MODEL 30HFA-CW FULLY-AUTOMATIC COCOON STRETCH WRAP SYSTEM OPERATOR S MANUAL

Transcription

1 MODEL 30HFA-CW FULLY-AUTOMATIC COCOON STRETCH WRAP SYSTEM OPERATOR S MANUAL Kalamazoo

2 Table of Contents Introduction 3 Warranty 3 Assembly 4 Set-up 4 Film loading variable tension 4 Controls 5 Operating instructions 6 Maintenance 7 Trouble shooting 7 Programming the AC drives (Telemecanique) HFA-CW System layout 0- Turntable base parts list 2-3 Turntable disc parts list 4-6 Film holder parts list 7-8 Film arm and cutter parts list 9-2 Air system Spiral tower parts list Control panel parts list Sub panel parts list Film variable tension parts list Wring diagram Programming guide 4 PLC program Kalamazoo 2

3 Introduction Congratulations! Your purchase of a Kalamazoo Fully-Automatic Cocoon Stretch Wrap 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 () 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. Kalamazoo 3

4 Assembly Your Cocoon 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 may not be crated. Any damage done in transit most 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 will do everything possible to assist you in these matters. The system was shipped fully assembled. Place the system on the floor and wirer in the main power supply per the wiring dia. 480/3/60Hz. 40AMP. This system will require air : cfm Set-Up Procedures The Spiral module and Turntable are designed to run smoothly together. Before wrapping the first roll of product, check the AUTO/MANUAL functions of the Turntable, Product Roller, and Film Carriage. Then center a roll of product on the Turntable Product Rollers and JOG the Turntable Disc to check for clearances. After the system has need checked and is ready to be put into production, push the RESET TO HOME push button. Load the film per the drawing. Use the FILM HOLDER selector switch and lower the film hold bars. Pull about 4-5 feet of film out of the film delivery system and lay the tail end of the film across the center of the film holder box and turn the FILM HOLDER selector switch to AUTO. The film holder bars will come up and hold the film. Make sure all of the AUTO/MANUAL selector switches are set to AUTO. Loading the film for Variable Tension If your wrapper is equipped with a Kalamazoo 30 Variable Tension Film Delivery System, place a roll of 30 stretch film on the film core holder so it unwinds clockwise. Pull out 4-5 feet and make into a tail. Thread the film counter-clockwise around the right idler roller and clockwise around the black rubber covered tension roller and counter-clockwise around the left idler roller. 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. Kalamazoo 4

5 Controls ) E-STOP: Turns off the main control relay. The system will not run. 2) POWER ON: Powers up the system. 3) POWER OFF: Turns the system off. 4) CYCLE ENABLE:Turns the system on. The green light will flash 5) CYCLE START: Starts the wrap cycle from the control cabinet. 6) CYCLE STOP: Stops all moving parts and reset all timers and counts. 7) CYCLE INTERRUPT: Stops the wrap cycle. But does not reset the program counters or timers. 8) REINFORCING - 2-3: Changes the wrap program from layer to 2 or 3 layers. 9) RESET TO HOME: Resets the system. Film carriage will lower to the bottom limit switch the home position, Turntable will move forward to the autostop switch the home position, and the Film arm will move back to the home position. Film holder will close. 0) FILM LIFT Raise/Auto/Lower: Manually moves the film carriage. ) TABLE JOG Auto/Manual : Used to manually run the turntable. 2) PRODUCT ROLL Auto/Manual: Used to manually run the product roller. 3) FILM ARM Fwd./Auto/Back : Used to manually run the film arm. 4) FILM HOLDER Auto/Lower: Used to lower the film holder bars so the film can be loaded. 5) REMOTE CONTROL START: Starts the wrap cycle from the fork truck. Make sure all of the AUTO/MANUAL selector switches are set to AUTO before pushing the Cycle Start push button. Limit Switches, Photo-eyes, and Sensors ) Load Height Photo-eye: This photo-eye is located on the film delivery head. The photo-eye will locate the top of the product, being the film delivery head back down to the middle of the product and it will determine the wrap cycle. 2) Top Limit Switch: This switch is located on the film delivery head. The top limit switch will stop the film deliver head when it get to the top of the film carriage. 3) Bottom Limit Switch: This switch is located on the film delivery head. The bottom limit switch will stop the film deliver head when it get to the bottom of the film carriage. (Home position) 4) Autostop Limit Switch: This switch is located on the turntable deck plate. The autostop limit switch counts the revolutions of the turntable disc and stop the turntable disc at the end of the cycle. (Home position) 5) Film Arm Forward Sensor: This sensor is located on the film arm post. The film arm forward sensor will stop the film arm in the forward motion. 6) Film Arm Back Sensor: This sensor is located on the film arm post. The film arm back sensor will stop the film arm in the back motion. (Home position) Optional Safety railing with photo-eye The optional safety railing and safety railing photo-eyes will keep the system from starting if the fork truck is still in the way after loading the product. If a person and/or fork truck gets in front of the photo-eyes the system will shut down. Kalamazoo 5

