Kalamazoo OPERATORS MANUAL. MODEL# 4FAC42-TP-PUCC FULLY-AUTOMATIC CONVEYORIZED STRETCH WRAPPER with TOP PLATEN and POPUP 3-CHAIN CONVEYOR

Transcription

1 Kalamazoo MODEL# 4FAC42-TP-PUCC FULLY-AUTOMATIC CONVEYORIZED STRETCH WRAPPER with TOP PLATEN and POPUP 3-CHAIN CONVEYOR OPERATORS MANUAL 07/27/09 Kiet 1

2 Table of Contents Warranty 3 Installation 4 Electrical Connection 4 Air Connection 4 Wrapping Operation 4 External Controls 4 Internal Controls 5 Remote Console Controls 5 Film Loading Powered Prestretch 5 Programming the AC Drives (Telemecanique) 6 Stretch Wrap System Adjustments 7 Maintenance 7 Lubrication 8 Chain Tension 8 Trouble Shooting 9 Technical and Customer Service 9 System Layout Remote Control Console 12 Photo-eye and Reflector Stands 13 Top Platen Load stabilizer w/ Film Holder Powered Prestretch Spiral and Top Platen Tower Main control panel Sub Panel Air System Popup Conveyor Turntable Disc and Roller Conveyor Turntable Base Output Storage Conveyor 48 Wiring Diagram

3 Introduction Congratulations! Your purchase of a Kalamazoo Model 4FAC42-TP-PUCC Fully-Automatic Spiral Stretch Wrapping System will provide you with years of efficient stretch wrapping service. Your investment will ensure that your products will arrive cleaner, with less damage and pilferage at their destination at a lower cost to you. Warranty Kalamazoo, Inc. (KPS) agrees to furnish the purchaser, without charge, F.O.B. the factory, any part found to be defective in either material or workmanship within one (1) year from date of shipment, provided the purchaser gives immediate notice of any defect and description of that defect to KPS. KPS reserves the right to inspect any defective part to verify the defect and to determine probable cause of same. The liability of KPS under this warranty is limited to furnishing replacements for defective parts, and unless otherwise agreed to in writing, the purchaser shall bear the expense of installation. Failure of equipment or parts due to abuse, misuse, neglect, incorrect operating techniques or power line drops or surges shall not constitute failure because of defective material or workmanship, and are expressly excluded from this warranty. The above is the only warranty with no other guarantees which extend beyond the above and the seller disclaims any implications including but not limited to a warranty of merchantability. 3

4 Installation The machine will need to be placed on the floor per drawing 4FAC42-TP-PUCC-LO (next page). The Storage conveyor and sensors will need to be wired into the junction box on the turntable base or the main cabinet. A power line 460/3/60Hz. 30 amp. Will need to be supply to the machine and an 80 P.S.I. Air line. Once the machine is up and running it will need to be aliened, leaved, plumped and bolted to the floor. Electrical Connection 460/3/60Hz. 30 amp. connect power lines to the disconnect switch per wiring drawing. (This system is supplied with solid state AC drives, PLC, and sensors. A clean power source must be supplied to the system without voltage spikes or drops.) Air Connection 80 P.S.I. (Air must be clean and dry) Wrapping Operation 1 Turn the disconnect to on. 2 Push the green Power On button. The button will light up. 3 Push the Cycle Start button. The green stack light will come on. (signifies system is available) 4 Convey the product to the Turntable conveyor, (note: attach the input conveyor sensor six inches in front of the input conveyor) as soon as the product gets in front of the sensor and if the system is ready the Turntable conveyors will come on and transport the product onto the Turntable. The stack light will change from green to yellow (signifies system in use) 5 The automatic wrap cycle will start. The turntable disc will ramp up to full speed and the stretch film will be applied to the top of the product. The turntable will decal to the home position and stop. The film arm will move the film in front of the film holder and the film holder will grab the film. The film arm hot wire will come on and cut the film and wipe it. 6 The Top Platen and Film carriage will return to the home position. ( top of carriage) 7 After the product is wrapped and the Storage conveyor is ready the Turntable Popup conveyor will raise the product and convey the product off of the Turntable and on to the Storage conveyor. The stack lights will change from yellow to green. (signifies system is available) 8 End of wrap cycle. 9 The product is now ready to unload. 10 If the Storage conveyor is not unloaded after three loads and the next product is wrapped and waiting to be unload from the Turntable conveyor the stack lights will change from yellow to red. (signifies system is full) 11 If the film runs out or breaks the Turntable conveyor and Film Head will automatically return to the home position and the red stack light will start flashing. Push the E-stop button. Reload the film. Push the Power On button. Place the film holder button to up, lay the film over the film holder and return film holder button to auto. Push the Cycle Start button. 4

