Kalamazoo MODEL# 4FAC42-TP-PUCC FULLY-AUTOMATIC CONVEYORIZED STRETCH WRAPPER with TOP PLATEN and POPUP 3-CHAIN CONVEYOR OPERATORS MANUAL 07/27/09 Kiet 1
Table of Contents Warranty 3 Installation 4 Electrical Connection 4 Air Connection 4 Wrapping Operation 4 External Controls 4 Internal Controls 5 Remote Console Controls 5 Film Loading Powered Prestretch 5 Programming the AC Drives (Telemecanique) 6 Stretch Wrap System Adjustments 7 Maintenance 7 Lubrication 8 Chain Tension 8 Trouble Shooting 9 Technical and Customer Service 9 System Layout 10-11 Remote Control Console 12 Photo-eye and Reflector Stands 13 Top Platen Load stabilizer w/ Film Holder 14-15 Powered Prestretch 16-22 Spiral and Top Platen Tower 23-25 Main control panel 26-33 Sub Panel 34-36 Air System 37-38 Popup Conveyor 39-41 Turntable Disc and Roller Conveyor 42-44 Turntable Base 45-47 Output Storage Conveyor 48 Wiring Diagram 49-57 2
Introduction Congratulations! Your purchase of a Kalamazoo Model 4FAC42-TP-PUCC Fully-Automatic Spiral Stretch Wrapping System will provide you with years of efficient stretch wrapping service. Your investment will ensure that your products will arrive cleaner, with less damage and pilferage at their destination at a lower cost to you. Warranty Kalamazoo, Inc. (KPS) agrees to furnish the purchaser, without charge, F.O.B. the factory, any part found to be defective in either material or workmanship within one (1) year from date of shipment, provided the purchaser gives immediate notice of any defect and description of that defect to KPS. KPS reserves the right to inspect any defective part to verify the defect and to determine probable cause of same. The liability of KPS under this warranty is limited to furnishing replacements for defective parts, and unless otherwise agreed to in writing, the purchaser shall bear the expense of installation. Failure of equipment or parts due to abuse, misuse, neglect, incorrect operating techniques or power line drops or surges shall not constitute failure because of defective material or workmanship, and are expressly excluded from this warranty. The above is the only warranty with no other guarantees which extend beyond the above and the seller disclaims any implications including but not limited to a warranty of merchantability. 3
Installation The machine will need to be placed on the floor per drawing 4FAC42-TP-PUCC-LO (next page). The Storage conveyor and sensors will need to be wired into the junction box on the turntable base or the main cabinet. A power line 460/3/60Hz. 30 amp. Will need to be supply to the machine and an 80 P.S.I. Air line. Once the machine is up and running it will need to be aliened, leaved, plumped and bolted to the floor. Electrical Connection 460/3/60Hz. 30 amp. connect power lines to the disconnect switch per wiring drawing. (This system is supplied with solid state AC drives, PLC, and sensors. A clean power source must be supplied to the system without voltage spikes or drops.) Air Connection 80 P.S.I. (Air must be clean and dry) Wrapping Operation 1 Turn the disconnect to on. 2 Push the green Power On button. The button will light up. 3 Push the Cycle Start button. The green stack light will come on. (signifies system is available) 4 Convey the product to the Turntable conveyor, (note: attach the input conveyor sensor six inches in front of the input conveyor) as soon as the product gets in front of the sensor and if the system is ready the Turntable conveyors will come on and transport the product onto the Turntable. The stack light will change from green to yellow (signifies system in use) 5 The automatic wrap cycle will start. The turntable disc will ramp up to full speed and the stretch film will be applied to the top of the product. The turntable will decal to the home position and stop. The film arm will move the film in front of the film holder and the film holder will grab the film. The film arm hot wire will come on and cut the film and wipe it. 6 The Top Platen and Film carriage will return to the home position. ( top of carriage) 7 After the product is wrapped and the Storage conveyor is ready the Turntable Popup conveyor will raise the product and convey the product off of the Turntable and on to the Storage conveyor. The stack lights will change from yellow to green. (signifies system is available) 8 End of wrap cycle. 