6 Operating Instructions Loading the film. ) If you are loading the film for the first time. Push the RESET TO HOME button. 2) Turn the FILM HOLDER selector switch to LOWER. The film holder bars located on the turntable will lower. 3) Load the film per the drawing and lay the film tail across the center of the FILM HOLDER box. 4) Turn the FILM HOLDER selector switch to AUTO the film hold will raise grip the film. 5) The system is now ready for the first load. Loading the product to be wrapped. ) Make sure the GREEN light is on and the system is ready. 2) Bring the product to the stretch wrapper and lower the product onto the rollers. Make sure to center the product onto the rollers. 3) Remove the fork truck prong from the product and make sure there is nothing in the way. 4) Push the REMOTE CONTROL START button to start the automatic wrap cycle. 5) The GREEN light will go off and the YELLOW light will come. ( System Busy ) 6) The film carriage will raise to the top of the product and return to the middle of the product. 7) The turntable will start turning the product. 8) After the first revolution the film tension will come on and put tension to the film. 9) After the second revolution the product rollers will come on and start rotating the product. The film holder will open and release the film. 0) After the product is wrapped the YELLOW light will go off and the GREEN light will come back on system is ready to be unloaded. ) End of wrap cycle. Kalamazoo 6

7 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 wheels 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 chain every three (3) months. Chain should be lubricated with a penetrating type commercial chain lube. (Do not over tighten chains.) 5) Lubricate pillow blocks with #2 grease every three (3) months. 6) Lubricate the turntable wheel with #2 grease every three (3) months. 7) Check the all electrical equipment for arcing and/or burning replace if necessary. 8) Check all push buttons and limit switch for shorts or sticking. Troubleshooting When any problem develops, review the operating instructions. Diagnose specific problems and review the options below. Push the E-STOP button in wait min.. This will denergize the AC drives and reset a fault. Check wall receptacle for power. Check all cords for cut. (Fork Lift Trucks damage cords.) ⓿ STOP the spiral carriage and the turntable. ⓿ Push the RESET TO HOME push button. DISCONNECT POWER FROM MACHINE Check both top and bottom limit switches for damage, sticking, or internal shorts. Open the cabinet door. Visually inspect for loose wires and for signs of arcing or burning of any of the components. Check all breakers.. Check optional variable tension brake controller for AC in and DC out. Check for damage wires and cords. Check the AC drive for errors. Check brake pads. It is advisable to call for technical assistance at this point. Technical and Customer Service is available from Kalamazoo, 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 7

