pass, diverting the products on arrival.

The by-pass activation interrupts and stops the automatic feeding linked to the machine.

Active the function “JOG” ( impulse motion)

Moves forward axis “jaws”, in slow motion, independent from the other motors, activated only with pressed key and while the machine is stationary Moves reward axis “jaws”, in slow motion, independent from the other motors, activated only with pressed key and while the machine is stationary. Moves forward axis “product infeed” in slow motion independent from the other motors; activated only with pressed key and while the machine is stationary. Moves at the same time the film unwinding roller, the

itudinal sealing rollers and discharge belt forward in

lon slow motion independent from the other motors; activated with pressed key only and while the machine is stationary. (Optional) It allows to lift the jaws and to carry out the emptyin

field

of the bags, introducing the related value in the

Attention!! This key is enabled with stopped machine only.

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MULTIFUNCTIONAL KEYBOARD

Keys for insertion of numerical values.

Key for insertion of sign “–“ (minus) for negative value (– nn).

Key for insertion of sign “.” (full stop, comma) for decimal values.

Keys for changing values by one unit steps.

Key deleting the numerical value entered or, in editing phase, the product name.

Confirm Key.

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RECALL KEYS

Key displaying “cover page”.

Key for scrolling forward or backward the pages of the operative program.

Key displaying “INDEX” page.

Key displaying page with enabling functions and options

Key to display the “Production statistics”.

Help on line

Key to enable the “Help on line”.

ctivating the key and pressing on whatever figure, there will be activated a “Help” window with a short description of the interested object, as in the example of the following figure).

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PRELIMINARY OPERATION

LANGUAGE SELECTION

Within limits the language of the operator interface can be selected and/or changed. In order to turn on a different language from the one appearing upon power up proceed as follows:

1 With key open INDEX page;

Touch key “Service sub-menu” On the following visualized page

touch key “Language selection”.

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4. In the window listing the available languages select the desired language.

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USER PASSWORD

The “Master” password (set by manufacturing company) is supplied at delivery of the machine. It allows to carry out permanent modifications (saving) of the data set in relation to the various parameters of the operating program and other operations concerning the deletion, creation, copying and denomination of the products from the page “Product list”. The setting of this code also allows the creation of a new user password (to be set directly by the user and called password “operator” ), and after its setting, it allows to carry out the same operations which can be executed by means of the “master” password (included the creation of another new password). Therefore the main aim of the “master” password is to re-enter the functions protected by means of the code, in case password “operator” , entered by the user of the machine, will be forgotten.

The “Master” password should therefore be accessible by the person in charge of the production, only. NOTE: Without password the operator is always entitled to changing data

temporarily, however, without memorising them and thus overwriting existing data.

The following table lists those functions that are accessible with each protection level.

PROTECTION LEVEL ACTIVATED FUNCTIONS

None

Password “Operator”

(defined by the user – initially the code set by

the factory is 3)

Password “Master”

(defined by ILAPAK and can’t be modified

251200)

– Page “PRODUCTS LIST”

load

– Page “PRODUCTS LIST”

save

copy

– exceeds the password “Operator” defined by the user

– same functions of password “Operator”

, delete , new ,

, edit .

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ENTERING THE PASSWORD

Enter the password as follows:

1. With key open INDEX page.

2. Touch key “Service sub-menu”.

3. On page “Service”

touch key “Password access”.

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4. With the following window visualized

digit the “Master” password (defined by ILAPAK).or the “Operator” password. Each entered numeric value will be displayed in the window through an asterisk.

NOTE: In case of typing error, use key to delete the entered password.

5. Confirm the entered code with .

6. With key “<- Back ” open SERVICE page.

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DEACTIVATION OF THE PASSWORD

To deactivate the possibility to use the protected functions by the password mode and resetting the normal use conditions, proceed as follows:

1. With the following window visualized.

touch key “Disabile Password”.

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MODIFICATION OF PASSWORD “OPERATOR”

In order to change the existing password “Operator” as follows:

1. With key open INDEX page.

2. Touch key “Service sub-menu”.

3. On page “Service”

touch key “User password change”.

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4. With the following window visualized

5. Digit the “OLD PASSWORD”, confirm the entered code with .

6. Digit the “NEW PASSWORD”, confirm the entered code with .

7. Digit the “CONFIEM PASSWORD”, confirm the entered code with .

Each entered numeric value will be displayed in the window through an asterisk.

NOTE: In case of typing error, use key to delete the entered password.

8. Confirm the entered code with .

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OPERATION CYCLE START

Make certain that the machine is connected to the compressed air line and that the air pressure on the manometer of the filter-reducer group is adjusted at a value of 6 bar. If necessary, act on the regulator.

If the machine is equipped with a water sealing cooling system, make certain that it is connected to the installation and the related tap is open.

Make certain that the EMERGENCY stop buttons are unlocked. Introduce the main switch on the back closing board of the electrical cabinet.

1. When displaying the “introduction Page”,

with highlighting the following alarm message

EMERGENCY ON

Main guarding or eventual other auxiliary

guarding open. Close the guarding and, in

case the key switch |GUARDING is

disabled (position 0), press the power ON

pushbutton

push the green POWER button and then touch key “

Emergency stop

” from the screen.

to reset the alarm message

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BASE PAGE

The machine running is confirmed by the display of the following “main” page. NOTA: All mechanical settings of the machine (provided no changes have been carried

out meanwhile) as well as parameters and values appearing on the various menu pages refer to this particular product.

If it is intended to continue with this product this is considered a start of Production as described in paragraph “PRODUCTION”. Though the machine is already set up, it is nevertheless recommended to check, for safety reasons, the mechanical settings and compare them to the values on menu pages “Adjustments” and “Dimensions”.

If the product to be wrapped does not correspond to the previous one, however adjustments and data are in the product memory (the product appears in the “Product list”) a size change has to be carried out which is described in paragraph “SIZE CHANGE”.

