Sealed Air SeleCTech,SLCT-FAL5645 User Manual

User Guide

Sealing Machine SLCT-FAL5645

SeleCTech™

Model SLCT-FAL5645

Sealing Machine

This manual is a comprehensive reference for the SeleCTech™ Model SLCT-FAL5645 Sealing Machine. It includes information on machine speciﬁ cations, safety, parts ordering, system setup, operation, general maintenance, and general troubleshooting.

Table of Contents

SECTION A. SPECIFICATIONS ....................................................................A-1

SECTION 1. GENERAL INFORMATION ....................................................1-1

SECTION 2. INSTALLATION .......................................................................2-1

SECTION 3. OPERATION .............................................................................. 3-1

SECTION 4. GENERAL MAINTENANCE & TROUBLESHOOTING .....4-1

SECTION 5. REFERENCE DOCUMENTS ................................................... 5-1

This manual has been designed to serve as a reference guide for the SeleCTech™ Model SLCT-FAL5645 Sealing Machine.

NOTICE

Sealed Air® and the 9 Dot Logo are registered trademarks of Sealed Air Corporation.

This document is copyrighted. The material contained herein is protected under the US Copyright Act of 1976. This document, in whole or in part, may not be copied, photocopied, reproduced, translated or reduced to any electronic or machine-readable form without the prior written permission of Sealed Air Corporation (US).

Manufactured in China exclusively for Sealed Air Technology Enhanced by Shanklin® Engineering

Sealed Air Corporation assumes no responsibility for any errors that may appear in this document.

Section A. General Information

SLCT-FAL5645 Sealing Machine

SECTION A. SPECIFICATIONS

This section details information about machine speciﬁ cations and machine parts illustrations.

A.1 SEALING MACHINE SPECIFICATIONS

A.1 SEALING MACHINE SPECIFICATIONS ................................. A-3

A.2 ILLUSTRATION OF MACHINE PARTS ...................................A-4

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Section A. General Information

SLCT-FAL5645 Sealing Machine

A.1 SEALING MACHINE SPECIFICATIONS

Speciﬁ cation Description

Machine dimensions (L) x (W) x (H) 1795 mm x 985 mm x 1570 mm Packing dimensions (L) x (W) x (H) (100~450) x mm x (60~350) mm x (5~120 ) mm Sealing bars size (L) x (H) 565 mm x 460 mm Packing ﬁ lm 23 in Packing capacity 30 pcs/min Conveyor speed 26 m/min Film POF, PE Sealing blade temperature 180°C to 230°C Voltage 240 V/1P 3 kW Motor power 320 W Electric power 2.5 KW Weight 330 kg Pressure 4 kg Noise Emission 70 dB(A)

Figure A–1 Sealing Machine Dimensions

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Section A. General Information SLCT-FAL5645 Sealing Machine

A.2 ILLUSTRATION OF MACHINE PARTS

Use Figure A-2 to identify the major parts of the machine:

1. Control Panel 2. Seal Area 3. Selvage Winder

4. Film Unwind 5. Infeed Conveyor 6. Leveling Feet

1

4

2

5

3

6

Figure A–2 Machine Parts Illustration

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SLCT-FAL5645 Sealing Machine

SECTION 1. GENERAL INFORMATION

This section details information about safety , transporting, technical support, warranty information, and equipment certiﬁ cation(s).

IMPORTANT

The Safety section contains information for operating and working on the equipment. ALL personnel working on or around the equipment are urged to read and understand the Safety Section and any additional safety information placed throughout this manual.

1.1 SAFETY SECTION .........................................................................1-3

1.1.1 Residual Risks ....................................................................1-3

1.1.2 Pictogram Label Warning Deﬁ nitions .............................1-3

1.1.2.1 General Hazard Pictogram ............................... 1-4

1.1.2.2 Electrical Hazard Pictogram ............................1-4

1.1.2.4 Lifting Hazard Pictogram ................................. 1-4

1.1.2.5 Entanglement Hazard Pictogram ..................... 1-4

1.1.2.6 Pinch Point Hazard Pictogram .........................1-5

1.1.2.7 Shear Hazard Pictogram ................................... 1-5

1.1.2.8 Hidden Knife Warning Pictogram ...................1-5

1.1.2.9 Crushing Hazard Pictogram ............................. 1-5

1.1.2.10 Safety Glove Pictogram ................................... 1-6

1.1.2.11 Safety Eye Wear Pictogram .............................1-6

1.1.3 General Warnings ..............................................................1-7

1.1.4 Energy Isolation .................................................................1-7

1.2 MACHINE TRANSPORT & CRATING ......................................1-11

1.2.1 Uncrating the Machine ......................................................1-11

1.3 TECHNICAL AND CUSTOMER SERVICE SUPPORT ............1-12

1.3.1 Technical Service Support .................................................1-12

1.3.2 Ordering Spare Parts.........................................................1-12

1.3.3 International Customer Service Contacts........................1-12

1.4 CERTIFICATION ...........................................................................1-13

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Section 1. General Information

SLCT-FAL5645 Sealing Machine

1.1 SAFETY SECTION

DO NOT place this packaging system into operation or undertake maintenance and/or troubleshooting procedures until all personnel associated with the equipment have become aware of the warnings and potential hazards outlined in the Safety Section and throughout this document. It is further advised that the user of this equipment follow the manufacturer’s Safety statements, cautions, warnings, and energy isolation recommendations while taking the extra precaution of performing their own safety inspection on the equipment before putting it into operation or servicing it.

1.1.1 Residual Risks

Although extensive precautions have been taken in the design and manufacture of this packaging system, all risk of potential hazards cannot be removed and operation of this equipment involves certain residual risks. To minimize exposure to any residual risks associated with operating or servicing the machine, ensure that all employees read and understand the safety policies and instructions for working on and around this machine.

CAUTION

If in doubt about a hazard associated with this machine, contact a Sealed Air Account Representative prior to operating or working on the machinery.

WARNING

It is the employer’s responsibility to ensure that:

• Personnel are properly trained

• Personnel follow proper safety procedures. Under no circumstance should this machine be run with:

• Any of its guards removed

• Any non-functioning safety devices.

