Kalamazoo Packaging Systems. Division of Kal-Tek, Inc. SEMI-AUTOMATIC STRETCH WRAP SYSTEM OPERATOR S MANUAL 02/01//05

Transcription

1 Kalamazoo Packaging Systems Division of Kal-Tek, Inc. MODEL 4000M-SA SEMI-AUTOMATIC STRETCH WRAP SYSTEM OPERATOR S MANUAL 02/0//05

2 Table of Contents Warranty Assembly... 3 Set up... 4 Film loading constant prestretch...4 Film loading variable tension.5 Program controls.5 Operating Instructions Maintenance... 6 Trouble Shooting... 6 Program the AC Drives (Telemecanique)....7 Table & tower parts list..8- Control panel parts list Sub panel parts list..5-6 Film constant prestretch parts list Film variable tension parts list 2-23 Available options Quick Calibration of the Scale.26 Wiring Diagram PLC program

3 Introduction Congratulations! Your purchase of a Kalamazoo Model 4000M-SA Semi-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 Packaging Systems, 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 () 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. Modular Design All Kalamazoo stretch wrap equipment is of modular design to grow and adjust to your specific packaging requirements. Your system has the ability to grow with you in the future. You can change modules to adjust to whatever your packaging requirements may be. Kalamazoo Packaging Systems, Inc. 3

4 Assembly Your 4000M-SA Stretch Wrap System has been assembled and tested at our manufacturing plant and released for shipment by a qualified technician. If the unit was shipped via common carrier, it will be on a pallet. If the unit was delivered by our truck or by your distributor s truck it may not be placed on a pallet. Any damage done in transit should be reported to the carrier immediately. All our shipments are sent F.O.B. Grand Rapids, Michigan, therefore; the customer is responsible to settle any damage claims with the transportation company. Kalamazoo Packaging Systems will do everything possible to assist you in these matters. Once the machine was cleared for shipment at the factory, It was put on a pallet and wrapped completely assembled. No electrical wires were removed or disconnected for shipping. Remove the unit from the pallet. The machine is now ready for operation and should be plugged into an independent 5 volt, 20 amp. power source. NOTE: The use of an extension cord may reduce the efficiency and life of the machine and is not recommended. Set-Up Procedures The spiral module and turntable are designed to run smoothly together. Before wrapping the first pallet, check the AUOT/MANUAL functions of the turntable and the FILM RAISE and FILM LOWER functions of the spiral. Then center a load on the turntable and jog to check clearances. Loading The film If your wrapper is equipped with our Kalamazoo Constant Prestretch Film Delivery System, place a roll of 20 stretch film on the film core holder and open the film door. Thread the film clockwise around the back rubber covered tension rollers and close the film door. CONSTANT PRESTRETCH Kalamazoo Packaging Systems 4

5 Loading the film for optional variable tension If your wrapper is equipped with our Variable Tension Film Delivery System, place a roll of 20 stretch film on the film core holder and open the film door. Thread the film clockwise around the black rubber covered tension roller and 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. VARIABLE TENSION program controls ) E-STOP - Turns off the main control relay. The system will not run. 2) CYCLE START Starts the wrap cycle. 3) CYCLE INTERRUPT- Stops the wrap cycle. But does not reset the program or counters. 4) REINFORCING 2 3 Changes the reinforcing wraps on the bottom and top of the load. 5) FILM RAISE Manually raises the film carriage. 6) FILM LOWER Manually lowers the film carriage. 7) TABLE JOG AUTO/MANUAL Turn to manual to run the turntable. 8) PHOTO-EYE ON/OFF- Turns the photo-eye on and off. 9) Optional Film Tension Control. Turn the knob clockwise to increase film tension. 0 Film Lift Speed Control. Turn the knob clockwise for less over wrap and counter clockwise for more over wrap. Turntable Speed Control. Turn the knob clockwise to make the table rotate faster and counter clockwise to slow the table down. Easy operating instructions ) Attach the film to the pallet securely. 2) Select the amount of reinforcing wraps for the top and bottom.. 2) Push the CYCLE START button. 3) ( STAND CLEAR ) 4) Adjust the OPTIONAL FILM TENSION CONTROL knob to obtain the correct amount of film stretch. 5) After the reinforcing wrap are applied to the bottom of the load the film carriage will travel to the top and stop it will place the reinforcing wraps on the top of the load. 6) The film carriage will return to the bottom. 7) The turntable will decelerate and autostop. 8 End of wrap cycle. Kalamazoo Packaging Systems 5

6 Maintenance ) Check and tighten any loose fasteners. 2) Check all electrical connections and replace any worn or frayed cords. 3) Clean and lubricate the tower channels where the rollers run with #2 grease every three months, more frequently if the unit is in an especially dirty location. 4) Lubricate and adjust the turntable drive 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 the main control relay for burning or arcing replace if necessary. 7) Check all push buttons and limit switch for shorts or sticking. Troubleshooting Machine not running at all When any problem develops, review the operating instructions. Diagnose specific problems and review the options below. Push the E-STOP button in wait min.. Turn the button to reset. This will denergize the AC drives and reset a fault. Check wall receptacle for power. Check Power cord for cut. (Fork Lift Trucks damage cords.) ⓿ STOP the spiral carriage and the turntable. DISCONNECT POWER FROM MACHINE Check both top and bottom limit switches for damage, sticking, or internal shorts. Remove panel cover. Visually inspect for loose wires and for signs of arcing or burning of any of the components. Check belt tension. Check brake controller for AC in and DC out. Check for damage cords. Check the AC drive for errors. Check brake pads. It is advisable to call for technical assistance at this point. Check for damage cords. Technical and Customer Service is available from Kalamazoo Packaging Systems, Monday through 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 - (66) National - (800) Kalamazoo Packaging Systems 6

7 TELEMECANIQUE ALTIVAR AC DRIVE PROGRAMMING To change a parameter in the AC Drive.. Press the up or down key to get into the parameter you would like to change. 2. Press the ENT key. 3. Use the up/down arrow key to change the value. 4. Press the ENT key. 5. Press the ESC key. 4000M-SA TURNTABLE DRIVE ACC 5.0 Turntable acceleration time DEC 6.0 Turntable deceleration time SP4 5.0 Preset speed 4 TDC 0. SFR 2khz. STA 0% 4000M-SA FILM CARRIAGE DRIVE ACC 2.5 Turntable acceleration time DEC 0. Turntable deceleration time TDC 0. SFR 2khz. STA 0% 7

8 8

9 Kalamazoo Packaging Systems PARTS MANUAL: 4000M-TURNTABLE & TOWER ITEM PART# GRAINGER DESCRIPTION QTY M DISC 2 L8 3G836 3/8-6x FLAT HEAD CAP SCREW M CENTER SHAFT LC89 2 SNAP RING L009 TURNTABLE CENTER BEARING 6 L3 2F792 /4 x /4 x KEYWAY B40x SPROCKET G22 3-/4 x 2. x /2 TURNTABLE WHEELS G450 /2 X 3-/2 WHEEL AXLE 7 0 L26 2U390 /2-3 JAM NUTS 7 L3 2F792 /4 x /4 x KEYWAY L50 50B2x SPROCKET L074 #50 CHAIN x M TURNTABLE & TOWER WELDMENT 5 L54 3F257 5/6-8x -/2 SOCKET SET SCREW 2 6 L46 2U747 5/6-8 NUT 2 7 L49 4P492 5/6 SAE WASHER 2 8 L65 4P473 3/8 USS WASHER 4 9 L83 4P208 3/8-6x -/2 HEX HEAD CAP SCREW 4 20 L65 4P473 3/8 USS WASHER 4 2 L78 4P434 3/8-6 NYLOCK NUT Z64 57: INLINE REDUCER A247 CORD GRIP 24 3ea. 4ga. RED & ea. 4ga. GREEN WIRE 3 25 L2 2F788 3/6 x 3/6 X 3/4 KEYWAY 26 L80 4P206 3/8-6x HEX HEAD CAP SCREW 4 27 L64 2V02 3/8 LOCK WASHER 4 9

10 Kalamazoo Packaging Systems PARTS MANUAL: 4000M-TURNTABLE & TOWER ITEM PART# GRAINGER DESCRIPTION QTY N96 /2HP AC TEFC MOTOR 29 L6 5K48 6/32x -/2 MACHINE SCREW ( 4000M-SA) Z096 AUTO STOP LIMIT SW. SPRING ARM ( 4000M-SA) A247 CORD GRIP ( 4000M-SA) W66 6/3 SJ CORD ( 4000M-SA) X820 3/8-6 KNOB x M-OLSB OUTER LIMIT SWITCH BRACKET M-ILSB INTER LIMIT SWITCH BRACKET CONV. ROLLER BEARING M-STIR IDLER ROLLER HEX SHAFT 37a M-STDR DRIVE ROLLER HEX SHAFT M-STIR IDLER BELT ROLLER M-STDR DRIVE BELT ROLLER ROLLER SPRING M-STTC-0 TOWER TOP COVER 42 L5 4P92 5/6-8x HEX HEAD CAP SCREW 4 43 L47 4P503 5/6 LOCK WASHER 4 44 L48 4P472 5/6 USS WASHER M-STMM-0 FILM LIFT MOTOR MOUNT Z284 60: R/A REDUCER 47 L80 4P206 3/8-6x HEX HEAD CAP SCREW 4 48 L64 2V02 3/8 LOCK WASHER L3 40B3x 5/8 SPROCKET 50 L2 2F788 3/6 x 3/6 X 3/4 KEYWAY N96 /2HP AC TEFC MOTOR A247 CORD GRIP 53 3ea. 4ga. RED & ea. 4ga. GREEN WIRE # 40 CHAIN x 23 w/ MASTER LINK M-STD TOWER BACK COVER 56 /4-20 BUTTON HEAD SCREWS 8 0

11 Kalamazoo Packaging Systems PARTS MANUAL: 4000M-TURNTABLE & TOWER ITEM PART# GRAINGER DESCRIPTION QTY. 55 /4-20 BUTTON HEAD CAP SCREW M-H-BP CARRIAGE BELT PLATE 57 L20 4P46 0/24 KEPS NUT 4 58 L6 2V023 #0 WASHER 4 59 L2 5K796 0/24x 3/4 TRUSS HEAD M-BELT #20 BLACK PVC 8 x M-H-CP CONSTANT PRESTRETCH FILM DELIVERY HEAD M- CONTROL PANEL (SEE PAGE 0 & ) OPTIONAL SCALE 63 L5 /2-20x 2-/2 H.H.C.S L09 /2-20 NUTS 9 65 L0 /2 LOCK WASHER K LOAD CELL LOAD CELL FEET 3

12 EMERGENCY STOP TI500E CYCLE STOP CYCLE START CYCLE INTERRUPT REINFORCING 2 3 FILM RAISE FILM LOWER TABLE JOG AUTO/MANUAL PHOTO EYE OFF/ON FILM TENSION FILM LIFT SPEED TURNTABLE SPEED FILM TENSION 3 AMP. FILM LIFT TURNTABLE MAIN 5 AMP. 5 AMP. 5 AMP. 2

13 Kalamazoo Packaging Systems PARTS MANUAL: 4000M-SA CONTROL PANEL ITEM PART # GRAINGER DESCRIPTION QTY 4000M-SA 4000M-SA DECAL RED PUSH/PULL NC ( E-STOP ) RED MUSHROOM PUSH BUTTON NO ( CYCLE STOP ) GREEN FLUSH PUSH BUTTON NO ( CYCLE START ) RED FLUSH PUSH BUTTON ( CYCLE INTERRUPT ) NO CONTACT BLOCK FOR ABOVE POSITION SELECTOR SWITCH 2NO ( REINFORCING ) BLUE PUSH BUTTON NO ( FILM RAISE ) YELLOW PUSH BUTTON NO ( FILM LOWER ) NO CONTACT BLOCK FOR ABOVE POSITION SELECTOR SWITCH NO ( TABLE JOG ) 3

14 Kalamazoo Packaging Systems PARTS MANUAL: 4000M-SA CONTROL PANEL ITEM PART # GRAINGER DESCRIPTION QTY POSITION SELECTOR SWITCH NO ( PHOTO-EYE ON/OFF ) K POTENTIOMETER w/ KNOB (OPTIONAL FILM TENSION) K POTENTIOMETER w/ KNOB (FILM LIFT SPEED) K POTENTIOMETER w/ KNOB (TURNTABLE SPEED) PANEL MOUNT FUSE HOLDER XC 3AMP. FUSE (OPTIONAL FILM TENSION) XC2 5AMP. FUSE (FILN LIFT) C20 8 AMP. FUSE (TURNTABLE) XC4 5 AMP. FUSE (MAIN) SCALE DISPLAY TI-500E ( OPTIONAL SCALE ) 4

15 5

16 Kalamazoo Packaging Systems PARTS MANUAL: 4000M-SA SUB PANEL ITEM PART # GRANGER DESCRIPTION QTY MITSUBISHI PLC (FXS-20MRES/UL) POLE FUSE HOLDER AMP FUSE M50 90/80v DC CONTROLLER (OPTIONAL FILM TENSION) TELE. /2 hp. 5v INPUT 230v 3 ph. OUTPUT TELE. /2 hp. 5v INPUT 230v 3 ph. OUTPUT SUMMING CARD (OPTIONAL SCALE) X847 2PDT 30a. MAIN CONTROL RELAY (MCR) TERMINAL STRIP VOLT OUT LET 6