5 External Controls (located on control cabinet) 1 EMERGENCY STOP: Red (push off/ turn to reset); Stops the wrap program and removes power from all motors. 2 ALEEN-BRADLEY: Touch screen: 3 POWER ON: Green lighted push button; Turns on the machine power and lights up the Power On button. 4 POWER OFF: Red push button; Turns off the machine power. Internal Controls (located inside of the control cabinet) 1 Top Platen AC Drive: Do not adjust. The Platen and Film carriage must travel at the same speed so the stretch film does not pull out of the Film holder. 2 Spiral AC Drive: Do not adjust. The Film and Platen carriage must travel at the same speed so the stretch film does not pull out of the Film holder. 3 Turntable AC Drive: Changes the speed of the Turntable. 4 Roller and Popup Conveyor: AC Drive: Changes the speed of the Roller and Popup Conveyors. 5 Output Conveyor AC Drive: Changes the speed of the Output Storage conveyor. 6 Prestretch AC Drive: Changes the force to load of the Stretch film. To Program the AC Drive parameters. (see page 6 ) Remote Console Controls (located on each side of the system) 1 BYPASS: Push the blue BYPASS button if the load is not to be wrapped. 2 EMERGENCY STOP: Red (push off/ turn to reset); turns off all motors. Film Loading Powered Prestretch Your wrapper is equipped with a Kalamazoo Powered Prestretch Film Delivery System, place a roll of stretch film 20 or 10 with spacer on the film core holder and open the film door. Thread the film clockwise around the two black rubber covered tension rollers and counter-clockwise around the Dancer Bar Roller. Close the film door. Once the film is loaded and the desired film tension is arrived at, the film tension need not be adjusted again until the brand of film or the film thickness is changed. Powered Prestretch 5

6 Allen-Bradley MicroFlex 4 AC DRIVE PROGRAMMING Top Platen (1hp) P HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P ACCEL TIME A DECEL TIME A092 4 AUTO RSTRT TRIES Spiral (1hp) P HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P ACCEL TIME A DECEL TIME A ACCEL 1 TIME A DECEL 1 TIME A LOW SPEED A092 4 AUTO RSTRT TRIES Turntable (2hp) P HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P ACCEL TIME A DECEL TIME A ACCEL 1 TIME A DECEL 1 TIME A LOW SPEED A092 4 AUTO RSTRT TRIES Table Roller and Popup Conveyor (1hp) P OVERLOAD CURRENT P HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P ACCEL TIME A DECEL TIME A AUTO RSTRT TRIES Output Conveyor (2hp) P HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P ACCEL TIME A DECEL TIME A AUTO RSTRT TRIES Prestretch (1hp) P HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P ACCEL TIME A DECEL TIME A AUTO RSTRT TRIES 6

7 Stretch Wrap System Adjustments Top of product over wrap: Change the top over wrap by increasing or decreasing the photo-eye timer. Film top and bottom limit switches: Loosen the wing nuts on the mounting base and slide the limit switches up or down in the unistrut. NOTE; The system will automatically senses product wrap height with the Top Platen limit switch, so no adjustment of film carriage top limit switch is usually required. Platen top and bottom limit switches: No adjustments required. Warning!! MAKE SURE THAT THE POWER SUPPLY IS DISCONNECTED BEFORE ATTEMPTING TO SERVICE ANY COMPONENTS. IF THE POWER DISCONNECT IS OUT OF SIGHT, LOCK IT IN THE OPEN POSITION AND TAG IT TO PREVENT UNEXPECTED APPLICATION OF POWER. Maintenance 1) Check and tighten any loose fasteners. 2) Check all electrical connections and replace any worn or frayed cords. 3) Clean the towers where the rollers run every three months, more frequently if the unit is in an especially dirty location. 4) Lubricate and adjust the tower drive and driven chains every three (3) months. Chain should be lubricated with a penetrating type commercial chain lube. 5) Lubricate pillow blocks with #2 grease every six months. 6) Check all control relays for burning or arcing replace if necessary. 7) Check all push buttons and limit switch for shorts or sticking. 8) Check incoming power 480/3/60Hz. 30 amp. 9) Check air supply. 80 P.S.I. The system will not run without air. Cleaning : Periodically clean dirt accumulations from machine, especially around moving parts and drive components, preferably by vacuuming. 7

8 Lubrication Bearings The bearings have been greased at the factory and are ready to run. It is recommended that all mounted bearings and support wheels be relubricated with #2 grease every six months. ( Do Not Over Grease ) Chains Clean, lubricate and adjust chains every 3 month. Chain should be lubricated with a penetrating type commercial chain lube. ( Do Not Over Tight Chains ) Gear Reducers For new reducers, change the oil 120 hours after the reducer starts operating (based on 8 hours per day of operation). After the first oil change, change oil every 2000 operating hours, or once a year. whichever occurs first. ( Do Not Over Fill Reducers ) Temperature Lubricant F AGMA # F AGMA #7 Certain conditions (dust, water, etc.) may require a change of lubricating periods as dictated by experience. Chain Tension Film Lift Chain Tension - Loosen chain adjuster axle located at the top of the tower, move the chain adjusters on both sides equally until chain is tight, retighten the axle nut. (DO NOT OVER TIGHTEN). Film Lift Motor Chain Tension - Remove back lower cover of machine. Loosen four mounting bolts, tighten chain tensioning screw and retighten mounting bolts. (DO NOT OVER TIGHTEN). Platen Lift Chain Tension - Loosen chain adjuster axle located at the top of the tower, move the chain adjusters on both sides equally until chain is tight, retighten the axle nut. (DO NOT OVER TIGHTEN). Platen Motor Chain Tension - Remove back lower cover of machine. Loosen four mounting bolts, tighten chain tensioning screwand retighten mounting bolts. (DO NOT OVER TIGHTEN). Turntable Roller Conveyor Drive Chain - Loosen turntable roller conveyor gearmotor bolts. Tighten chain with tensioning screw provided, retighten turntable roller conveyor gearmotor bolts. (DO NOT OVER TIGHTEN). Popup Conveyor - Loosen chain adjuster axle located at the front end of the conveyor, move the chain adjusters on both sides equally until chain is tight, retighten the axle nut. (DO NOT OVER TIGHTEN). Prestretch - Remove cover Loosen the prestretch motor mount bolts. Adjuster chain by rotating motor by hand and retighten the bolts. (DO NOT OVER TIGHTEN). 8