For a product to be wrapped for the first time (i.e. product data not memorised and product not appearing in the “Product list”) all values have to be established and a complete new programming is required. The latter is the object of the following paragraph

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CREATION OF A NEW PRODUCT

Setting the machine up for a completely new product should normally be carried out either in the manufacturer's place after completing the machine or during commissioning through qualified personal of the manufacturer or one of his subsidiaries or agents. This is the way one can be certain that the machine has been set to the best of its possibilities and provides output and efficiency. Nevertheless the following sections provides complete information on all aspects of setting up a "new product" including programming the setting values of the product. The instructions follow a certain logical sequence, which has proven to be the best way of obtaining the desired results. The individual steps should therefore be carried out exactly the described sequence.

database

The first operation of programming a new product is the opening of a new database, which can be done in two different ways:

A. Creating a new data base based on the “default values”, i.e. the values pre-set in

the program (see the next paragraph)

B. Copying an existing database, (i.e. starting from the values) of a similar previously

programmed product and adjusting them to the new product (see paragraph products list management)

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Creation of a new database

In order to create a new database proceed as follows:

1. Enter user password.

2. With key open INDEX page.

3. Touch key “Product list” to op en page illustrated below.

4. Touch key on page “Product list” to open the new window illustrated below which prompts entering the denomination of the product being programmed right now

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The default product name proposed by the system consists of “product” followed by a number corresponding to the next free memory position.

5. If you want to change the default name displayed on the page, digit the new denomination using the alphabetic and/o numeric keys. NOTE: If you don’t want to change the denomination, the new created product

will keep the initial default name.

6. After checking for correct spelling confirm with and thus memorise the product name; the window will close and the new product will appear amongst the other on the “Product list”.

7. After the following window has appeared

confirm with .

8. After memorising the product name the latter has to be uploaded into the operational memory.

With keys

and select the newly created product name in the

“Product list”.

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9. Touch key ; successful loading of the product is confirmed with the visualization on the page of the relative message and of the new product name.

This creates the basis for the further programming of the new product. The subsequent establishing and entering of data is described in the following paragraphs.

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MECHANICAL MACHINE ADJUSTMENTS

The mechanical adjustments and configurations to be made to the machine before production refer to the selected product and are carried out according to its size and features.

DETERMINING THE STEP OF THE PRODUCT FEED LUGS

The feeding bed chain is equipped with hooks for fixing the product feed lugs. These hooks are positioned so as to allow the lugs to be mounted in various steps according to the size of the product to be packed. The step of the product feed lugs is determined by applying the following formula

where P = Step of product feed lugs (expressed in chain links)

L = Product length (in mm) H = Product height (in mm) S = Thickness of jaws (generally 30 mm)

12.7 = Conversion factor equal to the length of a chain link (1/2”)

For example, for a product that is 160 mm long and 60 mm high to pack on a machine with standard jaws, the corresponding step will be:

L+H+S+20%H

12,7

(160 +60+30+ (60x20%))/12.7 = 20.63 21

The lug step to use on your machine will be the next highest multiple of the hook step shown on the technical sheet to the one that has just been calculated.

Let’s continue the example, to pack a product of a size requiring a minimum step of 21 links, a machine with a feeding chain with 1 block mounted every 8 links will require the correct step to be 24 as this is the next highest multiple of 8 after 21.

NOTE: In case of printed film, the cut pitch (bag length) will be determined by the distance of the printing notches.

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INSERTING THE INFEED LUGS

The height of the infeed lugs is determined by the height of the product whilst their width is limited by the folding box aperture. After dropping back the lugs have to pass freely through the latter and must not touch on the folding box base. In order to insert the lugs at the previously determined pitch it is necessary moving the infeed chain. This is achieved as follows:

1. Press key infeed forward, until the infeed chain has reached the desired

position;

Upon touching key the infeed chain starts moving immediately (though at low

speed). While the chain is in motion the orange and green signal lights of the light column will flash alternately.

CAUTION: Move the chain solely the way described above! Do NOT

use the START key for this purpose.

2. Extract the previously used pushers by pulling and holding outwards the spring-loaded

locking pin (3) and, simultaneously, pull the pusher (2) upwards and out from the carrier block.

3. Insert new pushers (1) into the blocks (2) and make sure pin (3) settles in with an

audible “click”.

1.LUG

2.SUPPORT

3.PIN

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Fixed Folding box

The fixed folding box is constructed on size for each determined products. The possibility to wrap a product using an already existent folding box depends first of all on its physical dimensions and then on the requirements of the wrapping (in particular the film timing). The guides of the folding box (tunnel) are provided with holes for a limited width adjustment. These adjustments serve essentially to optimise the operation of the folding box and not to suit it to the product width. For the assembling of the fixed folding box, proceed as follows:

1. Position the rear plate and the front plate (1) one after the other onto the fixed bolts

of the conveyor support and fix them by means of the locking handles (2). NOTE: Make certain that the points of the folding box are perfectly centred among the film pulling rollers.

2. Make sure that the internal guides (3) are parallel and that the product to be packed

runs smoothly.

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Adjustable Folding Box (Optional)

For the assembling of the adjustable folding box, place it on the fixed bolts of the folding box support and block it with the knobs (3), in an analogous way to the fixed folding box.

ATTENTION: The width adjustment of the adjustable folding box is in relation to

physical limits as follows:

– maximum product width = 220 mm

For the adjustments “A”, “B”, “D” and “C” of the adjustable folding box (to display the icons, it is necessary to introduce the number “0” according to the fixed folding box in page “Manual adjustments”) there aren’t any fixed rules; it is recommended to start from the adjustments of an already tested product with similar dimensions and to modify the adjustments according to the necessity.

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Adjusting Product guides

1. Loosen the knobs (2) and move the feeding product guides (1) towards the outside.

2. Place two products on the conveyor belt: one partially in the folding box and the other at the end of the folding box well centred with the feeding axis.

3. Place the guides (1) near the products and lock the knobs (2)

N.B.: Make sure that the guides are equidistant from the centre of the feeding chain.

To make it easier for the product to move onto and along the feeding bed, the guides can be slightly wider towards the outside of the bed. Also make sure there is no step between the guide and the tunnel of the conveyor against which the product could jam

 Copyright ILAPAK Italia S.p.a

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DETERMINING THE WIDTH OF THE REEL

The kind of film reel used must be defined according to its width, the value of which is calculated as follows:

2 x (product width + product height) + 40 mm

MOUNTING FILM REELS

- Loosen the front reel locking cone (1) and turn the handle (2) anti-clockwise until the retainer (6) leaves its housing (4).

