MODEL 4FAC51 CONVEYORIZED STRETCH WRAP SYSTEM

Transcription

1 Kalamazoo Packaging Systems Division of Kal-Tek, Inc. MODEL 4FAC51 CONVEYORIZED STRETCH WRAP SYSTEM OPERATOR S MANUAL 1

2 Table of Contents Introduction...3 Warranty...3 Getting Started.4 Film Loading.4 Machine Layout... 5 Stretch Wrapper Console..6 Operating Instructions 7 Customer Service 8 Program Controls.8 Maintenance.8 Trouble shouting..8 Parts Manual Input Conveyor Turntable Disc Film Holder Turntable Turntable Disc Lock Pin Spiral Tower Sub Panel Controls Powered Prestretcher Film Arm w/ Cutter Output Conveyor Air layout..32 Telemecanique Drive settings..33 Wiring Diagram Modicon 984 PLC Program.44-2

3 Introduction Congratulations! Your purchase of a Kalamazoo Model 4FAC51 Stretch Wrap System will provide you with years of efficient spiral stretch wrapping of your product. Your investment will ensure that your products will arrive cleaner, with less damage and pilferage at their destination at a lower cost to you. Kalamazoo Packaging Systems products carry a LIMITED LIFETIME WARRANTY on all K.P.S. manufactured components; all parts not manufactured by Kalamazoo Packaging Systems will be subject to the original manufacturer s warranty. 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 during the warranty period, provided the purchaser gives immediate notice of any defect and description of that defect to KPS. KPS reserves the right to inspect any defective part to verify the defect and to determine probable cause of same. The liability of KPS under this warranty is limited to furnishing replacements for defective parts, and unless otherwise agreed to in writing, the purchaser shall bear the expense of installation. Failure of equipment or parts due to abuse, misuse, neglect, incorrect operating techniques or power line drops or surges shall not constitute failure because of defective material or workmanship, and are expressly excluded from this warranty. The above is the only warranty with no other guarantees which extend beyond the above and the seller disclaims any implications including but not limited to a warranty of merchantability. 3 Kalamazoo Packaging Systems, Inc.

4 Getting started! The machine will need to be placed on the floor per drawing 4FAC51-LO (next page). The conveyors and sensors will need to be wired into the main control enclosure. A power line of 460/3/60HZ. 40 amp. Will need to be supply to the machine and an 80 P.S.I. Air line. Once the machine is up and running it will need to be aliened, leaved, plumped and bolted to the floor. WARNING: MAKE SURE THAT POWER IS OFF BEFORE LOADING THE FILM Film Loading Your wrapper is equipped with our Kalamazoo Powered Prestretch Film Delivery System. Place a roll of 20 stretch film on the film core holder and thread per diagram below. After loading the film turn the power back on and lower the film holder place the film over the film holder and put the film holder back to auto. 4

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6 STRETCH WRAP CONSOLE POWER ON Turns system on the button will light up green. POWER OFF Turns system off. E-STOP - Shuts off the main control relay, stops cycle and resets timers and counters. STOP Stops the automatic cycle. CYCLE START - System is now ready to start loading the product. The green stack light will turn on. INTERRUPT WRAP CYCLE Interrupts the system. But does not reset timers and counters. The POWER ON light will flush fast. When the system is ready to start push the CYCLE START RESET TO HOME Resets the machine to the home position. Film carriage to the bottom limit switch, turntable to home position. REINFORCINR WRAPS Programs the amount of wraps on the bottom and top of the load. TURNTABLE JOG Manually runs the turntable only. ( will not work if the green stack light is on) FILM CARRIAGE RAISE/AUTO/LOWER Raise and lowers the film manual. ( will not work if the green stack light is on) FILM ARM FWD./AUTO/BACK Manually moves the film straitening arm. ( will not work if the green stack light is on) FILM HOLDER AUTO/LOWER After loading the film lower the film holder and place the film across the film holder guard and put the film holder back to auto. ( will not work if the green stack light is on) INPUT CONV. FWD/AUTO/REV. Manually runs the input conveyor, will not work if the machine is in the cycle start program. ( will not work if the green stack light is on) TABLE CONV. FWD/AUTO/REV. Manually runs the table conveyor will not work if the machine is in the cycle start program. ( will not work if the green stack light is on) OUTPUT CONV. FWD/AUTO/REV. Manually runs the conveyor will not work if the machine is in the cycle start program. ( will not work if the green stack light is on) 4 SPARE BUTTON HOLES 6