9 Troubleshooting When any problem develops, review the operating instructions. Diagnose specific problems and review the options below. Push the E-STOP button in wait 1 min.to make sire all of the AC drive have reset. Turn the button to reset. Check wall receptacle for power. Check air supply. Check all cords for cut. (Fork Lift Trucks damage cords.) Check to make sure the Disconnect and the E-stop button are on. DISCONNECT POWER FROM MACHINE Check all limit switch and sensors for damage, sticking, or internal shorts. Visually inspect for loose wires and for signs of arcing or burning of any of the components. Check chain tension. Check for damage cords. Check the AC drive for errors. It is advisable to call for technical assistance at this point. Technical and Customer Service is available from Kalamazoo, Inc., Monday thru Friday 7:30 A.M. to 4:00 P.M. (EST). Stock is maintained on parts to allow us to ship the same day on most orders. If you have a problem, we want to know about it! Please call and report any difficulties you may encounter. Local - (616) National - (800)

10 10

11 SYSTEM LAYOUT: 4FAC42-TP-PUCC ITEM PART/DWG.# DESCRIPTION PAGE# 1 2B-CONSOLE INPUT 1 CONSOLE (BYPASS & E-STOP) 2 PHOTO-EYE w/ GUARD PART PRESENT 1 SENSOR 13 3 PHOTO-EYE w/ GUARD INPUT 1 SENSOR FAC42-CONTROL PANNEL ALLEN-BRADLEY and PUSH BOTTONS 4 M-4FAC42-AIR AIR SYSTEM PHOTO-EYE w/ GUARD INPUT 2 SENSOR 13 6 PHOTO-EYE w/ GUARD PART PRESENT 2 SENSOR B-CONSOLE INPUT 2 CONSOLE (BYPASS & E-STOP) 8 SENSOR OUTPUT CONVEYOR FRONT SENSOR 9 SENSOR OUTPUT CONVEYOR BACK SENSOR 10 4FAC42-PLATEN TOP PLATEN w/ FILMHOLDER FAC42-PRESTRETCH 20 PRESTRETCH w/ FILMARM FAC42-TOWER STRETCH WRAPPER TOWER FAC42-SUB SUB PANEL FAC42-POPUP POPUP 3-CHAIN CONVEYOR FAC42-DISC DISC and ROLLER CONVEYOR FAC42-BASE TURNTABLE BASE MS CHAIN OUTPUT STORAGE CONVEYOR

12 Kalamazoo Parts Manual : 2B-CONSOLE ITEM PART # DESCRIPTION QTY 1 2B-CONSOLE TWO BUTTON CONSOLE 1 2 D-4FCA42-SC DECAL TWO BUTTON CONSOLE (BYPASS/E-STOP) BLACK PUSH BUTTON (BYPASS) N.O. CONTACT BLOCK E-STOP BUTTON PUSH OFF/TURN TO RESET N.C. CONTACT BLOCK 1 12

13 Kalamazoo Parts Manual : PHOTO-EYE, REFLECTOR, and GUARDS ITEM PART # DESCRIPTION QTY 1 Q45-GUARD Q45 PHOTO-EYE GUARD BANNER Q45 PHOTO-EYE MOUNTING BRACKET 1 4 PE-SUPPORT A-3300 UNISTRUT x PE-SUPPORT PHOTO-EYE and REFLECTOR UPRIGHT BANNER 2 ROUND REFLECTOR 1 7 PE-TARGET BANNER 2 ROUND REFLECTOR MOUNT 1 13

14 Kalamazoo Parts Manual : 4FAC42-PLATEN ITEM PART # DESCRIPTION QTY 1 4FAC42-TP-05 PLUNGER LOCK COLLAR 1 2 4FAC42-TP-04 SHAFT LOCK COLLAR /2 2-BOLT FLANGE BEARING 2 14

15 Kalamazoo Parts Manual : 4FAC42-PLATEN ITEM PART # DESCRIPTION QTY 4 4FAC42-TP-1.5AU 1-1/2 I.D. 2-PORT AIR UNION 1 5 4FAC42-TP-02 PLATEN PLATE x 40 x 40 FOAM 1 7 4FAC42-TP-05 PLUNGER 1 8 4FAC42-TP-03 LOCK PIN MOUNT 1 9 4FAC42-TP-06 LOCK PIN LOCK CYLINDER BRACKET LOCK CYLINDER /3 SJ CORD H.D. LIMIT SWITCH H.D. LIMIT SWITCH ADJUSTABLE ARM CORD GRIP /4 EXC. CAM ROLLER /4 CAM ROLLER CORD GRIP COILED CORD TUBE COILED AIR LINE /2 CORD GRIP FAC42-PS-12 CARRIAGE SIDE LOAD MOUNT CAM ROLLER FAC42-FH-04R FILMHOLDER BAR RIGHT FAC42-FH-05 FILMHOLDER ADJUSTABLE BAR MOUNT /8x 1-3/8 PER. FLANGE BEARING FAC42-FH-07 FILMHOLDER SHAFT /8 SHAFT COLLAR FAC42-FH-06 FILMHOLDER LEVER ARM FAC42-FH-04L FILMHOLDER BAR LEFT FAC42-FH-03 FILMHOLDER BASE PLATE CYLINDER ROD CLEVIS FILM HOLDER CYLINDER PIVOT BRACKET SET 1 15