1.1.2 Pictogram Label Warning Deﬁ nitions

This paragraph deﬁ nes the meaning of each of the pictograms used on the equipment and in the machine warnings and cautions outlined in the Safety Section and throughout this manual.

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Section 1. General Information SLCT-FAL5645 Sealing Machine

1.1.2.1 General Hazard Pictogram

This symbol is used to signify the presence of a hazard to personnel working on or around the equipment.

Use caution when following instructions and/or when working around machine parts labeled with this symbol. Refer to the contents of this manual for speciﬁ c hazards and concerns.

1.1.2.2 Electrical Hazard Pictogram

This symbol is used to signify the presence of an electrical hazard to personnel working on or around the equipment.

Turn off and lock out system power before servicing equipment or when following instructions labeled with this symbol.

1.1.2.3 Heat Warning Pictogram

These symbols are used to signify the presence of a thermal hazard to personnel working on or around the equipment.

Do not remove any protective guards and keep extremities clear of parts labeled with this symbol. Allow the system to cool completely and turn off and lock out system power and air before servicing equipment when this safety label is present or when following instructions labeled with this symbol.

1.1.2.4 Lifting Hazard Pictogram

This symbol is used to signify the presence of a lifting hazard. Personal injury hazard may occur if an object is lifted without the proper technique or assistance.

Use assistance and/or proper technique when moving or lifting objects labeled with this symbol or when following instructions labeled with this symbol.

1.1.2.5 Entanglement Hazard Pictogram

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SLCT-FAL5645 Sealing Machine

This symbol is used to signify the presence of moving parts that may present an Entanglement hazard to personnel working on or around the equipment.

Moving parts can crush and cut. Do not remove protective guards and keep extremities clear of moving parts at all times when this safety label is present. Turn off and lock out system power before servicing equipment or when following instructions labeled with this symbol.

1.1.2.6 Pinch Point Hazard Pictogram

This symbol is used to signify the presence of moving parts that may present a pinch point hazard to personnel working on or around the equipment.

Moving parts can crush and cut. Do not remove any protective guards and keep extremities clear of moving parts at all times when this safety label is present. Turn off and lock out system power before servicing equipment or when following instructions labeled with this symbol.

1.1.2.7 Shear Hazard Pictogram

This symbol is used to signify the presence of moving parts that may present a cutting or shear hazard to personnel working on or around the equipment.

Moving parts can shear and cut. Do not remove any protective guards and keep extremities clear of moving parts at all times when this safety label is present. Turn off and lock out system power before servicing equipment or when following instructions labeled with this symbol.

1.1.2.8 Hidden Knife Warning Pictogram

This symbol is used to signify the presence of a hidden knife that may present a cutting hazard to personnel working on or around the equipment.

Moving parts can crush and cut. Do not remove any protective guards and keep extremities clear of moving parts at all times when this safety label is present. Turn off and lock out system power before servicing equipment or when following instructions labeled with this symbol.

1.1.2.9 Crushing Hazard Pictogram

This symbol is used to signify the presence of moving parts that may present crushing hazards to personnel working on or around the equipment.

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Section 1. General Information SLCT-FAL5645 Sealing Machine

Moving parts can crush. Do not remove any protective guards and keep extremities clear of moving parts at all times when this safety label is present. Turn off and lock out system power before servicing equipment or when following instructions labeled with this symbol.

1.1.2.10 Safety Glove Pictogram

This symbol is used to signify the presence of a possible hand hazard injury as a result of working on or around the equipment. In conjunction with safe work practices, Personal Protective Equipment (PPE) is required when this label is present. Wear the most appropriate type of safety glove for protection against cuts, scrapes, punctures, and lacerations when this label is present.

Safety glove selection should be based on the gloves performance characteristics relative to the speciﬁ c task(s) to be performed, conditions present, duration of use, and the actual and potential hazards identiﬁ ed.

1.1.2.11 Safety Eye Wear Pictogram

This symbol is used to signify the presence of a possible eye injury hazard as a result of working on or around the equipment. In conjunction with safe work practices, Personal Protective Equipment (PPE) is required when this label is present.

Personal protective eye equipment must meet certain design criteria to be used as safety equipment and must be worn when workers are at risk from ﬂ ying particles, liquid/caustic/ acid chemicals or vapors, or operations that may emit light.

1.1.2.12 Machine Guard Pictogram

This symbol is used to signify the presence of a hazard to personnel working on or around the equipment when a machine guard(s) is not in place.

Do NOT operate this equipment when guards are missing or open. Serious injury could occur!

1.1.2.13 Machine Handling Pictogram

This symbol is used to signify the need for a certiﬁ ed forklift operator and is also used to indicate the correct forklift tine placement when lifting the machine.

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Section 1. General Information

SLCT-FAL5645 Sealing Machine

Do not attempt to move this system from its crate manually; a trained operator should use the appropriate machine handling equipment to move the machine. Serious injury and/or damage to the machine could occur!

1.1.3 General Warnings

This paragraph contains general warnings and cautions. In addition to these warnings, other pertinent warnings and cautions have been placed in relevant places throughout this manual.

WARNING

To minimize potential for personal injuries, ensure that machine operators and others working on or around the machinery are properly trained in correct equipment use and safe operating procedures.

WARNING

The use of plastic ﬁ lms in sealing and/or shrinking equipment may result in the release of hazardous fumes due to the degradation of the ﬁ lm at high temperatures. Before using any plastic ﬁ lm in this equipment, the manufacturer or supplier of the ﬁ lm should be contacted for speciﬁ c information on the potential release of hazardous fumes.

Adequate ventilation should be provided at all times.

WARNING

Keep all extremities, loose clothing, jewelry, and hair away from moving assemblies and conveyors.

WARNING

Worn or frayed conveyor belts are hazardous and should be replaced promptly.

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Section 1. General Information SLCT-FAL5645 Sealing Machine

WARNING

Never operate this or any moving equipment without all covers and guards in place. The internal mechanisms of packaging machinery contain numerous shear, pinch, and in-running nip points capable of causing severe injury and permanent disﬁ gurement.