- Turn the front reel locking cone (1) clockwise by about 90° to allow the retainer (6) to pass through the hole (5) in the cone

- Pull the front reel locking cone (1) off the roller (3)

- Insert the reel on the roller (3)

- Replace the front locking cone (1) by passing the retainer (6) through the hole (5) of the cone

- Turn the cone anti-clockwise by about 90° to allow the retainer (6) to be placed in the housing (4) of the cone Lock the reel by turning handle (2) and check it is installed correctly.

364

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INSERTING FILM

WARNING:

AKE CARE TO AVOID GETTING BURNT IF THIS PROCEDURE IS CARRIED OUT WITH HOT SEALING ROLLERS

WARNING

OPERATE ON THE MACHINE ONLY WITH MACHINE STOPPED, WITH EMERGENCY BUTTON PRESSED

1. After mounting the reel, unwind the film onto the take up rollers as shown in the diagram on the relative plate.

NOTE:

The film unwind change for machine version (left or right) and for film type. For this reason this is an approximate picture. For a right film unwind refer to the film unwind label fixed on the machine

2. Open the drive rollers with key

3. Insert the film among the folding box wings and guides.

4. Take the film from the conveyor output and pull out the edges from the conveyor exit to insert them into the drive and sealing rollers.

5. Close the drive rollers

, making certain that the film remains well stapled

among both edges.

 Copyright ILAPAK Italia S.p.a

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ADJUSTING THE MECHANICAL ARM

Adjust the positions of the adjustable lever (1) and tensor roller (3). To adjust lever (1) move control (2) while to move take up roller (3) use controls (4) and (5).

When programming a new product, the “X” and “Y” values shown on the memo page are correctly defined when the film, in the section between the take up roller (3) and the conveyor (2), forms an upside-down “U”.

NOTE: Correct machine operation depends on the correct position of the film in the

conveyor and on the elimination of any tension irregularities or bending.

3 1

 Copyright ILAPAK Italia S.p.a

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ADJUSTING THE FILM REEL BRAKE

The reel brake may be adjusted by tightening or loosening the hand wheel 1. N.B.: Increase or decrease braking according to the width of the film reel installed: the

wider the film the greater the braking.

 Copyright ILAPAK Italia S.p.a

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JAW HEIGHT ADJUSTMENT

(for machines without related adjustment servomotor)

Version “CARRERA 2000 PC 400”

The selection of the jaw height ensures that transverse sealing is positioned as required for the height of the product to be wrapped. Before carrying out this selection, make sure that the electrical power supply is disconnected. Loosen the two screws (1) that lock the jaw assy. Rotate the handwheel (2) to change jaw height by referring to the millimetre rule (3) and as required to attain a position corresponding to approx. Half the height of the product to be wrapped. Tighten the screws (1), and write down the jaw height data in the product chart.

1 1

1. Jaw assy locking screws 2 Jaw height adjustment

handwheel

3 Millimetre rule

Jaw height selection

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Version “CARRERA 2000 PC 250”

The selection of the jaw height ensures that transverse sealing is positioned as required for the height of the product to be wrapped. Before carrying out this selection, make sure that the electrical power supply is disconnected. Loosen the three bolts (1—3-4) that lock the jaw support plate Rotate the screw (2) to adjust jaw height by referring to the millimetre rule to attain a position corresponding to approx. Half the height of the product to be wrapped. Tighten the four bolts (1-3-4-), and write down the jaw height data in the product chart.

Jaw height selection

1 Right locking bolt 2 Jaw height adjustment screw 3 Left locking bolt 4 Lower locking bolt

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MOUNTING THE INTERCHANGEABLE PRODUCT SUPPORT

Consult the Product Sheet to identify the required product support and mount as follows:

1. Make sure the machine is in the “in phase stop” position (jaws open). If not, move it by pressing the green start button and then the red in-phase stop button .

2. Position the interchangeable product support (1) and fix with the two screws (2) to the shaft of the lower jaw (3).

If the type of support to use has not yet been defined (for example during the new product programming phase), the diameter may be determined as follows:

Diameter = jaw centre to centre distance - product height After completing mechanical adjustments, the configured parameters concerning the new

product must be saved.

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ENTERING PRODUCT DIMENSIONS AND ADJUSTMENTS

With key open INDEX page.

Touch key ‘Product related data’ to display the following page.

Press the keys in relation to the dimensional data fields and introduce the new values.

Use the keys value for big modifications, using the keys of the numerical pad.

 Copyright ILAPAK Italia S.p.a

and for small modifications, while key in directly the desired

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NOTE: At the end of each introduction, confirm the just entered parameter by

pressing key .

NOTE: The fields in relation to the dimensions of the reel band, the folding box, the

product support and the product feed lugs are as a memo only:



Film reel width.

Folding box number

 Pusher width.

 Pusher Height.

 Pusher Thickness.

 Product Support.

While the following parameters have to be compulsorily entered since they are requested by the electronic control system for the synchronisation of the axles:



Product length.

Product width (only in case, where the cardboard placer device has been

installed) .

 Product height (only for machines with servomotor for the jaw height

adjustment).



After having entering all the data of this page, press key

Lug pitch.

to pass to the following

page or press key ‘Manual settings’ to pass to page “MAIN INDEX”.

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Press the keys in relation to the manual settings fields and enter the new value, always

using the keys and for small modifications or keying in directly the desired value for big modifications by means of the numerical pad.

NOTE: At the end of each introduction, confirm the just entered value by pressing key

Press the area “X” and enter the value in degrees in relation to the oscillating lever inclination of the reel holder; enter in the area “Y” a value in mm in relation to the position of the tensor roll.

If you work with an adjustable folding box in the fields “A”, “B”, “C” and “D”

enter the values expressed in mm.

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Only for machines without servomotor for the jaw height adjustments: enter the value in

mm in relation to their position . WARNING: After having entered the value in relation to the product height, make

certain to carry out the jaw height adjustment, as described in section: MECHANICAL SETTINGS OF THE MACHINE”.

If there is installed a mechanical blowing device, enter the value in mm in relation to the

depth of the pneumatic blowing device nozzles and the value connected with the nozzles position of the pneumatic blowing device

After entering all data return to BASE page by touching key or repeatedly.