8 Model # 30HFA-CW TELEMECANIQUE ALTIVAR 3 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. Turntable- Telemecanique ATV3 AC Drive Programming bfr Parameter Code Assignment Setting bfr Motor Frequency 60 Settings Menu SEt- Code Assignment Setting ACC Acceleration time 6.0 dec Deceleration time 0.0 HSP High Speed 60.0 UFr IR Compensation 50 SP2 Second Preset Speed 0.0 SP3 Third Preset Speed Start at 0.0 SFr Switching Frequency 2.0 Drive Control Menu drc Code Assignment Setting tun Auto-Tuning Yes UFt Voltage/Frequency Ratio L I/O Menu I-O- Code Assignment Setting tcc Conf. Terminal Block 2C Display Menu Sup- Code Assignment Setting rfr Output Frequency Applied Enter Film Lift- Telemecanique ATV3 AC Drive Programming bfr Parameter Code Assignment Setting bfr Motor Frequency 60 Settings Menu SEt- Code Assignment Setting ACC Acceleration time 0. dec Deceleration time 0. HSP High Speed 50.0 StA Frequency Loop 0 SFr Switching Frequency 2.0 Drive Control Menu drc Code Assignment Setting tun Auto-Tuning Yes I/O Menu I-O- Code Assignment Setting tcc Conf. Terminal Block 2C Display Menu Sup- Code Assignment Setting rfr Output Frequency Applied Enter Kalamazoo 8

9 Model # 30HFA-CW TELEMECANIQUE ALTIVAR 3 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. Product Roll- Telemecanique ATV3 AC Drive Programming bfr Parameter Code Assignment Setting bfr Motor Frequency 50 Settings Menu SEt- Code Assignment Setting ACC Acceleration time 2.0 dec Deceleration time 2.0 HSP High Speed 30.0 StA Frequency Loop 0 SFr Switching Frequency 2.0 Drive Control Menu drc Code Assignment Setting tun Auto-Tuning Yes I/O Menu I-O- Code Assignment Setting tcc Conf. Terminal Block 2C Display Menu Sup- Code Assignment Setting rfr Output Frequency Applied Enter Kalamazoo 9

10 0

11 PARTS MANUAL: 30HFA-CW LAYOUT ITEM DESCRIPTION QTY. PAGE # TURNTABLE BASE TUNRTABLE DISC FILM HOLDER FILM ARM and FILM CUTTER SPIRAL TOWER CONTROL PANEL SUB PANEL FILM DELIVERY 3-33 Kalamazoo

12 2

13 Item KPS # Manu. Manu. # Description Qty. 30HFA-CW- TABLE-08A 2 F2537, F255, F257 Turntable Driven Sprocket 5/8-x 2-/2 H.H.C.S. Lock Washer, SAE Washer Dodge FC-SCM Bolt Piloted Flange Bearing United N Slip Ring Dual Air Tube Equipment United S50N04KP Slip Ring 4-cir Equipment 6 L85, L88 3/8-6x 2 H.H.C.S., 3/8 Fender Washer United N Slip Ring Dual Air Tube Equipment Coupler 8 30HFA-CW- TABLE-05 Slip Ring Cover 9 F35 0/24x 3/4 T.H Albion ZJ /4 x 6 Axle Bolt & Nut Albion NX x 3 Trionix Wheel Brewer SO-5 Chain Tensioner Idler Shaft Machine Brewer 40BF #40-Teeth Idler Sprocket Machine 4 F25, F95, F97 /2-20x 2 H.H.C.S. Lock Washer, SAE Washer Brewer SL Chain Tensioner Machine (Manual Adj.) 6 30HFA-CW- TABLE Not Shown Kalamazoo PARTS MANUAL: 30HFA-CW TURNTABLE KPS KPS KPS Turntable Base SDRC 40RIVx2 #40 Chain w/ Master Link Kalamazoo 3