WARNING

Do not place pressurized containers or volatile, ﬂ ammable, or explosive materials on, into, or through a shrink tunnel. Resulting ﬁ re or explosion can cause serious injury.

WARNING

Heat sealing jaws and shrink tunnel openings on packaging machines get very hot. Keep hands away while machinery is in operation and use caution if the machine has been running recently.

WARNING

Only approved packaging speciﬁ cations and parts should be used with this system.

Use of other packaging materials and/or parts on the system may cause unforeseen damage to the machinery and pose safety hazards. When unauthorized use of parts or materials has occurred, Sealed Air Corporation reserves the right to refuse services including but not limited to: maintenance, troubleshooting, supplies, and parts provided by Sealed Air (US).

WARNING

In order to prevent injury to personnel and/or machinery, do not increase settings on either electrical or mechanical overload safety devices.

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SLCT-FAL5645 Sealing Machine

WARNING

Do not make any modiﬁ cations to the programmable logic controller’s (PLC’s) control program, the electrical circuitry, or the mechanical assemblies of this machinery. Such modiﬁ cations may introduce hazards not associated with this machinery.

Sealed Air Corporation cannot be held responsible for malfunctions, personal injury, or property damage resulting from such unauthorized modiﬁ cations.

WARNING

Use of extension cords to connect the system to a power supply is prohibited. The system’s power cord MUST be plugged into a grounded source.

WARNING

In order to prevent injury to personnel and/or machinery, proper equipment ground, in accordance with the national, state, and local electric codes, must be applied to the machine.

WARNING

Do not tamper with, or make any modiﬁ cations to, the programmable logic controller’s (PLC’s) control program, the electrical circuitry, the electrical wiring or the mechanical assemblies of this machinery. Such modiﬁ cations may introduce hazards not associated with this machinery.

Shanklin Corporation cannot be held responsible for malfunctions, personal injury, or property damage resulting from such unauthorized modiﬁ cations.

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Section 1. General Information SLCT-FAL5645 Sealing Machine

1.1.4 Energy Isolation

The following guidelines are provided to establish a minimum requirement for the disconnection/ isolation of energy sources whenever maintenance or service is performed on equipment and associated parts. It is further advised that an independent safety study be performed on the machinery, its installation, and Lockout/Tagout procedures.

CAUTION

Prior to following any maintenance or troubleshooting procedures outlined in this manual, review these important steps.

1. Read all warnings and cautions listed in this manual’s Safety Section (“1.1 Safety Section” on page 1-3) and throughout this manual.

2. Shut the equipment down using normal stopping procedure then engage the Emergency Stop (E-Stop) push button switch by pushing it down.

3. Ensure that all controls are in a neutral or OFF position.

4. The equipment may be isolated from its energy sources by unplugging the main power cord.

5. Then applicable, the equipment may be isolated from pneumatic sources by disconnecting the main air line.

6. Follow the appropriate Lockout/Tagout recommendations at your facility during shutdown, maintenance, and restart of the equipment.

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Section 1. General Information

SLCT-FAL5645 Sealing Machine

1.2 MACHINE TRANSPORT & CRATING

Follow these guidelines for uncrating and recrating the machine.

1.2.1 Uncrating the Machine

1. Use the appropriate machine handling equipment to transport the crated machine.

2. Remove the top and sides of the packing crate and all secondary packing material surrounding

the machine (shrink wrap, zip ties, cardboard etc).

3. When applicable, smaller components such as zip-tied pneumatic lines and electrical wiring

may be secured on top of the machine’s conveyor. Remove those components and set them aside for installation.

4. Note that a tool box is shipped with each machine. Locate and remove the tool box along

any associated packing material.

with

5. There are circular forklift icons on each side of the machine. These icons indicate the correct

location for the forklift tines to be placed when moving the machine.

6. Have a qualiﬁ ed operator move the machine off of the shipping pallet to where it will be stationed.

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Section 1. General Information SLCT-FAL5645 Sealing Machine

1.3 TECHNICAL AND CUSTOMER SERVICE SUPPORT

Follow these guidelines to obtain support from Technical Service or to order spare parts from Customer Service.

1.3.1 Technical Service Support

• Order parts by contacting a Sealed Air Representative or Distributor.

• Have the following information available:

• Company name and contact information.

• Equipment model and serial number.

• A detailed description of the technical issues experienced.

1.3.2 Ordering Spare Parts

• Order parts by contacting a Sealed Air Representative or Distributor.

• Have the following information available:

• Company name and contact information including: shipping address, department (when

applicable), phone number, and shipping address.

• The equipment’s model and serial number.

• Part number information obtained from: an assembly drawing (contained in the back of

this manual) - or - the part data from the nameplate of the speciﬁ c part being replaced.

1.3.3 International Customer Service Contacts

International contact information for replacement parts and technical assistance:

• Sealed Air Africa (Pty) Ltd. +27 11 923 4600 Fax: +27 11 392 1025

• Sealed Air Australia Ltd. +1 800 0808 481 Fax: 1 800 250 650

• Sealed Air Packaging (Shanghai) Co. Ltd. +86 21 3920 2988 Fax: +86 21 3920 2999

• Diversey Gulf FZE +971 4 8819470/31 Fax: +971 4 8819488

• Sealed Air Hong Kong Ltd. +852 2178 7876 Fax: +852 2407 3385

• Sealed Air (India) Pte. Ltd. +91 80 4050 7333 Fax: +91 80 4117 1301

• Sealed Air HK Ltd.-Indonesia Rep +62 21 5793 8858 Fax: +62 21 5793 8859

• Sealed Air (Israel) Ltd. +972 2 5337438 Fax: +972 2 5337439

• Sealed Air (Japan) Ltd. +81 3 5644 1110 Fax: +81 3 5644 1160

• Diversey Eastern & Central Africa Ltd. (Kenya) +254 703 040 247 Fax: +254 703 040 888

• Sealed Air (Korea) Ltd. +82 31 763 1716 Fax: +82 31 763 4744

• Sealed Air (Malaysia) Sdn Bhd +60 3 5569 6363 Fax: +60 3 5569 2682

• Diversey Maroc s.a. (Morocco) +212 522 756 506 Fax: +212 522 756 572/73

• Sealed Air New Zealand +64 9 813 9800 Fax: +64 9 813 9801

• Diversey West Africa Limited (Nigeria) +234 1 825 5511 Fax: +234 813 086 5000-6