16 Kalamazoo Parts Manual : 4FAC42-PRESTRETCH-TOP ITEM PART # DESCRIPTION QTY M-HPS-C TOP COVER M PERSTRETCH FILM LOADING DECAL 1 3 L21 10/32 x 3/4 TRUSS HEAD D-HANDLE FILM DOOR LATCH 1 5 L7 8/32 x 3/4 NACHINE SCREW w/ LOCK NUTS 4 16

17 Kalamazoo Parts Manual : 4FAC42-PRESTRETCH-TOP ITEM PART # DESCRIPTION QTY WARNING DECAL for PRESTRETCH E-STOP BUTTON NC CONTACT BLOCK #35 CHAIN x L2 3 /16 x 3/16 x 3/4 KEYWAY Q45 BANNER PHOTO-EYE BANNER PHOTO-EYE 4-PIN 6 CABLE BANNER PHOTO-EYE TIMMING MODULE BANNER PHOTO-EYE MOUNTING BRACKET B36 x 5/8 FINISH BORE SPROCKET CORD GRIP B36 x 3/4 FINISH BORE SPROCKET #99 SPRING MICRO SWITCH DANCER BAR MICRO SWITCH COLLAR 1 19 L78 3/8-16 NYLOCK NUT 2 20 L66 3/8 LOCK WASHER 2 21 L64 3/8 USS WASHER 2 22 L80 3/8-16 X 1 H.H.C.S 3 23 L66 3/8 LOCK WASHER 3 24 L64 3/8 USS WASHER B10 x 5/8 SPROCKET (250% Pre-Stretch) B11 x 5/8 SPROCKET (220% Pre-Stretch) B13 x 5/8 SPROCKET (170% Pre-Stretch) B15 x 5/8 SPROCKET (135% Pre-Stretch) B17 x 5/8 SPROCKET (105% Pre-Stretch) 1 26 L38 1/4-20x 1 H.H.C.S L31 1/4 LOCK WASHER 4 28 L32 1/4 USS WASHER /8x 1-3/8 PER. FLANGE BEARING /4 HP INLINE GEAR MOTOR 1 17

18 18

19 Kalamazoo Parts Manual : 4FAC42-PRESTRETCH-BASE ITEM PART # DESCRIPTION QTY /8 x 1 3/8 FLANGE BEARING M-HPS-DB DANCER BAR ROLLER x 20 3/ M-HPS-DB DANCER BAR ROLLER SHAFT x 20 5/ M-HPS-IR IDLER ROLLER M-HPS-IRS IDLER ROLLER SHAFT 1 6 L81 3/8-16 x 1 FLAT HEAD M-HPS-DB DANCER BAR 1 8 L145 5/8 SPRING WASHER THRUST WASHER O.D. x 15 FILM CORE M-HPS-IRS IDLER ROLLER SHAFT 1 12 L55 5/16-18 x 1 FLAT HEAD 2 13 L66 3/8 SAE WASHER 2 14 L80 3/8-16 x 1 H.H.C.S FAC42-PS-01 4FAC42-TP-PUCC 20 PRESTRETCH BASE DOOR HINGE PIN 1 17 L80 3/8-16 x 1 H.H.C.S L64 3/8 LOCK WASHER 2 19 L66 3/8 SAE WASHER FAC42-PS-11 4FAC42-TP-PUCC COILED CORD HOLDER MOUNT 1 21 L66 3/8 SAE WASHER 2 22 L77 3/8-16 NUT CORD GRIP /2 COILED CORD /15 COILED CORD TUBE COILED AIR LINE /2 CORD GRIP /4 EXC. CAM ROLLER /4 CAM ROLLER 4 30 L65 3/8 USS WASHER L60 3/8-24 NYLOCK JAM NUT 8 19

20 Kalamazoo Parts Manual : 4FAC42-PRESTRETCH-BASE ITEM PART # DESCRIPTION QTY 32 4FAC42-PS-12 CARRIAGE SIDE LOAD MOUNT CAM ROLLER FILMARM CYLINDER MOUNT PIN 1 35 L33 1/4 SAE WASHER 4 36 L31 1/4 LOCK WASHER 4 37 L38 1/4-20 x 1 H.H.C.S FILMARM CYLINDER MOUNT 1 39 L66 3/8 SAE WASHER 2 40 L64 3/8 LOCK WASHER 2 41 L80 3/8-16 x 1 H.H.C.S /8 x 5/8 PRECISION FLANGE BEARING 4 43 L145 5/8 SPRING WASHER O.D. BRAKE ROLLER M-HPS-FD1 FILM DOOR ROLLER M-HPS-FD1 FILM DOOR ROLLER SHAFT M-HPS-FD FILM DOOR 1 48 L52 5/16-18x 1 BUTTON HEAD 4 20