14 4

15 PARTS MANUAL: 30HFA-CW TURNTABLE DISC Item KPS # Manu. Manu. # Description Qty. 30HFA-CW- DISC-0 KPS Product Roller Chain Guard 2 F727, F720, F722 /4-20x 3/4 H.H.C.S. Lock Washer, SAE Washer SDRC 50 2RIV Double #50 Chain w/ Master Link x 5 5/ Martin D50B60x3- KW2SS D50B60x3 Roller Driven Sprocket 5 F60 3/4 x 3/4 x 2-3/4 Keyway 6 30HFA-CW- DISC- 7 30HFA-CW- DISC-2 8 F308, F285, F287 KPS Product Drive Roller (can be use as a idler roller) KPS Product Idler Roller 3/4-6x 3 H.H.C.S. Lock Washer, SAE Washer Dodge P2B-E-300R 3 Pillow Block Bearing 4 0 F2500, F255, F Martin D50B7x.875 -KW2SS 5/8- Nut, Lock Washer, SAE Washer D50B7x.875 Roller Drive Sprocket 2 F30 3/8 x 3/8 x -3/4 Keyway Sumitomo CNHMH- 630YA-87 4 F277, F255, F HFA-CW- DISC-08 -/2hp. 20RPM Inline Gearmotor 5/8-8x 2-/2 H.H.C.S. Lock Washer, SAE Washer KPS Roll Motor Slide Plate Kalamazoo 5

16 PARTS MANUAL: 30HFA-CW TURNTABLE DISC Item KPS # Manu. Manu. # Description Qty. 6 F2758 5/8-x 2-2-3/4 F.H Kleinhuis 234N3402 Cord Grip McMaster Carr 9 F990, F900, F97 20 F990, F900, F97 2 F727, F720, F HFA-CW- DISC HFA-CW- DISC 820K45 4/4 STO Cord (Product Roller) /2-3x 2 S.S.S, Nut, SAE Washer /2-3x 2 S.S.S, Nut, SAE Washer /4-20x 3/4 H.H.C.S. Lock Washer, SAE Washer KPS Turntable Disc Access Cover KPS 30HFA-CW Turntable Disc Kleinhuis 234N202 7/8 Cord Grip /4 Air Hose 2 26 F727, F720, F722 /4-20x 3/4 H.H.C.S. Lock Washer, SAE Washer 27 FILMHOLD-C KPS Film Holder Cover Automation Direct RL066 Reflector 7-/4x -3/4 29 F55 0/24x 3/4 T.H Kalamazoo 6

17 7

18 PARTS MANUAL: FILM HOLDER Item KPS # Manu. Manu. # Description Qty. FILMHOLDER- CB Film Holder Clamp Bar ( Right & Left ) KPS 3/8 Red Air Hose x 6 (Glued on to the drive clamp bar) 3 F0 3/6 x 3/6 x -/2 Keyway /8 Shaft Collar 3 5 FILMHOLDER- CBS02 Film Holder Clamp Bar Driven Shaft Bailey /8 x -3/8 PER. Bearing 4 Sales 7 F033, F05, F07 8 FILMHOLDER- CBS0 5/6-8x H.H.C.S., Lock Washer, SAE Washer Film Holder Clamp Bar Drive Shaft 9 F0 3/6 x 3/6 x 3/4 Keyway 0 FILMHOLDER- CBL FILMHOLDER- ABH 2 F726, F720, F722 3 FILMHOLDER- BP0 set Film Holder Clamp Bar Lever Film Holder Adjustable Bar Holder /4-20x 5/8 H.H.C.S. Lock Washer, SAE Washer Film Holder Base Plate Bimba D-23- Rod Clevis Bimba 73-DP Film Holder Cylinder (-/2 Bore x 3 Stroke) Bimba D-229 Pivot Bracket set 7 F725, F720, F722 KPS KPS KPS KPS KPS KPS /4-20x /2 H.H.C.S. Lock Washer, SAE Washer Kalamazoo 8

