INSTRUCTION MANUAL CASE CONTROL TGA-200I CASE ERECTOR

Transcription

1 INSTRUCTION MANUAL CASE CONTROL TGA-200I CASE ERECTOR THIS INSTRUCTION MANUAL IS FOR: MODEL NO: TGA-200I REVISION NO: 6.0 SERIAL NO.: DATE PURCHASED: FROM: DURABLE PACKAGING CORP Dansher Road Countryside, Illinois TEL: (708) FAX: (708)

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3 TABLE OF CONTENTS TABLE OF CONTENTS... I CHAPTER INTRODUCTION...1 Left Hand And Right Hand Models...1 Inspection And Set-Up Of Unit...1 Lubrication...2 Air Line And Electrical Connections...3 Safety Precautions...4 Inspecting Cases Prior To Set-Up...4 CHAPTER CASE SIZE CHANGE-OVER...6 CHAPTER PNEUMATIC - MECHANICAL OPERATION...13 Switch S.S TROUBLESHOOTING...15 Suction Cup Problems...15 Formed Cases Are Not Square...16 Boxes Jamming After Pick-Off...17 Rough Operation Of The Squaring Arm...18 PNEUMATIC DEVICES ADJUSTMENTS...18 Squaring Pressure Adjustment...18 Carriage Cylinder No.4: Speed To Home:...20 Carriage Cylinder No.4: Speed To Deliver Box:...20 Pivot Cylinder No.L: Speed To Rotate:...20 Pivot Cylinder No.L: Speed To Home Position:...20 Speed To Square Box:...20 Kicker Cylinder - Speed Up:...20 Kicker Cylinder - Speed Down:...20 Brake Cylinder...20 MAINTENANCE...21 Case Test Mode...21 Cleaning...21 PNEUMATIC PARTS - WHAT THEY ARE AND DO...22 CHAPTER TAPE HEAD / SEALER...24 ASSEMBLY (FIGURE 2)...25 INSTALLATION...26 TAPE LOADING...28 ADJUSTMENT...30 ALIGNMENT OF TAPE HEADS...32 MAINTENANCE...33 CARE OF TAPES...36 TROUBLESHOOTING...37 SEALER PARTS REPLACEMENT...38 i

4 SERVICE POLICY...40 WARRANTY...41 SPARE PARTS KIT INFORMATION...42 PARTS SECTION...44 ASSEMBLY/PARTS/SCHEMATIC DRAWINGS CARTON FEEDER ASSEMBLY MAGAZINE ADJUSTER ASSY. - L.H MAGAZINE ADJUSTER ASSY. - R.H BOX FEED CONTROL ASSY WELDED FRAME ASSEMBLY L.H WELDED FRAME ASSEMBLY R.H VALVE ASSEMBLY CARRIAGE CYLINDER ASSEMBLY MAGAZINE LIFT ASSEMBLY - L.H MAGAZINE LIFT ASSEMBLY - R.H SLIDING DOOR ASSY. L.H SLIDING DOOR ASSY. R.H MAGAZINE GUIDE ASSY. - R.H MAGAZINE GUIDE ASSY. - L.H FLAP KICKER L.H FLAP KICKER R.H BOX OPEN & SQ. ARM ADJ. ASSY. 200L BOX OPEN & SQ. ARM ADJ. ASSY. 200R CONTROL PANEL CARRIAGE L.H CARRIAGE R.H ELECTRIC ON DEMAND MANIFOLD TYPICAL L.V. LAYOUT - R.H TYPICAL L.V. LAYOUT - L.H PNEUMATIC SCHEMATIC PNEUMATIC LADDER SCHEMATIC SEALER SECTION TAPE HEAD ASSEMBLY...CP LEADING TAPE ARM ASSEMBLY...702A-NC.001 TRAILING TAPE ARM ASSEMBLY...712A-NC.001 BRAKE ROLLER ASSEMBLY, 2" PLASTIC CUT-OFF ARM ASSEMBLY...741P-C.000 CORE HOLDER ASSEMBLY STARTER ASSEMBLY SIDE ARM ADJUSTER ASSEMBLY 200 I R.H SIDE ARM ADJUSTER ASSEMBLY 200 I L.H SIDE DRIVE ASSEMBLY 200 I R.H SIDE DRIVE ASSEMBLY 200 I L.H ELECTRIC SCHEMATIC ii DURABLE PACKAGING CORP. Printed in USA

5 SPECIFICATIONS OPERATION: The exclusive Squaring-Arm pulls a case from the magazine, squares it, then grips the case on three sides as the flap kicker kicks up the trailing minor flap. The carriage then advances, folding the lead minor flap. It then transfers the case to the drive side belts and the major flaps are closed. The case is then sealed. FEATURES: * Welded Steel Frame * Easy To Operate * Simple Changeover * On - Demand or continuous Operation SPEED: Up to 20 c.p.m. (based on case characteristics) AIR REQUIREMENTS: 80 p.s.i., approx. 3/4 c.f./cycle ELECTRICAL REQUIREMENTS: 120 Volts VAC single phase MAGAZINE Capacity: Up to 125 cases (depending on board test), optional 300 and 500 case extended magazines. MACHINE DIMENSIONS: Overall Height: 63 1/2" Overall Width: 87 1/2" Overall Length: 109 " TABLE HEIGHT: Standard: 24" to 34" Optional: 22" CASE SIZE RANGE: OPTIONAL: Consult factory STANDARD ** Min Max Length: 8 (1) 20 Width: 6 16 Height: 4 (2) 16 **THE STANDARD MACHINE MAY NOT ACCOMMODATE CERTAIN CASE SIZE COMBINATIONS (i.e. SHORT HEIGHT AND LONG LENGTH AND WIDTH). CONSULT THE FACTORY. (1) This dimension may be exceeded if length plus one half of width is less than or equal to 28". (2) This dimension may be exceeded if height plus one half of width is less than or equal to 24". AVAILABLE Options: * Pack Station (PS-2) * Quick Change Pack Station (PS-100-2A) * Electric Signal On-Demand (air signal on-demand standard.) * Power Driven 300 or 500 Case Magazines DURABLE PACKAGING CORP. Printed in USA iii