7 OPERATING INSTRUCTIONS 1 Turn the disconnect to on. 2 Push the Power On button. 3 Push the Cycle Start button. The Green stack light will come on. (signifies system is available) 4 Convey the product to the input conveyor, (note: attach the input conveyor sensor six inches in front of the input conveyor) as soon as the product gets in front of the sensor the input and turntable conveyors will come on and transport the product onto the turntable conveyor. The stack lights will change from Green to Yellow (signifies system in use) 5 The automatic wrap cycle will start. The turntable disc will ramp up to full speed and the film carriage will start to raise. Once the film carriage gets to the top of the product it will place the reinforcing wraps to the top and return to the bottom and place the reinforcing wraps to the bottom of the product. The turntable will decal to the home position and stop. The film arm will move the film over the film holder and the film holder will grab the film. The film arm hot wire will come on and cut the film. The film arm will move forward to wipe down the film and then move back out of the way. End of wrap cycle. 6 After the product is wrapped the turntable and output conveyors will come on and convey the product to the end of the output conveyor. The stack lights will change from Yellow to Green (signifies system is available) 7 The product is now ready to unload. 8 If the output conveyor is not unloaded and the next product is wrapped and waiting to be unload from the turntable conveyor the stack lights will change from Yellow to Red. (signifies system is full) 9 If the film runs out or breaks the turntable conveyor and film head will automatically return to the home position and the Red stack light will start flushing. Push the E-stop button. Reload the film. Push the Power On button. Place the film holder button to down, lay the film over the film holder and return film holder button to auto. Push the Cycle Start button. 10 Rewraps; The system must be empty. Place the product onto the output conveyor, move the fork trunk out of the way and push the rewrap button. The product will return to the turntable conveyor and start the automatic wrap cycle. ( The Red stack light will come on signifies system is full until the product is wrapped and is conveyed onto the output conveyor then the stack lights will change from Red to Yellow signifies system is available). Technical and Customer Service is available from Kalamazoo Packaging Systems, Inc., 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 - (616) National - (800)

8 PROGRAM CONTROLS Modicon PCL: See manufacturer's manual. Lift Speed: Varies the film carriage speed, changing the amount of film overlap. See manufacturer's manual. Turntable Speed: Varies the speed of the turntable, which varies the wrap cycle time and the film overlap. See manufacturer's manual. Prestretch Speed : Varies the film tension. Conveyor Speed: Varies the speed of the conveyors. See manufacturer's manual. Maintenance WARNING: MAKE SURE THAT POWER SUPPLY IS DISCONNECTED BEFORE ATTEMPTING TO SERVICE ANY COMPONENTS. IF THE POWER DISCONNECT IS OUT OF SIGHT, LOCK IT IN THE OPEN POSITION AND TAG IT TO PREVENT UNEXPECTED APPLICATION OF POWER. CLEANING Periodically clean dirt accumulations from machine, especially around moving parts and drive components, preferably by vacuuming. GENERAL Check and tighten any loose fasteners. Check all electrical connections and replace any worn or frayed cords. Troubleshooting When any problem develops, review the operating instructions. Diagnose specific problems and review the options below. Check wall receptacle for power. Check Power cord for cut. (Fork Lift Trucks damage cords.) Check turntable sensor to make they are working. ⓿ Push E-STOP button to clear the system and than push the HOME button. Try operating it again. DISCONNECT POWER FROM MACHINE Check both top and bottom film sensor switches for damage, or internal shorts. Remove panel cover and check that all relays are firmly seated in their bases. Visually inspect for loose wires and for signs of arcing or burning of any of the components. It is advisable to call for technical assistance at the point. 8