21 21

22 Kalamazoo Parts Manual : 4FAC42-FILMARM ITEM PART # DESCRIPTION QTY /8 x 1 3/8 Flange Bearing FILMARM CYLINDER ROD EYE 1 3 FILMARM-S20 FILMARM ROLLER 2 4 FILMARM-S20 FILMARM ROLLER SHAFT /4 O.D. x 3/4 I.D. FLANGE BRG FAC42-FA-02 FILMARM WELDMENT FILMARM CYLINDER PIN 1 8 U101 L A 1/8 PIPE TEE ELBOW U56R00 OIL LEVEL TUBE 2 11 FILMARM-HC FILMARM HEAD COVER 2 12 L x 3/4 THP /16-18 x 2 BRASS THREADED ROD 2 14 L46 5/16-18 NUTS /16 INSOLADED BUSHING 4 16 L80 3/8-16 x 1 H.H.C.S L64 3/8 LOCK WASHER 4 18 L66 3/8 SAE WASHER ga. HOT WIRE x HOT WIRE SPRING # /2 CORD GRIP /8 SHAFT COLLAR LONG 1/8 PIPE NIPPLE FILMARM AIR/OIL TANK 2 22

23 23

24 Kalamazoo Parts Manual : 4FAC42-TOWER ITEM PART # DESCRIPTION QTY TOP SHAFT 5/8-11 x 4-1/2 H.H.C.S. 2 2 L144 5/8 SAE WASHER TOWER CHAIN ADJUSTER (LEFT) TOWER TOP SPROCKET SHORT SPACER /8 x 1-3/8 PRE. FLANGE BEARING B22 TOWER TOP ADJUSTABLE SPROCKET (KPS) TOWER TOP SPROCKET LONG SPACER 2 8 L141 5/8-11 NUT 2 9 L142 5/8 LOCK WASHER TOWER CHAIN ADJUSTER (RIGHT) 2 11 L51-8 5/16-18 x 1 gr.8 H.H.C.S L46-8 5/16-18 NUT gr L6 6/32 x 1-3/4 MACHINE SCREW H.D. LIMIT SWITCH ADJUSTABLE ARM H.D. LIMIT SWITCH 4 16 L30 1/4-20 WING NUT H.D. LIMIT SWITCH BRACKET SET CORD GRIP 1/2 NPT /3 SJ CORD PLATEN TOP LIMIT SWITCH /3 SJ CORD SPIRAL TOP LIMIT SWITCH /3 SJ CORD SPIRAL BOTTOM LIMIT SWITCH /3 SJ CORD PLATEN BOTTOM LIMIT SWITCH 1 23 L157 3/4-10 NUT 4 24 L158 3/4 LOCK WASHER 4 25 L160 3/4 SAE WASHER /4 2-BOLT FLANGE BEARING 4 27 L71 3/8-24x 1-1/4 H.H.C.S L64 3/8 LOCK WASHER 8 29 L65 3/8 USS WASHER 8 24

25 Kalamazoo Parts Manual : 4FAC42-TOWER ITEM PART # DESCRIPTION QTY B22x 3/4 SPROCKET (SPIRAL & PLATEN) BOTTOM SHAFT 2 32 L2 3/16 x 3/16 x 3/4 KEYWAY B12x 3/4 SPROCKET (SPIRAL DRIVEN) B22x 3/4 SPROCKET (PLATEN DRIVEN) FAC42-TOWER 4FAC42-TP-PUCC TOWER WELDMENT 1 36 SEE PAGE 26 4FAC42-TP-PUCC CONTROL PANNEL 1 36 SEE PAGE FAC42-TP-PUCC VALVE BANK BASE CABINET COVER 1 38 L24 10/24 TRUSS HEAD x 3/ CORD GRIP /4 STO YELLOW CORD (SPIRAL) HP. 480/3/60Hz. 56C MOTOR (FILM & PLATEN LIFT) 2 42 L2 3/16 x 3/16 x 3/4 KEYWAY :1 R/A REDUCER 56C (FILM LIFT) 1 44 L64 3/8 LOCK WASHER 8 45 L80 3/8-16x 1 H.H.C.S L48 5/16 USS WASHER 8 47 L47 5/16 LOCK WASHER 8 48 L50 5/16-18x 3/4 H.H.C.S FAC42-TOWER-03 LIFT MOTOR MOUNT #50 CHAIN x 28-1/2 (FILM LIFT) B10x 5/8 SPROCKET (SPIRAL DRIVE) 1 52 L2 3/16 x 3/16 x 3/4 KEYWAY :1 R/A REDUCER 56C (PLATEN LIFT) #50 CHAIN x 31-7/8 (PLATEN LIFT) B10x 5/8 SPROCKET (PLATEN DRIVE) TOWER CHAIN GUARD 1 57 L40 1/4-20 x 3/4 MACHINE SCREW 8 57 L33 1/4 SAE WASHER 8 57 L31 1/4 LOCK WASHER STACK LIGHT KIT (RED-YELLOW-GREEN) 1 25

26 4FAC42 TP PUCC EMERGENCY STOP POWER ON POWER OFF Kalamazoo (800) Kalamazoo Parts Manual : 4FAC42-CONTROL PANEL ITEM PART # DESCRIPTION QTY 1 D-4FAC42-CC 4FAC420TP-PUCC CONTROL CABINET DECAL PUSH/PULL RED MUSHROOM (E-STOP) N.C. CONTACT BLOCK TOUCHSCREEN GREEN LIGHTED PUSH BUTTON (POWER ON) N.0.CONTACT BLOCK vDC GREEN LIGHT MODULE RED MUSHROOM PUSH BUTTON (CYCLE STOP) N.O.CONTACT BLOCK 1 26