6 A WORD OF CAUTION READ DO NOT DO NOT DO NOT DO NOT DO NOT These instructions before operating the machine. Be sure you understand them. If you do not, ask a supervisor to explain them. Remove any guards or bypass any safety devices on the machine. They are for YOUR protection. Put fingers, hands, elbows, etc. into the operating areas of the machine unless power is off. Wear ties, loose clothing or any other items that may become entangled in the machine. Lay tools, food or personal equipment on the machine where it may fall into working area. Become over-confident; most accidents occur when people are over-confident, tired or distracted. It is the purchaser s responsibility to request or implement specific design changes in the equipment to comply with any special safety regulations, procedures or operational conditions required by the purchaser s corporate policies. DAILY SAFETY CHECKS 1. Inspect the machine before turning on the power. Look for loose, worn, damaged, or broken parts. Check for loose chains or belts, and kinks in air hoses, etc. 2. Report any usual actions or noises of the machine to your supervisor. Check that all the guards are in place and working. DURABLE PACKAGING CORP. Printed in USA v

7 Chapter 1 INTRODUCTION The TGA-200 is a pneumatically actuated case erector that is adjustable to form cases in a variety of cubic sizes. Both left hand exit (TGA-200L) and right hand exit (TGA-200R) models are available. A durable frame supports: (1) The magazine assembly for the feeding of cases; (2) The squaring arm, which picks off a flat case, erects it, and closes the trailing minor flap; (3) The carriage assembly, which closes the lead minor flap and delivers the box to the sealer belts. The integral case sealer transports the box over the major flap folding rods, and the taping head, then out of the machine. For those unfamiliar with air components, a description of various components is included in the section "Pneumatic Parts -- What They Are And Do." LEFT HAND AND RIGHT HAND MODELS The left hand model TGA-200L is designed for cases with right side up printing on the case side positioned to the right of the manufacturing joint of the case. The right hand model TGA-200R is designed for cases with right side up printing on the case side positioned to the left of the manufacturing joint of the case. The manufacturing joint of each case is faced away from the machine when placed in the magazine. INSPECTION AND SET-UP OF UNIT 1. Inspect the machine for any damage that may have occurred during shipment. 2. Check and remove any shipping bindings from the unit's mechanisms. CAUTION: Lock collars are used to secure the carriage plate assembly during shipping. Remove both lock collars. DO NOT LEAVE THEM ON THE SHAFT. 3. Install the case erector machine on level surface with sufficient surrounding area to position magazine. Install leveling legs and level machine. 4. (Refer to Magazine Assembly DWG or ) Remove all shipping bindings securing the magazine to the erector. While lifting up from the bottom of the magazine, swing the top out away from the erector. Position the magazine so that it is angled down towards the machine at approximately twenty degrees from horizontal, and align the magazine side rail mounting holes with the corresponding mounting holes in the side frame. Attach the nuts and bolts supplied and tighten them and the hardware securing the magazine side rail braces. (See note on following page.) Note: The angle of the magazine in relation to the frame can be changed by repositioning the side braces in the magazine side rails. DURABLE PACKAGING CORP. Printed in USA 1

8 LUBRICATION CAUTION: Do not attempt to fill the lubricator under line pressure. If the lubricator has not been supplied filled with oil, proceed to fill according to the. procedure following steps Before connecting air to the machine, fill the air lubricator Ref. assembly No or Part No ) with S.A.E. No. 10 non-detergent oil. The oil should be paraffin base mineral oil with aniline point in the range viscosity of seconds at 100 Deg. (S.A.E. No. 10). The following oils or exact equivalents without additives are satisfactory: MANUFACTURE Esso Gulf Oil Co. Gulf Oil Co. Atlantic Richfield Shell Oil Co. Shell Oil Co. Socony Mobil Socony Mobil Socony Mobile Standard Oil Co. Sun Oil Co. Sun Oil Co. OIL NUMBER Spinesstic 38 Gulfcrest 44 Gulfcrest 41 Duro Oil 150 L1001 # 27 Light Mobil DTE Light Velocite #10 Mobil-Kote #501 Stanoil #15 Sunvis #16 Sunoco 916 or DURABLE PACKAGING CORP. Printed in USA

9 The use of kerosene, animal or vegetable fats should be avoided for additives or cleaning agents. AIR LINE AND ELECTRICAL CONNECTIONS 1. Blow out the hose for several seconds, before connecting the air to the machine. Connect the plant air feed which must be at least 90 p.s.i. 2. The gauge on the machine should read 75 p.s.i. Do not change this setting. Any adjustments to the regulator will affect the pre-set timing cycles. 3. Plug the 3-pronged electrical cord from the sealer section into the 115 Volt polarized grounded outlet. DO NOT ATTEMPT TO DEFEAT THIS GROUND. DURABLE PACKAGING CORP. Printed in USA 3

10 SAFETY PRECAUTIONS 1. DO NOT PUT HANDS OR HEAD INTO CARRIAGE AREA WHEN MACHINE IS IN OPERATION. MAKE SURE EMERGENCY STOP SWITCH IS FULLY PRESSED IN BEFORE MAKING ADJUSTMENTS. 2. CAUTION: IF THE MACHINE IS STOPPED BY THE EMERGENCY STOP BUTTON DURING A CYCLE, MANUALLY PUSH THE CARRIAGE BACK TO ITS "HOME POSITION". BEFORE RESTARTING PUSH THE SQUARING ARM WITH THE SUCTION CUPS AGAINST THE CASES IN THE MAGAZINE. THE NORMAL STOPPING PROCEDURE IS TO TURN THE 3 POSITION SELECTOR SWITCH TO THE OFF POSITION. INSPECTING CASES PRIOR TO SET-UP To check the cases follow this procedure: 1. Are the cases all the same size? 2. Are they oriented all the same way in a bundle? 3. Are they cut square and even? 4. When manually rotated open, can the minor flaps be closed without interference with the major flaps? (Case slots must be wide enough to allow clearance.) 5. Are the slots even? Is manufacturing joint glued straight and spaced properly? 6. If the cases have a glued manufacturer's joint, is there excess glue on the inside essentially gluing the case together? Please check each shipment of cases to assure quality boxes are being supplied. 4