19 9

20 PARTS MANUAL: 30HFA-CW FILM ARM Item KPS # Manu. Manu. # Description Qty. FILMARM-P- 30HFA-CW 2 F090, F000, F07 Film Arm Post 5/6-8x 2 S.S.S., Nut, SAE Washer 4 F853, F65, F67 7/6-20x -/2 H.H.C.S. Lock Washer, SAE Washer Bimba CB500 Clevis Bracket 6 F553, F35 3/8-24x -/2 S.H.C.S., Lock Washer Bimba RE437 7/6-20 Rod Eye 9 FILMARM-SB KPS Barrel Sensor Bracket 0 F93, F720, F722 /4-28x H.H.C.S. Lock Washer, SAE Washer Banner S8SP6DQ Banner 8mm Barrel Sensor Dodge VPS- Pillow Block 2 6/5X TRD TA-MP4-2 Bore x 5.5 Stroke Cylinder 2x5.5-TH Banner MQDC- Banner 30 4-Pin Cable F24, F95, F97 4 FILMARM- ARM-30HFA-CW /2-20x -/2 H.H.C.S. Lock Washer, SAE Washer 30HFA-CW Film Arm 5 F553, F35 3/8-24x -/2 S.H.C.S., Lock Washer Bimba CB500 Clevis Bracket 7 FILMARM-SC KPS Barrel Sensor Cam 2 8 F336, F35, F37 KPS KPS 3/8-6x -3/4 H.H.C.S. Lock Washer, SAE Washer 9 FILMARM-HC KPS Film Arm Head Cover 2 20 F440 0/32x 3/4 T.H Kalamazoo 20

21 PARTS MANUAL: 30HFA-CW FILM ARM Item KPS # Manu. Manu. # Description Qty Bailey /8 x -3/8 Flange Bearing 4 Sales 22 FILMARM-S30 KPS 30 Film Arm Idler Roller 2 23 FILMARM-S30 KPS 30 Film Arm Idler Roller Shaft 2 24 F333, F35, F37 3/8-6x H.H.C.S. Lock Washer, SAE Washer Advance 0662 /2 Cord Grip 2 Control 26 F300, F37 3/8-6 Nut, SAE Washer 4 27 FILMARM- BTR 5/6-8 x 2 Brass Threaded Rod 2 28 F000 5/6-8 Nuts 4 29 FILMARM- HWI KPS KPS Film Arm Hot Wire Insulator Ace #22 Hot Wire Spring #22 Hardware MOR MOR- Hot Wire 2ga. x 3 Electric NICH Kalamazoo 2

22 22

23 PARTS MANUAL: FILM HOLDER and ARM AIR SYSTEM Item KPS # Manu. Manu. # Description Qty Wilkerson V Lock Out/Shut Off Unit Wilkerson B8-03- Filter Regulator Unit 3,7, MAC FKGO #Q MAC 82 Series Assembly (sol., reg., and gages) MAC AT250x7 Oil Tank MAC Lockout Valve Bimba TA-MP4-2 Bore x 5.5 Stroke Cylinder MAC 2x5.5-TH (FILM ARM) /4 Flow Control Bimba 73-DP -/2 Bore x 3 Stroke Cylinder (FILM HOLDER) Film arm air over oil system Use standard hydraulic oil for the air over oil system on the film arm. To add or replace the hydraulic oil in the system. Manually extend the film arm all the way out, the oil will be transferred from one oil tank to the other oil tank. One tank should be filled with hydraulic oil from the top of the tank and the other tank will only have of hydraulic oil in it. If you need to add hydraulic oil remove the top air line on the oil tank so the oil does not get into the solenoid, remove the oil tank fill plugs located on top of the oil tanks and fill to about from the top. Reinstall the air line and the fill plug and manually return the film arm. Add hydraulic oil to the other tank if needed the same way. Kalamazoo 23