17 7

18 Kalamazoo Packaging Systems PARTS MANUAL: CONSTANT PRESTRETCH FILM DELIVERY ITEM PART# GRAINGER DESCRIPTION QTY M-H-C FILM COVER CONSTANT PRESTRETCH FILM DELIVERY DECAL 3 L2 5K796 0/24 x 3/4 TRUSS HEAD SCREW D-HANDLE FILM DOOR LATCH 5 L7 5K772 8/32 x 3/4 MACHINE SCREWS w/ LOCKNUTS TIMING BELT (STANDARD) /2 x L2 2F788 3/6 x 3/6 x 3/4 KEYWAY TOOTH PULLEY(STANDARD) TOOTH PULLEY(STANDARD) 0 L80 4P206 3/8-6x HEX HEAD CAP SCREWS 4 L64 2V02 3/8 LOCK WASHERS 4 2 L66 4P493 3/8 SAE WASHERS M-H-TP02 FILM TOP PLATE /8 x -3/8 FLANGE BEARINGS 4 5 L45 5/8 SPRING WASHER M-H-R 20 BRAKE ROLLERS /8 x -3/8 FLANGE BEARINGS M-H-D02 20 FILM DOOR ROLLER M-H-D03 FILM DOOR ROLLER SHAFT M-H-D 20 FILM DOOR 2 L58 3G86 5/6-8x FLAT HEAD CAP SCREW HINGE PIN 8

19 Kalamazoo Packaging Systems PARTS MANUAL: CONSTANT PRESTRETCH FILM DELIVERY ITEM PART# GRAINGER DESCRIPTION QTY THRUST WASHER DIA. x 5 FILM CORE 25 L55 3G820 5/6-8x -/2 FLAT HEAD CAP SCREW M-H-R0 FILM HEAD SUPPORT SHAFT M-H-BP 20 FILM BASE PLATE x -/2 X 3/4 CARRIAGE WHEELS 4 29 L6 CARRIAGE WHEEL SPRING CARRIAGE WHEEL SPACER L6 6/32x-3/4 MACHINE SCREWS 4 32 L6a #6 WASHER A095 LIMIT SWITCH (ROLLER ARM) CORD GRIP W66 6/3 SJ CORD TERMINAL STRIP 37 #6 x 3/4 SHEET METAL SCREWS /7 COILED CORD CORD GRIP 40 L29 /4-20 NYLOCK NUT 4 L32 /4 USS WASHER /4 x -3/8 FLANGE BEARING BELT TENSIONER SHAFT 44 L38 /4-20x -/2 HEX HEAD CAP SCREW 9

20 PARTS MANUAL: 4000M-CP CONSTANT PRESTRETCH FILM DELIVERY OPTIONAL TENSION PULLEYS AND BELTS ITEM PART# DESCRIPTION QTY 28 PONUDS OF PULL TOOTH PULLEY TOOTH PULLEY 073 BELT TENSIONING KIT 27 POUNDS OF PULL TOOTH PULLEY TOOTH PULLEY 073 BELT TENSIONING KIT 25 POUNDS OF PULL TOOTH PULLEY TOOTH PULLEY 073 BELT TENSIONING KIT 9 POUNDS OF PULL TOOTH PULLET TOOTH PULLEY 073 BELT TENSIONING KIT 7-3/4 POUNDS OF PULLEY ( STANDARD) TOOTH PULLEY TOOTH PULLEY 6 POUND OF PULL TOOTH PULLET TOOTH PULLEY 073 BELT TENSIONING KIT POUNDS OF PULLEY TOOTH PULLEY TOOTH PULLEY 073 BELT TENSIONING KIT 20

21 2

22 Kalamazoo Packaging Systems PARTS MANUAL: VARIABLE TENSION FILM DELIVERY ITEM PART# GRAINGER DESCRIPTION QTY M-H-C FILM COVER FILM-VT VARIABLE TENSION FILM DELIVERY DECAL 3 L2 5K796 0/24 x 3/4 TRUSS HEAD SCREW FILM DOOR LATCH 5 L7 5K772 8/32 x 3/4 MACHINE SCREWS w/ LOCKNUTS /4 90v DC BRAKE 7 L2 2F788 3/6 x 3/6 x 3/4 KEYWAY 8 5/6-8 x -/4 HHCS 9 5/6-8 NUT 0 L80 4P206 3/8-6x HEX HEAD CAP SCREWS 4 L64 2V02 3/8 LOCK WASHERS 4 2 L66 4P493 3/8 SAE WASHERS M-H-TP02 FILM TOP PLATE /8 x -3/8 FLANGE BEARINGS 2 5 L45 5/8 SPRING WASHER M-H-R 20 BRAKE ROLLERS /8 x -3/8 FLANGE BEARINGS M-H-D02 20 FILM DOOR ROLLER M-H-D03 FILMOOR ROLLER SHAFT M-H-D 20 FILM DOOR 2 L58 3G86 5/6-8x FLAT HEAD CAP SCREW HINGE PIN 22