11 NOTES DURABLE PACKAGING CORP. Printed in USA 5

12 Chapter 2 CASE SIZE CHANGE-OVER 1. Before you begin Push in the RED Emergency stop button located on the control panel, and turn the selector switch (S.S.I.) to the off position. This will prevent accidental start-up during changeover. Refer to figure 1. Pull the box feeder all the way to its back position and latch. Remove all the cases from the magazine. NOTE: Major panels are not used for the case width measurement. The manufacturer seal is located only on the right or left major flap. 2. Measure the case width Open a case until it is squared. Hold the case so that the width end with the glued joint is facing you. 3. Set the scaled magazine siderail Loosen the two locking levers that hold the scaled siderail in position. Reposition the guide so that its outside edge indicates the previously measured width dimension on the scale. Tighten the locking levers. Refer to figure 3. NOTE: Do not measure the side of the cases that has the glued joint. Place the opposite width end of the case against the scale on the magazine. Measure the width of the case against the scale on the front of the magazine. You will use this dimension for all the scale setting on the machine. Refer to figure 2. 6

13 5. Set the Tri-Grip suction cup Loosen the small locking lever on top of the suction cup bracket and position the bracket so that its pointer indicates to the previously measured width on the scale. Tighten the locking lever. Refer to figure Set the magazine height Rotate the magazine lift crank, located below the magazine, clockwise (up) or counterclockwise (down) is to position the pointer to indicate the previously measured width dimensions on the scale. Refer to figure 4. NOTE: If the cup on the Tri-Grip tends to drag on the case, move cup scale setting no more than 1/4" wider than the case setting. 6. Set the squaring arm A constant center line is designed into the case erector. The squaring arm adjustment centers the width of the case to the plow (machine center line). Set the squaring arm through the rear door by pivoting it away from the home position and then squaring the arm. Refer to figure 6A. NOTE: While at this station, unlock the magazine guide clamp handle. DURABLE PACKAGING CORP. Printed in USA 7

14 Check to be sure that the vacuum selector switch (S.S.3) mounted on the control panel is in the activated (pulled out) position. Next, loosen the large locking lever on top of the squaring arm. Using the scale and pointer located behind the arm, position the arm so that its pointer indicates the previously measured width dimension on the scale. Tighten the locking lever. Return the squaring arm to the home position. Refer to figure 6B. NOTE: The next operation is only required for extremely long or high cases. The position of the outermost suction cup is changed only if the case length or height varies greatly. For extreme length variances loosen the two socket head cap screws and move the mounting channel horizon tally so that the suction is distributed evenly. This is usually required on only the outermost cup. Make certain that the two vertically aligned vacuum cups are positioned close to the score of the case side. For extreme height variance, vertical movement is accomplished by loosening the screw on the vertical channel. Loosen ONLY the screw entering the square nut in the channel for vertical movement. The adjoining screw, which adjusts the equal lengths of the vacuum cup pipes, is factory set. If the adjoining screw setting has been changed, it must be readjusted to have a 4" space between the edge of the aluminum block and the inner surface of the suction cup. NOTE: Before starting the machine after setup, always return the squaring arm to the home position. 7. Set the carriage Pull the carriage away from the home position (figure 7B). Loosen the two locking knobs securing the carriage wheels. Position the pointer so that it aligns with the previously measured width dimension on the scale. Tighten the locking knobs. Refer to figure 7A. 8

15 NOTE: Before starting the machine after setup, always return the carriage unit to the home position 8. Set the opposite magazine braking siderail Loosen the two locking levers that hold the unscaled braking magazine siderail in position. Turn off the brake cylinder set up switch (SS-4). Place an unerected case into the magazine with one edge held against the previously set scaled magazine siderail. With the magazine brake cylinder in the retracted position adjust the opposite magazine braking siderail. The magazine braking siderail should have approximately 1/8" to 1/4" clearance between it and the edge of the case. Tighten the locking levers. Refer to figure 8. NOTE: The plow is never adjusted up, down, left, or right. The height of the lead flap folder mounted on the plow must be the same as the flap kicker ( see flap kicker assembly) when the kicker is in the up position. Push the carriage back to the home position and close the rear door. Refer to figure 7B. NOTE: Do not move the middle rail section that contains the box feeder. 9. Set the box feed control height Loosen the opposing locking lever on the magazine guide assembly. Place an unerected case the magazine with the bottom of the case against the bottom box stops of the magazine. Holding the case up vertically, lower the box feed control assembly until the flat of the top DURABLE PACKAGING CORP. Printed in USA 9

16 box stop is 1/16 to 1/8 of an inch above the top edge of the case. Tighten the locking levers on both sides. Refer to figure 9. For square cases, position the top box stop over only one flap, the flap closest to the sealer section. The springs should not fall into the slot in the case. They should be no closer than one inch from the case slot. Refer to figure 10B 10. Center the box feed control Insert a case into the magazine. Unlock the clamp handle of the box feed control. Using the clamp handle as a reference point move the box feed control until it is approximately centered on the case. Refer to figure 10A. 11. Load cases in magazine Before loading cases into the magazine make certain that the squaring arm and carriage are in the home position. Refer to figures 6B and 7B. Pull out the Emergency Stop button to restore power to the erector. Load a minimum of 25 cases into the magazine. Make certain that all the cases are aligned in the same direction and that the first case does not go 10

17 beyond the bottom box stops. Refer to figure 9. The minor (width) panel facing away from the machine always goes toward the machine exit. The major (length) panel on the side facing toward the machine always goes toward the machine exit. Refer to figure 11. Unlatch and lower the box feeder (weight with handle) against the cases. Switch on the magazine brake (S.S.4) located on the side of the magazine. Refer to figure Rotate the three position selector switch (figure 12B) from the OFF position (A) to the AUTO position (B) to allow a case to start forming. When the case has squared, rotate the selector switch to the OFF position (C). NOTE: A loading bar is provided with your machine so that you can load the magazine while the machine is running. To use the loading bar first place the loading bar behind the cases in the magazine. Next pull the case feeder up and latch it at the top of the magazine. Load additional cases behind the loading bar. After the magazine is loaded unlatch and lower the case feeder against the cases and remove the loading bar. 12. Set the sealer belts 1. Open the sealer belts wider ( x ) than the carriage wheels by rotating the crank in the open direction. Refer to figure 12A. DURABLE PACKAGING CORP. Printed in USA 11