9 The product is now ready to unload. 10 If the Storage conveyor is not unloaded after three loads and the next product is wrapped and waiting to be unload from the Turntable conveyor the stack lights will change from yellow to red. (signifies system is full) 11 If the film runs out or breaks the Turntable conveyor and Film Head will automatically return to the home position and the red stack light will start flashing. Push the E-stop button. Reload the film. Push the Power On button. Place the film holder button to up, lay the film over the film holder and return film holder button to auto. Push the Cycle Start button. 4
External Controls (located on control cabinet) 1 EMERGENCY STOP: Red (push off/ turn to reset); Stops the wrap program and removes power from all motors. 2 ALEEN-BRADLEY: Touch screen: 3 POWER ON: Green lighted push button; Turns on the machine power and lights up the Power On button. 4 POWER OFF: Red push button; Turns off the machine power. Internal Controls (located inside of the control cabinet) 1 Top Platen AC Drive: Do not adjust. The Platen and Film carriage must travel at the same speed so the stretch film does not pull out of the Film holder. 2 Spiral AC Drive: Do not adjust. The Film and Platen carriage must travel at the same speed so the stretch film does not pull out of the Film holder. 3 Turntable AC Drive: Changes the speed of the Turntable. 4 Roller and Popup Conveyor: AC Drive: Changes the speed of the Roller and Popup Conveyors. 5 Output Conveyor AC Drive: Changes the speed of the Output Storage conveyor. 6 Prestretch AC Drive: Changes the force to load of the Stretch film. To Program the AC Drive parameters. (see page 6 ) Remote Console Controls (located on each side of the system) 1 BYPASS: Push the blue BYPASS button if the load is not to be wrapped. 2 EMERGENCY STOP: Red (push off/ turn to reset); turns off all motors. Film Loading Powered Prestretch Your wrapper is equipped with a Kalamazoo Powered Prestretch Film Delivery System, place a roll of stretch film 20 or 10 with spacer on the film core holder and open the film door. Thread the film clockwise around the two black rubber covered tension rollers and counter-clockwise around the Dancer Bar Roller. Close the film door. Once the film is loaded and the desired film tension is arrived at, the film tension need not be adjusted again until the brand of film or the film thickness is changed. Powered Prestretch 5
Allen-Bradley MicroFlex 4 AC DRIVE PROGRAMMING Top Platen (1hp) P035 60.0 HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P039 0.1 ACCEL TIME A040 0.1 DECEL TIME A092 4 AUTO RSTRT TRIES Spiral (1hp) P035 27.5 HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P039 0.1 ACCEL TIME A040 0.1 DECEL TIME A067 2.0 ACCEL 1 TIME A068 1.0 DECEL 1 TIME A071 15.0 LOW SPEED A092 4 AUTO RSTRT TRIES Turntable (2hp) P035 45.0 HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P039 1.0 ACCEL TIME A040 0.1 DECEL TIME A067 0.1 ACCEL 1 TIME A068 0.1 DECEL 1 TIME A071 10.0 LOW SPEED A092 4 AUTO RSTRT TRIES Table Roller and Popup Conveyor (1hp) P033 12.0 OVERLOAD CURRENT P035 60.0 HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P039 0.1 ACCEL TIME A040 0.5 DECEL TIME A092 4.0 AUTO RSTRT TRIES Output Conveyor (2hp) P035 44.0 HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P039 0.1 ACCEL TIME A040 0.1 DECEL TIME A092 4.0 AUTO RSTRT TRIES Prestretch (1hp) P035 54.0 HSP P036 2 START SOURCE DI1 P038 1 EXTERNAL POT. P039 1.0 ACCEL TIME A040 0.5 DECEL TIME A092 4.0 AUTO RSTRT TRIES 6
Stretch Wrap System Adjustments Top of product over wrap: Change the top over wrap by increasing or decreasing the photo-eye timer. Film top and bottom limit switches: Loosen the wing nuts on the mounting base and slide the limit switches up or down in the unistrut. NOTE; The system will automatically senses product wrap height with the Top Platen limit switch, so no adjustment of film carriage top limit switch is usually required. Platen top and bottom limit switches: No adjustments required. Warning!! MAKE SURE THAT THE POWER SUPPLY IS DISCONNECTED BEFORE ATTEMPTING TO SERVICE ANY COMPONENTS. IF THE POWER DISCONNECT IS OUT OF SIGHT, LOCK IT IN THE OPEN POSITION AND TAG IT TO PREVENT UNEXPECTED APPLICATION OF POWER. Maintenance 1) Check and tighten any loose fasteners. 