27 ITEM DESCRIPTION 1 MAIN SCRN 2 NO FAULTS 3 MENU SCRN 4 AUTO MODE 5 MANUAL MODE 6 AUTO CYCLE START 7 CYCLE PAUSE 8 AUTO END OF CYCLE 9 INPUT 1 REWRAP FUNTION Returns the touch screen to the main screen. If a fault happens a massage will appears. Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) Putts the system in the automatic mode. Manual button will not work. Putts the system in manual mode. Push to start the automatic cycle. Push to pause the cycle. Returns system to home. Spiral and Platen up. Popup conveyor down. Turntable to home and locked. Push to rewrap the product of input 1 side. (Right hand side) 10 INPUT 2 REWRAP Push to rewrap the product of input 2 side. (Left hand side) 11 MACHINE HOME Reset the system to the home position. 12 NO FAULTS If button is blue, read fault in box 2. Fix fault and push the blue no fault button 27

28 ITEM DESCRIPTION FUNTION 1 GOTO CONFIG Used to set-up the touch screen. 2 MAIN SCRN Returns to the main screen. 3 FILM/HEAD MANUAL 4 ROLLER/TABLE MANUAL Used to run the film carriage in the manual mode. Used to run the turntable. (Roller table, Disc, Popup conveyor) 5 LOAD FILM Film loading button. 6 PROGRAM SET-UP 7 LAMP TEST Test the stack light Changes wrap program. (Top wraps, Center wraps, Bottom wraps, 10 or 20 film) 28

29 ITEM DESCRIPTION FUNTION 1 MAIN SCRN Returns the touch screen to the main screen. 2 MENU SCRN Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) 3 PLATEN/SPIRAL DISABLE Used to move the Platen and Spiral carriages separately. 4 PLATEN UP Manually raises the Platen carriage. 5 PLATEN DOWN Manually lowers the Platen carriage. 6 SPIRAL UP Manually raises the Spiral carriage. 7 SPIRAL DOWN Manually lowers the Spiral carriage. 8 PLATEN PIN EXT. Extents the Platen lock pin. 9 PLATEN PIN RET. Returns the Platen lock pin. 10 FILM ARM RET Returns the film arm to home. 11 FILM ARM EXT Extents the film arm. 12 HOT WIRE ON Manually turn the hot wire on. 13 FILM HOLDER CLOSED Manually closes the film holder. 14 FILM HOLDER OPEN Manually opens the film holder. 29

30 ITEM DESCRIPTION FUNTION 1 MAIN SCRN Returns the touch screen to the main screen. 2 MENU SCRN Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) 3 ROLLER CONV FWD Roller conveyor manual forward. 4 ROLLER CONV REV Roller conveyor manual reverse. 5 POPUP CONV FWD Popup conveyor manual forward. 6 POPUP CONV REV Popup conveyor manual reverse. 7 POPUP CONV RAISE Popup conveyor manual raise. 8 POPUP CONV LOWER Popup conveyor manual lower. 9 OUTPUT CONV FWD Output conveyor manual forward. 10 OUTPUT CONV REV Output conveyor manual reverse. 11 TABLE FWD Turntable manually forward. 12 TABLE PIN UP Turntable lock pin extent. 13 TABLE PIN DOWN Turntable lock pin retract. 30

31 ITEM DESCRIPTION FUNTION 1 MAIN SCRN Returns the touch screen to the main screen. 2 MENU SCRN Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) 3 AUTO MODE Return system to automatic mode. Manual buttons will not work. 4 MANUAL MODE Return system to manual mode. The automatic cycle will not work. 5 LOAD FILM Push to load film. Spiral and Platen carriage will lower and the film holder will open. 6 LOAD FILM COMPLETE After loading film. Pull film out to the film holder and push the button. The film holder will close to hold the film. The spiral and platen carriage will return to the home position. (up) 31

32 ITEM DESCRIPTION FUNTION 1 MAIN SCRN Returns the touch screen to the main screen. 2 MENU SCRN Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) 3 INPUT 1 TOP PROG 4 INPUT 1 10 ROLL PROG 5 INPUT 1 TOP/CTR PROG 6 INPUT 1 20 ROLL PROG Top band only input 1 side. Push if using 10 film. Input 1 side. Top and center bands only. Input 1 side. Push if using 20 film. Input 1 side. 7 TOP WRAP Top wrap counter. 3 wrap minimum. 8 CTR WRAP Center wrap counter. 3 wrap minimum. 9 BOT WRAP Bottom wrap counter. 3 wrap minimum. 32

33 ITEM DESCRIPTION FUNTION 10 BOT WRAP Bottom wrap counter. 3 wrap minimum. 11 CTR WRAP Center wrap counter. 3 wrap minimum. 12 TOP WRAP Top wrap counter. 3 wrap minimum. 13 INPUT 2 10 ROLL PROG 14 INPUT 2 TOP/CTR PROG 15 INPUT 2 20 ROLL PROG 16 INPUT 2 TOP/CTR PROG Push if using 10 film. Input 2 side. Top and center bands only. Input 2 side. Push if using 20 film. Input 2 side. Top and center bands only. Input 2 side. 33