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Section 1. General Information

SLCT-FAL5645 Sealing Machine

• Sealed Air Philippines, Inc. +63 2 845 9400 Fax: +63 2 2811 6679

• Diversey KSA-Arabian Modern Company (Saudi Arabia) +966 3 847 6986-7 Fax: 966 3 847 6989

• Sealed Air (Singapore) Pte. Ltd. +65 6861 1828 Fax: +65 6861 5221

• Sealed Air (Taiwan) Ltd. +886 3 324 2988 Fax: +886 3 324 3088

• Sealed Air (Thailand) Ltd. +66 2 834 6800 Fax: +66 2 834 6888

• Diversey Kimya Sanayi ve Ticaret A.S. (Turkey) +90 216 578 6400 Fax: +90 216 578 6401

• Sealed Air (Singapore) Pte. Ltd.-Vietnam Rep Ofﬁ ce +84 8 6292 4251 Fax: +84 8 6296 2606

• Czech Republic +420 224 315 863

• France, Osny +33 (0)3 86 92 04 58

• Germany, Alsfeld +49 (0)6631 96680

• Greece, Shimatari Viotias +30 22620 32551

• Hungary, Újhartyán +36 (06)29 573 300

• Italy, Bellusco +39 039 6835 1

• The Netherlands, Nijmegen +31 (0)24 3710111

• Poland, Ozarów Mazowiecki +48 (0)22 7217 530

• South Africa, Spartan +27 (0)11 923 4600

• Spain, Abrera +34 93 773 8325

• Sweden, Aneby +46 (0)380 47100

• UK, Kettering +44 (0)1536 315700

•

1.3.4 Regulatory Compliance

The SeleCTech SLCT-FAL5645 sealing machine meets essential health and safety requirements

and is in conformity with the relevant EC Directives.

.

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Section 2. General Information

SLCT-FAL5645 Sealing Machine

SECTION 2. INSTALLATION

This section details information about installing and adjusting the sealing machine. The machine has already been careully checked and tuned Before leaving the factory. Only

trained operators are allowed to make the adjustments necessary in order to pack products of different dimensions.

2.1 SELECT THE MACHINE INSTALLATION LOCATION ........ 2-3

2.2 ADJUSTING THE HEIGHT OF THE SEALING MACHINE ... 2-3

2.3 LOADING THE SHRINK FILM ...................................................2-4

2.3.1 Film Loading. .....................................................................2-4

2.3.2 Adjusting Film ....................................................................2-4

2.3.3 Front Conveyor Belt Adjustment ....................................2-5

2.3.4.1 Film Sealing ........................................................ 2-6

2.4 SEALING SAFETY SENSOR ........................................................2-7

2.5 REMOVING THE WASTED SIDE FILM .................................... 2-8

2-1

Section 2. General Information

SLCT-FAL5645 Sealing Machine

2.1 SELECT THE MACHINE INSTALLATION LOCATION

The sealing machine should placed well-lit and dry place. It should be positioned away from dusty, ﬂ ammable, explosive and corrosive areas.

Placing the sealing machine too close to the ventilation system may cause unstable ﬁ lm delivery. .

2.2 LEVELING THE SEALING MACHINE

Refer to Figure 2-1 for the following system leveling/height adjustment procedure. The steps apply to all four (4) feet on the base of the system.

1. Use a spanner to loosen the lock nut (1) at the sealing machine base.

2. Use a spanner to

is at the required height, tighten the lock nut

turn the nut on the height adjustment screw (2). When the sealing machine

Figure 2–1 Sealing Machine Leveling/Height Adjustment

(1) up to the base of the machine.

1

2

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Section 2. General Information SLCT-FAL5645 Sealing Machine

2.1 LOADING THE SHRINK FILM

When the ﬁ lm is properly loaded the motorized ﬁ lm unwind assembly provides ﬁ lm as required by the packing process.

2.1.1 Film Loading Micro-switch and Contact Wheel

The micro switch located above the left side of the dancer assembly controls the operation of the ﬁ lm delivery motor. When the actuator wheel on the side of the arm touches the micro-switch, the ﬁ lm delivery motor starts running. When the ﬁ lm pressure relaxes, the arm lowers, the actuator wheel no longer touches the micro-switch, and the motor stops. The actuator should just slightly touch the micro-switch.

Micro switch

Actuator Wheel

Dancer Bar Arm

Figure 2–2 Film Delivery Assembly

2.1.2 Film Feed Roller Height Adjustment

1. Loosen the locking nuts on each end of the ﬁ lm feed roller,

2. Adjust the ﬁ lm roller set up or down as required, based on

the height of sealing area.

2-4

Roller Locks

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Section 2. General Information

SLCT-FAL5645 Sealing Machine

Figure 2–3 Roller Locks

2. The proper height adjustment will be based on actual operating conditions. Irregular, jumping motion of the ﬁ lm delivery may indicate the need to adjust the delivery angle.

2.1.3 Conveyor Belt Adjustment

The conveyor belt tension is set at the factory, but may loosen over time. If the belt becomes loose refer to Figure 2-4 as you use the belt tension adjustment procedure described here:

1. Loosen the Lock Nuts (1) and (2)

2. Turn the adjusting nut (3) clockwise to push the roller forward to increase the belt tension.

3. It is important to make the same adjustment on the other side of the conveyor.

(3) (2)

(1)

Figure 2–4 Belt Tension Adjustment

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Section 2. General Information SLCT-FAL5645 Sealing Machine

2.1.3.1 Film Sealing

Before operating the system, check to ensure that the seal wires and upper jaws are clean. Any residual ﬁ lm caught on or between the wires and the ceramic beads can cause poor seals. The lower beds should also be kept in good condition. Over time the Teﬂ on tapes may show impressions from the wire and some discoloration, this is normal, but burned or blackened tapes should be replaced. This could be an indication of too much pressure or uneven pressure.