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10 PARTS LIST 4FAC51 INPUT CONVEYOR Ref. Part Number Description Qty :1 R/A REDUCER 2.37CD 56C FACE (BOSTON) /4hp /3/60hz. 56C FACE (BALDOR) B28x 1-1/8 DRIVE SPROCKET #40 CHAIN x? (DRIVE) #40 CHAIN x? ( DRIVEN) Q45 PHOTO-EYE POLARIZED 10-30vDC Q45 BANNER PHOTO-EYE GUAED REFLECTOR 2.2 ROUND 1 7 DWG.# PE-TARGET REFLECTOR MOUNTING BRACKET Q45 QUICK-DISCONNECT CABLE 1 9 DWG.# 4FAC TR 10-3/4 TRANSITION ROLLER 1 10 DWG.# 4FAC51-7.5TR 7-1/2 TRANSITION ROLLER 1 11 DWG.# 4FAC PCR 54-1/2 POWERED CONVEYOR ROLLER MINI-BEAM SENSOR (AUTOSTOP) ^ QUICK DISCONNECT CABLE ^ 1 10

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12 Ref. Part Number Description Qty :1 R/A REDUCER 2.06CD 56C FACE (BOSTON) /4hp /3/60hz. 56C FACE (BALDOR) B18x 1 SPROCKET (DRIVE) B14x 1 SPROCKET ( DRIVEN) #40 CHAIN x? (DRIVE) #40 CHAIN x? ( DRIVEN) 3 7 4FAC51- FILMHOLDER-03 8 DWG.# 4FAC TR 9 DWG.# 4FCA TR FILM HOLDER COVER /2 DISC TRANSITION ROLLER DISC TRANSITION ROLLER DISC TRANSITION ROLLER CHAIN 40B10x 5/ DWG.# 4FAC TR 12 DWG.# 4FAC PTR 13 DWG.# 4FAC PCR 14 DWG.# 4FAC PDR DISC TRANSITION ROLLER /2 POWERED TRANSITION ROLLER /2 POWERED CONVEYOR ROLLER /2 POWERED DRIVE ROLLER /8 2-BOLT FLANGE BEARING BOLT FLANGE BEARING #40 CHAIN TRANSITION ROLLER REFLECTOR 1.7 ROUND 1 18 DWG.# 4FAC51- DISC-12 PARTS LIST 4FAC51 TURNTABLE DISC REFECTOR BRACKET 1 12

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14 Ref. Part Number Description Qty 1 DWG.# 4FAC51- FILMHOLDER-01 FILM HOLDER BASE PLATE FILM HOLDER CYLINDER PIVOT BRACKET FILM HOLDER CYLINDER SPHERICAL ROD END 1 5 DWG.#4FAC51- FILMHOLDER-05 FILM HOLDER LEVER /8 x 1-3/8 PLASTIC PER. BEARING /8 SHAFT COLLAR 4 8 DWG.# 4FAC51- FILMHOLDER-05 9 DWG.# 4FAC51- FILMHOLDER DWG.# 4FAC51- FILMHOLDER-02 PARTS LIST 4FAC51 FILM HOLDER FILM HOLDER DRIVE SHAFT 1 FILM HOLDER DRIVEN SHAFT 1 FILM HOLDER DRIVEN SHAFT SLIDE PLATE FAC51-FILMHOLDER-04 FILM HOLDER BARS (1 RIGHT & 1 LEFT ) 1 SET 14

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16 PARTS LIST 4FAC51 TURNTABLE BASE Ref. Part Number Description Qty :1 HORIZONTAL REDUCER (56C) /4hp /3/60hz. 56C FACE (BALDOR) x 2 DRIVE WHEEL w/ HUB PILLOW BLOCK DIA. X 3-1/4 OUTPUT SHAFT x 2 SWIVEL CASTER /2 4-BOLT FLANGE BEARING 1 8 TURNTABLE DISC LOCK PIN (see parts list table lock) TURNTABLE SLIP RING w/ 2-PORT AIR 1 10 DWG.# 4FAC51-TABLE-07 TURNTABLE CENTER SHAFT Q45 PHOTO-EYE POLARIZED 10-30vDC Q45 PHOTO-EYE CORD Q45 BANNER PHOTO-EYE GUAED 2 11 DWG.# PE-SUPPORT PHOTO-EYE SUPPORT BRACKET REFLECTOR 2.2 ROUND 2 12 DWG.# PE-TARGET REFLECTOR MOUNTING BRACKET 2 12 DWG.# PE-SUPPORT PHOTO-EYE SUPPORT BRACKET 2 16

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18 Ref. Part Number Description Qty 1 DWG.# 4FAC51- TABLELOCK-03 PARTS LIST 4FAC51 TABLE LOCK TURNTABLE LOCK PIN TABLE LOCK CYLINDER FOOT BRACKET LIMIT SWITCH ( ROLLER ARM ) 1 18