23 Kalamazoo Packaging Systems PARTS MANUAL: VARIABLE TENSION FILM DELIVERY ITEM PART# GRAINGER DESCRIPTION QTY THRUST WASHER DIA. x 5 FILM CORE 25 L55 3G820 5/6-8x -/2 FLAT HEAD CAP SCREW M-H-R0 FILM HEAD SUPPORT SHAFT M-H-BP 20 FILM BASE PLATE x -/2 X 3/4 CARRIAGE WHEELS 4 29 L6 CARRIAGE WHEEL SPRING 4 30 CARRIAGE WHEEL SPACER L6 6/32x-3/4 MACHINE SCREWS 4 32 L6a #6 WASHER A095 LIMIT SWITCH (ROLLER ARM) CORD GRIP W66 6/3 SJ CORD TERMINAL STRIP 37 #6 x 3/4 SHEET METAL SCREWS /7 COILED CORD CORD GRIP 23

24 Kalamazoo Packaging Systems PARTS MANUAL: Available Options: ITEM PART# DESCRIPTION QTY 30 CONSTANT PRESTRETCH FILM DELIVERY M-H-R 30 BRAKE ROLLER M-H-D02 30 FILM DOOR ROLLER M-H-D03 30 FILM DOOR ROLLER SHAFT M-H-D 30 FILM DOOR M-H-BP 30 FILM BASE PLATE 30 VARIABLE TENSION FILM DELIVERY M-H-R 30 BRAKE ROLLER M-H-D02 30 FILM DOOR ROLLER M-H-D03 30 FILM DOOR ROLLER SHAFT M-H-D 30 FILM DOOR M-H-BP 30 FILM BASE PLATE 4000M RAMP 4000M SCALE RAMP 4000M POWERED WALKIE RAMP BUILT IN 4,000 lb. SCALE DISPLAY SUMMING CARD K LOAD CELL RUBBER LOAD CELL FEET 3 24

25 Kalamazoo Packaging Systems PARTS MANUAL: Available Options: ITEM PART# DESCRIPTION QTY //60hz POWER REQUIREMENTS TELE. /2 hp. 5v INPUT 230v 3 ph. OUTPUT TELE. /2 hp. 230v INPUT 230v 3 ph. OUTPUT va TRANEFORMER 60 TURNTABLE DISC M 60 DIA. TURNTABLE DISC w/ -/4 SKIRT 5,000 lb. CAPACITY 230/3/60hz /4 x 2. x /2 TURNTABLE WHEELS /2 X 3-/2 WHEEL AXLE +5 0 L26 /2-3 JAM NUTS /2HP AC TEFC MOTOR /4HP AC TEFC MOTOR TELE. /2 hp. 5v INPUT 230v 3 ph. OUTPUT TELE. /2 hp. 230v INPUT 230v 3 ph. OUTPUT TELE. hp. 230v INPUT 230v 3 ph. OUTPUT va TRANEFORMER 5,000 lb. SCALE K LOAD CELL K LOAD CELL 3 ADJUSTABLE AUTOSTOP 3a ADJUSTABLE AUTOSTOP CAM M CENTER SHAFT w/o AUTOSTOP CAM 25

26 NEW INCELL TI-500E QUICK CALIBRATION (Blue decal) 500LBS. 3000LBS. 4000LBS. 6000LBS. K-CELL 4K-CELL 4K-CELL 6K-CELL PUSH THE DIP SWITCH IN THE BACK OF THE SCALE READ OUT TO THE LEFT. TURN ON THE SCALE. F PUSH ZERO PUSH NET PUSH UNIT F PUSH PRINT F9 PUSH ZERO 0 PUSH NET PUSH UNIT F9 PUSH PRINT F0 PUSH ZERO 0 PUSH PRINT PUSH NET PUSH UNIT F0 PUSH PRINT F6 PUSH ZERO PUSH ZERO 0 PUSH NET PUSH UNIT F6 PUSH PRINT F7 PUT KNOW WEIGHT ON SCALE PUSH ZERO USE THE TARE-PRINT BUTTON TO TELL SCALE THE WEIGHT PUSH NET PUSH UNIT REMOVE WEIGHT AND PUT PUSH THE DIP SWITCH BACK TO RIGHT. END. 26

27 27

28 28

29 29

30 30

31 3

32 32

33 33