Contact between the sealing blade and the sealing base can be checked as follows:

1. Put a white paper between the sealing blade and base.

2. Manually operate the sealing and cutting process once to see if the force of the sealing and cutting action is even on the white paper.

3. If it is uneven, loosen the lock nuts and turn the adjusting screws. (Caution this adjustment must be made with the machine power off and the assembly cooled down.)

4. Tighten the locking nut

Adjustment

Screws

Adjustment Screws

Figure 2–5 Sealing Assembly

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Section 2. General Information

SLCT-FAL5645 Sealing Machine

2.2 SEALING JAW SAFETY

To prevent injury, product crushing or machine damage the jaw is equipped with several safeties that will stop the machine operation if a product or other object is inside the sealing area when the sealing blade lowers.

The operation of the jaw safety circuit should be veriﬁ ed at least once per day. The jaw safety circuit is designed to reopen the jaws immediately whenever the jaws contact an object upon closing. The test requires attempting to make a seal with a rubber test object between the jaws. When functioning properly, the jaw safety circuit will force the machine into an Emergency Stop state upon contact with the test object.

2.2.1 Jaw safety Veriﬁ cation Test

1. Ensure that all guards are in place. All doors and hoods must be closed.

2. Connect the compressed air supply for the machine.

3. Power up the machine.

4. Press the E-STOP button.

5. Test object should be resilient. Preferably a spare piece seal bed material (3/8” thick silicone rubber). Place the test object on the conveyor belt between the seal jaws.

6. Release the E-STOP button by twisting clockwise.

7. Put the machine into a READY state by pressing the READY button (Blue).

8. Perform the test by pressing the manual seal button. The button must be held down until the jaws close completely.

• PASS INDICATION: Jaws close and then immediately reopen; the READY light Flashes.

• FAIL INDICATION: Jaws do not reopen immediately and/or READY light remains on.

9. Repeat Steps 4-8 several times with the rubber object at different points along the entire length

of each seal jaw to ensure the integrity of the Jaw Safety Circuit.

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Section 2. General Information SLCT-FAL5645 Sealing Machine

Adjust Actuator

Figure 2–6 Safety Actuator

If the jaw safety does not work properly: Loosen the top actuator screw and raise or lower it to allow the sensor to detect the packing product quickly. The distance between the two touch screws should not be too long, otherwise, the sealing blade will alarm and stop operation before completing the sealing and cutting action.

2.3 REMOVING THE WASTE FILM (SELVAGE)

The ﬁ lm trimmed from the side during the packing process is called selvage. Selvage is collected on a wheel located in a compartment at the front of the machine. Refer to Figure 2-7 and follow the next procedure to remove the waste ﬁ lm that has accumulated on the selvage winder.

1. Open the door to access the selvage winder.

2. Loosen the wheel lock on the front of the wheel, and remove the guide plate.

3. Remove the waste ﬁ lm,

4. Replace the guide plate and tighten the locking cap.

5. Run out some ﬁ lm and re feed the selvage to the wheel. If the wheel slips during the receiving process, tighten the locking nut a little bit to increase the friction of the selvage receiving reel

Wheel Lock

Selvage Winder

Location

Guide Plate

2-8

Figure 2–7 Selvage Winder

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Section 2. General Information

SLCT-FAL5645 Sealing Machine

2-9

Section 3. Operation

SLCT-FAL5645 Sealing Machine

SECTION 3. OPERATION

This section details information about installing and adjusting the sealing machine. Before machine delivery, the machine has already been precisely checked and tuned. “Do

not” change the setting unless it is necessary. However, trained operators are allowed to make adjustments to some of the necessary settings in order to pack different dimensions of the packing products.

3.1 CONTROL PANEL .........................................................................3-3

3.2 NAMEPLATE ..................................................................................3-4

3.3 INSTALLING THE SHRINK FILM .............................................3-5

3.4 FUNCTIONS ....................................................................................3-10

3.5 OPERATION .................................................................................... 3-12

3-1

3.1 CONTROL PANEL

1234567

Section 3. Operation

SLCT-FAL5645 Sealing Machine

891011121314151617

Figure 3–1 Control Panel

Call

out

1 Main Circuit Breaker Switch turns ON/OFF the power input 2 Resets the machine (Flashes Blue light until pushed) 3 Starts the conveyor 4 Stops the conveyor 5 Cycles the sealing/cutting process once 6 Manually runs the ﬁ lm feed motor until the button is released 7 Emergency stops the machine. Must be released to restart machine. 8 Not Used

9 Sets the temperature of the Front sealing blade 10 Selects Horizontal Sensor mode for rectangular or square products 11 Sets the temperature of the Side sealing blade 12 Sensor mode to control the packing process 13 Sets the conveyor run time for length of ﬁ lm at the back of the product 14 Switches ON/OFF the heater for the sealing blades 15 Sets the sealing/cutting dwell time 16 Sets the conveyor run time for ﬁ lm length at the front of the product 17 Power ON light (Green)

Description

3-3

Section 3. Operation SLCT-FAL5645 Sealing Machine

3.2 NAMEPLATE

Figure 3–2 Nameplate

Call out Description Call out Description

1

2

3

4

5

6

MODEL Number Vn (Rated voltage) FLA (Rated current) S/N (Serial number) Date of Manufacture Short-circuit current (SCCR)

7 8

9 10 11

HZ (frequency) SCHEMATIC LARGEST LOAD (Amps) WEIGHT MAXPSI

3-4

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Section 3. Operation

SLCT-FAL5645 Sealing Machine

3.3 INSTALLING THE SHRINK FILM

The dimensions of the packing product are width (W), the height (H), and the length (L) as shown in Figure 3–33.

Figure 3–3 Packing Product Dimensions

1. Start the conveyor.

2. Check that the belt is tracking at the center of the bed. If not, follow the adjustment procedure on Page 2-5 to adjust the belt.

3. Select the appropriate shrink ﬁ lm: Width of shrink ﬁ lm = W (Product Width) + H (Product Height) + 5” ~ 7” (depends on the height of the packing product).