2) Check all electrical connections and replace any worn or frayed cords. 3) Clean the towers where the rollers run every three months, more frequently if the unit is in an especially dirty location. 4) Lubricate and adjust the tower drive and driven chains every three (3) months. Chain should be lubricated with a penetrating type commercial chain lube. 5) Lubricate pillow blocks with #2 grease every six months. 6) Check all control relays for burning or arcing replace if necessary. 7) Check all push buttons and limit switch for shorts or sticking. 8) Check incoming power 480/3/60Hz. 30 amp. 9) Check air supply. 80 P.S.I. The system will not run without air. Cleaning : Periodically clean dirt accumulations from machine, especially around moving parts and drive components, preferably by vacuuming. 7
Lubrication Bearings The bearings have been greased at the factory and are ready to run. It is recommended that all mounted bearings and support wheels be relubricated with #2 grease every six months. ( Do Not Over Grease ) Chains Clean, lubricate and adjust chains every 3 month. Chain should be lubricated with a penetrating type commercial chain lube. ( Do Not Over Tight Chains ) Gear Reducers For new reducers, change the oil 120 hours after the reducer starts operating (based on 8 hours per day of operation). After the first oil change, change oil every 2000 operating hours, or once a year. whichever occurs first. ( Do Not Over Fill Reducers ) Temperature Lubricant 25-125 F AGMA #8 15-60 F AGMA #7 Certain conditions (dust, water, etc.) may require a change of lubricating periods as dictated by experience. Chain Tension Film Lift Chain Tension - Loosen chain adjuster axle located at the top of the tower, move the chain adjusters on both sides equally until chain is tight, retighten the axle nut. (DO NOT OVER TIGHTEN). Film Lift Motor Chain Tension - Remove back lower cover of machine. Loosen four mounting bolts, tighten chain tensioning screw and retighten mounting bolts. (DO NOT OVER TIGHTEN). Platen Lift Chain Tension - Loosen chain adjuster axle located at the top of the tower, move the chain adjusters on both sides equally until chain is tight, retighten the axle nut. (DO NOT OVER TIGHTEN). Platen Motor Chain Tension - Remove back lower cover of machine. Loosen four mounting bolts, tighten chain tensioning screwand retighten mounting bolts. (DO NOT OVER TIGHTEN). Turntable Roller Conveyor Drive Chain - Loosen turntable roller conveyor gearmotor bolts. Tighten chain with tensioning screw provided, retighten turntable roller conveyor gearmotor bolts. (DO NOT OVER TIGHTEN). Popup Conveyor - Loosen chain adjuster axle located at the front end of the conveyor, move the chain adjusters on both sides equally until chain is tight, retighten the axle nut. (DO NOT OVER TIGHTEN). Prestretch - Remove cover Loosen the prestretch motor mount bolts. Adjuster chain by rotating motor by hand and retighten the bolts. (DO NOT OVER TIGHTEN). 8
Troubleshooting When any problem develops, review the operating instructions. Diagnose specific problems and review the options below. Push the E-STOP button in wait 1 min.to make sire all of the AC drive have reset. Turn the button to reset. Check wall receptacle for power. Check air supply. Check all cords for cut. (Fork Lift Trucks damage cords.) Check to make sure the Disconnect and the E-stop button are on. DISCONNECT POWER FROM MACHINE Check all limit switch and sensors for damage, sticking, or internal shorts. Visually inspect for loose wires and for signs of arcing or burning of any of the components. Check chain tension. Check for damage cords. Check the AC drive for errors. It is advisable to call for technical assistance at this point. Technical and Customer Service is available from Kalamazoo, Inc., Monday thru Friday 7:30 A.M. to 4:00 P.M. (EST). Stock is maintained on parts to allow us to ship the same day on most orders. If you have a problem, we want to know about it! Please call and report any difficulties you may encounter. Local - (616) 534-2600 National - (800) 253-4625 9
10