 Copyright ILAPAK Italia S.p.a

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ENTERING THE OPERATING PARAMETERS OF THE MACHINE

While entering the operating parameters of the machine it is necessary to move between different menu pages.

Those pages can either be opened by scrolling with keys and or touching

the related key on INDEX page Information on specific accessories, which may be fitted to the machine but are not mentioned in this section, can be found in the manufacturers' documentation for the unit in question.

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“TEMPERATURE” PAGES

The set temperatures (delimited area by the green frame) are displayed in the first column of the page, while the actual detected temperatures by the probes are displayed in the second column. The warning lights in the column on the right indicate the condition of the resistances (the blinking in the yellow colour indicates that the resistances are in heating phase).

Temperature first hot rollers pair.

Temperature second hot rollers pair.

Temperature third hot rollers pair.

Temperature lower jaw.

Temperature upper jaw.

Set temperature to 20°C to suppress all the alarm

conditions in relation to the temperatures. During the creation of a new product, there can be applied some established values for

the displayed parameters, for the same kind of film used for other products, which are already stored in the program.

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To carry out modifications of the displayed values, proceed as follows: – Press the keys in relation to the values field to be modified.

Use the keys and for small modifications, while key in directly the desired value for big modifications, by means of the keys of the numeric pad.

NOTE: At the end of each introduction, confirm the just entered parameter pressing key

Make certain that the heating phase is activated (enabled functional key ). NOTE: A safety circuit stops the machine from being started erroneously before the

heating elements have reached the set temperatures; Should it, nevertheless, be necessary to run the machine while the heaters are

not up to temperature yet, the safety circuit can be bypassed by deactivating

the functional key .that allows the disabling of the temperature alarm conditions.

At the end of the machine running phase out of temperature limits make certain

to re-activate the functional key

in order to re-activate the safety circuit

and the temperature alarm conditions.

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“TEMPERATURES ACCORDING TO THE MACHINE SPEED

If in page “Special functions” is activated the functional key alternatively to the previous page of the temperatures, the following page is displayed which allow the programming of the automatic temperatures control of the sealing groups according to the production speed of the wrapping machine.

The automatic control function is based on the values, detected from the established temperature curves for each sealing group.

The temperatures curves are set defining the extreme points “t1” and “t2”, which represent respectively the optimal heating values of the related sealing group to the minimum and maximum production speed of the wrapping machine.

Only as information is represented in the following graphics, a temperature curve of the sealing group, applying to point “t1” the value of 115 °C for a minimum speed of 90 pieces/minute, to point “t2” the value of 140 °C for a maximum speed of 140 pieces/minute.

The related excellent temperature value, pre-established by the curve will be automatically selected with activated automatic control function, for each production speed modification of each sealing group.

°C

160 150 140 130 120 110 100

90 80

ppm

100

ppm

110

ppm

120

ppm

130

ppm

140

ppm

Pz/min

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For the definition of the points “t1” and “t2” proceed as follows:

Press key Using the numeric pad, enter the parameter field

a quite low value representing a minimum

production speed of the machine and confirm the entered value with key

. Then set in each displayed parameter on the page an excellent temperature value, defined in testing phase according to the used kind of film and to the established minimum speed.

Confirm each set value with key .

Then press key and enter the parameter field

a maximum production speed value of the machine

Confirm the entered value with key . Then set in each displayed parameter on the page an excellent temperature value,

defined in testing phase according to the used kind of film and to the established

maximum speed. Confirm each entered value with key .

After making certain of the correct entered values, press key to start the automatic temperatures control phase and carry out the saving of the parameters.

NOTE: To deactivate the automatic temperatures control of each sealing group in

relation to the production speed of the machine, deactivate the related

functional key .

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PAGE “PRODUCTION RELATED DATA”

This page allows the entering of the production data in relation to the operation of the machine. During the entering phase of a new product, it is compulsory to enter the data regarding the film tensioning, the length of the desired wrapping bag en the maximum speed the machine can reach during the phase production. For the meaning and the setting of the other data in relation to the settings, which have to be carried out during the running of the machine, see the instructions of the next paragraphs.

Product – to bag centring

Print - to bag centring

Web tension

Bag expelled in empty mode with jaws open

Lug Position

Jaw speed compensation

Cut-off length (or register spot pitch)

Max. adjustable machine speed

Off Set parameter Jaws angle open

To introduce the parameters necessary for the running of the machine, observe the following instructions:

parameter in relation to the bag length.

NOTE: The theoretical film cut-off length calculated according to the formula

(L + H + S) + 10%

or, if panel printed, registered film is used, the pitch of the print registration marks measured over several pitches.

Introduce the bag length value; use the keys and for small modifications and key in directly the desired value for big modifications by means of the pad keys.

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NOTE: At the end of each introduction, confirm the just entered parameter pressing

key .

parameter in relation to the maximum speed; enter the related value proceeding as described in the previous point. NOTE: For each product the maximum permissible speed can be programmed in order to

avoid running the machine too fast by for the given seal temperatures and thus producing poor seals. The set value represents the maximum speed value that can be entered in the Home page.

. Parameter related to the film tensioning; introduce an already

established value for a product similar to the one that is being wrapped.

NOTE: In the absence of any other value it is advised to start with the default value of

2 kg.

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Off Set Parameter

The sealing jaws and the film of the wrapping should have the same speed during the length of their meeting, in order to obtain a correct transversal sealing. The PC of the machine will automatically calculate the sealing phase, according to the product data and the machine data. However, in case of very tall products, the jaws can intercept the film before having equalized their speed to the speed of the film, thus causing a breaking.

In this case it is possible to modify the starting point of the sealing phase, by operating in the following way:

On page “”Production related data”

enter a small variation to the value quoted in field

by means of the keys

or and confirm with key .

NOTE: This field can only be displayed upon entering of the user’s password Wrap some products at an average speed and check that the problem has been

solved. If necessary, carry out some further value changes in field .

NOTE: The Off Set parameter is very important for the correct working of the wrapping

machine. Therefore, if some other production problems should be verified as a result of the executed changes, get in touch with the ILAPAK servicing.