4. Adjust the infeed conveyor Height (see Figure 3–4): Rotate the conveyor adjusting wheel to adjust the height of the triangular plate. The correct position is about 1/2 H (Product Height) + 5~10mm.

5. Adjust of the infeed conveyor relative to the product guide (Figure 3-4)by placing a product on the belt and then squeezing the handle on the front of conveyor unit. This will enable movement of the conveyor unit to the appropriate width which is W (Product Width) plus one-third of the product height.

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Section 3. Operation SLCT-FAL5645 Sealing Machine

Product Guide

is mounted

to side of the

machine

Inverting Heads above and below infeed conveyor

Figure 3–4 View FAL 5645 from the Infeed end

6. Put the shrink ﬁ lm onto the Film Unwind rollers (see Figure 3–5).

a. Loosen the locking nut of the left side ﬁ lm positioning rod (1) and adjust the ﬁ lm

location. Tighten the locking nut after adjustment

b. Loosen the locking nut of the right side ﬁ lm positioning rod (2) and adjust the rod to

width of the shrink ﬁ lm + 5 mm. Tighten the locking nut after adjustment.

c. The open side of the shrink ﬁ lm must face to the ﬁ lm positioning rod (2).

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Section 3. Operation

SLCT-FAL5645 Sealing Machine

Folded Film Open Side

Film Positioning

Rod 1

Film Positioning Rod 2

Web Separator

Inverting Heads above and below infeed conveyor

7. Switch the Temperature Controllers ON and adjust the temperature of the front and side sealing wires for the type of ﬁ lm being used.

Film Type Required Temperature Film Type Required Temperature

PE Film 220°C~240°C POF Film 200°C~220°C

Figure 3–5 Film Unwind Assembly

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Section 3. Operation SLCT-FAL5645 Sealing Machine

8. Loading the Shrink Film (see Figure 3–6 and Figure 3–7).

Feed Film here

Figure 3–6 Overhead View of Film Puller Assembly

Start Film Feed here

Figure 3–7 Film Assembly

9. After the sealer reaches the set temperature, press the Manual operation button once, the Sealer will move once, and jaws will remain open.

10. Turn on the conveyor, and place a product on the infeed conveyor. The machine should advance ﬁ lm and cycle the sealer once. The wrapped product will exit the machine.

11. Continue to run the ﬁ lm feed, while pulling the selvage end of the ﬁ lm until the selvage can be wound 2~3 times on the receiving reel (Figure process automatically.

3-8

3–8). Now the machine can run the packing

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Selvage Path

Illustration

12. Switch the conveyor ON, put the packing product on the conveyor and make sure that your hands are completely away from the conveyor surface.

Section 3. Operation

SLCT-FAL5645 Sealing Machine

Selvage Reel Cover Lock

Figure 3–8 Selvage Reel

13. Adjust the sealing and cutting process as necessary. (Figure

3–9).

Film Seal Line

Conveyor Direction

Figure 3–9 Sealing and Cutting Adjustment

14. Adjust of the front extra ﬁ lm length (Length A of Figure 3–9), to the best length approximately 1/3 H. The adjustment procedure is as follows:

a. When A is too long, shorten the distance between the sensor and the sealing blade by

increasing the conveyor time setting on switch #16 in Figure 3-1.

b. If A is too short, adjust the conveying time for the extra ﬁ lm length at the front of the

product, increasing the conveying time to increase the extra ﬁ lm length at the front of the box.

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Section 3. Operation SLCT-FAL5645 Sealing Machine

Sealing and Cutting Blade

Sealing and Cutting Base

Packing Product

Optical Sensor

Figure 3–10 Horizontal Sensors

15. The best rear extra ﬁ lm length (B of Figure 3–9), is 1/2 H between the product and the rear seal. Adjust the

conveyor time setting on switch #13 in Figure 3-1 to increase the ﬁ lm length

at the rear of the package.

16. Different shrink ﬁ lms have different sealing time (Typically 0.3~0.6 seconds). The ﬁ lm must be sealed and cut completely and steadily without holes. Poor ﬁ lm cutting may be caused by overheating on the sealing process. Adjusting the sealing dwell time or the sealing temperature should eliminate this issue.

17. When the sealing and cutting line is good, the adjustment process is ﬁ nished.

3.4 FUNCTIONS

• The machine includes a warning system, and a safety function.

• The sealing and cutting process can operate continuously.

• Simple machine operation can match various sizes of packing products.

• PLC and optical sensor control are applied on this machine.

• Two types of optical sensors (Horizontal type and Vertical type): Horizontal type optical sensors (as shown in

Figure 3–10) are applied on packing square or rectangular product.

It includes a wait function. The Vertical optical sensor is mostly used for packing thinner products, but there is no wait function on this sensor.

• According the characteristics of the product, there are two types of the sensor mode selection: Standard type and point-to-point compensation type (as shown on

3-10

Figure 3–11):

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Section 3. Operation

SLCT-FAL5645 Sealing Machine

• When the products are in rectangular or square shape, Standard sensor mode should be

applied.

• If the packing products are an irregular shape or transparent, then the Point-to-point

Compensation sensor mode should be applied and the Conveying Time switch adjusted to control the ﬁ lm length.

Packing Product

Optical Sensor

Packing Product

Optical Sensor

Figure 3–11 Packing Product Sensor Mode

18. The sealing blade of this machine can be used on the POF and PE Shrink Film. When using on the PE Shrink Film, the sealing blade must be covered by heat-resisted adhesive tape to prevent the blade from directly contacting the PE ﬁ lm.

Sealing Blade

Protective Plate

Heat-resisted Adhesive Tape

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Section 3. Operation SLCT-FAL5645 Sealing Machine

3.5 OPERATION

3.5.1 Typical Operation

The machine employs an infeed conveyor and a discharge conveyor mounted at the same elevation to convey product through the machine. The upper seal jaws and lower seal beds both pivot such that they meet at the center line of the package when a seal is being made. The infeed conveyor carries product through the ﬁ lm inverting head where it is surrounded with plastic shrink ﬁ lm supplied by a powered ﬁ lm unwind assembly. When the product reaches the proper position in the sealing area, the conveyors stop and the Sealer cycles, making a seal and cutting ﬁ lm on two edges of the package. After sealing is completed, the seal jaws open and the discharge conveyor carries the product out of the machine while the infeed conveyor simultaneously delivers the next product to the sealing area.