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20 PARTS LIST 4FAC51 SPIRAL TOWER Ref. Part Number Description Qty 1 DWG.# 4FAC51-TOWER TOWER BASE SQD LIMITS SWITCH w/ 1/5 LEVER ARM LIMIT SWITCH OUTER BRACKET LIMIT SWITCH INTER BRACKET RIGHT HAND TOWER CHAIN ADJ LEFT HAND TOWER CHAIN ADJ /8-18x 4-1/2 TOWER ADJ. BOLT w/washers&nut TOWER TOP SPROCKET SHORT SPACER /8 x 1-3/8 PRE. FLANGE BEARING B22 TOWER TOP SPROCKET (KPS) TOWER TOP SPROCKET LONG SPACER B12x3/4 SPROCKET (DRIVEN) TOWER BOTTOM SHAFT /4 2-BOLT FLANGE BRG B22x3/4 SPROCKET 1 16 DWG.# 351 TOWER MOTOR MOUNT :1 R/A REDUCER 1.33CD 56C FACE (DAYTON) /2HP 460/3/60hz. AC MOTOR 56C (BALDOR) B10x 5/8 SPROCKET (DRIVE) #50 CHAIN FAC51-TOWER-08 TOWER CHAIN GUARD STATION MANIFOLD FILTER/REG w/ LOCK OUT AIR/OIL TANK (FILM ARM) STACK LIGHT KIT 24vDC (RED, YELLOW, and GREEN) 1 20

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22 PARTS LIST 4AFC51 SUBPANEL Ref. Part Number Description Qty PDT RELAY (POWER OFF RELAY) BASE FOR ABOVE v DC POWER SUPPLY 10amp POLE FUSE HOLDER AMP. FUSE (PLC) 1 MODICON PLC PROCESSOR PRIMARY BACKPANES SECONDARY BACKPANES INPUT RACK 24v DC OUTPUT RACK 24v DC (TRANSISTOR) OUTPUT RACK 24v DC (RELAY) POLE FUSE HOLDER AMP. FUSE (PRESTRETCHER) /2HP 480/3/60hz. AC DRIVE TELE. (PRESTRETCHER) POLE FUSE HOLDER AMP. FUSE (FILM LIFT) /2HP 480/3/60hz. AC DRIVE TELE. (FILM LIFT) TRANSFORMER 1500va 480 PRIMARY/ 120 SECOUNDARY POLE FUSE HOLDER AMP. FUSE (PRIMARY) POLE FUSE HOLDER AMP. FUSE (SECONDARY) POLE FUSE HOLDER AMP. FUSE (TURNTABLE) /4HP 480/3/60hz. AC DRIVE TELE. (TURNTABLE) 1 22

23 PARTS LIST 4FAC51 SUBPANEL Ref. Part Number Description Qty POLE FUSE HOLDER AMP. FUSE (TABLE CONVEYOR) /4HP 480/3/60hz. AC DRIVE TELE. (TABLE CONVEYOR) POLE FUSE HOLDER AMP. FUSE (INPUT CONVEYOR) /4HP 480/3/60hz. AC DRIVE TELE. (INPUT CONVEYOR) POLE FUSE HOLDER AMP. FUSE (OUTPUT CONVEYOR) /4HP 480/3/60hz. AC DRIVE TELE. (OUTPUT CONVEYOR) PDT RELAY (HOT WIRE) BASE FOR ABOVE PAYNE CONTROL (HOT WIRE) AMP. DISCONNECT w/ 11.8 SHAFT POLE FUSE HOLDER AMP. FUSE (MAIN) AMP. POWER RELAY (MCR) POLE TERMINAL STRIP 5 23

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25 PARTS LIST 4FAC42SS PUSH BUTTON Ref. Part Number Description Qty 1 4FAC51 DECAL 4AFC51 CONTROL DECAL PUSH OFF/TURN TO RESET (E-STOP) LIGHTED GREEN PUSH BUTTON 24vDC (POWER ON) RED PUSH BUTTON (POWER OFF) RED MUSHROOM PUSH BUTTON (STOP) GREEN PUSH BUTTON (START CYCLE) RED PUSH BUTTON (CYCLE INTERRUPT) BLUE PUSH BUTTON (RESET TO HOME) POSITION SPRING RETURN (REINFORCING WRAPS) POSITION (TABLE JOG) POSITION SPRING RETURN (FILM CARRIAGE) POSITION SPRING RETURN (FILM ARM) POSITION SPRING RETURN (FILM HOLDER) POSITION SPRING RETURN (INPUT CONV.) POSITION SPRING RETURN (TABLE CONV.) POSITION SPRING RETURN (OUTPUT CONV.) 1 25