24 24

25 Item KPS # Manu. Manu. # Description Qty. 30HFA-CW- TOWER McMaster Carr KPS 30HFA-CW Tower Weldment 5993K89 4-Prong Knob 3/8-6 Knob x KPS 4000M-OLSB Outer Limit Switch Bracket KPS 4000M-ILSB Inter Limit Switch Bracket Miller Bearing FC-70-7H.9 Conveyor Roller Bearing KPS 4000M Drive & Idler Roller Hex Shaft KPS 4000M-STIR Idler Belt Roller KPS 4000M-STDR Drive Belt Roller Diamond Wire 0 30HFA-CW- STTC KPS DWC-05L M Drive & Idler Roller Spring 30HFA-CW Spiral Tower Top Cover SQD XVPC34 Red Lense SQD XVPC35 Amber Lense SQD XVPC33 Green Lense SQD XVPC4 500mm Base SQD XVPC02 4 Tulip Mounting Base 2 F033, F05, F06 Kalamazoo PARTS MANUAL: 30HFA-CW TOWER 5/6-8x H.H.C.S. Lock Washer, USS Washer M-STMM-02 KPS Film Lift Motor Mount Dodge 20Q40L56 40: R/A Reducer 2.0CD 56C 5 F333, F35 3/8-6x H.H.C.S., Lock Washer Martin 40BS3 5/8 40B3x 5/8 Sprocket 7 F2 3/6 x 3/6 X 3/4 Keyway Baldor VM3542 3/4HP AC Motor (Film Lift) Kleinhuis 234N3402 Cord Grip McMaster 820K45 4/4 STO Cord (Film Lift) Kalamazoo 25

26 Item KPS # Manu. Manu. # Description Qty SDRC #40RIV # 40 CHAIN x 23 w/ Master Link 22 30HFA-CW- STTD 23 30HFA-CW- STBD 24 F740, F720, F722 30HFA-CW Back Door Top 30HFA-CW Back Door Bottom /4-20x 3/4 B.H.S.C.S. Lock Washer, SAE Washer Sumitomo CHHM5-5hp. 20RPM Inline Gearmotor 675YB-87 (Turntable) Kleinhuis 234N3402 Cord Grip McMas- 820K45 4/4 STO Cord (Turntable) 28 F2837, F287 3/4-0x 3-/2 H.H.C.S. SAE Washer 29 F2800, F285, F287 3/4-0 Nut, Lock Washer, SAE Washer 30 F50 5/8 x 5/8 x 2-/2 Keyway Martin 40B8 2-3/4 40B8x 2-3/4 Sprocket (Turntable Drive) 32 30HFA-CW- TABLE-2 Sprocket Retainer 33 F933, F95 /2-3x H.H.C.S., Lock Washer 34 Item 4 / page 22 Air/oil Tanks 2 35 Item / page 22 Lock Out/Shut Off Unit, Filter Regulator Unit, MAC 82 Series Assembly 36 See Page Control Panel 37 See Page Sub Panel 38 F992 /2-3x 3 S.S.S HFA-CW- TABLE-0 40 F727, F720, F722 Kalamazoo PARTS MANUAL: 30HFA-CW TOWER KPS KPS KPS KPS Two Piece Chain Guard /4-20x H.H.C.S. Lock Washer, SAE Washer Kalamazoo 26

27 Item KPS # Manu. Manu. # Description Qty Banner QD Pin Sensor Cable 42 F205, F200 6/32x M.S., #6 Keps Nut HFA-CW- TABLE Banner SM32LVAG QD KPS Autostop Sensor Mount and Guard Autostop Sensor M-BS KPS Belt Strap 46 F55, F400, F50 Kalamazoo PARTS MANUAL: 30HFA-CW TOWER 0/24x 3/4 T.H., #0 Washer, Keps Nut KPS #20 BLACK PVC 8 x 8.5 Belt 48 See page M-H30-4VT 30 Variable Tension Film Delivery 4 Kalamazoo 27

28 Packaging Systems Model # 30HFA CW Control Panel Layout 30HFA CW EMERGENCY STOP POWER ON POWER OFF CYCLE ENABLE CYCLE START CYCLE STOP CYCLE INTERRUPT LAYERS 2 3 RESET TO HOME FILM LIFT RAISE/AUTO/LOWER TURNTABLE AUTO/MANUAL PRODUCT ROLLER AUTO/MANUAL FILM ARM FWD./AUTO/BACK FILM HOLDER AUTO/LOWER Kalamazoo (800) Kalamazoo PARTS MANUAL: 30HFA-CW CONTROL PANEL Item KPS # Manu. Manu. # Description Qty. D-30HFA- CW KPS Control Panel Decal SQD. SQDXB4 BT SQD. XB4BW3 3B5 Red Push/Pull Button (EMERGENCY STOP ) Laminated Green Push Button (POWER ON ) SQD. SQDZB4 BA4 Red Flush Push Button (POWER OFF ) Kalamazoo 28