34 34

35 Kalamazoo Parts Manual : 4FAC42-SUB PANEL ITEM PART # DESCRIPTION QTY FNQ FUSE (PRIMARY) POLE FUSE HOLDER FNQ FUSE (SECONDARY) POLE FUSE HOLDER FNM FUSE (PLC) POLE FUSE HOLDER ALLEN-BRADLEY MICROLOGIX INPUT EXPANSION 24vDC OUTPUT RELAY OUTPUT RELAY VOLT AC OUTLET PAYEN HOTWIRE CONTROL (CR-1) 2PDT RELAY (CR-1) 8-PIN BASE (POR) 4PDT RELAY (POR) 14-BASE (MPR) 40-AMP. RELAY FNQ FUSE (PLATEN) POLE FUSE HOLDER ALLEN-BRADLEY 1 HP. AC DRIVE (PLATEN) FNQ FUSE (SPIRAL) POLE FUSE HOLDER ALLEN-BRADLEY 1 HP. AC DRIVE (SPIRAL) DISCONNECT SWITCH FUSED ROD EXTENSION HANDLE mm EXTENSION SHAFT AMP FUSE CLASS J FNQ FUSE (TURNTABLE) POLE FUSE HOLDER ALLEN-BRADLEY 2 HP. AC DRIVE (TURNTABLE) 1 35

36 Kalamazoo Parts Manual : 4FAC42-SUB PANEL ITEM PART # DESCRIPTION QTY FNQ FUSE (ROLLER & POPUP CONV.) POLE FUSE HOLDER ALLEN-BRADLEY 1 HP. AC DRIVE (R & P CONV.) FNQ FUSE (TURNTABLE) POLE FUSE HOLDER ALLEN-BRADLEY 2 HP. AC DRIVE (TURNTABLE) FNQ FUSE (PRESTRETCH) POLE FUSE HOLDER ALLEN-BRADLEY 2 HP. AC DRIVE (PRESTRETCH) va TRANSFORMER TERMINAL STRIP 8 36

37 1 2 Kalamazoo Parts Manual : 4FAC42-AIR SYSTEM ITEM PART # DESCRIPTION QTY 1 Q MAC 82 SERIES VALVE BANK ASSEMBLY LOCK OUT UNIT JOINER KIT FILTER REGULATER UNIT 1 37

38 38

39 39

40 Kalamazoo Parts Manual : 4FAC42-POPUP CONVEYOR ITEM PART # DESCRIPTION QTY #50 ROLLER CHAIN x #50 ROLLER CHAIN x 1 3 L141 5/8-11 JAM NUT TOWER CHAIN ADJUSTER (RIGHT) 3 5 4FCA42-PU-17 #50 IDLER SPROCKET SPACER #50 IDLER SPROCKET TOWER CHAIN ADJUSTER (LEFT) /8-11 x 4-1/2 H.H.C.S A112 EXTERNAL RETAINING RING FCA42-PU-18 CENTER CHAIN CONVEYOR IDLER SPROCKET PIN 2 11 L200 3/4-10x 1 H.H.C.S L158 3/4 LOCK WASHER 4 13 L160 3/4 SAE WASHER FCA42-PU-11 GUIDE CAPS 4 15A 98409A237 INTERNAL RETAINING RING 8 15B LINEAR BALL BEARING 1-9/16 O.D. x 1 I.D. x 2-1/ FCA42-PU-09 GUIDE 4 16 L80 3/8-16 x 1 H.H.C.S L64 3/8 LOCK WASHER L66 3/8 SAE WASHER L49 5/16 SAE WASHER L47 5/16 LOCK WASHER L51 5/16-18x 1 H.H.C.S AIR SPRING 4 23 L70 3/8-24x 1 H.H.C.S L158 3/4 LOCK WASHER 8 25 L160 3/4 SAE WASHER 8 26 L72 3/8-24x 1-1/2 H.H.C.S L158 3/4 LOCK WASHER L160 3/4 SAE WASHER 16 40

41 Kalamazoo Parts Manual : 4FAC42-POPUP CONVEYOR ITEM PART # DESCRIPTION QTY 29 4FCA42-PU-11 GUIDE SHAFT FCA42-PU-10 AIR SPRING MOUNTIONG PLATEN FCA42-PU-07 1 DRIVE SHAFT FCA42-PU-19 50B25x1 SPECIAL SPROCKET FCA42-PU-16 1 DRIVEN SHAFT #50 ROLLER CHAIN x B10x 1 SPROCKET BOLT FLANGE BEARING HP. AC MOTOR TENV (56C) 1 38 L64 3/8 LOCK WASHER 4 39 L80 3/8-16 x 1 H.H.C.S Q60H56 R/A REDUCER (HOLLOW SHAFT) FCA42-PU-08 REDUCER MOUNT 1 42 L66 3/8 SAE WASHER 4 43 L64 3/8 LOCK WASHER 4 44 L70 3/8-24x 1 H.H.C.S L49 5/16 SAE WASHER 4 46 L47 5/16 LOCK WASHER 4 L53 5/16-18x 1-1/4 H.H.C.S. 4 41