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27 PARTS LIST 4FAC51 20 POWER PRESTRETCH FILM DELIVERY Ref. Part Number Description Qty 1 4FAC51-FILMHEAD-09 ENCLOSURE 1 2 4FAC51-FILMHEAD-02 BASE 1 3 4FAC51-FILMHEAD-10 COVER FILM CORE THRUST WASHER 1 6 4FAC51-FILMHEAD FILM ROLLER 2 7 4FAC51-FILMHEAD DANCER BAR 1 7 #97 DANCER BAR SPRING /8 x 1-3/8 FLANGE BRG B35x 5/8 SPROCKET B11x 5/8 SPROCKET (210% STRTECH) B13x 5/8 SPROCKET (165% STRETCH) B15x 5/8 SPROCKET (130% STRETCH) BB20H IDLER SPROCKET FAC51-FILMHEAD-08 IDLER SPROCKET HOLDER LO70x 5/8 SHAFT COUPLING LO90 SPIDER /2HP 460/3/60hz. AC MOTOR 56C (BALDOR) :1 R/A REDUCER (DAYTON) FAC51-FILMHEAD-04 MOTOR MOUNT FAC51-FILMHEAD-12 DANCER BAR LIMIT SWITCH CAM MICRO LIMIT SWITCH /4 S.S. CAM FOLLWER /4 S.S. EXC. CAM FOLLWER BANNER Q45 PHOTO-EYE with TIMER BANNER MOUNTING BRACKET 1 27

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29 PARTS LIST 4FAC51 20 FILM ARM with HOT WIRE Ref. Part Number Description Qty /2 BORE x 5 STROKE FILM ARM CYLINDER ROD CLEVIS CLEVIS BRACKET /8 PILOT CHECK VALUE BANNER 18mm BARREL SENSOR BANNER 30 4-PIN CABLE 2 3 4FAC51-FILMARM-05 PROX SENSOR CAM /4 PILLOW BLOCK 2 5 4FAC51-FILMARM-01 BASE 1 6 4FAC51-FILMARM-03 FILM CUTTER HEAD 1 7 4FAC51-FILMARM-02 FILM ARM 1 8 4FAC51-FILMARM-03a FILM ARM CUTTER HEAD COVER /8 x 1-3/8 FLANGE BEARING FAC51-FILMARM-06 FILM ARM CUTTER HEAD ROLLER & SHAFT /16-18 x 2 BRASS THREADED ROD /16 INSOLADED BUSHING 4 13 L46 5/16-18 NUTS HOT WIRE HOT WIRE SPRING # FILM WIPER BRUSH #7x6 x FILM WIPER BRUSH HOLDER x

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31 PARTS LIST 4FAC51 OUTPUT CONVEYOR Ref. Part Number Description Qty :1 R/A REDUCER 2.37CD 56C FACE (BOSTON) /4hp /3/60hz. 56C FACE (BALDOR) B28x 1-1/8 SPROCKET #40 CHAIN x? (DRIVE) #40 CHAIN x? ( DRIVEN) Q45 PHOTO-EYE POLARIZED 10-30vDC Q45 BANNER PHOTO-EYE GUAED Q45 QUICK-DISCONNECT CABLE 1 9 DWG.# 4FAC TR 10-3/4 TRANSITION ROLLER 1 10 DWG.# 4FAC51-7.5TR 7-1/2 TRANSITION ROLLER 1 11 DWG.# 4FAC PCR 54-1/2 POWERED CONVEYOR ROLLER REFLECTOR 2.2 ROUND 1 12 DWG.# PE-TARGET REFLECTOR MOUNTING BRACKET 1 31

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33 33 TELEMECANIQUE DRIVE SETTINGS PRESTRETCHER FILM LIFT TURNTABLE CONVEYORS FFE FFE FFE FFE

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