INSTRUCTION HANDBOOK OM2 Pakaging mahine for sanitary napkins Mahine-No.: 2622668.11.01 Year of onstrution: 2007 Version 1 dated 2007-12-03 Keep for further referene!
Manufaturer addresses / Customer servie addresses OPTIMA filling and pakaging mahines GmbH Steinbeisweg 20 74523 Shwäbish Hall Tel. +49 (0) 791 506 0 Fax +49 (0) 791 506 1300 servie@optima-ger.om www.optima-ger.om OPTIMA Mahinery Corporation 1330 Contrat Drive Green Bay, WI 54304-0173, USA Tel. +1 (920) 339-2222 Fax +1 (920) 339-2233 info@optima-usa.om www.optima-usa.om OPTIMA do Brasil Rua Joana Foresto Storani, 500 13280-000 Vinhedo - SP - Brazil Tel. +55 19 3886 9800 Fax +55 19 3886 9810 info@optima-bra.om www.optima-bra.om OPTIMA Korea Ltd. Room 909, Hanshin Offie 11-9 Shinheon-dong, Songpa-gu Seoul 138-733 South Korea Tel. +82 2414 7105 Fax +82 2414 7106 info@optima-kr.om SOS OPTIMA Japan Co. Ltd. 362 Shimizu-ho, Karawamahi-dori Nijio-agaru, Nakagyo-ku Kyoto 604, Japan Tel. +81 75 2 23 15 88 Fax +81 75 2 23 15 95 optima@alles.or.jp OPTIMA Mexio OPTIMA pakaging mahines S.A. de C.V. San Jorge 192 Col. Santa Ursula Coapa Delg. Coyoaan 04850 Mexio Tel. +52 55 5421-0271 Fax +52 55 5610-4452 optima-mex@optima-mex.om In ase of emergeny please ontat our 24-hour servie Tel. +49 (0) 791 506 0 or Tel. +49 (0) 7333 808 133 Page 2
INFORMATION We have designed, onstruted and prepared you mahine using state-of-the-art tehnology to meet urrent requirements. Our servies If you are planning any onversions, please ontat us we will assist you. We will also take the used mahine bak or take are of orret disposal. If you annot find the answer to a problem with the help of this instrution manual, please ontat us we will help you. Conventions of representation Speial haraters d UPPER CASE TEXT Meaning Indiates an enumeration Indiates a proess instrution Indiates an operating element Copyright 2007 This doumentation is proteted by opyright. No part of this publiation may be translated, reprodued, stored in a retrieval system, or transmitted, in any form or by any means - graphi, eletroni or mehanial, inluding photoopying, reording, taping- without the prior permission of the publishers. The right to make tehnial modifiations for further development is reserved. You an help us to improve our instrution manual by submitting your suggestions for improvement. Many thanks! Page 3
Notes Page 4
Table of ontents Table of ontents 1 Safety.......................................... 9 1.1 General information............................. 9 1.2 Intended use................................. 11 1.3 Improper use................................. 11 1.4 Safety information............................. 12 1.4.1 Hazard ategories........................... 12 1.4.2 Information symbols......................... 12 1.5 Warning and information signs.................... 13 1.6 Residual risk.................................. 21 1.7 Target groups................................. 21 1.7.1 Authorized persons.......................... 21 1.8 Assignment of tasks to persons................... 22 1.9 Definitions of operator qualifiations............... 22 1.9.1 Semi-skilled person.......................... 22 1.9.2 Mehani.................................. 22 1.9.3 Eletrially skilled person.................... 23 1.9.4 Eletrially instruted person................... 23 1.9.5 Wording 'to be able'.......................... 23 1.10 Definition of tasks:............................ 24 1.10.1 Tasks.................................... 24 1.10.2 M....................................... 24 1.10.3 E....................................... 24 1.11 Protetive devies............................ 25 1.12 Loations of the protetive devies............... 26 1.12.1 POWER supply disonneting devie.......... 27 1.13 COMPRESSED AIR supply disonneting devie.... 28 1.13.1 Monitoring the new building-up of ompressed air 29 1.13.2 VERSA valves (air dump valves)............. 30 1.13.3 EMERGENCY STOP button................. 31 1.13.4 Disonneting swith safety relay............. 32 1.13.5 Guards................................. 33 1.14 Safety omponents........................... 34 1.14.1 Marking of safety omponents................ 34 1.14.2 Safety parameters to be set.................. 35 1.15 Software for safety appliations.................. 36 1.15.1 Marking of PLC inputs and outputs............. 36 1.15.2 Safety parameters to be set................. 37 1.16 Safety information............................ 37 1.16.1 Residual-urrent operated iruit breakers....... 37 1.17 Cheking the protetive devies................. 38 1.17.1 Proedure................................ 38 1.18 Personal protetive equipment................... 39 1.19 Maintenane................................. 40 1.20 Fire fighting................................. 41 1.21 Aident report............................... 41 Seite 5
Table of ontents 2 Tehnial data.................................. 43 2.1 Dimensions.................................. 43 2.2 Produt speifiation........................... 43 2.3 Pakage speifiation.......................... 43 2.4 Output...................................... 43 2.5 Eletrial data................................. 43 2.6 Compressed air supply......................... 43 2.7 Emissions.................................... 43 2.8 Immission.................................... 44 2.9 Rating plate.................................. 44 3 Mahine desription............................. 45 3.1 Produt flow.................................. 45 3.2 Module overview OM2.......................... 46 3.3 Operator positions............................. 47 3.4 Drive........................................ 48 3.5 Funtional groups.............................. 49 3.5.1 Bar onveyor............................... 49 3.5.2 Compression unit.......................... 50 3.5.3 Funtional sheme of ompression............ 51 3.5.4 Overhead onveyor......................... 52 3.5.5 Color marks on the overhead onveyor......... 53 3.5.6 Spreader plates / sution arms................ 54 3.5.7 Bag infeed................................ 55 3.5.8 Bag stak height regulation.................... 56 3.5.9 Bag buffer................................. 57 3.5.10 Guides in front of the welding station.......... 58 3.5.11 Welding station........................... 59 3.5.12 Welding station holding brake................ 60 3.5.13 Side gussetting........................... 62 3.5.14 Pakage disharge........................ 63 4 Mahine ommissioning.......................... 65 4.1 Installation................................... 66 4.2 Connetion................................... 66 4.2.1 Compressed air onnetion.................... 66 4.2.2 Eletri onnetion.......................... 66 4.3 Swithing-on.................................. 67 4.3.1 Power supply............................... 67 4.3.2 Pneumati energy supply.................... 68 4.4 Deommissioning.............................. 69 4.5 Reommissioning.............................. 69 5 Operating elements.............................. 71 5.1 Operator station OM2........................... 71 5.2 PanelView 600................................ 72 Seite 6
Table of ontents 5.2.1 Main sreen................................ 72 5.3 JOG button................................... 73 5.4 Release welding station overload luth............ 73 5.5 Pressure regulator............................. 74 6 Mahine operation............................... 75 6.1 Mahine start................................. 75 6.1.1 Requirements for start........................ 75 6.1.2 Normal start................................ 75 6.2 Stopping the mahine.......................... 76 6.2.1 Mahine stop............................... 76 6.2.2 Mahine stop using an EMERGENCY STOP button 76 6.2.3 Restart after EMERGENCY STOP.............. 76 6.3 Funtions of keys and buttons.................... 77 6.4 Manual funtions.............................. 78 6.4.1 Manual funtions of the pakaging mahine....... 78 6.4.2 Manual funtions bag infeed.................. 79 6.5 LOGIN...................................... 80 6.6 Format data.................................. 81 6.6.1 Copying the format data...................... 81 6.6.2 Format hangeover......................... 82 6.7 Cam data.................................... 83 6.8 Produt parameters............................ 84 6.9 Welding ontroller OPTITHERM 420............... 85 6.9.1 Setting the welding temperature................ 85 6.9.2 Welding ontroller zero alibration.............. 86 7 Fault and warning messages...................... 87 7.1 Stak light.................................... 87 7.2 Alarm messages.............................. 88 7.3 Warning messages............................ 92 8 Format settings................................. 93 8.1 General remarks.............................. 93 8.2 Format hangeover on the ontrol unit............. 93 8.3 Mehanial settings............................ 93 8.4 Bar onveyor................................. 94 8.5 Overhead onveyor............................ 95 8.6 Compression unit.............................. 95 8.7 Filling station................................. 96 8.8 Sution arms................................. 97 8.9 Bag infeed................................... 98 8.10 Bag buffer................................... 98 8.11 Guides in front of the welding station.............. 99 8.12 Welding station.............................. 100 8.12.1 Setting/heking the welding jaw pull......... 101 8.13 Side gussetting.............................. 102 Seite 7