18 3. Close the belts on the sealer until they come in contact with the sides of the case. Refer to figure 12C. Start the sealer belts to complete the change-over. 13. Operating procedures After completing the set-up, you must make a decision on which mode of operation you would like to use. Refer to figure 13. THE HAND (on demand) MODE: This mode of operation gives the operator flexibility to make a case when and if the needed. With the switch in the HAND position, cases are continuously formed until a formed case blocks the standard photocell. The carriage then returns to and remains in the HOME position until the case blocking the eye is removed to initiate another cycle. The formation of cases can also be controlled by an optional limit or foot valve at the exit end of the machine. THE AUTO MODE This mode of operation will start the erector and continually cycle even if all the cases have been exhausted. If a jam occurs, or if for any reason the machine must be immediately stopped, press the EMERGENCY STOP button and the machine will stop in its cycle. After the jam is cleared, manually push the carriage back to the HOME position and then (1) set the selector switch to the OFF position, (2) twist EMERGENCY STOP button to reset, (3) set the selector switch to desired position (i.e. HAND or AUTOMATIC), (4) push the start button. 12

19 Chapter 3 PNEUMATIC - MECHANICAL OPERATION Refer to the schematic (dwg ) of the pneumatic system, the Pneumatic Ladder Schematic (dwg ) and to the location drawing of limit valves and cylinders (drawing or ) while reading the description below of the pneumatic and mechanical events during one cycle of the machine. As illustrated, a filter and regulator are in the air line at the input to the machine. The regulator is set for 90 PSI. Filtered, unlubricated air is supplied to the vacuum pumps. A lubricator located on the pillar supplies filtered, lubricated air to all other pneumatic components. The lubricator is set to supply approximately one (1) drop of oil every seven (7) cycles. With the machine in the HOME position, the following events occur in one cycle as the switch is placed in the AUTOMATIC or HAND position. A. Limit valve LV-1 is in a passing position. (Switch S.S.1 is in HAND or AUTO position.) B. Air is applied through LV-1 and S.S.1 to the #14 pilot of power valve PV-1. C. PV-1 shifts. Air is applied through PV-1 to the #12 pilots of PV-5 and PV-2. D. PV-5 shifts to create a vacuum at the vacuum cups to secure the case. PV-5 also exhausts the 90 PSI pressure from the rod end of the squaring cylinder, allowing the 5-15 PSI present on the piston end of this cylinder to extend it. E. PV-2 shifts to retract the pivot cylinder No.1. The secured case is formed as its case side is momentarily restrained by the holdback finger and the opposite case side is pulled back by the vacuum cups as the squaring plate rotates by the action of cylinder No.1. Simultaneously the action of the squaring cylinder No.2 rotates the squaring arm to finish the fold and form the squared case just before cylinder No. 1 finishes its stroke. At the end of the pivot cylinder No.1 stroke, LV-1 becomes non-passing. F. Near the end of pivot cylinder No. 1 stroke, a pin actuates LV-2 to apply air to the #12 pilots of PV-3, PV-4 and PV-6. NOTE: The squaring pressure regulator supplies a reduced pressure to the squaring cylinder during its cycle. It is factory set to permit the case to be formed smoothly by coordinating the rotation rate of the squaring arm with the rotation rate of the squaring plate. Improper adjustment of this setting will drastically alter the performance of the machine, therefore caution should be used when changing this setting. Refer to Pneumatic Devices Adjustments for instructions if adjustment becomes necessary. G. PV-3 shifts to supply 90 PSI to PV-7 and to apply air to the #14 pilot of PV-7. PV-7 shifts to increase the squaring pressure from 5-15 PSI up to 90 PSI to insure the completion of the squaring process. DURABLE PACKAGING CORP. Printed in USA 13

20 H. PV-6 shifts to establish the flow path from PV-4 to the carriage cylinder. PV-4 shifts to cause the kicker cylinder No.3 to extend and apply the flap kicker to close the trailing minor flap of the case. I. PV-4 also retracts the carriage cylinder No. 4, which advances the carriage towards the box. The lead flap folder folds the lead flap and the carriage wheels position themselves along the sides of the box. J. LV-3, located on the edge of the carriage, is actuated as the carriage nears the end of its travel. K. When LV-3 becomes passing, air is applied to the #14 pilots of PV-5, and PV-3. L. PV-3 shifts to release the signal from PV-7. PV-7 then shifts the pressure on the piston end of the squaring cylinder from 90 PSI back down to 5-15 PSI. Simultaneously, PV-5 shifts to cut off the 90 PSI to the venturis and applies 90 PSI to the rod end of the squaring cylinder, retracting it. M. As the carriage reaches the end of its travel towards the squaring arm, LV-4 is actuated. LV-4 applies air to the #14 pilot of PV-4. PV-4 then retracts the flap kicker cylinder and extends the carriage cylinder, starting the carriage towards the home position. N. As the carriage is driven further back, LV-5 is actuated and applies a signal to the #14 pilot of PV-2. PV-2 shifts, supplying air to extend the pivot cylinder, returning to the home position. O. As the carriage is driven further back, LV-6 is actuated and applies a signal to the #14 pilot of PV-6. PV-6 shifts, supplying a speed cushion for the carriage return. P. LV-1 is engaged and becomes passing. The photoeye, with the selector switch in the HAND position, stops the machine in the HOME position. When the photoeye is actuated by the leading edge of the exiting case, air supply to LV-1 is shut off. The photoeye may be located downstream from the case erector, if desired. Q. The weight of several cases in the magazine actuates LV-7 and LV-10. LV-7 becomes passing to extend brake cylinder No. 5. The brake cylinder applies force on the guide rail and acts to prevent the weight of the rear cases in the magazine from exerting excessive pressure on the forward cases. R. LV-10 becomes passing to extend brake cylinder No.6 which applies force on the top edge of the case (in fourth or fifth position in the magazine) to assist in limiting pressure on the forward cases. S. When the sliding doors are opened, the LV-9 becomes passing. The air is applied to the #12 pilot of the PV-9. The PV-9 shifts to cause shut off of the air supply on the manifold. Simultaneously, air/electric switch shifts off power on the electric motors. The erector is then shut down. 14