SYSTEM LAYOUT: 4FAC42-TP-PUCC ITEM PART/DWG.# DESCRIPTION PAGE# 1 2B-CONSOLE INPUT 1 CONSOLE (BYPASS & E-STOP) 2 PHOTO-EYE w/ GUARD PART PRESENT 1 SENSOR 13 3 PHOTO-EYE w/ GUARD INPUT 1 SENSOR 13 4 4FAC42-CONTROL PANNEL ALLEN-BRADLEY and PUSH BOTTONS 4 M-4FAC42-AIR AIR SYSTEM 30-31 5 PHOTO-EYE w/ GUARD INPUT 2 SENSOR 13 6 PHOTO-EYE w/ GUARD PART PRESENT 2 SENSOR 13 7 2B-CONSOLE INPUT 2 CONSOLE (BYPASS & E-STOP) 8 SENSOR OUTPUT CONVEYOR FRONT SENSOR 9 SENSOR OUTPUT CONVEYOR BACK SENSOR 10 4FAC42-PLATEN TOP PLATEN w/ FILMHOLDER 14-15 11 4FAC42-PRESTRETCH 20 PRESTRETCH w/ FILMARM 16-22 12 4FAC42-TOWER STRETCH WRAPPER TOWER 23-25 12 4FAC42-SUB SUB PANEL 27-29 13 4FAC42-POPUP POPUP 3-CHAIN CONVEYOR 32-34 14 4FAC42-DISC DISC and ROLLER CONVEYOR 35-37 15 4FAC42-BASE TURNTABLE BASE 38-40 16 MS-09-0670 3-CHAIN OUTPUT STORAGE CONVEYOR 12 26 12 40 40 41 11
Kalamazoo Parts Manual : 2B-CONSOLE ITEM PART # DESCRIPTION QTY 1 2B-CONSOLE TWO BUTTON CONSOLE 1 2 D-4FCA42-SC DECAL TWO BUTTON CONSOLE (BYPASS/E-STOP) 1 3 2070600 BLACK PUSH BUTTON (BYPASS) 1 3 2071500 1 N.O. CONTACT BLOCK 1 4 2071100 E-STOP BUTTON PUSH OFF/TURN TO RESET 1 4 2072000 1 N.C. CONTACT BLOCK 1 12
Kalamazoo Parts Manual : PHOTO-EYE, REFLECTOR, and GUARDS ITEM PART # DESCRIPTION QTY 1 Q45-GUARD Q45 PHOTO-EYE GUARD 1 2 2132650 BANNER Q45 PHOTO-EYE 1 3 2130040 MOUNTING BRACKET 1 4 PE-SUPPORT A-3300 UNISTRUT x 8 1 5 PE-SUPPORT PHOTO-EYE and REFLECTOR UPRIGHT 1 6 2131820 BANNER 2 ROUND REFLECTOR 1 7 PE-TARGET BANNER 2 ROUND REFLECTOR MOUNT 1 13
Kalamazoo Parts Manual : 4FAC42-PLATEN ITEM PART # DESCRIPTION QTY 1 4FAC42-TP-05 PLUNGER LOCK COLLAR 1 2 4FAC42-TP-04 SHAFT LOCK COLLAR 1 3 1210749 1-1/2 2-BOLT FLANGE BEARING 2 14
Kalamazoo Parts Manual : 4FAC42-PLATEN ITEM PART # DESCRIPTION QTY 4 4FAC42-TP-1.5AU 1-1/2 I.D. 2-PORT AIR UNION 1 5 4FAC42-TP-02 PLATEN PLATE 1 6 5380421 2 x 40 x 40 FOAM 1 7 4FAC42-TP-05 PLUNGER 1 8 4FAC42-TP-03 LOCK PIN MOUNT 1 9 4FAC42-TP-06 LOCK PIN 1 10 2701535 LOCK CYLINDER BRACKET 1 11 2701535 LOCK CYLINDER 1 12 2098500 16/3 SJ CORD 1 13 2108900 H.D. LIMIT SWITCH 1 14 2108820 H.D. LIMIT SWITCH ADJUSTABLE ARM 1 15 2103400 CORD GRIP 2 16 1217600 3/4 EXC. CAM ROLLER 4 17 1217500 3/4 CAM ROLLER 4 18 2103400 CORD GRIP 1 19 2100513 COILED CORD 1 20 2800654 4 TUBE COILED AIR LINE 1 21 2103450 1/2 CORD GRIP 4 22 4FAC42-PS-12 CARRIAGE SIDE LOAD MOUNT 4 23 1209500 1 CAM ROLLER 4 24 4FAC42-FH-04R FILMHOLDER BAR RIGHT 1 25 4FAC42-FH-05 FILMHOLDER ADJUSTABLE BAR MOUNT 1 26 1206500 5/8x 1-3/8 PER. FLANGE BEARING 4 27 4FAC42-FH-07 FILMHOLDER SHAFT 2 28 1215000 5/8 SHAFT COLLAR 3 29 4FAC42-FH-06 FILMHOLDER LEVER ARM 1 30 4FAC42-FH-04L FILMHOLDER BAR LEFT 1 31 4FAC42-FH-03 FILMHOLDER BASE PLATE 1 32 2702010 CYLINDER ROD CLEVIS 1 33 2701537 FILM HOLDER CYLINDER 1 34 2702020 PIVOT BRACKET SET 1 15
Kalamazoo Parts Manual : 4FAC42-PRESTRETCH-TOP ITEM PART # DESCRIPTION QTY 1 4060290 4000M-HPS-C TOP COVER 1 2 4060340 4000M PERSTRETCH FILM LOADING DECAL 1 3 L21 10/32 x 3/4 TRUSS HEAD 6 4 8134980 D-HANDLE FILM DOOR LATCH 1 5 L7 8/32 x 3/4 NACHINE SCREW w/ LOCK NUTS 4 16
Kalamazoo Parts Manual : 4FAC42-PRESTRETCH-TOP ITEM PART # DESCRIPTION QTY 6 4060350 WARNING DECAL for PRESTRETCH 1 7 2064000 E-STOP BUTTON 1 8 2064310 NC CONTACT BLOCK 1 9 1083500 #35 CHAIN x 3 1 10 L2 3 /16 x 3/16 x 3/4 KEYWAY 3 11 2132560 Q45 BANNER PHOTO-EYE 1 11 2132570 BANNER PHOTO-EYE 4-PIN 6 CABLE 1 11 2132520 BANNER PHOTO-EYE TIMMING MODULE 1 12 2132530 BANNER PHOTO-EYE MOUNTING BRACKET 1 13 1077770 35B36 x 5/8 FINISH BORE SPROCKET 1 14 2103450 CORD GRIP 4 15 1077780 35B36 x 3/4 FINISH BORE SPROCKET 1 16 7055250 #99 SPRING 1 17 2108550 MICRO SWITCH 1 18 4060360 DANCER BAR MICRO SWITCH COLLAR 1 19 L78 3/8-16 NYLOCK NUT 2 20 L66 3/8 LOCK WASHER 2 21 L64 3/8 USS WASHER 2 22 L80 3/8-16 X 1 H.H.C.S 3 23 L66 3/8 LOCK WASHER 3 24 L64 3/8 USS WASHER 3 25 1075750 35B10 x 5/8 SPROCKET (250% Pre-Stretch) 1 25 1076000 35B11 x 5/8 SPROCKET (220% Pre-Stretch) 1 25 1076500 35B13 x 5/8 SPROCKET (170% Pre-Stretch) 1 25 1077000 35B15 x 5/8 SPROCKET (135% Pre-Stretch) 1 25 1077500 35B17 x 5/8 SPROCKET (105% Pre-Stretch) 1 26 L38 1/4-20x 1 H.H.C.S. 4 27 L31 1/4 LOCK WASHER 4 28 L32 1/4 USS WASHER 4 29 1206500 5/8x 1-3/8 PER. FLANGE BEARING 4 30 1056010 1/4 HP INLINE GEAR MOTOR 1 17
18