Table of ontents 8.14 Pakage disharge........................... 103 9 Maintenane................................... 105 9.1 General remarks............................. 105 9.2 Drive....................................... 106 9.3 Compression unit............................. 107 9.4 Spreader plates / sution arms.................. 108 9.5 Bag buffer................................... 108 9.6 Pakage disharge............................ 109 9.7 Overhead onveyor........................... 110 9.7.1 Replaing the overhead onveyor hains........ 110 9.8 Welding station............................... 111 9.8.1 Welding jaw struture....................... 112 9.8.2 Replaing the upper welding jaw............... 113 9.8.3 Replaing the lower welding jaw.............. 114 9.8.4 Replaing the ut knife..................... 115 9.8.5 Cut knife installation position.................. 116 9.9 Cleaning.................................... 117 9.9.1 Authorized detergents:...................... 117 9.9.2 Unauthorized detergents:.................... 117 10 Dismantling and disposal....................... 119 10.1 Disposal................................... 119 Index........................................... 121 Seite 8
Safety 1 Safety 1.1 General information INFORMATION This hapter informs you about g the intended and improper use of the mahine, g the persons authorized to operate the mahine, g the hazard ategories depending on the type of hazard and severity of injuries, g all protetive devies releasing a safety funtion of the mahine, g the tests and intervals for heking the protetive devies for orret funtioning g the loations on the mahine where warning and information signs are stuk on to inform you about residual risks still existing g the designation of the safety omponents in the iruit and pneumati plans, the safety parameters to be set and information on safety-assisted software, g the safety inspetions and safety inspetion intervals to be made by you and OPTIMA for maintenane reasons g the possibilities of fire fighting and measures to prevent fires. INFORMATION In addition to this instrution handbook, please also observe g the prohibition, warning and mandatory signs, together with any warning information attahed to the mahine, g the legal provisions regarding aident prevention, industrial safety and environmental protetion, g the instrution handbooks of manufaturers of purhased equipment. INFORMATION This mahine needs eletri urrent and ompressed air for funtioning. By using these energies immediate risks for persons are existing like g by eletri shok or short iruit g by the pressure of the ompressed air still built-up g as well as risks by mehanial movement and heat. Page 9
Safety INFORMATION Numerous protetive devies are installed on the mahine as protetion against these risks For example g insulation of eletri wires, g fuses for short-iruit and overheating, g pressure reduers for overpressure, g housings as protetion for not getting in ontat with eletri ontats, g overs that over hazardous mehanial movements, g warning and information signs on residual risks, g devies to stop the mahine in emergenies or for safe stopping of hazardous movements when opening guards to lear faults, g devies to disonnet the mahine from energy systems and soures. Many of these protetive devies are neither readily identifiable nor separately speified in the instrution handbook. You should never modify the mahine or the mahine software without first obtaining the agreement of OPTIMA. Otherwise there is the risk that your modifiations also modify protetive devies and safety funtions so that again the known injury risks and even new injury risks might been aused. Any damage on the mahine as small it might be an result in the loss of safety. Remedy to all damages immediately or harge OPTIMA to do so. Always keep this instrution handbook ready to hand near the mahine. If you lose it, you an order another opy by indiating to us the OPTIMA mahine number. Page 10
Safety 1.2 Intended use The mahine may only be used for pakaging sanitary napkins into premade PE-bags. The mahine may be operated only in an industrial area as speified by EN 61000-6-4 hapter 7.1 (eletromagneti ompatibility). 1.3 Improper use Aording to 61000-6-4 (Eletromagneti Compatibility) hapter 7.1, the mahine must not be used in residential, business or ommerial areas or in small businesses. The mahine may not be used for pakaging g foodstuffs g explosive substanes, g substanes apable of forming an explosive dust-air mixture, g substanes apable of forming an explosive gas atmosphere, g pyrophori produts, g hazardous substanes. The mahine may not be operated in an explosive atmosphere or out of doors. WARNING! Danger of injury from unintended use. If the mahine is not used by authorized personnel as desribed in the instrution handbook or if modifiations are made without the authorization by OPTIMA filling and pakaging mahines GmbH, personnel may be injured and the mahine damaged. Furthermore please omply with g this instrution handbook, g the working instrutions to be made out by the operating ompany, g the inspetion and maintenane instrutions given on the lubriation and maintenane shedules. Page 11
Safety 1.4 Safety information 1.4.1 Hazard ategories The table below shows whih symbols and signal words indiate hazards and possible onsequenes. Symbol Signal word Definition Consequenes for DANGER! Immediate hazard Death or serious injury WARNING! CAUTION! Possible hazardous situation Less hazardous situation Possible death or serious injury Slight or minimal injury Personnel WARNING! Possible damaging situation Damage to the mahine, to its environment and to the produt Equipment 1.4.2 Information symbols Symbol Signal word Definition INFORMATION User tips and other important/useful information and notes Page 12
Safety 1.5 Warning and information signs The warning and information signs on the mahine: g must not be removed, g must be learly legible. Chek the signs regularly. Control abinet Id: 100 97 067 Id: 100 90 110 Id: 100 90 110 Id: 101 50 855 Page 13
Safety Control abinet Id: 100 90 110 Id: 100 90 110 Page 14
Safety Bag infeed Id: 100 96 963 Id: 101 05 014 Id: 101 27 750 Id: 101 553 07 Id: 101 55 307 Page 15
Safety Overhead onveyor, operator side Id: 101 55 307 Id: 101 01 377 Overhead onveyor, operator side Id: 101 01 377 Page 16
Safety Bar onveyor, operator side Id: 100 90 313 Id: 101 55 307 Overhead onveyor, operator side Id: 100 90 313 Id: 101 55 307 Id: 100 97 057 Page 17
Safety Welding station, operator side Id: 101 30 019 Id: 100 99 629 Id: 101 27 750 Id: 100 97 057 Id: 100 97 067 Page 18
Safety Welding station, drive side Id: 100 99 629 Id: 101 27 750 Id: 100 97 057 pakage disharge Id: 100 96 963 Page 19
Safety Main drive Id: 100 97 057 Page 20
Safety 1.6 Residual risk The mahine has been designed in ompliane with the European Diretive 98/37/EC (Diretive of Mahines) Appendix I 'Essential Safety and Health Requirements for the Design and Constrution of Mahines and Safety Equipment'. When ommissioned, this mahine omplies with state-of-the-art tehnology. However there is always a residual risk for the personnel and mahine, as its operation involves: g hazardous mehanial movements, g eletrial voltages and urrents. 1.7 Target groups This instrution handbook is addressed to authorized persons. 1.7.1 Authorized persons Authorized persons regarding operation, setting and maintenane are the instruted and trained speialists employed by the operating ompany and manufaturer of the mahine. The operating ompany is responsible for: g personnel training, g ensuring ompliane with the safety instrutions, g and adherene to the instrution handbook. Authorized persons regarding operation, setting and maintenane must g have been trained, g have been speifially assigned to the task, g and must have read and ompletely understood the relevant hapter of the instrution handbook before starting work, g be familiar with the protetive devies and regulations. Page 21
Safety 1.8 Assignment of tasks to persons Works to be done Set-up Operation Cleaning Faults Maintenane Category A Category B Convert Set Format hange Teah Swithing-on Start of operation Produe Stop Swith-off Clean Disinfet Flush Detet Loate Remedy Detet Loate Repair Inspet Maintain Replae parts M E M E Operating personnel Semi-skilled person Mehani Eletrially skilled person Eletrially instruted person Assignment of tasks to operators without restritions Assignment of tasks to operators with restritions (see definition of operator qualifiation) 1.9 Definitions of operator qualifiations 1.9.1 Semi-skilled person Person possessing a general and tehnial omprehension and experiene and understanding the funtioning of pakaging mahines. This person must be able to detet and avoid risks in the assigned field of tasks. 1.9.2 Mehani Person with appropriate training and experiene who is able to detet and avoid mehanial risks as well as risks resulting from energies like ompressed air and hydraulis. Persons having a professional training as mehani, mehatronis engineer, mehanial engineer and others. Page 22