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“ACCESSORIES” PAGE

Press key to display Index page. Press key “Accessories” to display the following page.

The page showed above is merely indicative, as it may vary based upon the number and type of accessories installed on your machine.

The display of the pages called in the following paragraphs can be performed by calling directly the desired page through the relevant key on the above mentioned page and,

subsequently, by pressing key and , in order to scroll the various pages. For the parameter setting, it is possible to start the machine at low speed or in “JOG” mode and to detect the enabling/disabling position in the box indicating current position, transferring then the value into the relevant fields.

For the data input, proceed as follows:

- Press the key of the value to be changed in relation to the required function.

- For little changes, press keys and , while for great changes, input

directly the desired value using the keys of the numeric key pad.

- At the end of each operation, confirm the last input parameter by pressing key

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Description of parameters

The various functions of the operation parameters in relation to the different accessories devices, which can be installed on the machine, are described in this page.

In the column “Start” are set the values in degrees of a virtual machine cycle, which determine the point where the activation of the device should start.

In the column “Stop” are set the values instead, which determine the point of the machine cycle where the operation of the device is deactivated.

The value “Actual” of the machine phase (machine cycle degrees) is displayed in the

first column of the page linked to the image of the camera .

The parameter “Time” defines the duration, expressed in millisecond, of the optional activation.

The parameter “Duration” defines the duration, expressed in degrees, of the optional activation.

The parameter “t/msec” allows the entering of a value that defines and advanced intervention of the option according to the set value in parameter “Start” en is generally used during production phase at high speed.

To introduce the data proceed as follows: – Press the key of the value to be modified in relation to the requested function.

Use the keys and for small modifications and key in directly the desired value for big modifications, by means of the numeric pad.

NOTE: At the end of each introduction, confirm the just entered parameter by

pressing key . Next are described the most common functions used on the machine. For the settings of the parameters in relation to other accessories, refer to the specific technical documentation.

 Copyright ILAPAK Italia S.p.a

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ACCESSOIRES PAGE: PRINTER/GUSSET/CARDBOARD CUTTER

Printer

Signal (impulse) to control a printer device at the outside. Program the parameters “Start” and “Stop” as requested to obtain that the print marking appears on the desired point. The control sign (not the marker device) can be activated or deactivated by means of the

related functional key .

Gusset

The related parameters “Start” en “Stop” determine respectively the activation an d the deactivation of the pneumatic gusset assembled on the transversal sealing group. In order to enable the operation of the pneumatic gusset, activate the related functional

key Program the parameters “Start” and “Stop” in relation to the characteristics of the product

to be wrapped.

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Cardboard cutter

Signal (impulse) for the control of a cardboard cutter device Program the parameter “Start” to carry out the cutting of the cardboard in such a way to time the device with the feeding of the wrapping machine. The cardboard cutter device can be activated or deactivated by means of the related

functional key .

Independent cut

Signal (impulse) for the control of the independent cutting blade. Program the parameters “Start” and “Stop” as requested in order to obtain that the blade can cut and divide the just produced bags. Attention Set the start value at 179° and stop at 181°. Only in case where the device

can’t cut the film, modify the values of 1° (start 178°, stop 182°)

The advance of the blade out-coming can cause breaking of it. Set both values at 0° to wrap the bags without the help of the accessory device.

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ACCESSOIRES PAGE: LABEL APPLICATOR/SPRAY

Label applicator

The related parameters “Start” and “Delay (t/msec)” determine respectively the activation and the anticipation of the label applicator device intervention. To enable the operation of the label applicator, activate the related functional key

Spray

The related parameters “Start” and “Stop” determine respectively the activation and the intervention time of the spray device. To enable the operation of the pneumatic blowing device, activate the related functional key.

The parameter allows selecting the intervention of the device on the products.

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Various accessory pages

Following are showed the pages of the most frequently accessories used on the machines.

For the setting of the parameters of the accessories installed on your machine, make reference to the technical explanation in Section “Accessories” of this manual.

Device name

Operating

parameters

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"USER CAMS" PAGE

The page “User cams” allows the programming of four independent main cams, which can be used for the control of the peripheral unit installed on the machine a/o on the auxiliary appliances. The operation of the cams can be synchronized with one of the reference axles (feeding axis, film axis, jaw axis) , which angular position (expressed in degrees of a virtual machine cycle) is displayed in the lower page part. Furthermore, according to the requirements, the duration of the operation of each main cam can be configured both according to an established angle of the machine cycle, as well as according to a fixed established time.

– The parameter “Start” defines the position (referred to a point of the

machine cycle) where the option operation has to be activated.

– The parameter “Stop” defines the position (referred to a point of the

machine cycle) where the option operation has to be deactivated. NOTE: This parameter can be displayed only when the next parameter “Temp”

is set to zero.

- The parameter “Duration”

the optional activation.

 Copyright ILAPAK Italia S.p.a

defines the duration, expressed in degrees, of

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– The parameter “Time” defines the duration, expressed in millisecond, to

activate the option. NOTE: If this parameter is set, the program eliminates automatically the

previous “Stop” parameter.

– The parameter “Sincr.” defines the axis where the optional operation is

synchronized for the positions Start and Stop:

–

1 = feeding motor axis

2 = film unwinding motor axis

3 = jaw motor axis

– The parameter “t/msec” allows entering a value, that defines an

advanced intervention of the option regarding the set value in the parameter “Start” and is generally used in production phase at high speed.

Programming procedures NOTE: Press on the related field for the setting of the parameters and enter the value

using the numeric pad or the keys and . Confirm each entered

value by pressing key .

Press on the related field to parameter “Sincr.” and enter the number corresponding to the axis, where the cam should be synchronized. Adjust the speed to the minimum value and start the machine pressing the button START. When the position of the machine cycle is obtained, where the optional operation has to be activated, detect the value in degrees noted in the field in relation to the position of the reference axis where the cam has been synchronized. Then stop the machine.

Press on the field in relation to parameter “Start” and enter the value detected in the previous point.

 Copyright ILAPAK Italia S.p.a

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Operation duration according to a machine cycle angle

Adjust the speed to the minimum value and start the machine pressing the button START. When the position of the machine cycle is reached, where the optional function should be deactivated detect the value in degrees noted in the field in relation to the reference axle where the cam has been synchronised. Then stop the machine.