21 SWITCH S.S.3 When the red emergency stop button S.S.2 and the knob of the vacuum selector switch S.S.3 are pushed in, a vacuum is applied to the cups without air being applied to any other part of the machine. This feature is used in checking the process of squaring the cases, checking the amount of vacuum, and filter disc cleaning TROUBLESHOOTING Adjustments to the machine are necessary when a change-over in the size of cases occurs. Additional adjustments may be required when the grade of the case stock used is changed, when humidity alters the texture of the stock, or other conditions vary. SUCTION CUP PROBLEMS Suction cups do not pull box from magazine, or partially pull and then drop the box. Possible Solutions: A. Box feed control is too low and holding back case. Position control at higher level. B. Side guides are holding cases too tightly or too long. In order to prevent cases from falling into the machine while the arm is in the delivery position, pressure is applied to one of the magazine side guide rails by cylinder No. 5. Flow controls and a regulator attached to LV-7 control the speed and pressure of cylinder No.5. Both the speed and pressure to the cylinder may have to be adjusted depending on the size and weight of the cases being run. This is a trial and error setting procedure. C. If the squaring arm cylinder starts with the initial squaring pressure set too high, the suction cups will be pulled off of the box. Refer to Pneumatic Devices Adjustment for the procedure for setting the squaring pressure. D. Check that the box feeder moves up and down the feeder guides smoothly and that the cross members on the box feeder are adjusted up and down to yield a firm even pressure against the cases. E. Check that suction cups are parallel (in HOME position) with case side. Approximate setting of suction cups is 4 inches from aluminum clamp block to button inside of vacuum cups. F. Check the vacuum at each suction cup. At 75 P.S.I. on the main regulator each cup should pull approximately 8 to 9 inches of mercury. Proceed as follows to check the vacuum. NOTE: If a vacuum gauge is not available, one can be purchased from Durable. The part number is The vacuum test plate part No. is DURABLE PACKAGING CORP. Printed in USA 15

22 1. Push in both the red emergency stop S.S.2 and black vacuum buttons S.S.3. This will start the vacuum. Place test assembly (consisting of vacuum test plate part no and gauge part no ) against the erector vacuum cup. After getting a reading, block vacuum generator exhaust to remove test plate. Repeat this test for each cup. If the vacuum is less than 7 to 8 inches of mercury, check that there are no leaks in the power air lines or fittings that connect the vacuum pumps to the suction cups. If any leaks are found, repair or replace the line or fitting as required. Reset for vacuum. If the vacuum reading is still low, flush the filter disc located inside the vacuum cup by removing the tube from the fitting and using an air gun alternate air bursts into the open fitting then the filter disk. With the line still off place a finger over the exhaust located on the bottom end of the venturi. This will reverse the air flow and flush any corrugated dust out of the vacuum,inspect for any build-up of case fibers and remove. Reinstall in reverse order. If the low vacuum problem persists, using an Allen wrench remove the cap off the venturi and clean the vacuum generator pump. 2. A second method is more of a case porosity test. With the vacuum gauge, insert the gauge in a series circuit between the vacuum cup and venturi and place the suspect case on the cup and follow the chart below. VACUUM RESULTS (10) In. Hg. VACUUM COMPLETELY BLOCKED (5) In. Hg. CASE SHOULD PULL OUT, LOOK FOR to (10) In. OTHER FORMS OF RESISTANCE ON Hg. THE CASE. (4) In. Hg. CASE POROSITY IS BORDER LINE. CONSULT CASE MANUFACTURE TO BELOW (4) In. Hg. DECREASE POROSITY IN LINER CASE WILL MOST LIKELY NOT RUN CONSULT CASE MANUFACTURE FORMED CASES ARE NOT SQUARE. Possible Solutions: A. Check to determine if cases are square and flat against squaring plate. Cases should not be away from or crushed into squaring plate. B. Check to insure that scale settings on squaring plate and magazine are set for the carton's width. C. If scale settings are correct, make sure the squaring plate stops at 90 degrees to the carriage rollers, when box is rotated. Adjust cylinder rod end of pivot cylinder, if necessary, to accomplish this. This is rarely necessary. 16

23 CAUTION: IN STEPS C AND D CHECK CUSHIONS OF CYLINDERS TO DETERMINE THAT CYLINDERS AREN'T SHORT STROKING. DO NOT MAR PISTON ROD D. Check that squaring arm is at a 90 angle with the squaring plate. Adjust rod end of squaring cylinder, if necessary to accomplish this. E. If steps B, C, & D above are correct and the box is not square and flat against squaring plate, move the two magazine side rails toward the squaring arm the same distance that the box was distanced from the squaring plate. F. If steps B, C, & D above are correct and box is crushed into the squaring plate, move the two magazine side rails toward the box exit. G. To check these adjustments for a square box, start with machine in HOME position. Press in vacuum selector switch S.S.3. Push the EMERGENCY STOP button. Power is now cut off, but the vacuum is activated to hold the box. Pick one case from magazine with cups and manually rotate squaring plate pivot cylinder retracted) and the square arm (squaring cylinder extended). Box should be "square" and held flat but not crushed against squaring plate. Repeat magazine side rail adjustments, if necessary. CAUTION: Before starting machine for normal operation, return machine to HOME position and pull outward the knob on vacuum selector switch S.S.3. Pull outward the EMERGENCY STOP button. BOXES JAMMING AFTER PICK-OFF Possible Solutions: A. Rear flap kicker cycles before boxes are squared. Adjust (clockwise) flow control at rod end of flap kicker cylinder for slower operation. B. Partially closed rear flap strikes plow. Adjust (counterclockwise) flow control at rod end of flap kicker cylinder for faster operation. C. Rear minor flap hits major flap as flap kicker cycles. Open flap kicker cylinder flow control to full speed. This might allow the flap kicker to force the minor flap past the major flap. Have case manufacturer cut a wider gap between flaps. D. Case raises up, drops off vacuum cups, or jams when rear flap kicker actuates. In this case the magazine is set too low, raise magazine with lift crank. E. The rear flap is not fully closed when the rear flap kicker actuates. In this case the magazine is set too high. Lower the magazine with the lift crank. DURABLE PACKAGING CORP. Printed in USA 17