42 42

43 Kalamazoo Parts Manual : 4FAC42-DISC & ROLLER CONVEYOR ITEM PART # DESCRIPTION QTY 1 L38 1/4-20x 1 H.H.C.S L33 1/4 SAE WASHER FCA42-DISC-08 UPPER GUARD 1 4 4FCA42-DISC-24 DRIVE CHAIN GUARD 1 5 L38 1/4-20x 3/4 H.H.C.S. 2 6 L31 1/4 LOCK WASHER 2 7 L33 1/4 SAE WASHER HP /3/60Hz. 56C MOTOR 1 9 L2 3/16 x 3/16 x 3/4 KEYWAY Q30R56 R/A REDUCER 1 11 L2 3/16 x 3/16 x 3/4 KEYWAY B15x 7/8 SPROCKET (DRIVE) 1 13 L80 3/8-16 x 1 H.H.C.S L64 3/8 LOCK WASHER 4 15 L66 3/8 SAE WASHER FCA42-DISC-10 ROLLER CONVEYOR MOTOR MOUNT 1 17 L55 5/16-18x 1 FLAT HEAD #50 ROLLER CHAIN x B13x 3/4 SPROCKET (DRIVEN) 1 20 L80 3/8-16 x 1 H.H.C.S L66 3/8 SAE WASHER /4 2-BOLT FLANGE BEARING 1 23 L78 3/8-16 NYLOCK NUT #50 ROLLER CHAIN x 7 25 L31 1/4 LOCK WASHER L28 1/4-20 NUT /4 3-BOLT FLANGE BEARING FCA42-DISC-25 CENTER BOX COVER 1 29 L38 1/4-20x 3/4 H.H.C.S L31 1/4 LOCK WASHER L33 1/4 SAE WASHER 10 43

44 Kalamazoo Parts Manual : 4FAC42-DISC & ROLLER CONVEYOR ITEM PART # DESCRIPTION QTY DOUBLE AIR TUBE (9.25 between fittings) FCA42-DISC TRANSITION ROLLER FCA42-DISC /8 TRANSITION ROLLER FCA42-DISC /8 TRANSITION ROLLER FCA42-DISC DRIVEN ROLLER FCA42-DISC-15 DRIVE ROLLER FCA42-DISC-16 DRIVEN ROLLER FCA42-DISC IDLER ROLLER FCA42-DISC IDLER ROLLER FCA42-DISC 4FAC42 TURNTABLE DISC WELDMENT PDT RELAY 110v COIL (ALTERNATING) 1 44

45 45

46 Kalamazoo Parts Manual : 4FAC42-TURNTABLE BASE ITEM PART # DESCRIPTION QTY 1 4FAC42-BASE-17 CENTER SHAFT 1 2 L114 1/2-20x 1-1/4 H.H.C.S. 4 3 L110 1/2 LOCK WASHER 4 4 L112 1/2 SAE WASHER /2 4-BOLT FLANGE BEARING 1 6 L77 3/8-16 NUT 2 7 L64 3/8 LOCK WASHER SLIP RING 1 9 L85 3/8-16x 2 H.H.C.S DOUBLE AIR TUBE (SWIVEL ONLY) 1 11 L TRUSS HEAD FAC42-BASE-08 SLIP RING COVER x2 WHEELS w/ TAPERED ROLLER BEARINGS 5 14 L200 3/4-10x 4-1/2 H.H.C.S L157 3/4-10 NUT FAC42-BASE-18 JUNCTION BOX /2 BORE x 3 STROKE TABLE LOCK CYLINDER 18 4FAC42-BASE-16C TABLE LOCK PIN 1 19 L38 1/4-20x 1 H.H.C.S L31 1/4 LOCK WASHER 2 21 L33 1/4 SAE WASHER HP AC MOTOR 56C FACE 1 23 L2 3/16 x 3/16 x 3/4 KEYWAY :1 INLINE REDUCER 1 25 L85 3/8-16x 2 H.H.C.S L65 3/8 USS WASHER 8 27 L77 3/8-16 NUT 4 28 L3 1/4 x 1/4 x 2-1/2 KEYWAY x2 DRIVE WHEEL w/ 1 HUB OUTPUT SHAFT

47 Kalamazoo Parts Manual : 4FAC42-TURNTABLE BASE ITEM PART # DESCRIPTION QTY 31 l72 3/8-24x 1-1/2 H.H.C.S L64 3/8 LOCK WASHER 2 33 L66 3/8 SAE WASHER PILLOW BLOCK 1 35 L157 3/4-10 NUT FAC42-BASE-19 SENSOR BRACKET SLIDE MOUNT T18 SENSOR BRACKET WORLD BEAM PHOTO-EYE FAC42-BASE-19 SENSOR BRACKET MOUNT FAC42-BASE TURNTABLE BASE WELDMENT FAC42-BASE-12 6 TRANSITION ROLLER 4 4FAC42-BASE-11 6 TRANSITION ROLLER MOUNT 4 L71 3/8-24x 1-1/4 H.H.C.S. 24 L64 3/8 LOCK WASHER 24 L66 3/8 SAE WASHER 24 47

48 Kalamazoo Parts Manual : 14 3-CHAIN STORAGE CONVEYOR ITEM PART # DESCRIPTION QTY 1 MET# BMQ R-140 IRONMAN REDUCER 30:1 (LH) 1 2 MET# HP 480/3/60Hz. AC MOTOR 143TC 1 3 H60B14Tx1-1/4 DRIVE SPROCKET 1 4 H6017Tx1-3/16 DRIVEN SPROCKET /16 4-BOLT FLANGE BEARING 3 6 HB60A13Tx5/8 IDLER SPROCKET #60 CHAIN 4 8 MS CHAIN STORAGE CONVEYOR FRAME OUTPUT FRONT SENSOR OUTPUT BACK SENSOR 1 48

49 49

50 50

51 51

52 52

53 53

54 54

55 55

56 56

57 57