Kalamazoo Parts Manual : 4FAC42-PRESTRETCH-BASE ITEM PART # DESCRIPTION QTY 1 1206000 5/8 x 1 3/8 FLANGE BEARING 10 2 4060370 4000M-HPS-DB DANCER BAR ROLLER x 20 3/8 1 3 4060380 4000M-HPS-DB DANCER BAR ROLLER SHAFT x 20 5/8 1 4 4060420 4000M-HPS-IR IDLER ROLLER 1 5 4060425 4000M-HPS-IRS IDLER ROLLER SHAFT 1 6 L81 3/8-16 x 1 FLAT HEAD 2 7 4060390 4000M-HPS-DB DANCER BAR 1 8 L145 5/8 SPRING WASHER 2 9 1208600 3 THRUST WASHER 1 10 6230800 2.95 O.D. x 15 FILM CORE 1 11 4060425 4000M-HPS-IRS IDLER ROLLER SHAFT 1 12 L55 5/16-18 x 1 FLAT HEAD 2 13 L66 3/8 SAE WASHER 2 14 L80 3/8-16 x 1 H.H.C.S. 2 15 4FAC42-PS-01 4FAC42-TP-PUCC 20 PRESTRETCH BASE 1 16 3387120 DOOR HINGE PIN 1 17 L80 3/8-16 x 1 H.H.C.S. 2 18 L64 3/8 LOCK WASHER 2 19 L66 3/8 SAE WASHER 2 20 4FAC42-PS-11 4FAC42-TP-PUCC COILED CORD HOLDER MOUNT 1 21 L66 3/8 SAE WASHER 2 22 L77 3/8-16 NUT 2 23 2103570 1 CORD GRIP 2 24 2100555 12/2 COILED CORD 1 25 2100540 18/15 COILED CORD 1 26 2800652 2 TUBE COILED AIR LINE 1 27 2103450 1/2 CORD GRIP 2 28 1217600 3/4 EXC. CAM ROLLER 4 29 1217500 3/4 CAM ROLLER 4 30 L65 3/8 USS WASHER 12 31 L60 3/8-24 NYLOCK JAM NUT 8 19
Kalamazoo Parts Manual : 4FAC42-PRESTRETCH-BASE ITEM PART # DESCRIPTION QTY 32 4FAC42-PS-12 CARRIAGE SIDE LOAD MOUNT 4 33 1209500 1 CAM ROLLER 4 34 2701972 FILMARM CYLINDER MOUNT PIN 1 35 L33 1/4 SAE WASHER 4 36 L31 1/4 LOCK WASHER 4 37 L38 1/4-20 x 1 H.H.C.S. 4 38 2701971 FILMARM CYLINDER MOUNT 1 39 L66 3/8 SAE WASHER 2 40 L64 3/8 LOCK WASHER 2 41 L80 3/8-16 x 1 H.H.C.S. 2 42 1206500 1 3/8 x 5/8 PRECISION FLANGE BEARING 4 43 L145 5/8 SPRING WASHER 4 44 6230660 4 O.D. BRAKE ROLLER 2 45 4060400 4000M-HPS-FD1 FILM DOOR ROLLER 2 46 4060410 4000M-HPS-FD1 FILM DOOR ROLLER SHAFT 2 47 4060320 4000M-HPS-FD FILM DOOR 1 48 L52 5/16-18x 1 BUTTON HEAD 4 20
21
Kalamazoo Parts Manual : 4FAC42-FILMARM ITEM PART # DESCRIPTION QTY 1 1206000 5/8 x 1 3/8 Flange Bearing 4 2 2800430 FILMARM CYLINDER 1 2 2701973 ROD EYE 1 3 FILMARM-S20 FILMARM ROLLER 2 4 FILMARM-S20 FILMARM ROLLER SHAFT 2 5 1207117 1-3/4 O.D. x 3/4 I.D. FLANGE BRG. 2 6 4FAC42-FA-02 FILMARM WELDMENT 1 7 2701972 FILMARM CYLINDER PIN 1 8 U101 L A 1/8 PIPE TEE 4 9 3109 56 11 ELBOW 4 10 1094U56R00 OIL LEVEL TUBE 2 11 FILMARM-HC FILMARM HEAD COVER 2 12 L81 10-32x 3/4 THP 8 13 1312060 5/16-18 x 2 BRASS THREADED ROD 2 14 L46 5/16-18 NUTS 4 15 1312070 5/16 INSOLADED BUSHING 4 16 L80 3/8-16 x 1 H.H.C.S. 4 17 L64 3/8 LOCK WASHER 4 18 L66 3/8 SAE WASHER 4 19 1312080 21ga. HOT WIRE x 22 1 20 1312020 HOT WIRE SPRING #22 1 21 2103450 1/2 CORD GRIP 2 22 1214985 3/8 SHAFT COLLAR 4 23 3 LONG 1/8 PIPE NIPPLE 4 24 2800435 FILMARM AIR/OIL TANK 2 22
23
Kalamazoo Parts Manual : 4FAC42-TOWER ITEM PART # DESCRIPTION QTY 1 3385210 TOP SHAFT 5/8-11 x 4-1/2 H.H.C.S. 2 2 L144 5/8 SAE WASHER 4 3 1079930 TOWER CHAIN ADJUSTER (LEFT) 2 4 3382520 TOWER TOP SPROCKET SHORT SPACER 2 5 1206500 5/8 x 1-3/8 PRE. FLANGE BEARING 4 6 1079910 50B22 TOWER TOP ADJUSTABLE SPROCKET (KPS) 2 7 3382530 TOWER TOP SPROCKET LONG SPACER 2 8 L141 5/8-11 NUT 2 9 L142 5/8 LOCK WASHER 2 10 1079940 TOWER CHAIN ADJUSTER (RIGHT) 2 11 L51-8 5/16-18 x 1 gr.8 H.H.C.S. 4 12 L46-8 5/16-18 NUT gr.8 4 13 L6 6/32 x 1-3/4 MACHINE SCREW 8 14 2108820 H.D. LIMIT SWITCH ADJUSTABLE ARM 4 15 2108900 H.D. LIMIT SWITCH 4 16 L30 1/4-20 WING NUT 4 17 2108890 H.D. LIMIT SWITCH BRACKET SET 2 18 2103450 CORD GRIP 1/2 NPT 8 19 2098500 16/3 SJ CORD PLATEN TOP LIMIT SWITCH 1 20 2098500 16/3 SJ CORD SPIRAL TOP LIMIT SWITCH 1 21 2098500 16/3 SJ CORD SPIRAL BOTTOM LIMIT SWITCH 1 22 2098500 16/3 SJ CORD PLATEN BOTTOM LIMIT SWITCH 1 23 L157 3/4-10 NUT 4 24 L158 3/4 LOCK WASHER 4 25 L160 3/4 SAE WASHER 4 26 1210500 3/4 2-BOLT FLANGE BEARING 4 27 L71 3/8-24x 1-1/4 H.H.C.S. 8 28 L64 3/8 LOCK WASHER 8 29 L65 3/8 USS WASHER 8 24