24 F. Break fault is present in cases near the vertical score on the cases. Lighten pressure on hold back spring. G. Cases break in center when lead minor flap of cases strikes the lead flap folder. Check the setting of the magazine. Adjust up if necessary. H. Cases do not open but fold into an "L" shape. Check inside of cases for glue, apply more downward pressure with the holdback spring. The holdback spring must slightly open the case before the arm takes over. NOTE: The position of the spring depends on the board test and stiffness of the cases. For heavy test cases the spring should be set at a steep angle and tightly pressed onto the box. For light test cases the angle should be slight and the spring set to grip box No. 1. This is a trial and error setting. I. Cases are crushed on plow. Check to see that the carriage rollers are equally spaced from the plow, readjust if required. Check that plow is in the center of machine. This is a factory setting. Make sure that pivot and squaring cycles are completed before carriage cylinder drives case into plow. Check that the plow is set at the same height as the trailing flap kicker. Check that magazine is at the right height. Check that the carriage rollers are not too tight. ROUGH OPERATION OF THE SQUARING ARM Arm "snaps" to the squared position after the pivot cylinder has finished its stroke. This is typically due to the squaring pressure being too low. Refer to Pneumatic Devices Adjustments for the procedure for setting the squaring pressure, step 2. PNEUMATIC DEVICES ADJUSTMENTS. PNEUMATIC DEVICES ADJUSTMENTS SQUARING PRESSURE ADJUSTMENT Step 1. Stop the machine, push in the emergency stop, and empty the magazine. Open the sliding door and locate the squaring pressure regulator, mounted near the manifold assembly. Gradually lower the squaring pressure (rotate the black knob 1/8-1/4 turn counterclockwise) and cycle the machine. Repeat this until the arm "snaps" to the squared position after the pivot cylinder has finished its stroke. Step 2. Gradually raise the squaring pressure (rotate the black knob 1/8-1/4 turn clockwise), cycling the machine after each adjustment, until the squaring cylinder finishes its stroke just prior to the pivot 18

25 cylinder finishing its stroke. This allows the squaring cylinder to operate smoothly at the lowest possible squaring pressure. DURABLE PACKAGING CORP. Printed in USA 19

26 CARRIAGE CYLINDER NO.4: Speed to HOME: The initial speed of the carriage to HOME is controlled by the flow control mounted on PV-6. When LV-6 is actuated to shift PV-6, the cushioning of the carriage to the HOME position is controlled by a more constricted flow control attached to PV-6. CARRIAGE CYLINDER No.4: Speed to deliver box: The speed of the carriage to the deliver box position is controlled by a flow control located on the back end of the carriage cylinder. PIVOT CYLINDER No.l: Speed to rotate: The speed to rotate is controlled by a large flow control on the back end of the cylinder. PIVOT CYLINDER No.l: Speed to HOME position: The speed to home is controlled by a flow control on the rod end of the cylinder. SPEED to SQUARE BOX: Controlled by the squaring pressure regulator. KICKER CYLINDER - Speed up: The flow control is located on the rod end of the kicker cylinder. KICKER CYLINDER - Speed down: The flow control is located on the back end of the kick cylinder. BRAKE CYLINDER The flow controls to regulate the speed of the brake cylinder are located under LV-6 (see typical valve & cylinder layout). 20

27 MAINTENANCE Maintenance is minimal for the TGA-200 case erector, but conducting the following program should insure trouble-free operation. The frequency of performing. these tasks is determined by the length of time and the frequency of the machine runs follow the chart below. CHECK ITEMS HIGH MODERATE LOW 7600 CASES PER SHIFT 3800 CASES PER SHIFT 1900 CASES PER SHIFT INSPECT AIR TUBING 6 MONTH 6 MONTH 6 MONTH FILL LUBRICATOR WEEKLY WEEKLY 2 WEEKS INSPECT BEARINGS 3 MONTH 6 MONTH 6 MONTH INSPECT SHAFTS 3 MONTH 6 MONTH 9 MONTH OIL SHAFTS DAILY WEEKLY WEEKLY INSPECT VACUUM CUPS WEEKLY MONTHLY 3 MONTH FITTINGS 6 MONTH 6 MONTH 9 MONTH FILTER DRAIN DAILY DAILY DAILY CLEAN FILTER DISKS DAILY WEEKLY MONTHLY INSPECT SEALER BELTS MONTHLY MONTHLY MONTHLY OIL TAPE HEAD BLADES DAILY DAILY DAILY BLOW OFF ERECTOR DAILY WEEKLY WEEKLY See trouble-shooting adjustments for suction cups, paragraph F (1) for cleaning procedure. Following the above procedures will greatly improve the performance of your erector CASE TEST MODE When the red emergency stop button is pushed in, and the knob of the vacuum selector switch S.S.3 is rotated to manual position, a vacuum is applied to the cups without air being applied to any other part of the machine. This feature is used in checking the process of squaring the cases, checking the amount of vacuum, and filter disc cleaning. CLEANING Pneumatic elements on the machine are well sealed. But industrial dust should be wiped from the machine once a day to insure proper performance. DURABLE PACKAGING CORP. Printed in USA 21

28 PNEUMATIC PARTS - WHAT THEY ARE AND DO Air Cylinder A closed metal cylinder of various diameters used to obtain an in-out motion. It has two ports, one on the "rod" end, one on the "back" or piston end. Power Valve An air switch used to reverse an air flow. The switch can be operated by a small air cylinder called a pilot, a spring or in other machines by hand, electrically, etc. Flow Control To control the speed of an air cylinder, exhaust air flow is restricted somewhat by a flow control. A flow control allows unrestricted flow into a cylinder and an adjustable restricted exhaust flow. The TGA-200 uses both knob or screwdriver adjustment types of flow controls. Counterclockwise adjustment allows more flow (faster speed) and clockwise adjustment allows less flow (slower speed). Limit Switch A mechanically operated air switch that opens or closes an air path. Pressure Regulator Controls air pressure reaching the machine or parts of the machine. Shuttle Essentially an air tee with check valves. Allows air to flow in or out an arm and to and from the leg but not arm to arm. Oiler Air systems require some oil to lubricate the cylinder and control valves. The TGA-200 oiler adds one drop of oil approximately every 7 cycles. No oil is added to the vacuum pump supply air. Non-detergent spindle oil is to be used. Vacuum Pump A venturi device that uses compressed air to create a strong vacuum. 22