3.5.2 Starting the Machine

1. Switch ON the Main Circuit Breaker to power the machine.

2. Turn ON or attach the air supply.

3. Switch ON the heater controls and allow the sealers to reach operating temperature.

4. Turn ON the conveyor.

5. Put a product onto the conveyor and the machine will pack the product automatically.

6. If abnormal machine operation occurs, then press the Emergency Stop switch to immediately stop the sealing machine.

7. The blue Reset Button will ﬂ ash until abnormal operation has been corrected and the E-Stop has been released by twisting it clockwise.

3.5.3 Shutting Down the Machine

1. Turn off the heater control switches and allow the sealer unit to cool down.

2. Next, switch off the power supply.

3. If it is necessary to shut-down the air supply, be aware that it will cause the sudden downward movement of the sealing/cutting jaws when the air is disconnected.

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Section 4. Maintenance & Troubleshooting

SLCT-FAL5645 Sealing Machine

SECTION 4. MAINTENANCE & TROUBLESHOOTING

This section details information about maintaining and troubleshooting the sealing machine.

4.1 MACHINE MAINTENANCE ........................................................ 4-3

4.2 TROUBLESHOOTING ..................................................................7

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Section 4. Maintenance & Troubleshooting

SLCT-FAL5645 Sealing Machine

4.1 MACHINE MAINTENANCE

Regular maintenance is the best way to ensure smooth operation and optimal machine life. The following are the general machine maintenance guidelines. Only trained machine operators and service technicians are authorized to perform maintenance on this machine.

IMPORTANT

Review and follow the Safety Guidelines in Chapter 1 of this Manual and site-speciﬁ c

Lock Out/Tag Out Procedures when necessary.

• Maintenance of Pneumatic Regulator Unit: When the water level reaches 2/3 of the height of the water ﬁ lter tank, the tank water must be

drained out. To drain water, pull down the ring on the water drain plug.

Water Drain

Figure 4–1 Pneumatic Regulator Unit

• Clean the Workstation before the start operation each day. a. Use only compressed air to clean the work area. b. Only use soft wood to clear the ﬁ lm reside on the sealing blade. Do not use metal or other

abrasive materials.

• Monthly Maintenance of the Selvage Receiving Wheel a. Remove the locking nut, take out the spring and the receiving wheel. b. Lubricate the contact surfaces of the receiving wheel and the center rod for smooth wheel

rotation

c. Replace the spring and receiving wheel and tighten the locking nut.

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Section 4. Maintenance & Troubleshooting SLCT-FAL5645 Sealing Machine

• Chain and wheel maintenance (every 3 months): a. Take off the cover and put the grease oil onto the gap between the chain and the wheel. b. Put the cover back on. c. Bearing and bearing holder maintenance: Service once every 3 months, using the

hydraulic pressure oil to lubricate the bearings and its parts.

• Check Tension and Tracking of the Conveyor Belt. a. After a period of operation, the conveyor belt may loosen. To adjust the belt tension,

loosen the two lock nuts on each tension adjustment screw. Turn the screw clockwise to tighten.

b. If the conveyer belt is not tracking down the middle of the bed, slightly turn the adjusting

screw on the side where the belt is close, in a clockwise direction. Allow the belt to run for a few minutes to see if it moves to the center. It may take several small adjustments

• If the Teﬂ on detaches from the sealing blade and ﬁ lms easily stick onto the blade, re-stall the new T eﬂ on or change the new sealing blade.

• Check the Teﬂ on tape covering the silicon bar. If the tape is damage, replace it.

• Change the heater tube if the heater cannot heat-up the temperature: a. Before replacement, check the watt and voltage of the heater, switch off the power and

wait the heater to cool-down. b. Disconnect the heater wire at the electric and control box. c. Loosen the locking screw of the heater tube and replace the heater tube. d. Make sure that all screws are tightened, then re-connect the heater wire at electric and

control box.

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Section 4. Maintenance & Troubleshooting

SLCT-FAL5645 Sealing Machine

• Change the silicon bar and the heat-resistant adhesive tape: Lower Sealing Frame

Heat-resistant Adhesive Tape

Silicon Bar

Sealing Base

Sealing Blade Base

Figure 4–2 Silicon Bar and the Heat-Resistant Adhesive Tape

a. Switch off the power and allow the sealing bars to cool-down Remove the old heat-

resistant adhesive tape.

b. Replace the silicon bar. Make sure the bar surface is ﬂ at. If necessary, trim away any

excess silicon bar.

c. Apply new heat-resistant tape and make sure the tape surface is ﬂ at.

• Replacement and adjustment of the sealing blades:

a. Remove the sealing blade shields.

Sealing Blade

Protective Shields

b. Remove the faulty sealing blade assembly

Figure 4–3 Sealing Blade Shields

5

Section 4. Maintenance & Troubleshooting SLCT-FAL5645 Sealing Machine

c. Replace the sealing blade and make sure the blade is between two guiding plates.

Figure 4–4 Front Sealing Blade without Shields

Sealing Blade

Figure 4–5 Sealing Blade.

Figure 4–6 Front blade alignment

d. Align the new front sealing blade by using the side sealing blade as a guide. e. Tighten the front blade set after the aligning the blade. f. Install the protective shields.