29 PARTS MANUAL: 30HFA-CW CONTROL PANEL Item KPS # Manu. Manu. # Description Qty SQD. SQDXB 4BA SQD. SQDZB 4BC SQD. SQDZB 4BC44 Green Flush Push Button (CYCLE ENABLE) Green Extended Push Button (CYCLE START ) Red Mushroom Push Button (CYCLE STOP ) SQD. SQDZB 4BZ0 NO Contact Block SQD. SQDZB 4BA SQD. SQDXB 4BD SQD. SQDZB 4BA SQD. SQDXB 4BD SQD. SQDXB 4BD SQD. SQDXB 4BD SQD. SQDXB 4BD SQD. SQDXB 4BD2 Red Flush Push Button (CYCLE INTERRUPT ) 3-Position Selector Switch (LAYERS -2-3) White Push Button (RESET TO HOME ) 3-Position Selector Switch (FILM LIFT ) 2-Position Selector Switch (TABLE JOG ) 2-Position Selector Switch (PRODUCT ROLL ) 3-Position Selector Switch (FILM ARM ) 2-Position Selector Switch (FILM HOLDER ) Kalamazoo 29

30 30

31 PARTS MANUAL: 30HFA-CW SUB PANEL Item KPS # Manu. Manu. # Description Qty. 200 Schneider Electric MG24425 AMP. -Pole Breaker (PLC) Mitsubishi FX2n-64MR- ES Mitsubishi PLC (FX2n-64MR) Omron LY2-24Vdc 2PDT Relay (CR3) Dayton 2A582 8-Pin Base Omron LY2-00Vac 2PDT Relay (CR) Dayton 2A582 8-Pin Base Schneider Electric MG AMP. -Pole Breaker (Film Tension) Minarik MM2300C 90vDC Controller (Film Tension) Applied Wireless RCR303B3R Remote Start Receiver Applied Wireless KTX 303B2 Hand Held Transmitter (Not Shown) Applied Wireless Ace Hardware DP303-7 Antenna (Not Shown) //60Hz. Outlet Omron LY2-00Vac 2PDT Relay (CR2) Dayton 2A582 8-Oin Base Schneider Electric MG AMP. 2-Pole Breaker (Primary) SQD. 9070T000D 000VA Transformer Schneider Electric MG AMP. -Pole Breaker (Secondary) Omron LY4-00Vac 4PDT Relay (POR) Dayton 2XC09 4-Pin Base SQD. LCD40G7 40 AMP. Main Control Relay SQD. GS-GU-3 Main Fused Disconnect SQD. GS-AE-2 Extension Shaft Kalamazoo 3

32 PARTS MANUAL: 30HFA-CW SUB PANEL Item KPS # Manu. Manu. # Description Qty SQD. LPJ-40SP 40 AMP. Fuse Payne 8D--0I Payne Controller (Hot Wire) Schneider Electric MG AMP. 3-Pole Breaker (Film Lift) Telemecanique ATV3H055N4 3/4hp. AC Drive 480/3/60Hz. (Film Lift) Schneider MG AMP. 3-Pole Breaker Electric (Turntable) Telemecanique ATV3HU40N4 5hp. AC Drive 480/3/60Hz. (Turntable) Schneider MG AMP. 3-Pole Breaker Electric (Product Roll) Telemecanique ATV3HU5N4 -/2hp. AC Drive 480/3/60Hz. (Product Roll) SQD. PK5GTA Cabinet Ground Bus Ideal IDE Terminal Strip 4 Kalamazoo 32

33 33

34 PARTS MANUAL: 4000M-H2-4VT 30 VARIABLE TEBSION FILM DELIVERY Item KPS # Manu. Manu. # Description Qty KPS 4000M-H2-C Film Cover KPS Variable Tension Film Delivery Decal 3 F440 0/32 x 3/4 Truss Head Screw 6 4 F32, F302 8/32 x 3/4 M.S., Keps Nut Precision MPD MPD v DC Brake 5/8 Torque Bore 6 F2 3/6 x 3/6 x 3/4 Keyway 7 F333, F35, F37, F300 Kalamazoo 3/8-6x H.H.C.S., Lock Washer, SAE Washer, (and 2 with Nuts) KPS 4000M-H2-TP-R Film Top Plate 9 F035, F07, F000 5/6-8 x -/2 H.H.C.S., SAE Washer, and Nut Kleinhuis 234N202 7/8 Cord Grip Carol /3 SJ Cord (Film Brake) Bailey /8 x -3/8 Flange Bearing 2 Sales 3 F258 5/8 Spring Washer KPS 4000M-H2-4VT-R 30 Brake Roller 4 Dia KPS 4 x -/2 X 3/4 Carriage Wheels 6 F288 3/4 Spring Washer KPS Carriage Wheel Spacer SKF TRA Thrust Washer SKF NTA Thrust Bearing KPS 2.95 Diameter x 20 Film Core McMaster 7088K5 6/8x 2 Coiled Cord Carr Kleinhuis 234N3402 Cord Grip KPS 4000M-H30-FHBP-4VT 30 Film Base Plate 23 F053 5/6-8x -/2 F.H.C.S Omron ZE-NA2-2S Limit Switch (Roller Arm)

35 PARTS MANUAL: 4000M-H2-4VT 30 VARIABLE TEBSION FILM DELIVERY Item KPS # Manu. Manu. # Description Qty. 25 F20 6/32x -3/4 Machine Screw Kleinhuis 234N202 7/8 Cord Grip 2 27 F250 #6 x 3/4 Sheet Metal Screw Ideal IDE Terminal Strip Carol /3 SJ Cord (Limit Switch) Bailey /8 x -3/8 Flange Bearing 4 Sales KPS -/4 PVC x 30 Idler Roller KPS 4000M-H2-30-R 30 Film Head Support Shaft Banner MQDC-406 Banner Photo-eye 4-pin cable 6 long 34 F540 0/24 x 2 SCREW Sick DS60 Photo-eye 2 Kalamazoo 35

36 36

37 37

38 38

39 39

40 40

41 Step Cycle Start = Film carriage raise (5 inches per second) Film carriage photo-eye off. m256 For example: If it takes 4 sec. to raise off the film carriage photo-eye it travels 20 inches. So Dia. is 56 inches 56*pi=76 inches of wrapping. 2 Divide 4 sec./ 2=2 sec. then lower film carriage Film carriage lower done. m24 3 Check wrapping layers Multi done. m27 4 Turntable forward y4 and timer 5 sec. After count. m220 5 y20 On film tension After 2 counts. m223 6 Open film holder y22 and product rollers forward y6 and start to count turntable Rotations. 7 Turn no turntable decel y5 and turn off product rollers y6 and after time delay lower film carriage to home position. 8 Turn off turntable y4 and y5. Turn off y20 film tension When turntable rotations reached. Turntable auto stop is made. Film carriage at home position. m226 m229 m232 9 Film arm forward y24. Film arm forward. m235 0 Close film holder y22 and turn no hotwire y2 for 5.5 sec. Film cut off done. m238 Product rollers forward y6 for 20 sec. Film tail done m24 2 Film arm back y25. Film arm back done m244 3 Cycle completed. Reset all counter and timers m247 Kalamazoo 4

42 42

43 43

44 44

45 45

46 46

47 47

48 48

49 49

50 50

51 5

52 52

53 53

54 54

55 55

56 56

57 57

58 58

59 59

60 60

61 6

62 62

63 63