29 NOTES DURABLE PACKAGING CORP. Printed in USA 23

30 Chapter 4 TAPE HEAD / SEALER The Durable Model CP-39 tape head is designed for both top and bottom installations. Both installations are covered in this section. Reference the pages that cover your machine s requirements. The tape head applies a U clip of pressure-sensitive tape to the top or bottom center seam of RSC (regular slotted cartons). Tape will be applied on the center of POL (partial overlap) cartons and FOL (full overlap) cartons. Your sealer works well with many machinery grade, pressure sensitive tapes. However, we recommend that you test your tape for acceptable performance. NOTE: Durable Packaging neither warrants nor recommends the use of any particular tape. Tape properties are subject to change by tape manufactures and Durable Packaging has no control over such changes. The customer assumes all responsibility for the quality and performance of tape. Although testing helps to characterize performance, long term satisfaction requires process quality control by the tape manufacture and proper tape storage and handling prior to use. (See care of tapes discussed later in this section.) 24

31 ASSEMBLY (FIGURE 2) Spare CP-39 tape heads come partially assembled for shipping purposes. The tools required to assemble the head are: Small adjustable wrench Standard slot head screwdriver (needed for setting the core holder) Phillips head screwdriver 1. Remove the tape head from shipping container, and discard the shipping wrapper. 2. Install the arm tension spring (1) by attaching the spring to the support post (2). 3. Install the cut-off arm spring (6) by attaching the spring to the support post (3). 4. Remove the nut (9), washer (10) and brake roller assembly (4). 5. Remove the phillips head screw (7) and nut (8). 6. Position the core holder support mount plate (5) on the outside of the tape head as shown and attach as follows: a. Align the mounting holes, install the phillips head screw (7) and secure with the nut (8). b. Install the brake roller assembly (4); secure it with washer (10) and nut (9). Figure 2 DURABLE PACKAGING CORP. Printed in USA 25

32 INSTALLATION Durable tape heads are interchangeable and can be used in top and bottom applications. Top Head (Figure 3) CAUTION: TURN OFF AIR SUPPLY AND ALL POWER BEFORE BEGINNING ANY WORK OR MAINTENANCE. 1. Assemble tape head. Refer to ASSEMBLY. 2. Raise the tape head (1) into position in the top of the sealing machine. Be sure that the front of the tape head faces the front of the machine. 3. Position the mounting plates (2) on top of the sealing machine flanges (3) and secure it with four #10-32 socket head flat head screws (5). 4. Snug-up mounting screws (5,). (Do not over tighten.) 5. Install a roll of tape. Refer to TAPE LOADING. 6. Adjust the tape tension, supports and tracking. Refer to ADJUSTMENT. 7. Align the tape head. Refer to ALIGNMENT OF TAPE HEADS. Figure 3 26

33 Bottom Head (Figure 4) CAUTION: TURN OFF AIR SUPPLY AND ALL POWER BEFORE BEGINNING ANY WORK OR MAINTENANCE. 1. Assemble the tape head. Refer to ASSEMBLY. 2. Install four alignment screws (2) in the four mounting holes (1). 3. Adjust the screws (2) so that the heads fit into the frame of the sealing machine. 4. Install jam nuts (3) (P/N S-30) on the screws (2) as shown. 5. Install a roll of tape. Refer to TAPE LOADING. 6. Adjust the tape tension, supports and tracking. Refer to ADJUSTMENT. 7. Position the tape head in the frame of the sealing machine. 8. Align the tape head. Refer to ALIGNMENT OF TAPE HEADS. Figure 4 DURABLE PACKAGING CORP. Printed in USA 27

34 TAPE LOADING NOTE: The bottom tape head must be lifted out of the sealing machine. CAUTION: TURN OFF AIR SUPPLY AND ALL POWER BEFORE BEGINNING ANY WORK OR MAINTENANCE. 1. Rotate the cam locking handle to the UNLOCK position. (See Figure 5) 2. Slide a roll of pressure sensitive tape (2) onto the core holder (4). The tape should be releasing from the left-hand side of the roll as shown (standard direction tape head). 3. Secure the tape roll by rotating the cam lock handle toward the LOCKED position (See Figure 5). Figure 5 Figure 6 28

35 4. Pull approximately 16 inches of tape out from the roll. Fold the end of the tape to eliminate tacky surfaces and to make threading easier. 5. Feed the tape first under the brake roller assembly (1, Figure 6), second over fluted roller (5), third through the opening in the front of the tape head and then down between the two tape supports (6). 6. Pull the tape hanging through the supports until the tape lies flat on all of the roller surfaces. 7. Pull the tape to the left (standard direction tape heads) and push upward on the rear roller (8) until the blade guard retracks and the tape is pulled across the blade, cutting the tape. DURABLE PACKAGING CORP. Printed in USA 29

36 ADJUSTMENT Tape Tension Some tapes release from the roll easily. Other tapes release with more resistance. Varying amount of tension are needed to obtain a clean tape cut off. Hard release tapes require less brake; easy release tapes require more. Periodic adjustments may be required due to the varying release characteristics of the tape. The tension knob (3, Figure 6) is used to put a slight brake on the tape roll. An additional braking adjustment can be made with the brake roller assembly (1, Figure 6). Both are important adjustments. Too little tension will result in the tape not being cut or uneven tape tab length. Too much tension stretches and wrinkles the tape and results in poor sealing or the tape snapping back. 1. Adjust the knob (3, Figure 6) until a perfect cutting of the tape is obtained. Turning the knob (3, Figure 6) clockwise increases the brake effect and turning the knob counter-clockwise decreases it. 2. If additional tension is required, adjust the knob on the end of the brake roller assembly (1, Figure 6). Turning the knob clockwise increases the brake effect and turning the knob counter-clockwise decreases it. 3. When using a fully loaded tape, more brake is required. After about half of the tape is used, braking should be lessened with the tension knob (3). Tape Supports The front tape support (2) must be in proper relationship to the tape and rear support (3). Figure 7 shows the proper positioning of the supports for smooth tape dispensing. During adjustment or replacement of the tape supports, the hexagon bar (1) may be rotated to achieve the illustrated position of the front tape support (2). To adjust, proceed as follows: 1. Using an open-end wrench or adjustable wrench, loosen the hexagon bar (1). 2. While holding the hexagon bar (1) with the wrench, use a phillips head screwdriver to loosen the screw (4). (Access to this screw is through a hole in the back cover plate.) 3. Adjust the position of hexagon bar (1). Figure 7 30

37 4. While holding the hexagon bar (1, Figure 7) in the correct position, retighten the phillips pan head screw. Tape Tracking The tape should be centered with the two plastic tape supports (2 and 3, Figure 7) and between the leather washers of the brake roller assembly (1, Figure 6) by moving the core holder (2) along its axle. To accomplish this centering: 1. Loosen the set screw (1) on the core holder axle. 2. Align the core holder (2) along its axle as needed to center the tape on the roller. 3. Retighten the set screw (1) to secure the adjustment. Figure 8 DURABLE PACKAGING CORP. Printed in USA 31

38 ALIGNMENT OF TAPE HEADS Top Head 1. Set the belts of the sealing machine for the width of a filled test carton. 2. Turn on the sealing machine and run the test carton through the machine. 3. Remove the carton, turn it 180 degrees and run the test carton through again. 4. Remove the carton and measure the offset difference between the first run and the second run. CAUTION: TURN OFF AIR SUPPLY AND ALL POWER BEFORE BEGINNING ANY WORK OR MAINTENANCE. 5. Loosen the mounting screws (5, Figure 3). 6. Adjust the tape head one half the distance determined in step 4 in the direction of the offset. 7. Tighten the mounting screws (5, Figure 3). (Do not over tighten.) 8. Run another test carton to check for proper adjustment. Bottom Head 1. Set the belts of the sealing machine for the width of a filled test carton. 2. If the sealing machine is equipped with a top taping head, raise it out of the way. 3. Turn on the sealing machine and run the test carton through the machine. 4. Remove the carton, turn it 180 degrees and run the test carton through again. 5. Remove the carton and measure the offset difference between the first run and the second run. CAUTION: TURN OFF AIR SUPPLY AND ALL POWER BEFORE BEGINNING ANY WORK OR MAINTENANCE. 6. Loosen the jam nuts (3, Figure 4). 7. Adjust the alignment screws (2, Figure 4) to move the tape head one half the distance determined in step 5 in the direction of the offset. The alignment screws (2, Figure 4) should be adjusted so that the head can be removed for tape loading. 8. Tighten the jam nuts (3, Figure 4). 9. Run another test carton to check for proper adjustment. 32

39 MAINTENANCE The taping head has been designed for long, trouble free service. The taping head will perform best when it receives routine maintenance and cleaning. Taping head components that fail or wear should be promptly repaired or replaced to prevent damage to other portions of the tape head. Lubrication CAUTION: TURN OFF AIR SUPPLY AND ALL POWER BEFORE BEGINNING ANY WORK OR MAINTENANCE. The tape head should be lubricated every 3 months or 250,000 cycles, whichever comes first. Refer to Figure 9 for lubrication points. Apply a small amount of multi-purpose grease. Blade Replacement NOTE: CAUTION: The bottom tape head must be lifted out of the sealing machine. TURN OFF AIR SUPPLY AND ALL POWER BEFORE ANY WORK OR MAINTENANCE. 1. If your machine is equipped with a top head, raise it out of the way. 2. Remove the spring (1, Figure 10) from the support post (2, Figure 10). This will allow the arms to retract along with the blade guard. CAUTION: THE KNIFE BLADE IS VERY SHARP. BE EXTREMELY CAREFUL WHILE HANDLING THE KNIFE BLADE. Figure 9 DURABLE PACKAGING CORP. Printed in USA 33

40 Figure 10 NOTE: The blade has a bevel cut on one side of the teeth and no bevel on the other side. Note the position of the bevel cut and the angle of the blade before removing. 3. Loosen the two screws securing the blade clamp (5) and remove the blade (4). 4. Position the new blade between the blade clamp (5) and the cut-off arm (3). Be sure that the bevel cut of the teeth faces the rear of the tape head and the blade is at a slight angle (See Figure 11). 5. Tighten the two screws securing the blade clamp (5). 6. Reconnect the spring (1) to the spring support post (2). Figure 11 34

41 Brake Roller Replacement and Cleaning The brake roller contacts the adhesive side of the tape. Use a solvent to clean the adhesive that may accumulate on the roller. CAUTION: NOTE: TURN OFF AIR SUPPLY AND ALL POWER BEFORE BEGINNING ANY WORK OR MAINTENANCE. The bottom tape head must be lifted out of the sealing machine. 1. Remove the nut (12), rib washer (11) and brake roller assembly. 2. Remove the screw (1) and washer (2) from the adjusting knob (3). 3. Unscrew the adjusting knob (3) from the axle (7). 4. Remove the four spring washers (4). Note the orientation of the spring washers for replacement. 5. Remove the D washer (5), leather washers (6), roller (8) and washer (9) from the axle (7). 6. Clean the roller (8) and the spring washers (4) with a solvent. Wipe off the axle (7) and coat it with a light grease. 7. Reassemble in the reverse order. Fluted Roller Cleaning CAUTION: NOTE: TURN OFF AIR SUPPLY AND ALL POWER BEFORE BEGINNING ANY WORK OR MAINTENANCE. The bottom tape head must be lifted out of the sealing machine. As the tape is pulled off the roll, some glue will remain on the unglued side of the tape. This residue glue can build up on the fluted roller (5, Figure 6). Use a solvent to clean the adhesive that may accumulate on the roller. Figure 12 DURABLE PACKAGING CORP. Printed in USA 35