Kalamazoo Parts Manual : 4FAC42-TOWER ITEM PART # DESCRIPTION QTY 30 1079900 50B22x 3/4 SPROCKET (SPIRAL & PLATEN) 2 31 3385220 BOTTOM SHAFT 2 32 L2 3/16 x 3/16 x 3/4 KEYWAY 4 33 1079750 50B12x 3/4 SPROCKET (SPIRAL DRIVEN) 1 34 1079900 50B22x 3/4 SPROCKET (PLATEN DRIVEN) 1 35 4FAC42-TOWER 4FAC42-TP-PUCC TOWER WELDMENT 1 36 SEE PAGE 26 4FAC42-TP-PUCC CONTROL PANNEL 1 36 SEE PAGE 30-31 4FAC42-TP-PUCC VALVE BANK 1 37 939-03 939 BASE CABINET COVER 1 38 L24 10/24 TRUSS HEAD x 3/4 8 39 2103400 CORD GRIP 4 40 2098600 16/4 STO YELLOW CORD (SPIRAL) 1 41 1052355 1HP. 480/3/60Hz. 56C MOTOR (FILM & PLATEN LIFT) 2 42 L2 3/16 x 3/16 x 3/4 KEYWAY 2 43 1063105 50:1 R/A REDUCER 56C (FILM LIFT) 1 44 L64 3/8 LOCK WASHER 8 45 L80 3/8-16x 1 H.H.C.S. 8 46 L48 5/16 USS WASHER 8 47 L47 5/16 LOCK WASHER 8 48 L50 5/16-18x 3/4 H.H.C.S. 8 49 4FAC42-TOWER-03 LIFT MOTOR MOUNT 2 50 1095000 #50 CHAIN x 28-1/2 (FILM LIFT) 1 51 1079000 50B10x 5/8 SPROCKET (SPIRAL DRIVE) 1 52 L2 3/16 x 3/16 x 3/4 KEYWAY 2 53 1063025 60:1 R/A REDUCER 56C (PLATEN LIFT) 1 54 1095000 #50 CHAIN x 31-7/8 (PLATEN LIFT) 1 55 1079000 50B10x 5/8 SPROCKET (PLATEN DRIVE) 56 3385330 939 TOWER CHAIN GUARD 1 57 L40 1/4-20 x 3/4 MACHINE SCREW 8 57 L33 1/4 SAE WASHER 8 57 L31 1/4 LOCK WASHER 8 58 2064800 STACK LIGHT KIT (RED-YELLOW-GREEN) 1 25
4FAC42 TP PUCC EMERGENCY STOP POWER ON POWER OFF www.kalpack.com Kalamazoo (800)253 4625 Kalamazoo Parts Manual : 4FAC42-CONTROL PANEL ITEM PART # DESCRIPTION QTY 1 D-4FAC42-CC 4FAC420TP-PUCC CONTROL CABINET DECAL 1 2 2064400 PUSH/PULL RED MUSHROOM (E-STOP) 1 2 2064530 2N.C. CONTACT BLOCK 1 3 2137700 6 TOUCHSCREEN 1 4 2064435 GREEN LIGHTED PUSH BUTTON (POWER ON) 1 4 2064510 2N.0.CONTACT BLOCK 1 4 2064540 24vDC GREEN LIGHT MODULE 1 5 2064420 RED MUSHROOM PUSH BUTTON (CYCLE STOP) 1 5 2064500 1N.O.CONTACT BLOCK 1 26
1 2 3 4 5 6 8 10 11 12 7 9 ITEM DESCRIPTION 1 MAIN SCRN 2 NO FAULTS 3 MENU SCRN 4 AUTO MODE 5 MANUAL MODE 6 AUTO CYCLE START 7 CYCLE PAUSE 8 AUTO END OF CYCLE 9 INPUT 1 REWRAP FUNTION Returns the touch screen to the main screen. If a fault happens a massage will appears. Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) Putts the system in the automatic mode. Manual button will not work. Putts the system in manual mode. Push to start the automatic cycle. Push to pause the cycle. Returns system to home. Spiral and Platen up. Popup conveyor down. Turntable to home and locked. Push to rewrap the product of input 1 side. (Right hand side) 10 INPUT 2 REWRAP Push to rewrap the product of input 2 side. (Left hand side) 11 MACHINE HOME Reset the system to the home position. 12 NO FAULTS If button is blue, read fault in box 2. Fix fault and push the blue no fault button 27
1 2 3 4 5 6 7 ITEM DESCRIPTION FUNTION 1 GOTO CONFIG Used to set-up the touch screen. 2 MAIN SCRN Returns to the main screen. 3 FILM/HEAD MANUAL 4 ROLLER/TABLE MANUAL Used to run the film carriage in the manual mode. Used to run the turntable. (Roller table, Disc, Popup conveyor) 5 LOAD FILM Film loading button. 6 PROGRAM SET-UP 7 LAMP TEST Test the stack light Changes wrap program. (Top wraps, Center wraps, Bottom wraps, 10 or 20 film) 28
1 2 3 12 13 14 4 5 6 7 8 9 10 11 ITEM DESCRIPTION FUNTION 1 MAIN SCRN Returns the touch screen to the main screen. 2 MENU SCRN Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) 3 PLATEN/SPIRAL DISABLE Used to move the Platen and Spiral carriages separately. 4 PLATEN UP Manually raises the Platen carriage. 5 PLATEN DOWN Manually lowers the Platen carriage. 6 SPIRAL UP Manually raises the Spiral carriage. 7 SPIRAL DOWN Manually lowers the Spiral carriage. 8 PLATEN PIN EXT. Extents the Platen lock pin. 9 PLATEN PIN RET. Returns the Platen lock pin. 10 FILM ARM RET Returns the film arm to home. 11 FILM ARM EXT Extents the film arm. 12 HOT WIRE ON Manually turn the hot wire on. 13 FILM HOLDER CLOSED Manually closes the film holder. 14 FILM HOLDER OPEN Manually opens the film holder. 29
1 2 11 12 13 3 4 5 6 7 8 9 10 ITEM DESCRIPTION FUNTION 1 MAIN SCRN Returns the touch screen to the main screen. 2 MENU SCRN Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) 3 ROLLER CONV FWD Roller conveyor manual forward. 4 ROLLER CONV REV Roller conveyor manual reverse. 5 POPUP CONV FWD Popup conveyor manual forward. 6 POPUP CONV REV Popup conveyor manual reverse. 7 POPUP CONV RAISE Popup conveyor manual raise. 8 POPUP CONV LOWER Popup conveyor manual lower. 9 OUTPUT CONV FWD Output conveyor manual forward. 10 OUTPUT CONV REV Output conveyor manual reverse. 11 TABLE FWD Turntable manually forward. 12 TABLE PIN UP Turntable lock pin extent. 13 TABLE PIN DOWN Turntable lock pin retract. 30
1 2 3 4 5 6 ITEM DESCRIPTION FUNTION 1 MAIN SCRN Returns the touch screen to the main screen. 2 MENU SCRN Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) 3 AUTO MODE Return system to automatic mode. Manual buttons will not work. 4 MANUAL MODE Return system to manual mode. The automatic cycle will not work. 5 LOAD FILM Push to load film. Spiral and Platen carriage will lower and the film holder will open. 6 LOAD FILM COMPLETE After loading film. Pull film out to the film holder and push the button. The film holder will close to hold the film. The spiral and platen carriage will return to the home position. (up) 31
1 2 3 4 16 15 5 14 6 7 8 9 10 11 12 13 ITEM DESCRIPTION FUNTION 1 MAIN SCRN Returns the touch screen to the main screen. 2 MENU SCRN Show the menu screen. (Film-Head, Roller-Table, Load-Film, Program Set-up) 3 INPUT 1 TOP PROG 4 INPUT 1 10 ROLL PROG 5 INPUT 1 TOP/CTR PROG 6 INPUT 1 20 ROLL PROG Top band only input 1 side. Push if using 10 film. Input 1 side. Top and center bands only. Input 1 side. Push if using 20 film. Input 1 side. 7 TOP WRAP Top wrap counter. 3 wrap minimum. 8 CTR WRAP Center wrap counter. 3 wrap minimum. 9 BOT WRAP Bottom wrap counter. 3 wrap minimum. 32
ITEM DESCRIPTION FUNTION 10 BOT WRAP Bottom wrap counter. 3 wrap minimum. 11 CTR WRAP Center wrap counter. 3 wrap minimum. 12 TOP WRAP Top wrap counter. 3 wrap minimum. 13 INPUT 2 10 ROLL PROG 14 INPUT 2 TOP/CTR PROG 15 INPUT 2 20 ROLL PROG 16 INPUT 2 TOP/CTR PROG Push if using 10 film. Input 2 side. Top and center bands only. Input 2 side. Push if using 20 film. Input 2 side. Top and center bands only. Input 2 side. 33
34
Kalamazoo Parts Manual : 4FAC42-SUB PANEL ITEM PART # DESCRIPTION QTY 1 2107811 8-FNQ FUSE (PRIMARY) 2 1 2107720 2-POLE FUSE HOLDER 1 2 2107811 20-FNQ FUSE (SECONDARY) 1 2 2107710 1-POLE FUSE HOLDER 1 3 2107811 3-FNM FUSE (PLC) 1 3 2107710 1-POLE FUSE HOLDER 1 4 2137203 ALLEN-BRADLEY MICROLOGIX 1400 1 5 2137206 8 INPUT EXPANSION 24vDC 1 6 2137215 8 OUTPUT RELAY 1 7 2137220 16 OUTPUT RELAY 1 8 2101550 110 VOLT AC OUTLET 1 9 1312010 PAYEN HOTWIRE CONTROL 1 10 2082500 (CR-1) 2PDT RELAY 1 10 2082600 (CR-1) 8-PIN BASE 1 11 2084500 (POR) 4PDT RELAY 1 11 2084600 (POR) 14-BASE 1 12 2080901 (MPR) 40-AMP. RELAY 1 13 2107772 3-FNQ FUSE (PLATEN) 1 13 2107730 3-POLE FUSE HOLDER 1 14 1319010 ALLEN-BRADLEY 1 HP. AC DRIVE (PLATEN) 1 15 2107772 3-FNQ FUSE (SPIRAL) 1 15 2107730 3-POLE FUSE HOLDER 1 17 1319010 ALLEN-BRADLEY 1 HP. AC DRIVE (SPIRAL) 1 17 2107450 DISCONNECT SWITCH FUSED 1 17 2107451 ROD EXTENSION HANDLE 1 17 2107452 40mm EXTENSION SHAFT 1 17 2107482 40 AMP FUSE CLASS J 3 18 2107785 5-FNQ FUSE (TURNTABLE) 1 18 2107730 3-POLE FUSE HOLDER 1 19 1319013 ALLEN-BRADLEY 2 HP. AC DRIVE (TURNTABLE) 1 35
Kalamazoo Parts Manual : 4FAC42-SUB PANEL ITEM PART # DESCRIPTION QTY 20 2107772 3-FNQ FUSE (ROLLER & POPUP CONV.) 1 20 2107730 3-POLE FUSE HOLDER 1 21 1319010 ALLEN-BRADLEY 1 HP. AC DRIVE (R & P CONV.) 1 22 2107785 5-FNQ FUSE (TURNTABLE) 1 22 2107730 3-POLE FUSE HOLDER 1 23 1319013 ALLEN-BRADLEY 2 HP. AC DRIVE (TURNTABLE) 1 24 2107762 2-FNQ FUSE (PRESTRETCH) 1 24 2107710 1-POLE FUSE HOLDER 1 25 1319013 ALLEN-BRADLEY 2 HP. AC DRIVE (PRESTRETCH) 1 26 2091080 1500va TRANSFORMER 1 27 2097000 12 TERMINAL STRIP 8 36
1 2 Kalamazoo Parts Manual : 4FAC42-AIR SYSTEM ITEM PART # DESCRIPTION QTY 1 Q1825380 MAC 82 SERIES VALVE BANK ASSEMBLY 1 2 2701901 LOCK OUT UNIT 1 2 2701910 JOINER KIT 1 2 2701900 FILTER REGULATER UNIT 1 37
38
39
Kalamazoo Parts Manual : 4FAC42-POPUP CONVEYOR ITEM PART # DESCRIPTION QTY 1 1085000 #50 ROLLER CHAIN x 2 2 1085000 #50 ROLLER CHAIN x 1 3 L141 5/8-11 JAM NUT 5 4 1079940 TOWER CHAIN ADJUSTER (RIGHT) 3 5 4FCA42-PU-17 #50 IDLER SPROCKET SPACER 14 6 1075500 #50 IDLER SPROCKET 7 7 1079930 TOWER CHAIN ADJUSTER (LEFT) 3 8 3385210 5/8-11 x 4-1/2 H.H.C.S. 7 9 98585A112 EXTERNAL RETAINING RING 4 10 4FCA42-PU-18 CENTER CHAIN CONVEYOR IDLER SPROCKET PIN 2 11 L200 3/4-10x 1 H.H.C.S. 4 12 L158 3/4 LOCK WASHER 4 13 L160 3/4 SAE WASHER 4 14 4FCA42-PU-11 GUIDE CAPS 4 15A 98409A237 INTERNAL RETAINING RING 8 15B 1212217 LINEAR BALL BEARING 1-9/16 O.D. x 1 I.D. x 2-1/4 4 15 4FCA42-PU-09 GUIDE 4 16 L80 3/8-16 x 1 H.H.C.S. 16 17 L64 3/8 LOCK WASHER 16 18 L66 3/8 SAE WASHER 16 19 L49 5/16 SAE WASHER 16 20 L47 5/16 LOCK WASHER 16 21 L51 5/16-18x 1 H.H.C.S. 16 22 6501099 AIR SPRING 4 23 L70 3/8-24x 1 H.H.C.S. 8 24 L158 3/4 LOCK WASHER 8 25 L160 3/4 SAE WASHER 8 26 L72 3/8-24x 1-1/2 H.H.C.S. 16 27 L158 3/4 LOCK WASHER 16 28 L160 3/4 SAE WASHER 16 40
Kalamazoo Parts Manual : 4FAC42-POPUP CONVEYOR ITEM PART # DESCRIPTION QTY 29 4FCA42-PU-11 GUIDE SHAFT 4 30 4FCA42-PU-10 AIR SPRING MOUNTIONG PLATEN 4 31 4FCA42-PU-07 1 DRIVE SHAFT 1 32 4FCA42-PU-19 50B25x1 SPECIAL SPROCKET 3 33 4FCA42-PU-16 1 DRIVEN SHAFT 1 34 1085000 #50 ROLLER CHAIN x 1 35 1080000 50B10x 1 SPROCKET 2 36 1210550 1 2-BOLT FLANGE BEARING 7 37 1055515 1HP. AC MOTOR TENV (56C) 1 38 L64 3/8 LOCK WASHER 4 39 L80 3/8-16 x 1 H.H.C.S. 4 40 1063025 17Q60H56 R/A REDUCER (HOLLOW SHAFT) 1 41 4FCA42-PU-08 REDUCER MOUNT 1 42 L66 3/8 SAE WASHER 4 43 L64 3/8 LOCK WASHER 4 44 L70 3/8-24x 1 H.H.C.S. 4 45 L49 5/16 SAE WASHER 4 46 L47 5/16 LOCK WASHER 4 L53 5/16-18x 1-1/4 H.H.C.S. 4 41
42
Kalamazoo Parts Manual : 4FAC42-DISC & ROLLER CONVEYOR ITEM PART # DESCRIPTION QTY 1 L38 1/4-20x 1 H.H.C.S. 11 2 L33 1/4 SAE WASHER 22 3 4FCA42-DISC-08 UPPER GUARD 1 4 4FCA42-DISC-24 DRIVE CHAIN GUARD 1 5 L38 1/4-20x 3/4 H.H.C.S. 2 6 L31 1/4 LOCK WASHER 2 7 L33 1/4 SAE WASHER 2 8 1052355 1HP. 230-480/3/60Hz. 56C MOTOR 1 9 L2 3/16 x 3/16 x 3/4 KEYWAY 1 10 1061350 17Q30R56 R/A REDUCER 1 11 L2 3/16 x 3/16 x 3/4 KEYWAY 1 12 1080130 50B15x 7/8 SPROCKET (DRIVE) 1 13 L80 3/8-16 x 1 H.H.C.S. 4 14 L64 3/8 LOCK WASHER 4 15 L66 3/8 SAE WASHER 4 16 4FCA42-DISC-10 ROLLER CONVEYOR MOTOR MOUNT 1 17 L55 5/16-18x 1 FLAT HEAD 4 18 1085000 #50 ROLLER CHAIN x 1 19 1080195 50B13x 3/4 SPROCKET (DRIVEN) 1 20 L80 3/8-16 x 1 H.H.C.S. 5 21 L66 3/8 SAE WASHER 10 22 1210500 3/4 2-BOLT FLANGE BEARING 1 23 L78 3/8-16 NYLOCK NUT 10 24 1085000 #50 ROLLER CHAIN x 7 25 L31 1/4 LOCK WASHER 11 26 L28 1/4-20 NUT 11 27 1210515 3/4 3-BOLT FLANGE BEARING 1 28 4FCA42-DISC-25 CENTER BOX COVER 1 29 L38 1/4-20x 3/4 H.H.C.S. 10 30 L31 1/4 LOCK WASHER 10 31 L33 1/4 SAE WASHER 10 43
Kalamazoo Parts Manual : 4FAC42-DISC & ROLLER CONVEYOR ITEM PART # DESCRIPTION QTY 32 2408895 DOUBLE AIR TUBE (9.25 between fittings) 1 33 4FCA42-DISC-18 42 TRANSITION ROLLER 6 34 4FCA42-DISC-20 33-7/8 TRANSITION ROLLER 1 35 4FCA42-DISC-21 23-5/8 TRANSITION ROLLER 1 36 4FCA42-DISC-17 35 DRIVEN ROLLER 1 37 4FCA42-DISC-15 DRIVE ROLLER 1 38 4FCA42-DISC-16 DRIVEN ROLLER 6 39 4FCA42-DISC-19 35 IDLER ROLLER 2 40 4FCA42-DISC-22 22 IDLER ROLLER 2 41 4FCA42-DISC 4FAC42 TURNTABLE DISC WELDMENT 1 42 2080520 3PDT RELAY 110v COIL (ALTERNATING) 1 44
45
Kalamazoo Parts Manual : 4FAC42-TURNTABLE BASE ITEM PART # DESCRIPTION QTY 1 4FAC42-BASE-17 CENTER SHAFT 1 2 L114 1/2-20x 1-1/4 H.H.C.S. 4 3 L110 1/2 LOCK WASHER 4 4 L112 1/2 SAE WASHER 4 5 1211600 1-1/2 4-BOLT FLANGE BEARING 1 6 L77 3/8-16 NUT 2 7 L64 3/8 LOCK WASHER 2 8 2408700 SLIP RING 1 9 L85 3/8-16x 2 H.H.C.S. 2 10 2408895 DOUBLE AIR TUBE (SWIVEL ONLY) 1 11 L24 10-24 TRUSS HEAD 18 12 4FAC42-BASE-08 SLIP RING COVER 1 13 1226320 6x2 WHEELS w/ TAPERED ROLLER BEARINGS 5 14 L200 3/4-10x 4-1/2 H.H.C.S. 5 15 L157 3/4-10 NUT 5 16 4FAC42-BASE-18 JUNCTION BOX 1 17 2702001 1-1/2 BORE x 3 STROKE TABLE LOCK CYLINDER 18 4FAC42-BASE-16C TABLE LOCK PIN 1 19 L38 1/4-20x 1 H.H.C.S. 2 20 L31 1/4 LOCK WASHER 2 21 L33 1/4 SAE WASHER 2 22 1055262 2HP AC MOTOR 56C FACE 1 23 L2 3/16 x 3/16 x 3/4 KEYWAY 1 24 1060155 18:1 INLINE REDUCER 1 25 L85 3/8-16x 2 H.H.C.S. 4 26 L65 3/8 USS WASHER 8 27 L77 3/8-16 NUT 4 28 L3 1/4 x 1/4 x 2-1/2 KEYWAY 1 29 1227600 8x2 DRIVE WHEEL w/ 1 HUB 1 30 3388050 OUTPUT SHAFT 1 1 46
Kalamazoo Parts Manual : 4FAC42-TURNTABLE BASE ITEM PART # DESCRIPTION QTY 31 l72 3/8-24x 1-1/2 H.H.C.S. 2 32 L64 3/8 LOCK WASHER 2 33 L66 3/8 SAE WASHER 2 34 1212500 1 PILLOW BLOCK 1 35 L157 3/4-10 NUT 4 36 4FAC42-BASE-19 SENSOR BRACKET SLIDE MOUNT 2 37 2131830 T18 SENSOR BRACKET 1 38 2131788 WORLD BEAM PHOTO-EYE 1 39 4FAC42-BASE-19 SENSOR BRACKET MOUNT 1 40 4FAC42-BASE TURNTABLE BASE WELDMENT 1 41 4FAC42-BASE-12 6 TRANSITION ROLLER 4 4FAC42-BASE-11 6 TRANSITION ROLLER MOUNT 4 L71 3/8-24x 1-1/4 H.H.C.S. 24 L64 3/8 LOCK WASHER 24 L66 3/8 SAE WASHER 24 47
Kalamazoo Parts Manual : 14 3-CHAIN STORAGE CONVEYOR ITEM PART # DESCRIPTION QTY 1 MET# BMQ-830-30-R-140 IRONMAN REDUCER 30:1 (LH) 1 2 MET# 102862 2HP 480/3/60Hz. AC MOTOR 143TC 1 3 H60B14Tx1-1/4 DRIVE SPROCKET 1 4 H6017Tx1-3/16 DRIVEN SPROCKET 4 5 1211410 1-3/16 4-BOLT FLANGE BEARING 3 6 HB60A13Tx5/8 IDLER SPROCKET 18 7 1085500 #60 CHAIN 4 8 MS-09-0670 14 3-CHAIN STORAGE CONVEYOR FRAME 1 9 2131784 OUTPUT FRONT SENSOR 1 10 2131784 OUTPUT BACK SENSOR 1 48
49
50
51
52
53
54
55
56
57