Safety 1.9.3 Eletrially skilled person Person with appropriate training and experiene who is able to detet and avoid mehanial risks as well as risks resulting from eletriity. Persons having a professional training as mehatronis engineer, eletrial engineering tehniian, eletrial engineer and others. 1.9.4 Eletrially instruted person Person advised and supervised by an eletrially skilled person who is then able to detet and avoid mehanial risks as well as risks resulting from eletriity. The mahine user defines the eletrotehnial work that an be done on the basis of the regulations for the prevention of industrial aidents valid on the site of mahine installation. 1.9.5 Wording 'to be able' A person is able, if he or she g shows the required harateristis mentioned above and g has understood the hapters of the instrution handbook important for the work to be done g was harged for the work and trained by the user of the mahine and g reeived further training by the mahine manufaturer on his own demand or on the demand of the mahine user. Page 23
Safety 1.10 Definition of tasks: 1.10.1 Tasks See yellow fields of the table. Maintenane: Antiipatory work on the mahine to maintain the mahine in operating order. The tasks refer to the mahine desribed in this instrution handbook. In the different hapters of the instrution handbook you will find the details of the work to be done. 1.10.2 M 1.10.3 E M means mehanial work. Mehanial work must not inlude eletrial work. E means eletri work. I.e. all work on omponents operated by hazardous eletri voltage. Hazardous eletri voltage is any voltage that is no PELV3 or SELV4. For details please refer to the iruit diagram of the mahine. PELV- or SELV-iruits of the mahine are iruits that are learly marked on the iruit diagram as suh. Page 24
Safety 1.11 Protetive devies Only operate the mahine with fully funtional protetive devies. Stop the mahine immediately if a protetive devie is defetive or inoperative. When a protetive devie triggered, the mahine should only be restarted after: g the ause of the malfuntion has been resolved, g it is lear that restarting the mahine won't ause any damage to personnel or equipment. WARNING! Never disable any protetive devies! If a protetive devie is intentionally disabled, there is a risk of danger to all personnel working on the mahine. Page 25
Safety 1.12 Loations of the protetive devies 3 2 3 1 3 4 6 6 3 4 5 5 6 Fig. 1-1: Top view 1 POWER supply disonneting devie 2 COMPRESSED AIR supply disonneting devie 3 EMERGENCY STOP button 4 Disonneting swith safety relay 5 VERSA valve (air dump valve) 6 Guard/protetive over Page 26
Safety 1.12.1 POWER supply disonneting devie The POWER supply disonneting devie is used to disonnet the mahine from the supply net. Fig. 1-2: POWER supply disonneting devie WARNING! When working on the mahine the POWER supply disonneting devie must be seured in the "0/OFF" position by padlok against unintentional swithing-on. WARNING! Ciruits in the ontrol abinets and terminal boxes that are still live even when the POWER supply disonneting devie is swithed off are marked with a warning sign. WARNING! When the mahine is unsupervised, e.g. at the end of a shift, the POWER supply disonneting devie must be swithed off, as a welding ontroller fault would pose a risk of fire. WARNING! Risk of damage to the mahine. Do not stop the mahine with the POWER supply disonneting devie. If you stop the mahine with the POWER supply disonneting devie, the mehanial omponents are subjet to inreased wear. Do not turn the POWER supply disonneting devie to the "0/OFF" position until you have stopped the mahine using the OFF button. Page 27
Safety 1.13 COMPRESSED AIR supply disonneting devie WARNING! The manual swith-on valve [1] is used as COMPRESSED AIR supply disonneting devie and must be seured in the "OFF" position with a padlok against unintentional swithing-on. 1 Fig. 1-3: COMPRESSED AIR supply disonneting devie, pakage outfeed WARNING! After swithing off the COMPRESSED AIR supply disonneting devie, the hain tensioning ylinders of the overhead onveyor and bar onveyor are still pressurized. Take notie of the orresponding warning noties [2] on the mahine. 2 Fig. 1-4: Warning notie on the mahine Page 28
Safety 1.13.1 Monitoring the new building-up of ompressed air INFORMATION If COMPRESSED AIR energy is not applied, the mehani parts might be moved intentionally or unintentionally during hangeover or other work. The valves [A] enable a maintaining funtion of the parts so that, if energy is again built up, possible dangerous movements are only exeuted while the doors are losed. Pressure swithes [B] monitor any ompressed air drop of the tensioning ylinders. The operator station displays a warning message to show the operators that unintended mahine movements might happen when the ompressed air is again built up. A B Fig. 1-5: View from drive side Page 29
Safety 1.13.2 VERSA valves (air dump valves) 1 Fig. 1-6: VERSA valve (air dump valve), operator side WARNING! The VERSA valves (air dump valves) only disonnet the ompressed air for moving ylinders. The tensioning ylinders for the driving hains of the bar onveyor and overhead onveyor remain pressurized. Swith off the ompressed air using a VERSA valve [1] before you open a guard door. Seure the VERSA valve with a padlok against unintentional swithingon again. Page 30
Safety 1.13.3 EMERGENCY STOP button WARNING! Do not use the EMERGENCY STOP buttons for protetion when working on the mahine. WARNING! Only press the EMERGENCY STOP button in a moment of danger! If the mahine is improperly stopped with the EMERGENCY STOP button, the mehanial omponents are subjet to inreased wear. 1 Fig. 1-7: Example for an EMERGENCY STOP button, operator side OM2 When an EMERGENCY STOP button [1] is pressed, all mahine movements are immediately stopped. The mahine does not end the work yle. Page 31
Safety 1.13.4 Disonneting swith safety relay WARNING! The disonneting swithes are used to disonnet the eletroni power supply for the onneted motors. It is possible that the motors and all other eletri omponents of the mahine are still energized via other voltage supply soures. 1 Fig. 1-8: Disonneting swith safety relay, operator side Swith off the disonneting swith [1] before opening a guard door. Seure the disonneting swith with a padlok against unintentional swithing-on again. Page 32
Safety 1.13.5 Guards The guard doors are seured by a safety swith and prevent aess to or reahing into the mahine during operation. The zone surrounded by the guards is designated as danger zone. WARNING! Do not use the door safety swithes for protetion when working on the mahine. WARNING! Do not use the door safety swithes for ordinary mahine stopping. If the mahine is improperly stopped using a door safety swith, the mehanial omponents are subjet to inreased wear. 1 2 Fig. 1-9: Door safety swithes on operator side, eletrially loked 1 Safety swith 2 Atuator Page 33
Safety 1.14 Safety omponents 1.14.1 Marking of safety omponents Safety omponents are marked with the SHW symbol. SHW is the abbreviation for Safety hardware. (Safety hardware) On the iruit diagrams, pneumati and hydrauli plans g several safety omponents are ombined with both the dot-and-dash outline and the SHW symbol on the upper left side in the outline. 5 0 9 Fig. 1-10: Representation on the plans of several safety omponents g individual safety omponents are marked with the SHW symbol at the left side or on top of the item designation with the German abbreviation (- BMK). * 5 0 9 5 0 9 * Fig. 1-11: Representation on the plans of an individual safety omponent INFORMATION Disonnet devies for overload protetion, overload protetion, or protetion against diret ontat suh as fuses, iruit-breakers, power iruit-breakers and residual-urrent iruit-breakers are basially always safety omponents and therefore not speially marked. Page 34
Safety WARNING! For all safety omponents with or without marking the following is valid g they must not be repaired, g they should only be exhanged for new and tested omponents, g they should only be exhanged for omponents of the same type, g they should only be set following the safety parameters given on the plans where the safety omponent is represented, g they must undergo a safety test together with the mahine after being installed. 1.14.2 Safety parameters to be set For orret funtion, safety parameters are preset on different safety omponents. The set safety parameters (for example delay time on EMERGENCY STOP devies, urrent turn-off values, pressure values on pressure regulators or pressure limiters, temperature limit values on heating regulators et.) are learly doumented on the plan where the safety omponent is represented. WARNING! The preset values for the safety parameters, given for the safety omponents, must not be modified. Before starting the mahine, the new safety omponents must be preset with these values. Page 35
Safety 1.15 Software for safety appliations 1.15.1 Marking of PLC inputs and outputs The funtions of the safety hardware are partly assisted in normal PLCs by software for safety appliations (SSW). SSW is the abbreviation for Safety software. PLC inputs and outputs that immediately supply information to the SSW assisting the safety hardware or to the safety hardware, g are marked with the SSW symbol diretly beside the PLC input. This marking is represented in the iruit diagram above the item designation (BMK). 5 5 9 * Fig. 1-12: PLC input marking g are marked with the SSW symbol diretly beside the PLC output. This marking is represented in the iruit diagram below the item designation (BMK), * 5 5 9 Fig. 1-13: PLC output marking WARNING! A safety software exists for all inputs and outputs with this marking. This software should only be modified by the mahine manufaturer. After eah software modifiation all safety-relevant areas must be tested before starting the mahine. Page 36
Safety 1.15.2 Safety parameters to be set Safety parameters are preset for the orret funtion of the safety software. The preset safety parameters are learly doumented in the program listing. They an only be modified by a speial aess ode. WARNING! The indiated preset values for the safety parameters must not be modified. Furthermore, they must be preset after any hange of program or parameter memory before starting the mahine. The mahine must be subjeted to a safety test. 1.16 Safety information 1.16.1 Residual-urrent operated iruit breakers Eletroni items with ontrolled semiondutors and radio interferene filters are used in the mahine ontrol system whih are not basially ompatible with all types of residual-urrent operated iruit breakers on the mahine's power supply system. WARNING! 1. Connetion to supply systems, where for the only protetion against diret and/or indiret ontat a residual-urrent-operated iruit breaker (RCCB) is provided, is not allowed. 2. In ase of fault the eletroni items of this mahine an ause the following earth fault urrents: g AC fault urrents g pulsating DC fault urrents g smooth DC fault urrents g almost smooth DC fault urrents Therefore, a onnetion to supply systems where, for additional protetion against indiret ontat or for protetion against fire by earth leakage, a RCCB is planned, is only allowed if the RCCB reognizes the above-mentioned earth fault urrents orretly. Otherwise the interruption in time of the eletrial iruit by the RCCB might fail. 3. The radio interferene filters of the eletroni items of this mahine ause earth fault urrents whih an unintentionally release the RCCB. Page 37
Safety 1.17 Cheking the protetive devies WARNING! Chek all protetive devies: g after rebuilds, maintenane work or damages as far as they might affet the safety of the mahine, g at least one a year. More heks within one year might be neessary if the mahine is permanently operated or operated in several shifts for a long period and thus the protetive devies are subjeted to inreased wear. 1.17.1 Proedure Ation Consequene Press eah EMERGENCY STOP button separately. Open eah guard door/protetive over separately. Swith off the COMPRESSED AIR supply disonneting devie. g g The mahine annot be started by pressing the START pushbutton at the operator station. The orresponding fault message is displayed on the operator panel. Unlok eah EMERGENCY STOP button after the hek and press the RESET button. Close eah guard/protetive over after the hek and press the RESET button. WARNING! The operating test of the POWER supply disonneting devie must only be done by a skilled person. WARNING! Immediately notify the personnel responsible about any damage, defets or hanges in operating performane and stop working on the mahine, if this is the ase. Page 38
Safety 1.18 Personal protetive equipment WARNING! In order to avoid ut injuries when the ut knife is hanged, the user must issue safety gloves with wrist protetion in appropriate sizes. Fig. 1-14: Safety gloves Page 39
Safety 1.19 Maintenane WARNING! Regular and orretly implemented maintenane is an important requirement for g operational reliability, g trouble-free operation, g long mahine life, g the quality of the produts manufatured. Equipment and devies supplied by other manufaturers must also be in perfet ondition. INFORMATION For repairs overed by the servie ontrat, ontat OPTIMA. WARNING! Components, that are still live even when the POWER supply disonneting devie is turned off, are additionally identified. Preparation: Stop the mahine with the OFF button. Turn the POWER supply disonneting devie to the "0/OFF" position before starting any maintenane and repair work. Turn the COMPRESSED AIR supply disonneting devie to the "OFF" position. Seure the POWER and COMPRESSED AIR supply disonneting devies with padloks against unintentional restarting. Keep the key in a safe loation. WARNING! After the maintenane and repair work is ompleted, the mahine must be returned to the ondition it was in at the time of ommissioning. Page 40
Safety 1.20 Fire fighting WARNING! Only use lass ABC fire extinguishers. Only use CO 2 fire extinguishers for eletrial fires. Unsuitable fire fighting equipment an: g result in toxi gases (vapors), g reate a hazardous situation with the eletrial mahine, g ause danger to life by eletri shok! Be aware of: g the loation and the operation of the fire extinguishers, g the suitable method for fire fighting, g the alarm plan for the fire brigade. 1.21 Aident report Immediately inform supervisors and OPTIMA about aidents and possible soures of danger. The faster they are reported, the faster a solution an be found to resolve those auses. Page 41
Safety Notes Page 42
Tehnial data 2 Tehnial data 2.1 Dimensions For mahine dimensions, please refer to projet drawing P2622668.11.01 in the appendix. 2.2 Produt speifiation Sanitary napkins Pakage sizes 1 x 10t / 2 x 15t / 2 x 25t 2.3 Pakage speifiation Pre-made PE-bags 2.4 Output Maximum 90 yles / min. 1-row 45 yles / min. 2-row 2.5 Eletrial data For onneting data, please refer to iruit diagram S26226681101. 2.6 Compressed air supply For onneting data, please refer to iruit diagram S26226681101. 2.7 Emissions Noise emission approx. 85 db(a) EMC industrial environments EN 61000-6-4 Heat: orresponding to the power onsumption Page 43
Tehnial data 2.8 Immission EMC industrial environments EN 61000-6-2 Ambient temperature +18 to +30 C max. air humidity 30% at +30 C / 80% at +20 C 2.9 Rating plate OM2 2622668.11.01 2007 The rating plate is loated on the overhead onveyor on the operator side. Page 44
Mahine desription 3 Mahine desription The mahine pakages sanitary napkins into pre-made polyethylene bags (PE-bags) and seal-welds the bags. The produts arrive as a stak from the onverter and are ompressed before being onveyed further down the line. The pakaging mahine OM2 ompresses the produt staks and subsequently pakages them into the pre-made PE-bags. The PE-bags are seal-welded. The PE-bags are onveyed into the filling area of the pakaging mahine by means of a bag infeed onveyor arranged at right angle to the pakaging mahine. 3.1 Produt flow Fig. 3-1: Produt flow sheme, ompression unit Page 45
Mahine desription 3.2 Module overview OM2 M9 M8 M6 M4 M3 M2 M5 Fig. 3-2: Top view OM2 M2 Bar onveyor M6 Overhead onveyor M3 Compression unit M8 Welding station and side folders M4 Spreader plates and sution arms M9 Disharge onveyor M5 Bag infeed Page 46
Mahine desription 3.3 Operator positions 1 2 Fig. 3-3: Top view 1 Operator station 2 Bag infeed Page 47
Mahine desription 3.4 Drive Produt flow 6 5 4 3 2 1 Fig. 3-4: Top view, drive side RH mahine 1 Cam mehanism of pakage disharge 2 Main drive 3 Cam mehanism of welding station 4 Belt pulley of overhead onveyor drive (via toothed belt on angular gearbox) 5 Cam mehanism of sution arms 6 Cam mehanism of spreader plates The funtional groups g spreader plates / sution arms g overhead onveyor g welding station and g pakage disharge are driven by the main drive via am mehanisms and angular gearboxes. The gearboxes and the main drive are installed on a mounting plate on the mahine rear side. Power transmission to gears is made by shafts and ouplings. Servo motors operate the funtional groups of bar onveyor and ompression. The bag infeed is made by a geared motor with infeed hain. Page 48
Mahine desription 3.5 Funtional groups 3.5.1 Bar onveyor 2 1 3 4 Fig. 3-5: Bar onveyor The produt staks are onveyed into the bar onveyor [1] by the onverter. The onveyor bars [2] onvey the produt staks to the ompression wheel. The produt side guides [3] are adjusted to the width of the produt. The height of the bar onveyor an be set via a spindle [4] on the operator side if the mahine is operated with ompression wheel. Page 49
Mahine desription 3.5.2 Compression unit 3 2 1 Fig. 3-6: Compression unit and bar onveyor The produt staks are pushed into the ompression unit [2] by the onveyor bars [1]. With the ompression unit, the produt formations are ompressed to the size of the finished pakage. The hold-down devies [3] prevent the produt formations from esaping upwards. 4 Fig. 3-7: Compression unit The produt staks are slowed down by the sution plate [4] when moving into the ompression unit. The vauum is made by means of a blower motor under the bar onveyor. Page 50
Mahine desription 3.5.3 Funtional sheme of ompression 1 Homing position: Press soft-touh [1] on the drive side Drive Parameter 090: <Compression Open Stroke> Produt interfae position Setting range 0...100 Drive Parameter 091: <Compression press stroke> Press position Setting range 0...60 Zero position: Produt disharge position Fig. 3-8: Funtional sheme of ompression Page 51
Mahine desription 3.5.4 Overhead onveyor 3 2 1 4 Fig. 3-9: Overhead onveyor The overhead onveyor is driven by a toothed belt [1] with a luth [2]. The luth is monitored by a proximity swith [3]. In ase of overload (for example produt jam) the luth disengages and the mahine stops. The disengaging moment of the luth an be set from 200 to 310 Nm. The set moment an be read on the luth. The pusher arms [4] of the overhead onveyor take the produt stak from the ompression wheel to the bag filling station and to the welding station. Page 52
Mahine desription 3.5.5 Color marks on the overhead onveyor 1 2 3 Fig. 3-10: View from operator side No overhead onveyor pusher must be in the area marked in red [1] during homing or synhronous run. The yellow/blak mark [2] indiates the losing range of the welding station. If an overhead onveyor pusher is within this marking, the overload luth of the welding station annot engage. In ases as desribed, rotate pusher arm out of the marked range by means of handwheel [3]. Page 53
Mahine desription 3.5.6 Spreader plates / sution arms 1 2 Fig. 3-11: Spreader plates / sution arms The sution arms [1] open the bags through sution and lifting. The spreader plates [2] are moved into the open bags and are then opened by pneumati ylinders. The spreader plates fix the bag during bag filling. After the bag is filled the ylinders are depressurized and the spreader plates return into the rear position. The spindle is used to set the filling station to the produt thikness. Page 54
Mahine desription 3.5.7 Bag infeed 2 3 5 4 1 Fig. 3-12: Bag infeed The bag infeed onveyor [1] onveys the bag staks into the filling area of the pakaging mahine. The bag staks are fixed in their position on the onveyor hain by holding pins. In the filling area, the bag staks are lifted by a lifting table [2]. The position of the lifting table is regulated through a lifting spindle drive [3] and a sensing finger [4] suh that the upper bag is always on the transport level. Proximity swithes [5] monitor the position of the lifting table and ontrol the different funtions (see next page). Different pin distanes for different bag widths are olor-marked on the onveyor hain. In ase of format hangeover (different bag size), the pins must be plaed on the orresponding olor marks. Page 55
Mahine desription 3.5.8 Bag stak height regulation B3158 Stak hange position B3157 Lifting table under bag buffer B3156 Lower position Fig. 3-13: Height regulation proximity swith B3158: Stak hange position: When the lifting table reahes the stak hange position, the stak hange is started. g The bag fingers move together. g The lifting table lowers until B3156. g The next bag stak is transferred onto the lifting table. B3157: Lifting table position under bag buffer: When the lifting table reahes B3157, the bag buffer fingers move apart. The lifting table ontinues lifting until the bag stak triggers the sensing finger. After reahing the sensing finger, the lifting table is lifted in steps of 1mm until B3158 is reahed. The position of the proximity swith B3157 depends on the stak height (number of bags per stak). B3156: Lower position: When the lifting table B3156 is reahed, the onveyor hain is started and the next bag stak is fed into the filling area. Page 56
Mahine desription 3.5.9 Bag buffer 2 1 2 Fig. 3-14: Sensing finger and bag buffer The number of bags remaining on the bag buffer fingers [2] during stak hange is regulated through the sensing finger [1]. The bag buffer fingers hold the remaining bags on a level with the transport level while the lifting table goes down to take up the next bag stak and to move it into the filling area. Page 57
Mahine desription 3.5.10 Guides in front of the welding station 1 2 3 1 Length adjustment lamping lever Height adjustment Fig. 3-15: Guides in front of the welding station The guides [1] guide the filled bag, so that the produt formation is maintained and orretly transported to the welding station. The guides are adjusted to the width of the pakage through the spindle regulation [2]. The sliding plate [3] an be moved into longitudinal diretion depending on the bag length and is also adjustable for height. Page 58
Mahine desription 3.5.11 Welding station Release luth The upper and lower welding jaw supports are losed via rods. The losed welding jaws seal-weld the filled bags. The bag trim is ut off by the ut knife and suked away by the hute in the lower sution rail. In ase of overload (for example produt jam) the luth on the drive side disengages. By pressing the button RELEASE CLUTCH on the operator side, the overload luth an manually be disengaged to open the welding station. Cut knife Lower sution rail Upper sution rail Upper welding jaw Lower welding jaw Fig. 3-16: Welding station Page 59
Mahine desription 3.5.12 Welding station holding brake 1 In ase of voltage drop (for example POWER supply disonneting devie swithed off), the overload luth [1] of the welding station disengages on the drive side. 2 The holding brake prevents the automati losing of the welding station in ase of voltage drop. To open the welding station when the POWER supply disonneting devie is turned OFF, the holding brake an be opened using the lever [2]. Fig. 3-17: Cluth and holding brake Page 60
Mahine desription g The pushers onvey the filled bags through the open welding station. g The welding station is losed by means of the rods. When losed, the welding jaws meet at a height that is level to the middle of the pakage. The hold-down devie and the sution rails firmly hold the film. g The ut knife trims off the bag trim. g The welding pressure is generated via the levers on the drive side. The hold-down devie is depressurized and the film is welded. The welding temperature an be set on the temperature ontrollers on the operator panel. g The welding station is opened. The ut off bag trim is suked away via the trim removal hute in the lower sution rail. Pressure for the hold-down devie is swithed-on when the welding station is open. Page 61
Mahine desription 3.5.13 Side gussetting 2 2 1 1 3 3 Fig. 3-18: Side gussetting When opening the welding jaws, the side folders [1] are moved to the outside via the guides [2]. When the welding jaws are losed, the folding fingers [3] form the side gusset of the bag during welding. Page 62
Mahine desription 3.5.14 Pakage disharge 3 2 1 4 Fig. 3-19: Pakage disharge The movable guides [1] guide the pakages through the open welding station. The side guides [2] are adjusted to the width of the finished pakage through the spindle regulation [3]. The vauum rail [4] slows the pakages down while they are being pushed through the welding station. Page 63
Mahine desription Notes Page 64
Mahine ommissioning 4 Mahine ommissioning DANGER! Before ommissioning the mahine, the user must protet the danger zones at the produt infeed and produt disharge of the pakaging mahine. The mahine may be ommissioned only after being fully assembled and onneted to the upstream and downstream mahines. Danger zone Danger zone Fig. 4-1: Top view Page 65
Mahine ommissioning 4.1 Installation DANGER! Danger of injury through inorret installation and onnetion of the mahine. Only speialized staff are allowed to install the mahine or transport the mahine to another plae. Do not install supplementary units from other manufaturers without the prior permission of OPTIMA. When lifting the mahine and its modules pay attention to the enter of gravity and ensure there is an even load distribution. 4.2 Connetion 4.2.1 Compressed air onnetion CAUTION! The mahine may be onneted to the ompressed air supply by qualified personnel only. Before onneting the mahine to the ompressed air network hek the tehnial data given on the pneumati plans. Partiular attention must be paid to all relevant loal regulations laid down by the fire authorities, all loal safety and aident regulations as well as the general regulations for onnetion of mahines to ompressed air systems. 4.2.2 Eletri onnetion DANGER! The mahine may be onneted to the power supply by qualified personnel only. The overurrent protetive devie for the supply line of the mahine must be seleted, and the mahine onneted to the power supply network, aording to the tehnial data in the iruit diagrams. Partiular attention must be paid to all relevant loal regulations laid down by the fire authorities, all loal safety and aident regulations as well as the eletrotehnial regulations for onnetion of mahines to the network. Pay attention to: g the orret diretion of rotation of the blowers, g the orret diretion of rotation of the motors, g the numbering of the plugs, g the numbering of the sokets, g the numbering of the ables. Page 66
Mahine ommissioning 4.3 Swithing-on 4.3.1 Power supply 1 Fig. 4-2: POWER supply disonneting devie Turn the POWER supply disonneting devie [1] on the ontrol abinet to the "I/ON" position. Page 67
Mahine ommissioning 4.3.2 Pneumati energy supply 3 2 1 Connet the air treatment unit to the ompressed air main supply [1]. Turn the COMPRESSED AIR supply disonneting devie [2] to the "ON" position. Lift the pressure setting knob [3]. Set the operating pressure by turning the pressure setting knob. Press down the pressure setting knob to lok it home. Fig. 4-3: View from drive side INFORMATION If the operating pressure drops below 4 bars, the pressure swith [4] swithes off the mahine automatially. The shutdown value of the pressure swith is a fatory setting and must not be modified. 4 Fig. 4-4: View from operator side Page 68
Mahine ommissioning 4.4 Deommissioning INFORMATION Only persons authorized by OPTIMA are allowed to deommission the mahine. 4.5 Reommissioning INFORMATION Only persons authorized by OPTIMA are allowed to reommission the mahine. DANGER! Danger of injury through inorret installation and onnetion of the mahine. Only persons authorized by OPTIMA are allowed to install the mahine or to transfer it to another plae. Do not add groups of other manufaturers without the prior permission of OPTIMA. Page 69
Mahine ommissioning Notes Page 70
Operating elements 5 Operating elements 5.1 Operator station OM2 1 3 5 2 4 6 7 8 Fig. 5-1: Operator station OM2 1 PanelView 600 2 EMERGENCY STOP button 3 OFF button 4 Illuminated ON button flashing = mahine ready stati = mahine started 5 Illuminated RESET button 6 Soket-ontat for JOG button 7 Lower welding temperature ontroller 8 Upper welding temperature ontroller Page 71
Operating elements 5.2 PanelView 600 WARNING! The surfae of the touh sreen is sensitive to a light touh of the finger, and an be damaged easily. Do not touh the sreen with any sharp or pointed objets, and never use solvents to lean the sreen. 5.2.1 Main sreen 3 4 1 2 5 6 7 8 9 10 11 12 1 Bagger status 7 Overhead onveyor position 2 Output display 8 Current fault messages 3 Symbol for EMERGENCY STOP button pressed 9 Fault message overview 4 Symbol for guard door opened 10 Formats, mahine parameters and ams 5 Symbol for ompressed air fault 11 Manual funtions 6 Bar onveyor position 12 Language seletion and PanelView onfiguration Page 72
Operating elements 5.3 JOG button 1 Fig. 5-2: JOG button The JOG button [1] an be used to hek mahine funtions after maintenane work or format hangeover. Connet the JOG button to the soket ontat on the operator panel. 5.4 Release welding station overload luth 1 Fig. 5-3: Release luth By pressing the button [1] the overload luth of the welding station an be disengaged to manually open the welding station for removal of produt jam. Page 73
Operating elements 5.5 Pressure regulator 1 Fig. 5-4: Pressure regulator The pressure regulators are used to set the pressure for the pneumati omponents. After losing the guard doors and pressing the RESET button, you an read the set pressure on the manometers. The pressure is dereased by turning the setting knob [1] lokwise and inreased by turning ounterlokwise. INFORMATION The setting values are to be gathered from the format setting sheets in the appendix. Page 74
Mahine operation 6 Mahine operation 6.1 Mahine start 6.1.1 Requirements for start g g g g g g g The mahine has been properly installed and onneted. The mehanial format settings are ompleted. All EMERGENCY STOP buttons are unloked. All guard doors are losed. No faults are present. The operating pressure is set on the ompressed air treatment unit. Produt infeed to the pakaging mahine is ensured. 6.1.2 Normal start READY FOR ENABLE HOMING ON SYNCHRONIZING READY FOR START RUNNING ON Page 75
Mahine operation 6.2 Stopping the mahine 6.2.1 Mahine stop g g Press the OFF button. The mahine ends the work yle and stops on the stopping point. The mahine remains ready and an be restarted immediately. Press the OFF button a seond time to open a guard door. 6.2.2 Mahine stop using an EMERGENCY STOP button g In ase of an emergeny, press an EMERGENCY STOP button The mahine stops immediately. WARNING! Only use EMERGENCY STOP buttons in emergeny situations! If, ontrary to its intended use, you use an EMERGENCY STOP button to stop the mahine, you will expose the mehanial parts to inreased wear. 6.2.3 Restart after EMERGENCY STOP EMERGENCY STOP situation EMERGENCY STOP pressed Guard door open. Compressed air supply below setpoint value. Proedure Unlok the EMERGENCY STOP button. Close the guard door. Inrease the ompressed air supply to obtain the setpoint value. Proedure: Remove all produt and film trims from the mahine. Eliminate the ause of the fault. Close the guard doors. Press the RESET button. Press the ON button. Page 76
Mahine operation 6.3 Funtions of keys and buttons yellow keys = ativate funtion / ative green keys = exeute funtion / exeutable Gray keys = funtion not exeutable Fig. 6-1: Key funtions Page 77
Mahine operation 6.4 Manual funtions INFORMATION To arry out manual funtions, press the bagger symbol or the bag handling symbol on the main sreen. 6.4.1 Manual funtions of the pakaging mahine 1 2 4 5 6 3 7 8 9 10 11 Fig. 6-2: Manual funtions 1 User message 7 Current sreen 2 Bagger homing 8 Manual funtions bag infeed 3 Swith on/off blower 9 Drive positions list 4 Ativate jog mode 10 Drive status list 5 Jog mode 11 Bak to main sreen 6 Single yle Page 78
Mahine operation 6.4.2 Manual funtions bag infeed 1 2 3 4 5 6 7 8 9 10 11 Fig. 6-3: Manual funtions bag infeed 1 User message 7 Manual funtions of the pakaging mahine 2 Ativate manual funtions 8 Current sreen 3 Funtion key onveyor hain 9 Drive positions list 4 Funtional keys of bag buffer fingers 10 Drive status list 5 Funtion key lifting table 11 Bak to main sreen 6 Funtional keys of lifting table flap Page 79
Mahine operation 6.5 LOGIN INFORMATION For data hanges and opy funtions you require a password. User is logged-on Change from main sreen to menu <GRADE> 1 User must log in On the sreen <GRADE>, press the symbol key [1] for LOGIN. Press the LOGIN key for your user level [2]. Enter password g The user is logged off automatially after a preset period of time. User levels 2 Page 80
Mahine operation 6.6 Format data 6.6.1 Copying the format data 1 2 Change from main sreen to menu <GRADE> Selet the format set to be opied using the arrow keys and press the key COPY [1]. Selet the position to whih you want to opy the data using the arrow keys and press the key PASTE [2]. Page 81
Mahine operation 6.6.2 Format hangeover 1 2 Change from main sreen to menu <GRADE> Use arrows to selet desired format [1] Press the CHANGE [2] key. 3 Exeute the format hangeover [3]. Page 82
Mahine operation 6.7 Cam data Change from main sreen to menu <GRADE> Change to the menu <PLS> [1]. 1 Selet the am you want to hange using the arrow keys [2] Press the ON, OFF or COMP key [3] to hange a value. 2 3 Page 83
Mahine operation 6.8 Produt parameters Change from main sreen to menu <GRADE> Change to the menu <PROD> [1]. 1 Selet the data reord you want to hange using the arrow keys [2] Press the key EDIT [3] key and enter the value. 2 3 Page 84
Mahine operation 6.9 Welding ontroller OPTITHERM 420 Display Menu hange ENTER: Store values HAND: Manual mode RESET: Reset after alarm Press < 2 se. next menu Keep pressed > 2 se. Return to home position UP DOW Set values Press < 2 se. hange step-by-step Keep pressed > 2 se. hange rapidly Fig. 6-4: Welding ontroller OPTITHERM 420 6.9.1 Setting the welding temperature Go to menu welding temperature SET temperature (welding temperature) ACTUAL temperature (measured) Set=175 C At=174 C Dynami bar ACTUAL temperature The desired welding temperature (setpoint) an be set by pressing the UP and DOWN keys. The maximum setpoint an be limited in menu 22 (alloy/ range) or in menu 23 (maximum temperature). The setpoint is displayed in the home position. Page 85
Mahine operation 6.9.2 Welding ontroller zero alibration Go to menu AUTOCAL Use the arrow keys to adapt the value of 20 C to the atual ambient temperature between 0 C and 40 C. AUTOCAL is started with ENTER. The down-ounter shows the running alibration proess. Then the basi menu is again displayed. Burn-in effet When first heated to approx. 200 C to 250 C, the alloy undergoes a nonreurring resistane hange produing a zero point error of 20 C to 30 C. Therefore the zero point must be orreted after some heating yles. Repeat AUTOCAL. INFORMATION After replaing a welding wire exeute a zero alibration with the AUTOCAL funtion. A new welding wire requires a burn-in proedure. INFORMATION The welding station must be losed to set the welding temperature. The neessary temperature depends on the properties of the film material and the output of the pakaging mahine. For more information, please refer to the OPTITHERM 420 instrution handbook in the appendix. Page 86
Fault and warning messages 7 Fault and warning messages 7.1 Stak light The stak light with the horn is situated on the mahine roof. Horn Red lamp Orange lamp White lamp Signal when the START button is pressed and when a mahine fault ours. Permanent light - fault Flashing light - warning Flashing light - replenish bag staks. Permanent light - Mahine is in automati mode. Fig. 7-1: Signal lamp with horn Page 87
Fault and warning messages 7.2 Alarm messages, No. Module / message text Remedy: 0097-0101 BG1 Estop... Unlok E-STOP button and press RESET. 0103 BG1 Estop from Extern E-STOP from up- or downstream mahine. 0128 BG1 Estop Relay not Ready Fault desription see instrution handbook PILZ PNOZ 11. Only eletrially skilled persons may perform the repair. 0130-0159 BG1 Guard... Close guard door / protetive over, swith on disonneting swith - RESET. 0160 BG1 Guard Door Safety relay not ready 0163 BG1 FastStop Ctrl Drives not Ready 0166 BG1 FastStop No Compressed Air 0167 BG1 FastStop Air bypassed or faulted 0168 BG1 Fast Stop Overload Power Contr Servo 0170 BG1 FastStop Ovrl./Power Loss 24VDC I/O Fault desription see instrution handbook PILZ PNOZ XV2. Only eletrially skilled persons may perform the repair. See Allen-Bradley Kinetix 6000 Multi Axis Servo Drive Installation Manual - setion 4: Troubleshooting Status Indiators. Only eletrially skilled persons may perform the repair. Chek ompressed air supply and onnetions. Chek funtioning and setting of the pressure swith. Chek ompressed air supply and onnetions. Chek funtioning and setting of the pressure swith. Chek fuses and motor iruit-breaker. Chek onnetions aording to iruit diagram. Only eletrially skilled persons may perform the repair. 0171 BG1 FastStop Ovrl./Power Loss 24VDC Servo 0172 BG1 FastStop Ovrl. 115/ 230V 0175-0177 BG1 FastStop Eletroni Fuse OB16E Chek fuses. Chek eletrial onnetions aording to iruit diagram. Only eletrially skilled persons may perform the repair. 0178 BG1 Main Power Supply Phase Fault Chek fuse. Chek eletrial onnetions aording to iruit diagram. Only eletrially skilled persons may perform the repair. 0179 BG1 Maintenane Swith Swith on the disonneting swith. Page 88
Fault and warning messages No. Module / message text Remedy: 0185 BG1 FastStop Reset Relay broken 0189 BG1 FastStop Seros Ring not up 0190 BG1 FastStop Servo DC- Bus not up 0290 BG1 FastStop Overload WJ Pressure 0291 BG1 FastStop Chek OHC out of RED AREA 0292 BG1 FastStop Overload OHC Cluth 0293 BG1 FastStop Overload Pakage Guide Cluth 0294 BG1 FastStop Overload WJ Cluth 0297 BG1 FastStop Clear Collision to Syn Mahine 0298 BG1 FastStop Start From Staker without Ready 0299 BG1 FastStop Flight Bar Missing OS 0300 BG1 FastStop Flight Bar Missing DS 0321 BH1 Safety devie malfuntion!! Chek!! 0322 BH1 Bag Feeding over open 0323 BH1 Bag Feeding Drive Fault 0324 BH1 Bag stak in Chain O. Side 0325 BH1 Bag Table Flap Timeout Chek ontator. Only eletrially skilled persons may perform the repair. RESET. Chek / replae the regulator. Only eletrially skilled persons may perform the repair. Remove produt from welding station. RESET. Use handwheel to move overhead onveyor pusher out of the area marked red Remove the produt jam. Remove the produt. Engage the luth using the hand wheel. Engage the luth. Remove the produt jam. Remove the produt. Engage the luth using the hand wheel. Pay attention to the position of the bar onveyor to avoid ollision with bar. Move overhead onveyor and bar onveyor with hand wheel. Chek signal exhange between pakaging mahine and staker. Chek the onveyor bars and light barriers. Chek / replae the disengaged onveyor bars for damages. Fault desription see instrution handbook PILZ PNOZ XV2. Only eletrially skilled persons may perform the repair. Close the protetive over. Chek frequeny onverter. Only eletrially skilled persons may perform the repair. Remove bag from infeed on operator side. Chek the ylinder of the lifting table flap. Page 89
Fault and warning messages No. Module / message text Remedy: 0326 BH1 Bag stak in Chain D. Side Remove bag from infeed on drive side. 0327 BH1 Overload Relay Chek ontator. Only eletrially skilled persons may perform the repair. 0328 BH1 Bag Lifting Motor Fault Chek lifting motor limit swith and temperature. Only eletrially skilled persons may perform the repair. 0329 BH1 Bag Feeding Timeout Replenish bag staks. 0331 BH1 Bag Lifting Timeout Chek ompressed air supply. Chek ylinder. Chek proximity swith on 0332 BH1 Bag Hold Finger move ylinder. together Timeout Replae defetive proximity swithes. 0333 BH1 Bag Hold Finger move apart Timeout 0386 BH1 No Bags in Bag Feed Chain 0387 BH1 Bag Storage almost empty 0355 BG1 Normal Stop Fault Resistron 0356 BG1 Normal Stop WJ Overload Position 0360 BG1 Normal Stop Overload Blowers 0361 BG1 Normal Stop by OFF Pushbutton 0362 BG1 Normal Stop Overtemperature 460VAC Trafo 0363 BG1 Normal Stop by Bag Handling 0418 BG1 Waiting for Downstream 0419 BG1 Waiting for bags in Bagger Mahine stops after 7 bag stak hanges. Replenish bag staks. RESET. With the bag buffer retrated, the mahine stops after 20 yles. Replenish bag staks. RESET. Chek welding ontroller, welding wire, Teflon and temperature setting. Remove produt from between the welding jaws. Chek fuses and motor iruit-breaker. Chek eletrial onnetions aording to iruit diagram. Only eletrially skilled persons may perform the repair. RESET. Chek transformer. Chek ooling unit in ontrol abinet. Chek setting of ooling unit. Only eletrially skilled persons may perform the repair. Fault was aused by pressing the stop button twie. RESET. Fault learane on downstream mahine. RESET. Chek setting of sensing finger / proximity swith. Replenish bag staks. Page 90
Fault and warning messages No. Module / message text Remedy: 0489 BG1 SSW Malfun. Rel. Brake Welding Station 0490 BG1 SSW Malfun. Release Brake Sution Arms 0770 BH1 Bag Feed Replenish Bag Staks Chek brake triggering [M2611]. Only eletrially skilled persons may perform the repair. Chek brake triggering [M2711]. Only eletrially skilled persons may perform the repair. Replenish bag staks. RESET. 0545-0575 0577-0607 0609-0639 BGR ModuleFault... BGR DriveFault... BGR AxisFault... See Allen-Bradley Kinetix 6000 Multi Axis Servo Drive Installation Manual - setion 4: Troubleshooting Status Indiators. Only eletrially skilled persons may perform the repair. Page 91
Fault and warning messages 7.3 Warning messages No. Module / message text Remedy: 0257 BG1 Warning Battery Power low or Missing 0258 BG1 Warning Prog.loaded from nonvol. Memory 0481 BG1 Warning Jogwire Plugged 0484 BG1 Warning BC Chain tension O.S./Replae 0485 BG1 Warning BC Chain tension D.S./Replae 0486 BG1 Warning OHC Chain tension O.S. /Replae 0487 BG1 Warning OHC Chain tension D.S. /Replae 0488 BG1 Warning Exte. Enoder faulted or missing 0514 BH1 Warnings Bag Feeding Contator not ready 0515 BH1 Warnings Bag Feeding over open 0516 BH1 Warnings Bag Feeding Replenish Bags 0517 BH1 Warnings Bag Feeding Bag in Chain OS 0518 BH1 Warnings Bag Feeding Bag in Chain DS Insert a new battery. Do not de-energize the system for battery hange - loss of data! Chek format data and parameters, whih might no longer orrespond to the mehanial omponents. Chek / replae battery. Automati mode is not possible with the JOG button onneted. Replae driving hains during next maintenane. Replae driving hains during next maintenane. Replae driving hains during next maintenane. Replae driving hains during next maintenane. Chek / replae enoder. Only eletrially skilled persons may perform the repair. Chek safety swith on guard or protetive over. Only eletrially skilled persons may perform the repair. Close the protetive over. Replenish bag staks. Remove bags form bag feeding hain at operator side. Remove bags form bag feeding hain at drive side. Page 92
Format settings 8 Format settings 8.1 General remarks WARNING! When working on the mahine the POWER and COMPRESSED AIR supply disonneting devies must be seured in the "0/OFF" position with a padlok against unintentional swithing-on. INFORMATION The mehanial settings for new formats must be determined by the operating ompany and filled into the setting sheets. If a value or a size part orresponds to the format whih has already been set, this needs only be heked on the mahine. 8.2 Format hangeover on the ontrol unit INFORMATION See Format hangeover on page 82. 8.3 Mehanial settings INFORMATION Please refer to the format setting sheets for setting the digital position indiators and sales. INFORMATION For size parts and their dimensions, refer to size part overview Q26226681101 in the appendix. Page 93
Format settings 8.4 Bar onveyor 2 2 1 3 After having loosened the lamping levers [2], set the guides [1] to the sale values speified on the format setting sheet. Set the lower guides to the width of the upper guides. Set transfer height of the bar onveyor [3] to the sale value speified on the format setting sheet. Fig. 8-1: Bar onveyor Page 94
Format settings 8.5 Overhead onveyor 1 Install the pusher plates [1] as speified on the format overview. Set the pusher plates as speified on the format setting sheet. Fig. 8-2: Overhead onveyor pusher 8.6 Compression unit 2 2 1 1 Set the ompression unit [1] as speified on the format setting sheet. Set the hold-down devies [2] as speified on the format setting sheet. Fig. 8-3: Compression unit Page 95
Format settings 8.7 Filling station 1 Set the width adjustment [1] to the value speified on the format setting sheet. 2 3 Set the lamping piee for the upper spreader plates [2] to the value speified on the format setting sheet. 4 Set the lamping piee [3] to the lamping height for the upper spreader plates. Set the hold-down devies [4] to the sale value speified on the format setting sheet. Fig. 8-4: Filling station Page 96
Format settings 8.8 Sution arms 1 2 Set the distane [1] between the sution heads as speified on the format setting sheet. Use the lever [2] to set the sution arm stroke as speified on the format setting sheet. Fig. 8-5: Sution arms INFORMATION Basi setting: In the upper position, the sution heads must be approx. 3 mm above the spreader plates. Page 97
Format settings 8.9 Bag infeed 1 Set the bag holding pins [1] as speified on the format setting sheet. Fig. 8-6: Bag infeed 8.10 Bag buffer 1 2 Set the ylinders [1] for the bag buffer fingers as speified on the format setting sheet. Install the bag buffer fingers [2] as speified on the format setting sheet. Fig. 8-7: Bag buffer Page 98
Format settings 8.11 Guides in front of the welding station 1 Set the width adjustment [1] to the value speified on the format setting sheet. Set the lower guide plate [2] as speified on the format setting sheet. 2 Fig. 8-8: Guides in front of the welding station Page 99
Format settings 8.12 Welding station 1 1 Set the rods of the upper welding jaw [1] as speified on the format setting sheet. Fig. 8-9: Welding station Page 100
Format settings 8.12.1 Setting/heking the welding jaw pull 1 g Set the pull of the upper welding jaw by means of the lever [1] on the drive side. Chek the pull of the ylinder of the upper welding jaw on the operator side as follows: Turn the overhead onveyor handwheel until the welding station is losed. 2 g If the welding station is losed the support of the upper welding jaw [2] is pulled upwards by approx. 1 mm. Fig. 8-10: Setting the welding jaw pull INFORMATION In ase of wrong settings g faults an our on the welding seam if the pull is too low g the overload luth disengages if the pull is too big. Page 101
Format settings 8.13 Side gussetting 1 2 Set the width adjustment [1] to the value speified on the format setting sheet. Set the side folders [2] as speified on the format setting sheet. Set the folding fingers [3] as speified on the format setting sheet. 3 3 Fig. 8-11: Side gussetting Page 102
Format settings 8.14 Pakage disharge 2 1 3 Set the width adjustment [1] to the value speified on the format setting sheet. Set the hold-down devies [2] to the sale value speified on the format setting sheet. Set the pakage brake [3] as speified on the format setting sheet. Fig. 8-12: Pakage disharge Page 103
Format settings Notes Page 104
Maintenane 9 Maintenane WARNING! Maintenane work may only be performed if the POWER supply disonneting devie and the COMPRESSED AIR supply disonneting devie are in the "0/OFF" position and eah has been seured with a padlok. In addition, note and release: g Any potential interferene voltages (e.g. from loking system wires); g Voltages exempt from the POWER supply disonneting devie; g Air pressure built-up (e.g. in the tensioning ylinders). INFORMATION For the lubriants to be used and the maintenane intervals please refer to the lubriation and maintenane shedules in the appendix. 9.1 General remarks WARNING! The soket-outlets at the ontrol abinet are exlusively reserved for onneting PCs and measuring instruments. INFORMATION For information on loking assemblies pay attention to the data sheets, mounting instrutions and instrution handbooks of the orresponding manufaturer. Loking assemblies are identified on the mahine by an information sign. Page 105
Maintenane 9.2 Drive Chek belt tension every 2000 operating hours Chek gear oil level at the inspetion glass every 640 operating hours Gear oil: Klüber Synthesa D460EP Fig. 9-1: Drive Page 106
Maintenane 9.3 Compression unit 2 1 3 Fig. 9-2: Compression unit Interval Lubriants (Lubriation and maintenane plan W10159768 in the appendix) 1 160 h Grease the guiding arriage as speified on the lubriation hart. 2 640 h Grease the drive shaft as speified on the lubriation hart. 3 640 h Chek the belt tension Page 107
Maintenane 9.4 Spreader plates / sution arms lean / replae sution head filter every 160 operating hours Chek and lubriate sliding blok every 160 operating hours Fig. 9-3: Spreader plates / sution arms 9.5 Bag buffer Lubriation hart see lubriation and maintenane plan no. W10156478 in the appendix every 160 operating hours: Chek and lubriate bag buffer guiding arriage Fig. 9-4: Bag buffer Page 108
Maintenane 9.6 Pakage disharge 1 1 3 3 2 4 4 Fig. 9-5: Pakage disharge Interval Lubriants (Lubriation and maintenane plan W10159833 in the appendix) 1 640 h Grease the drive shaft bearing as speified on the lubriation hart. 2 2000 h Clean spindle and lubriate with multi-purpose grease 3 160 h Grease the pakage guide as speified on the lubriation hart. 4 640 h Grease the width adjustment of the pakage guide as speified on the lubriation hart. Page 109
Maintenane 9.7 Overhead onveyor Lubriation hart see lubriation and maintenane plan no. W10166173 in the appendix every 160 operating hours: Regrease the overhead onveyor drive support Fig. 9-6: Overhead onveyor 9.7.1 Replaing the overhead onveyor hains Turn the overhead onveyor handwheel until the hain joints at the defletion wheels are aessible. Swith off the COMPRESSED AIR supply disonneting devie. Remove all pusher arms and pusher shafts. Open the hain joints on both hains and remove one side of eah hain from the joint. Attah the new hains to the hain joints. When you pull out the old hains, the new hains are simultaneously drawn into the hain guides. Before installing the new hains, hek all parts of the overhead onveyor for wear and replae any defetive parts. WARNING! The hains must be drawn-in symmetrially to ensure that the pusher shafts are at right angle to the hain. The open side of the hain joint must point away from the diretion of rotation of the hain. Remove the old hains from the hain joints and lose the joints. Install all pusher shafts and pusher arms. Page 110
Maintenane 9.8 Welding station Lubriation hart see lubriation and maintenane plan no. W10190921 in the appendix grease the guiding arriages every 160 operating hours grease the guiding arriages every 160 operating hours grease the drive shaft support every 640 operating hours grease the drive shaft support every 640 operating hours remove remains from filter fabri every 160 operating hours grease the rod ends every 160 operating hours lean the sution rails every 160 operating hours Fig. 9-7: Welding station INFORMATION After replaing the welding jaws exeute a zero alibration of the welding ontrollers with the AUTOCAL funtion. (See Welding ontroller zero alibration on page 86.) Page 111
Maintenane 9.8.1 Welding jaw struture Fiberglass strip support Fiberglass film PTFE Welding wire Teflon tape PTFE Welding wire Fiberglass film PTFE Fiberglass strip with rubber support Fig. 9-8: Welding jaw sheme Page 112
Maintenane 9.8.2 Replaing the upper welding jaw 1 2 3 4 4 5 Fig. 9-9: Welding station Turn the overhead onveyor handwheel until the welding station is open. Separate the ables on the operator and drive side [1]. Loosen the lamping srews [2] and remove the hold-down devie [3]. Loosen the lamping srews [4] and remove the welding jaw [5] by pulling it downwards. The installation is done in reverse order. Page 113
Maintenane 9.8.3 Replaing the lower welding jaw 1 1 2 Fig. 9-10: Welding station Turn the overhead onveyor handwheel until the welding station is losed. Pull out the able onnetors on the operator and drive side. Loosen the lamping srews [1] on the operator side and drive side. Open the welding station using the handwheel and remove the welding jaw [2] by pulling it upward. The installation is done in reverse order. Page 114
Maintenane 9.8.4 Replaing the ut knife WARNING! In order to avoid ut injuries when the ut knife is hanged, the user must issue safety gloves with wrist protetion in appropriate sizes. When working on and near the ut knife the plasti protetion must be plaed on the ut knife. WARNING! Take are that the ut knife does not fall onto the lower welding jaw, otherwise the latter might be damaged. INFORMATION You an remove the hold-down devie to make it easier to remove the ut knife. 1 2 Fig. 9-11: Cut knife Loosen the srews on the hold-down devie. Remove the hold-down devie by pulling it downwards. Loosen the srews on the ut knife [1]. Remove the ut knife by pulling it downwards [2]. The installation is done in reverse order. Page 115
Maintenane 9.8.5 Cut knife installation position A 1 B 1 2 3 Fig. 9-12: Cut knife installation position 1. Cut knife 2. Hold-down devie 3. Welding jaw A Installation position for a bag trim of 7 mm after welding seam (reommended by OPTIMA) B Installation position for a bag trim of 5 mm after welding seam WARNING! With an installation position for a bag trim of 5 mm after the welding wire there is the risk that the Teflon tape on the lower welding jaw might be damaged. Page 116