Press on the filed in relation to parameter “Stop” and enter the value detected at the previous point.

Operation duration in relation to an established fixed time

Press on the field in relation to the parameter “Time” and enter a value expressed in millisecond representing the optional operation duration.

The parameter “t/msec” has to be set next, after the start of the production phase and whenever a delay of the function controlled by the cam consequently to an increase in the speed of the machine is detected. If necessary, observe the same listed procedures, it is possible to program a second cam completely independent from the first one. Then enable the operation of the accessory device linked to “User cam 1” or “User cam 2”

or “User cam 3” or “User cam 4” activating the respectively functional keys ,

in page “Special functions – 2” .

 Copyright ILAPAK Italia S.p.a

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PAGE “FUNCTIONS”

On this page, displayed by means of the recall key , are the keys related to the activation or the deactivation of the options present on the machine. The functions enabled to operation depend on the options installed on the machine; following you can find a complete list of the available functions and their related associated keys.

Deactivated Activated Description

Activates/deactivates the error alarm message emitted by an external accessory device; programmable.

Suppresses the alarm “Error lug pitching” and permits operatin

the machine while infeed lugs are missing or

badly positioned.

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Deactivated Activated Description

Activates/deactivates the pneumatic gusseting device

Activates/deactivates the user-programmable cam #1 for the running of the external accessory devices.

Activates/deactivates the user-programmable cam #2 for the running of the external accessory devices.

Activates/deactivates the accessory printer device

Activates/deactivates the accessory cardboard cutter device.

Suppresses the alarm in relation to the temperature of the sealing groups (rollers and jaws)

Activates/deactivates the accessory label applicator device.

Activates/deactivates the automatic film reel splicer device

Activates/deactivates the photocell system (product safety) detecting misplaced products.

Stops jaws from closing when detecting product(s) within the area destined to the transverse seal and thus avoids damaging products and dirtying sealing jaws.

Activates/deactivates the back seal trim suck off device –

Activates/deactivates the control quality device

Activates/deactivates the accessory automatic feeder device

Activates/deactivates the accessory sprayer unit device

Activates/deactivates the print registration system for printed film

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Deactivated Activated Description

Activates/deactivates cam operation for the reference signal to an external label applicator device

Activates/deactivates the heating system of the jaws and sealing rollers

Activates/deactivates the ‘Temperatures according to the machine speed’.

Activates/deactivates the hic-up function mode

Activates/deactivates the external label applicator alarm signal

Activates/deactivates the programmable cut function mode

Activates/deactivates the “product on lug control” -

Activates/deactivates the motorised bars product support -

Activates/deactivates the Indy suck off device

Activates/deactivates the washing system.

Activates/deactivates empty bags from the discharge conveyor. This key is only operative with the machine in manual mode.

Reset counter.

 Copyright ILAPAK Italia S.p.a

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PRE-PRODUCTION

VERIFICATION OF SETTINGS AND ADJUSTMENTS

In order to verify the previously set parameters and the exactness of the just carried out mechanical adjustments, produce now some test bags as described in the following paragraphs.

Make certain that the functional key is deactivated (closed pulling rollers pair).

Turn function “no-product/no-bag” OFF with functional key .

With functional key disable product safety function. Open page “Temperatures” and check for correct temperature setting and whether set temperatures have been reached. Set machine speed to a quite low value, approximately 20-30 pieces/minute, in order to check the various packaging phases. Push START button and while the machine produces empty bags optimise film tracking and film tension as follows:

– Reel brake setting – adjust if necessary

NOTE: Setting of the brake is correct when the rocking arm stabilises in a (more

or less) central position and does not rock fore and back. – Lateral film tracking, i.e. is the film centred in the folding box and are both sides of

the “fin” of equal length – if necessary adjust film reel centring NOTE: The result of film reel centring will only show with some delay on the

folding box after some film has passed through. – Uniform shape and tension of and absence of folds from the “U” the film should

form between approach roller and folding box).

– If necessary try different positions of approach roller and/or increase web tension.

– For this purpose open page “Adjustments” and in field

enter a higher value for the film tension.

NOTE: Vary film tension in steps of no more than 0.5 kg at a time and check

continuously the result at the entry to the folding box.

- Check that the real bag length corresponds to the set value.

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– If the real bag length is inferior to the set length film tension if field

may be too high (see step c.) or reel brake may be set

too tight; if both are not the cause modify cut-off length in field

NOTE: If film is panel-printed do not modify parameter

cut-off

length at this point (see the following paragraph).

- Seal quality, i.e. seals free from folds and hermetic. Use a particular tool for the

tightness test of the sealing under pressure.

- In case of imperfect sealing, check the set temperatures in page “Temperatures”

ADDITIONAL TESTING PROCEDURES WITH REGISTERED PRINT

- Make sure all steps described above under previous paragraph have been carried out.

- Move scanning head laterally to a position where the register spot cuts the light beam

of the scanning head.

- With functional key enable print registration.

- Display the Home page.

- Start machine to produce empty bags and observe the indicator for the printed film

centring correction.

 Copyright ILAPAK Italia S.p.a

Ed 1 Rev 06 - June 2005 PAGE -82

(

)

(

Carrera 2000 PC Touch

Bag length

(mm)

Length Variation

increase

Length Variation

decrease)

NOTE: The indicator is enabled for operation only in presence of the photocell

for printed film and with the functional key activated.

- While machine is in motion watch the excursion of the illuminated bar on the indicator

and on which side (towards “left sector“ or towards “right sector”) it occurs.

NOTE: The bar illuminates each time a register mark passes the light beam of the

scanning head (photocell) and illustrates that the system works properly.

The entity of the excursion is proportionate to the amount of correction to

maintain the film registered (a full excursion of the illuminated bar towards “left sector“ or towards “right sector” indicates a print correction equal to 5 millimetres.

The direction of the illuminated bar indicates which way the print correction

operates:

- excursion towards right sector: cut-off setting is short

- excursion towards left sector: cut-off setting is long;

- If excursion comes on regularly more than 50 %, print correction has to work “too

hard” (due to cut-off having been set too long or too short; in either case touch

buttons or to change the cut-off length (bag length).

- Still with the machine in slow motion check whether the print image is centred

correctly on the pack.

- If correction is required:

- Display page “Adjustments” and insert in the field related to the print centring

the value in millimetres of the shifting, in order to obtain a centred print on

the bag.

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- For print shifting forward (toward the jaws) insert positive numbers, for shifting

backward insert negative numbers (-nn) (to insert sign “-“, touch key before typing the number).

- Confirm the entered value by means of key .

NOTE: The entered value corresponds to the real print shifting in millimetres on the

bag.

- Set machine in motion and check print position once again; if required, repeat

correction.

NOTE: Final and definite fine tuning of the cut-off length and the print image

position should be carried out under production conditions, i.e. while the machine operates with product and at full speed

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TEST RUN

According to the product dimensions, which have been previously set, the electronic control system of the machine, provides autonomously to calculate the vital operative parameters. However, the shape and the characteristics of the product can sometimes ask a series of accurate manual adjustments. Therefore start the production of a “new product” with a test run at maximum speed, controlling in a particular way the print position and other further points as described hereafter.

For this purpose proceed as follows

- Assure that the function keys “No product No bag” and “Misplace ”

are deactivated.

- Open page “Production related data”.

- Fill up infeed with products.

- Set the machine speed on production value, and start the machine

- Check the transfer of products from the infeed chain into the folding box and the film.

- Check the jaw speed during the sealing phase with reference to the film speed.

NOTE: The jaws speed should never overrun the film speed (causing tears of the

film itself): a slightly slow speed is to be preferred in some cases, instead.

If necessary, carry out the jaw speed adjustment as follows:

On page “Production data” select field inherent in compensation to the jaws speed and modify the related set default value of 100%.

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NOTE: Reducing the value slows down, increasing the value speeds up the sealing

jaws in relation to the film speed.

- Confirm each modification with ;

Verify the product centring in the bag. If the product is not centred in the bag, or if you want a packaging with a not centred product, display page “Production data” and

set in the field inherent in the product centring the desired movement value for the product. For forwarding movements of the product (towards the jaws) enter the positive number, for movements in the other direction, enter the negative number

(- nn) (for the entering of the sign “-“ press key before keying in the number)

Confirm with .

- Start the machine again for the production of further wrappings and carry out the

listed verifications from the following points and if necessary the related correction actions as described previously.

NOTE: Remember you MUST confirm each individual entry with .

- Verify the product centring in the bag

- Verify the Jaw-to-film speed (

)

- Verify the print centring on the bag )

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Carrera 2000 PC Touch

ADVANCED FUNCTIONS: MISPLACE - NO PRODUCT NO BAG

Product safety system (Misplace)

The Misplace function is used to stop one or more products that are out of phase with the action of the jaws getting caught up in them with consequent interruption of production. Two photoelectric cells located above the rollers check that, during the jaw sealing phase, no product is present inside the safety strip “x”. The length of this strip is determined by a number comprising the thickness of the jaws (generally 40) and the distance between the front of a product and the back of the following product feed lug.

If a product is detected inside the “X” strip, the jaws do not cut but remain open while the film continues at the same speed. When the last incorrectly positioned product has go ne through, the jaws start sealing once more.

NOTE If more than 5 consecutive products are detected as being in an incorrect position

the packing machine will stop

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Introduction of the function “Product safety”

Before wrapping the products with this activated function, it is necessary to carry out some mechanical settings and set some parameters, proceeding as follows:

Mechanical settings

The only mechanical adjustment to make for configuring the misplace function is the positioning of the photoelectric cell support as these must be adjusted according to the length of the bag to be packed.

To adjust the position of the photoelectric cell support on the graded scale to the value corresponding to the length of the bag to be packed.

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Entering parameters

In order to establish with a great accuracy the margins of the control area, an automatic detection system for the products position has been introduced and can be visualised through the operational page where you have access to as follows:

With key open INDEX page. Touch key “Product safety” to display the following page.

The “real “ distance in millimetres from the product end in closing phase in relation

to the cutting position and after executed cutting, the “real” distance in millimetres of the next product head will be detected automatically with each sealing.

ACTUALSETTINGS

“HEAD” LIMIT OF THE ZONE NEXT

TO THE CUTTING

“END” LIMIT OF THE ZONE PREVIOUS TO THE CUTTING

According to the detected positions and according to the desired margins, the “set” values are set, which delimit the control area inside the cutting area. NOTE Normally to set the value in the column “Settings”, a margin of about 5-10

millimetres should be subtracted from the related value, displayed in the column “Actual”.

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The minimum set value shouldn’t be inferior to the half thickness of the jaws, while the maximum “set” value shouldn’t exceed the minimum “actual” respectively detected value. The data noted in the previous figure, for example, delimit a control area equal to 53 mm distributed as follows: 25 mm before the cutting to verify the presence of a delayed product and 28 mm after the cutting to verify the presence of an advanced product. Each time an “actual” value results inferior to the “set” value, there is a MISPLACE intervention. In order to establish the correct “set” values, it is essential that the product position has already been optimised and that there won’t be significant next future modifications. In case of remarkable product position correction, it could be necessary to revaluate the set margins for MISPLACE. In case of MISPLACE intervention, it is possible to individuate if it is due to an advanced product (the product head enters the control area) or a delayed product (the product end hasn’t still left the control area), due to the switching on of yellow lamps, placed on the right of the data boxes. It is up to the operator to individuate the sliding cause or to revaluate the margins of the control limit introduction.

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Activation of the function “product safety” (Misplace)

For the activation of the function “product safety” proceed as follows:

With functional key enable the product safety function. With page “Product safety” opened, fill infeed with products and set machine in

operation. While products pass through the machine watch if “product safety” intervenes (jaws not closing); immediately recognise which of the yellow rectangles on the display has come on. Repeat the operation in order to gain more information on what is happening.

NOTE: By means of the yellow rectangles one can quickly determine which of the

products (the trailing or the leading) has been misplaced in which direction (forward or backward) –

If a really misplaced product has triggered the safety device it has obviously “done its job correctly”. Only if the triggering has been caused by a correctly placed product the “see-noproduct-window” of the parameter next to which the yellow rectangle has come on must be narrowed as follows:

- Touch on the parameter whose yellow rectangle has come on.

- With keys

or broaden the difference between “Actual” and “Set” values, i.e. increase the set value on icon 1 (“tail” of leading product has triggered safety) or decrease the set value on icon 2 (“head” of trailing product has triggered safety).

- Confirm each parameter modification with

NOTE: It may take several trial-and-error attempts before the product safety system

has been correctly programmed; therefore, if necessary, repeat steps a. – c.). After having ascertained the proper operation with correctly placed products move a product consciously in the film tube prior to the photocells (first forward, in a second test backward) and thus check the operation with misplaced products. If necessary, repeat steps a. – c. once again and correct set values further.

If necessary, repeat the settings procedures, till the system intervenes each time the product is moved forward or backward and the products aren’t positioned correctly.

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“No product / No bag”

The function “No Product/No Bag” allows to produce full bags only, thus preventing empty bags. A photocell, placed on the infeed, detects the presence of product. If the missing of one or more products on the infeed is detected at the end of the introduction of the last product in the bag, a signal to the PC is sent, which provokes the film and jaws stop; in this way the infeed continues to run, while sealing and cut-off are paused. This product waiting condition is signalled by the lighting of the orange warning lamp. When a new product arrives (detected by the photocell), the film synchronises again and the sealing and cutting cycle of the jaws restarts regularly.

Notes for the correct calibration of the photocell.

The calibration of the “No Product / No Bag” photocell should be carried out without product: the photocell should read the hook.

Conditions for the correct functioning

The “No Product/No Bag” is an option that can't be generalised for all the packing machines and for all the products to be wrapped. It’s like saying that the mechanical systems works, but the film nature or the physic conformation of the product itself may become an impossible obstacle for its application.

Therefore, it should be assumed as a rule that the good operation of the No product/ No bag function is to be checked only during the setting of the machine, with product and film in the effective productive conditions.

The problems coming from the application of the No Product / No Bag, are based essentially on three factors:

- the first one is represented by the possibility the product has to slip on the film during the waiting stop for the next product;

- the second is, on the contrary, the difficulty a particularly tacky product has to get into a stopped film or in acceleration phase.

- the third is given by the difficulty a product has, when it stops and restarts in an asynchronous way referred to the jaws, to overrun the product support. Therefore, it is probable that a heavy and short product, or a very light film, even if helped by the final pair of rollers, will find difficulties in reaching the outgoing conveyor belt.

Operating rules

The primary rule is, where possible, to stop the rollers as soon as the hook is upsidedown. This operation prevents the movement of the product inside the film. It may not be possible only if the rollers, due to the too advanced stop position, are not able to star and synchronise to the main motion before the jaws are in contact again for the next cutoff. In this case, it is compulsory to stop rollers and jaws simultaneously after the cut-off has been executed.

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Activating the “No product / No Bag” function

The activation of this function is performed through the related key .

Available instruments

According to the product and bag lengths, the PC is able to calculate autonomously the optimal conditions for the rollers and jaws stop. For the purpose of optimising the operating of the “No Prod/ No Bag”, it is possible to intervene by selecting the values of some significant data, which meaning will be deepened afterwards. Hereafter the data are listed:

sliding coefficient according to the product slipperiness, set a value between 1 and 5

film advance in the maximum measure of the calculated margin forcing the film start/stop when cutting as an

alternative to the decision autonomously taken by the PC to stop and restart the film when the hook flips-over

The electronic page dedicated to the No Prod/ No Bag is the following (it can be displayed by touching button “No prod/ No bag” in the Index page).

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Operating

Simplifying to the maximum, it is necessary to stop rollers and jaws waiting for a product pushed by the hook into the film. The main problems are represented by the need of stopping the jaws in “open” position, that is to say, after the cut-off, and as soon as the last presented product on the infeed has been completely introduced on the film by the hook. The PC, according to the entered data, can take a fundamental decision:

- to start the stop cycle with the jaws in open position at the cutting, then stop

the film during the hook flip-over;

- to start either the jaws stop cycle or the film stop in open position.

The fundamental condition that influences in taking such decision is related to the possibility the film has to accelerate, in order to be still synchronous when the jaws come in reciprocally contact. While in case of a film stop at the cut-off moment, the available margin corresponds to little less than a bag, in case of a stop at the hook flip-over, the margin should be assessed according to the bag position and referred to the next cut-off. To make it simpler, if the junction between a bag and the next one stops too close to the jaws, probably the film is not able to accelerate and synchronise before the cut-off.

Data needed for the automatic calculation

In order to allow the PC to calculate the conditions of the No pro/ No bag, first of all it is necessary to have already properly entered the data related to the product, namely:

- product length

- Product height

- bag length and to have found out the:

- optimal product position inside the wrap

Finally , it is necessary to assess a specific value of the No prod / No bag function, namely:

- sliding coefficient (which should be entered in the field

which allows to define the product deceleration and acceleration according to the product slipperiness.

The datum is related to the section of the bag length inside which the deceleration of the film is performed, followed by the acceleration. There are two possibilities:

- a very slippery product needs of an extremely smooth movement, to avoid its

misplacement in the film during the film stop and start phases; therefore, it is necessary to enter a coefficient 4, or even 5;

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ILAPack CARRERA 2000PC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SALES AGENTS AND SERVICE ORGANISATIONS

INTRODUCTION

KEEPING OF THE MANUAL

UPDATING OF THE MANUAL

COLLABORATION WITH THE USER

MACHINE IDENTIFICATION DATA

EC STAMPING AND SAFETY STANDARDS

SAFETY RULES

CLOTHING

ACCESS TO THE WORKING ZONE

MACHINE USE DESTINATION

MACHINE APPLICATION

RESIDUE RISKS ZONES AND OPERATIONS

WARNING SIGNS

RESIDUE DANGERS

SAFETY DEVICES

MACHINE INSTALLATION

MACHINE DEMOLITION

MACHINE CONTROLS

USER INTERFACE

PRELIMINARY OPERATION

OPERATION CYCLE START

MECHANICAL MACHINE ADJUSTMENTS

ENTERING PRODUCT DIMENSIONS AND ADJUSTMENTS

PRE-PRODUCTION