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Section 4. Maintenance & Troubleshooting

SLCT-FAL5645 Sealing Machine

4.2 TROUBLESHOOTING

Item Problem Possible Causes Recommended Action

Power not connected Connect the power cord

No power to the

1

machine

Main Circuit Breaker is OFF Turn “ON” the CB ON/OFF switch is damaged Change the switch Fuse is broken Change the fuse E-Stop is pressed Release the E-Stop

Power connected but

2

the machine does not work

PLC does not work Check the power

connection to PLC PLC is not functioning Change the PLC Door or Cover interlock open Check covers and doors The heater switch is ”OFF” Switch “ON” the heater Temperature is set too low Adjust the temperature Heater switch is not

Change the heater switch functioning

3 Heater does not work

The temperature controller is not functioning

Change the temperature

controller Relay (SSR) is not functioning Change the SSR The heater tube is not

Change the heater tube functioning

Relay (SSR) is not functioning Change the relay (SSR)

Temperature is out of

4

control

The ﬁ lm conveying

5

motor does not run

The temperature detector is loose out or not functioning

Temperature controller is not functioning

Film conveying switch is not functioning

The ﬁ lm conveying relay is not functioning

The ﬁ lm conveying motor is overloaded or overheated

The ﬁ lm conveying motor is not functioning

Tight back the detector or

change the detector

Change the temperature

controller

Change the ﬁ lm conveying

switch

Change the ﬁ lm conveying

relay

Remove the cause and

restart the system

Change the ﬁ lm conveying

motor

7

Section 4. Maintenance & Troubleshooting SLCT-FAL5645 Sealing Machine

Item Problem Possible Causes Recommended Action

The connecting point [1001] of PLC is not functioning

Change the connecting

point [1001] and the

program of PLC or Change

the PLC

Front conveyor motor

6

does not work

The relay of front conveyor motor is not functioning

The front conveyor motor is overloaded or overheated

The front conveyor motor is not functioning

The connecting point [1002] of PLC is not functioning

Change the relay of front

conveyor motor

Remove the cause and

restart the system

Change the front conveyor

motor

Change the connecting

point [1002] and the

program of PLC or Change

the PLC

Rear conveyor motor

7

does not work

Relay of rear conveyor motor is not functioning

The rear conveyor motor is overloaded or overheated

The rear conveyor motor is not functioning

The connecting point [1003] of PLC is not functioning

Replace the relay of rear

conveyor motor

Remove the cause and

restart the system

Replace the rear conveyor

motor

Change the connecting

point [1003] and the

program of PLC or Change

the PLC

The wasted ﬁ lm

8

receiving motor does not work

The sealing base unit

9

does not work

Relay of the wasted ﬁ lm motor is not functioning

Manual ﬁ lm conveying switch is not functioning

The wasted ﬁ lm motor is over loaded or overheated

The wasted ﬁ lm motor is not functioning

The connecting point [1004] of PLC is not functioning

The manual sealing operation switch is not functioning

Change the relay of the

wasted ﬁ lm motor

Change the manual ﬁ lm

conveying switch

Remove the cause and

restart the system

Change the wasted ﬁ lm

motor

Change the connecting

point [1004] and the

program of PLC or Change

the PLC

Change the manual sealing

operation switch

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Section 4. Maintenance & Troubleshooting

SLCT-FAL5645 Sealing Machine

Item Problem Possible Causes Recommended Action

10

Warning Buzzer of the sealing process is “ON”

The micro-switch of the sealing process is blocked

Product is pressed by the sealing blade

The machine stop when the sealing blade presses down and the buzzer is “ON”

Reposition the micro-

switch

Press the Manual sealing

operation switch to remove

the pressed product

Lower the actuator or

adjust the magnetic spring

switch of the cylinder

forwards to the normal

position Sealing time is short Increase the sealing time by

0.1 second until the proper

sealing time is achieved

11

Incomplete sealing or cutting, or the sealing line is broken

The upper sealing blade and the sealing base do not completely contact each other

Teﬂ on tape is damaged Change the Teﬂ on tape The silicon bar of the sealing

Adjust the sealing blade

position

Replace the silicon bar base is damaged

The protective plates are not

Adjust the protective plates completely contacted

12

The waste ﬁ lm conveying does not stop

Too much ﬁ lm residue is sticking on the sealing wire

optical sensors are out of alignment

Optical sensor is not

Clear the ﬁ lm residue and

lower dwell time

Align the optical sensors

until the sensor light is ON

Change the optical sensor functioning

13 Product pressed by the

side sealing blade

Product does not convey on the guiding side

Put the product correctly

on the guiding side of the

conveyor

14 Product pressed by the

front sealing blade

The Conveying time of extra ﬁ lm at the rear is too short and the product does not

Increase the conveying

time of extra ﬁ lm at the

rear side of the product completely pass through the sealing blade unit

The packing product is transparent or has an irregular

Try to use the point to point

compensation sensor mode shape

4-9

Section 4. Maintenance & Troubleshooting SLCT-FAL5645 Sealing Machine

Item Problem Possible Causes Recommended Action

15 The front conveyor belt

Improper front roller tension Adjust the belt tension

is tracking to either side during operation

16 Film loading is not

smooth or too tight to

Wrong ﬁ lm unwind setup Reload the ﬁ lm unwind,

see Fig. 4.3

load the ﬁ lm

17 Position change of the

upper or lower ﬁ lm layer

The parallel ﬁ lm roller set is not level

Stabilization of the shrink ﬁ lm

Adjust the parallel ﬁ lm

roller set, see Fig. 4.4

Change the ﬁ lm is not good

18 Cannot remove the

wasted ﬁ lm from the wasted ﬁ lm receiving reel or too loose

The spring of the reel is too tight or too loose

If the wasted ﬁ lm is too

tight, release the screw

outside the spring a little

bit or tight the screw a little

bit if the ﬁ lm is too loose.

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Section 4. Maintenance & Troubleshooting

SLCT-FAL5645 Sealing Machine

4-11

Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

SECTION 5. REFERENCE DOCUMENTS

This section details information about circuit diagrams, mechanical parts lists, and a pneumatic chart.

5.1 CIRCUIT DIAGRAMS ...................................................................5-3

5.2 MECHANICAL PARTS LIST ........................................................5-5

5.3 PNEUMATIC CHART ....................................................................5-19

5-1

5.1 CIRCUIT DIAGRAMS

Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

5-3

Section 5. Reference Documents SLCT-FAL5645 Sealing Machine

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5.2 MECHANICAL PARTS LIST

Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

5-5

Section 5. Reference Documents SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

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Section 5. Reference Documents SLCT-FAL5645 Sealing Machine

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5.3 PNEUMATIC DIAGRAM

Section 5. Reference Documents

SLCT-FAL5645 Sealing Machine

5-19

Sealed Air SeleCTech,SLCT-FAL5645 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual