62/,' 35( c,6,21

SOLID PRECISION FSB-60 | NSV-400 | NSTS-3000

Shrink Sleeve Labeller with Film Reservoir, Applicator and Shrink Tunnel

#21980

OPERATION MANUAL

&

PRODUCT SPECIFICATIONS

FOR

NSV-400

AUTOMATIC BANDING/SLEEVING

MACHINE

.,,_ NElV SOLID INTERNATIONAL CORPORATION 11F, 189 CHI HSIEN 2

ND ROAD, KAOHSIUNG, 80143, TAIWAN Phone Number: 886-7-286-9966 (4 Lines) Fax Number: 886-7-286-9988 (3 Lines) E-Mail: [email protected]. tw

: NEW SOLID INTERNATIONAL CORPORATION Table of Contents

INTRODUCTION SERVICE AND SUPPORT GENERAL INFORMATION GENERAL PRECAUTIONS

CHAPTER 1 PRODUCT FEATURES AND INSTALLATION 1.1 PRODUCT FEATURES 1.2 INSTALLATION 1.2.1 General Remarks and Steps 1.2.2 Operating Environment

CHAPTER 2 MACHINE SPECIFICATION 2.1 MAIN APPLICATOR UNIT 2.2 OPTIONS AND ACCESSORIES

CHAPTER 3 OPERATING PRINCIPLE 3.1 APPLICATOR OPERATING PRINCIPLE AND CONCEPTS 3.2 FILM SPOOL ASSEMBLY 3.2 AUTOMATIC FILM FEED CONCEPT 3.4 MATERIAL SPREADING UNIT: MANDREL 3.5 FILM CUTTING UNIT (CUTTER) 3.5.1 Film Cutting Concept 3.5.2 Setting the Rotary Blades 3.5.3 Adjusting Blade Position 3.6 PRODUCT SENSOR UNIT 3.7 VERTICAL HEIGHT ADJUSTMENT 3.8 CIRCUITRY CONTROL 3.9 PITCHING SCROLL 3.10 OVERALL SET-UP PROCEDURE

�HAPTER 4 DISPLAY AND OPERATION 4.1 DISPLAY 4.2 OPERATION 4.2.1 Setting up the film 4.2.2 HMI Screen Operation

CHAPTER 5 MAINTENANCE 5.1 MAIN MACHINE 5.1.1 Daily 5.1.2 Weekly 5.1.3 Monthly

CHAPTER 6 TROUBLESHOOTING

APPENDIX 1 Electric Circuit Diagram APPENDIX 2 Spare parts

1

2 2 2

5 5 5 6

7 7 9

11 11 12 13 15 15 15 16 17 1 8 1 8 19 19

21 39 39 40

43 43 '43 44

45

:, NEW SOLID INTERNATIONAL CORPORATION

INTRODUCTION

Thank you for purchasing our equipment. This manual is designed to provide you information on for the operation and maintenance of NSV-400 sleeve applicator.

Service and Support If you have any problem or queries regarding our Machinery, please feel free to contact our service agent: DFC PACKAGING GROUP 20 SUMMIT RD NOBLE PARK NORTH +61-3-9701 2000

General Information

-----. ( ,

♦ This manual has been produced to provide operating and service instructions for the NSV - 400 Sleeving Shrink Sleeve Applicator

♦ The machine has been designed to feed, cut and apply film bands or sleeves onto product fed via a conveyor at product rate of up to 400 per minute (Depending on the· size and shape of the product). After application the sleeve/band is wiped down on to the product prior to entering a heat tunnel.

♦ The products must be pitched before they reach the applicating driver and this can be achieved by a pitching scroll, rotary drum or other form of pitching devices.

♦ The required product pitch is dependent on the length of the sleeve/band and the longer the sleeve length the greater the pitch required.

♦ The sleeves/bands are retained on the shooting head (lower part of the mandrel), which is feed automatically at the placement position.

• The length of heat tunnel required to shrink the material tightly onto the product is dependent on the length of the sleeve/band and the application.

• The tunnel may be profiled, via air flow and temperature controls, to optimize the material shrink.

General Precautions ( 1 ) The Shrink Sleeve Applicator has been designed with due consideration to

operating safety as well as ease of maintenance.

( 2 ) Strict adherence to the following safety points is of the utmost importance:

I. The electrical enclosure has points at high voltage and extreme care should be taken when the access door is open should input power be supplied to the enclosure.

II. The opening of the access door to the enclosure is only to be carried out by qualified electrical service technicians.

2

� NEW SOLID INTERNATIONAL CORPORATION III. The system must be isolated and the main electrical. input lead should be isolated

from the electrical input socket before: • Making any readjustment to the system for different product runs. • Carrying out any maintenance work. • Opening the electrical enclosure access door.

( 3 ) All personnel likely to use or service the equipment must familiarize themselves with

the position of the emergency stop/switch.

( 4 ) All potentially hazardous moving parts of the equipment have been guarded where it is practically possible. The functional moving belts cannot be totally enclosed, however any objects moving through the system such as product packages and mispositioned sleeves must not be removed by hand whilst the belts are in motion.

( 5 ) Care must be taken to secure all lose clothing that might become entangled in the � belt systems. Jewellery which could be potential hazard should be removed.

( 6 ) Guards which have to be removed for maintenance must only be removed by fully qualified service technicians.

( 7 ) When guards are removed for maintenance extreme care must be taken where nip points exist at belt and roller drives and sprocket and chain drives.

( 8 ) Please read this manual carefully and follow the instructions when operating the machine.

( 9 ) For the sake of safety, please ensure the working environment is kept tidy with good lighting and ventilation.

( 1 o ) This manual is to be referred to and read prior to any repair and maintenance work done on the machine.

( 11 ) In the event of emergency, please disconnect or isolate power input before any repair or maintenance work is carried out. .._,,

( 12) The machine comes with 12 months warranty. The warranty will be void in the event of failure by the Customer to perform proper and regular maintenance, undertakes modifications to the Goods, or repairs are conducted other than in accordance with the written authority of New Solid International Corp ..

During installation, operation, repair and inspection, please note the following signs of warning and its meanings:

AWARNING

�

Rotating cutter head. Oo N01 opor•te vitlh Q'.Jaro l#'ffl01,od

LOCl<OUI I ll'IC)OUI bototo 1erv1c1nu

1:·002

3

� NEW SOLID INTERNATIONAL CORPORATION This is positioned at the cutter (film cutting unit). The unit consists of razor blades and present the danger of cutting and shearing. If the protective covers are being removed, and the safety doors are opened, the machine should not be operated.

This is positioned outside the safety doors and guards. Behind these doors are moving parts and presents the danger of possible injury.

RISK OF ELECTRIC

SHOCK This is positioned outside the electric cabinet/panel. There are live wires within these boxes/doors. Opening the cabinet/panel with the machine energized presents the danger of electric shock

4

.... :.. NEW SOLID INTERNATIONAL CORPORATION

1 . PRODUCT FEATURES & INSTALLATION

1.1 Product Features

1. Variable production speed ramp up and down 2. Has a capacity of 6 sets of recipe, reduce change-over time and input errors 3. User friendly Human Machine Interface - provides instant feedback on status and

errors, allows user to easily operate and address any issues occurred 4. Easy and fast change-over with mandrel and cutter 5. Rotory blade design, provides fast and accurate cutting with minimal hair-lines 6. Compact design with small footprint, easily cleaned and wipe-down 7. Stainless steel structure and surface with aluminum parts, meets food packaging

standards 8. Modulated design for easy assemble, disassemble, repair and maintain 9. Material/Film shortage forecast, error feedback and error log maximize production

monitoring and efficiency 10. High mechanical guarding and electrical safety standards

1.2 Installation

11.2.1 General Remark and steps

1. Please read and understand this manual prior to installation 2. Please ensure the correct power input if supplied for the equipment 3. Please ensure the machine is correctly earthed for both the electric system and the

equipment itself. 4. Please ensure only qualified electricians and engineers are used for installation,

repair and maintain the machine. 5. Please following safety precautions during installation. Failure to do so may incur

electrical shock, bodily harm and injuries. 6. Please level the machine, conveyor and all accessories on a flat and smooth floor. 7. Accurate sleeving requires correct and consistent positioning between the

applicator and the conveyor. The main unit must be locked-in with the conveyor.

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:NEW SOLID INTERNATIONAL CORPORATION 8. The conveyor must be not vibrate and/or transfer any vibrations or movements to

the applicating unit. 9. The center of the mandrel needs to be aligned with the center of conveyor belt. 10. Please ensure the film is correctly threaded through the rollers. 1 1 . Final step would be connecting the power to the isolator. Please ensure the external

power is correctly connected to the isolating switch (picture1 -1),

Picture1 -1

1.2.2 Operating Environment

1 . Temperature: 1 0 ~ 35 °c

2. Humidity: 20% ~ 80% (Non-condensing) 3. Good ventilation and lighting required. Need to keep away from direct sunlight to

ensure correct operation of photo-electric sensors used in the system

6

% NEW SOLID INTERNATIONAL CORPORATION 2 . MACHINE SPECIFICATION

2.1 Main Applicating Unit

1. F11m Slack . ..,_

2. Filrr, Roller 6. Film Roller

3. Film Siad, Driver •• •

7. film Sensor

8. Mandre1

9. LCD Control Panel

10. F�eding Driver Adjustment

11. Feedirig Driver

12. Mandrel Support

13. Film Cutting Unit

--------------- 14. Applicating Driver

0

\

MODEL POWER CURRENT SIZE WxHxL

NSV-400 3<D 4W 415V SOHz 20A 850 x 2030 x850(mm)

Applicator

7

II NEW SOLID INTERNATIONAL CORPORATION

GENERAL PARAMETERS

Product Rate

100-300 pcs per min depending on container shape and size

Sleeve Size

Lay-flat Size: Min. 80mm to Max. 160mm or size as per your order in original specification

Height: Min. 50mm to Max. 200mm or size as per your order in original specification

Sleeve/Band Materials

To ensure efficient operation of the machine, the lay-flat material must meet the following specification: no creases, even thickness distribution, straight and flat, not elastic or stretchy, smooth surface with a small seam overlap if any.

Flat Creases If the material is flattened with too greater pressure, molecular damage occurs at the creases on either side of the flat width. In extreme cases the material can split at the crease, but in general terms this heavy creasing will prove detrimental to the machine operation especially on heavier materials i.e. 0.05, 0.07 and 0.075 mm. cf9 NSV-400 is designed to operate with material thickness of 0.035 ~ 0.075 mm.

Product Size

Product diameter - size as per your order in original specification Product Height - 250mm maximum (based on 900mm conveyor height)

Product Pitch

Product must be supplied pitched before presenting to the sleeving head.

8

...,-

\/,·\'.?\,-," NEW SOLID INTERNATIONAL CORPORATION Product Centralizing (Guide Belts) o Product can be centralized, where required, by a set of guiding belt acting as a

centralizer unit mounted to the conveyor. The belt will also reduce product movement and eliminate product accumulations under shooting head.

o The machine is not protected from build back of product from a subsequent machine. o A constant flow of product is needed. No undue pressure of product must be allowed

to affect the operation of the pitching/centralizer mechanisms.

Steam Tunnels o Shrinking is achieved by Steam, manifold through a series of pipes designed to suit the

product. Steam tunnels are constructed on adjustable frame work systems which fit around the conveyor belt.

o Maximum product diameter: 130mm o Maximum product height: 300mm.

Wipedown System/Brushes o Wipedown System or Brushes are a set of rubber bands fixed on a central axis

which is driven by a small electric AC motor. (See Section 2.5) o Wipedown or Brushing is achieved by rotating soft rubber flails or bands to create

friction and drag the sleeve downwards on to the desired position.

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-NEW SOLID INTERNATIONAL CORPORATION 3 . OPERATING PRINCIPLE

3.1 Applicator Operating Principle and Concepts

1. NSV-400 is designed to sleeve or band round or certain non-circular products. 2. Lay flat sleeving material is fed from a spool, situated at the side of the machine, across

guide rollers to the film sensor and into the cutting unit. 3. Rubber friction bands positioned on a servo motor controlled film slack driver, feed the

material on demand. The feed cycle is initiated by a photo electric switch. The photo electric switch is activated by the applicating driver which ultimately delivers the cut sleeves/band onto the product.

4. Before reaching the cutting unit, the flat tube of film is spread out by a mandrel. 5. The material must able to take sufficient stress and strain to ensure non-breakage while

going through a mandrel. 6. The cutting unit contains six sets of rotating blade to cut sleeves/bands. 7. Control of the feed length is via an impulse base system or by photo registration on printed

material. 8. The applicating driver, and hence the sleeving operation, is initiated by a photo electric

switch situated on the main unit.

The description of the main units of the machine follows the film path from the material spool to placement on the product, in logical sequence.

13.2 Film Spool Assembly

♦ The full spool assembly consists of an aluminum back disc, a freely rotating stainless steel spindle with aluminum core supports, and an external cover plate. This is the assembly which the reel of material is loaded onto. The spool is unwound to supply the film to machine by a motor driven roller and nip roller system. Material is supplied on demand once a photo electric sensor is cleared and the drive is switched off after a timed period. See section 3.4.

♦ To load a new reel of film, refer to the illustration which shows the material unwind full spool assembly.

♦ Located in the center of the outer spool plate is a quick-lock device which secures the plate to the spool; this must be rotated anti-clockwise to enable removal of the plate. Place a new reel of film on the unwind spool, making sure the paper core is located over the aluminum core support of the back disc, and that the film unwinds in the direction shown. Replace the outer plate onto the reel and apply pressure to nip the reel of film between the back disc and covering plate. Rotate the quick-lock in a clockwise direction to secure the reel to the spool.

1 1

:!NEW SOLID INTERNATIONAL CORPORATION 3.3 Automatic Film Feed Concept

♦ Several Photoelectric switches mounted on various areas of the film threading passage emit an infrared light beam to detect the presence and position of the film.

• If the sensor detect the change in position of the film slack, i.e. the film is being withdrew, the P.L.C. will switch on the material unwind driver motor to dispense film from the full spool into the threading passage. When the film reserve reaches its normal position and the sensor detects it, film will cease to be dispensed.

♦ Having carried out the instructions in Section 3.9, press the machine START button located on the front of the machine and film will be dispensed into the material threading passage as described above.

•

.... • • •• • • • •• •• •• • • •• • • • • • �.:_i .... !J. } __ ,]: •.. . . • . • ••••··•••••··•••••·••• ::-.F·1:1;_:·-:-:.·• . . .

. . . . . . .

.

.

. .

.

. .

. . . . . . . . . ....... . . .. ... . . .

. • ti••·•···•··•··••• ·:._:··•11 .. -·l.--i;•i ,,:

FIGURE 3.3: Automatic Film Feed

(Shown with single film spool)

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: NEW SOLID INTERNATIONAL CORPORATION 3.4 Material Spreading Unit: Mandrel

Top Head • The sleeving material, referred to as film, is actually a continuous tube which has been laid flat and wound onto a core to form a reel.

• Before the film is cut to form a sleeve, it must be opened into a more circular shape. To achieve this film Material Spreader Mandrel, which is

Central Body commonly known as " Mandrel", like the one shown in the left is used. Each mandrel is manufactured to suit a particular size of film.

• Some larger mandrel will consist of a 3-Piece design: CD Top Head (1st Piece): The leading section on the

Shooting Base top has a bullet-style head with a stainless steel fin. This section is the leading unit of film spreading and it can be rotated to guide film flowing direction into the cutting unit.

Mandrel @ Central Body (2nd Piece): The body section consists of several bearing to support the weight of

the mandrel while film passing through it. ® Shooting Base (3rd Piece): The last section provides the temporary holding

space for the next label to be applied onto the container/product. This section can be made into various shapes to accommodating different container/product shapes.

,- • The layflat size of the film relevant to each spreader is marked on one of its fins. Select the correct size spreader for the film being used and insert it into the film a distance of approximately 150mm.

• Once the film is inserted into the mandrel, it is supported by adjustable mandrel support, material feed driver and applicating driver. To secure the mandrel, make sure all support rollers on each part are tightened properly

13

CNEW SOLID INTERNATIONAL CORPORATION

IJIII--- Mandrel Support

-- Feeding Driver

Cutter Set

• Once the mandrel is secured properly, the mandrel should not be able to be moved by hand, if there is movement, check all support roller and drivers.

• Once passing the mandrel, the film will be expanded and fed through, getting ready for the cutting set.

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: NEW SOLID INTERNATIONAL CORPORATION 3.5 Film Cutting Unit (Cutter)

3.5.1 Film Cutting Concept

• The film is cut by a set of seivo operated rotating blade, controlled by a P.L.C through sets of gear and belt.

• After the film is fed, it will stay there until the producUcontainer reaches the Product Sensor.

• Material is cut to length by the cutting unit, which contains 6 rotating blades. • The cutting stroke is initiated by the signal generated from product Sensor. The film

is cut and pushed it down to the applicating driver, while the uncut section standsby on the 3rd section waiting for the next cycle.

Cutting Knife Set

3.5.2 Setting the Rotary Blades

• The rotary blades are set at a distance so they do not cut into the mandrel or one another. This is done by using the Knife Setter, clearly marked for the size of the operating mandrel.

• Flip the Film Cutting Unit upside down and remove the two clear protective covers. Place the Knife Setter into the center hole/cavity.

1 • Rotate the driver so all the rotary blades are pointing to the Knife Setter. (CAUTION: Watch your fingers! Beware of the sharp blade tips!)

• Adjust the extension of the blades by loosening the screws and move the blade holders forward/backward. Re-tighten and lock the screws after adjustment.

• Give the driver a full rotation to ensure all blades are clear of any interference. When completed, rotate the driver so all the blades are pointing away from the center ( 180° away from the Knife Setter).

• Remove the Knife Setter from the hole and replace the clear protective cover.

1 5

: NEW SOLID INTERNATIONAL CORPORATION

3.5.3 Adjusting Blade Position

Only adjust the blade cutting position if the blade does not turn away after cutting action which continuously jams the material in the cutting unit.

• To adjust blade positioning, first loosen the belt tensioner, so you can move the Cutting Unit Belt freely.

CUTTING UNIT BFLT

SCREW

• Adjust the blade position by taking out the knife set and then, move the blade 180° away from the mandrel.

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,,,... iaii NEW SOLID INTERNATIONAL CORPORATION

3.6 Product Sensor Unit

1. Before sleeve application, products are detected as they approach the applicating driver by a photo electric sensor mounted in a necked housing.

2. The sensor signal initiates the applicating drive, and hence the sensor position is very critical to the timing of the sequence of operations.

3. To allow the signal to be advanced or retarded in the sequence the sensor is mounted on an adjustable block which runs in a leadscrew. Hand adjustments are provided at either end of the leadscrew to allow accurate positioning of the sensor.

4. If sleeve application is too early with reference to the product position, then the sensor should be moved in the direction of the product flow. If the application is too late then the sensor should be moved against the direction of the product flow

PRODUCT SENSOR INITIATES CYCLE TOO LA TE

Product Flaw

Adjust Sensor <�.�J=---=

PRODUCT SENSOR INITIATES CYCLE TOO EARLY

q;�·.\.. : � - - . . .. .. - - : 1 ,,, ' ' ' ) I : (��lf

l F� --- '·r:-:.f.:,; f�-=:_r;_;..:r----,

r ' ' I

·--------GJ I B------

Product Flow EZ�jJ>

Conveyor Bell

(Shown here with product travelling from left to right)

1 7

Applicating Driver

sleeve

.,. NEW SOLID INTERNATIONAL CORPORATION 3. 7 Vertical Height Adjustment

�

- �:1 I I ' i • I I f

The mandrel support, feed driver, film cutter and applicating driver are mounted on a common base plate (or platform). The base plate is in turn mounted, via low friction bearing blocks, on two vertical supporting pillars. The position of the applicator head unit (as high-lighted in the photo) can be adjusted vertically up and down through a motor; which enables machine to apply products of different label length, or accommodating different container/product heights.

3.8 Circuitry Control

• All the function provided by the system is all processed by the P.L.C. (Programmable Logical Controller). The P.L.C. will perform accordingly to the signal transmitted from various optical sensors. i.e. one from the product sensor, one from the film register, and one from the cutter.

• The applicating cycle sequence is as below: Cycle initiated by Product Sensor detecting container/product - Film cut -Feed film - Desired Label length Reached - Cycle Completed.

• These signals run through a low voltage circuit on DC 12/24V system. The P.L.C. sends these controlling signal to different relays and magnetic contactors to output AC 220V for various motors and drivers.

1 8

IINEW SOLID INTERNATIONAL CORPORATION • P.L.C. is located inside the electrical cabinet.

3.9 Pitching Scroll

♦ Products passing under the sleeving head must be adequately pitched and centrally aligned to achieve successful sleeve placement.

♦ A helical -plastic scroll provides a method of accepting choke fed products at infeed and separating and controlling them during sleeving application.

♦ The scroll is rotated by a A.C. motor and gearbox and sprocket drive and abuts the conveyor side. Such that, the motor speed can be adjusted to pitch at the desiring distance between each products.

,,--.. ♦ The helical size is portable, and can be changed to suit the product size accordingly.

3. 1 0 Overall Set-Up Procedure

) .

To set the machine prior to normal operation follows the procedure set out below:

1. Connect main power input and pneumatic supply line (if used) and switch machine on. 2. If product is provided pitched then align input conveyor guide rails such that product is

central to conveyor belt. 3. If pitching scroll is supplied with machine, set the front guide rail to control the product

centrally and adjust the scroll laterally such that the root just contacts the product. Maintain 1 mm clearance on the front guide rail. Set the height of the scroll such that its centre line lies just below the estimated centre of gravity of the product. Balance the production its side to estimate centre of gravity.

4. Load and thread the film following the film passage diagram provided on your unit. For those with a Film Reservoir, please refer to Film Reservoir Manual.

5. Engage support roller, feeding driver roller and applicating driver roller to make sure the mandrel is properly supported.

6. Place product on the conveyor beneath the applicating driver. There should be enough clearance (approx. 15% of label cut length or min. 25mm) between the end of the mandrel and the top of the product for the product to be applied properly. Adjust the clearance with the buttons on the touch panel marked "Machine Up" or "Machine Down" in the Manual Mode page

19

� NEW SOLID INTERNATIONAL CORPORATION 7. Adjust the conveyor guide rails to leave 1 to 2 mm overall clearance between the

product and the rails with the product placed centrally under the mandrel supported by applicating driver.

8. Adjust the wipe down skid plate (if used for TES applications) such that the correct amount of clearance between the plate and the top of the product is achieved. The clearance is the amount the sleeve will overlap the product top when shrunk in position.

9. Ensure product photo electric sensor is positioned to detect a product as it passes the band application position. See Section 3.6 for full product sensing set up and adjustment procedures.

1 O. Enter Auto Mode page and set the production speed by entering the figures. This will set the scroll output speed to feed and pitch the products. Please refer to Chapter 4 for _ _ detailed screen shots.

11. Switch conveyor on and adjust speed to match scroll output rate 12. Pass two products through system to test if it is pitched correctly. 13. The machine will cycle and leave one sleeve retained on the 3rd section (shooting base)

of the mandrel. 14.Remove the sleeves and check them for length (check the sleeve cut position on pre

printed sleeves). If the sleeve lengths are incorrect adjust the "Film length"or "Film Feed Offset". Adjusting the parameters refer to Chapter 4 (Adjust photo sensor position if photo registration and pre-printed sleeves are being used).

15. Repeat steps 12 to 14 until correct sleeve length is achieved. 16.Send five to ten units of products through the machine and check the last product for

sleeve application. 17. If necessary, adjust the product sensor to achieve central placement of the

sleeve/band over the product. If the sleeve is delivered too early move the sensor in the direction of the product flow. If the sleeve is delivered too late move the sensor against the direction of the product flow.

18. Finally adjust the skid wipedown plate (if used) to obtain the correct wipedown height of sleeve above the top of cap. Check the result after shrinking in the heat tunnel. If long neck sleeves or full body sleeves are being used adjust the brushes/wipedown flails (if used) such that wipedown to the product shoulder or to conveyor level is achieved as appropriate.

20

,,-._


4 . D I S P L A Y & O PE R ATI O N

4.1 Display

0. Welcome Screen

5PM SOL IO PREC IS ION MACHINERY CORPORATION

TILPHONE : 886-7-.2869966 (3 LINE)

FACSL.\ULE : 886-7-28699SS (2 LINE)

Touch the screen to enter Main Operation Screen

21

..-NEW SOLID IN11ERNATIONAL CORPORATION 1. Main Screen

3-1 -201 4 MAIN PAGE

3-1 -201 4

1 4:23

SPEED :

QUANTITY :

AUTO MODE PAGE

SYSTEM RSAOY

: display current date

: d isplay current time

SPEED : 200

QUANTITY : 1 29

200

1 29

MANUAL MODE PAGE

POWER

B. P .M.

B.P .M.

RESET

,=;UJ>J·JTIT"r'

1 4:23

PARAMETERS PAGE

FAULT QUEUE

SAFETY

RESET

: display current line speed

: display accumulated production

count

: Reset the accumulated production count to Zero ' - --

..... � � .. �� rt� _._ .. ., . ::s'<ll , . ��

: display the current - -- -- ··-----·� - - - -

status of the system, including any error messages if any

AUTO MODE PAGE

: Press to enter the page for automatic control mode

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: NEW SOLID INTERNATIONAL CORPORATION MANUAL MODE

PAGE

PARAMETERS

PAGE

: Press to enter the page for manual control mode

: Press to enter the page with parameter settings (password required)

FAULT QUEUE

SAFETY

R ESET

: Press to enter and edit the fault/error log

: Press to activate the control circuit of the system

: Press to enable the AC power supply to the motors

: Press to reset the Safety Circuit after a door being opened or emergency stop being activated

2. Auto Mode Page

3-1-2014 1 4:24 AUTO MODE

QUANTITY :

E NABL E AUTO MODI:

1 29

SPEED :

APPLICATING ROLLER :

ENABLE

l31WSHES

B.P.M.

HZ

HZ

HZ

23

MAIN PAGE

Sl AIH


MAI N PAGE

::-: \,f�r_.. .�· «'' -• ;... ', -:. ..... ...\: · ENABLE AUTO MODE

NOW l PRINTED LABELj

: f.t � � -, • ' . � l�

ENABLE · JAM. SENSOR --

. . ENABLE-: tow Pf�ODUCT .. SENSOR·· . . . - � .

�--·. �NABIJ� . ..-: · BANK:.up ·:,

I

-.. . . ·. ��-t-:J�QR .. . �:

: Press to return to Main Page

: Press to activate Automatic Mode (button change to green color when in-use)

: Press to start/stop production (button change to green color when in-use)

: Press to choose between using Clear Film (Non-Registration Mark) or Printed Label with registration reference

: Press to activate Jam sensor (button change to green color when in-use)

: Press to activate Low Product Sensor (button change to green color when in-use)

: Press to activate Bank-Up Sensor (button change to green color when in-use)

: Press to activate brushes during production (button change to green color when in-use)

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:NEW SOLID INTERNATIONAL CORPORATION

: Press to activate guiding belts during production (button change

to green color when in-use)

SPEED : 2 B.P.M.

: Display current production speed. Press the number to change the setting.

APPLICATING ROLLER 40.0 HZ

: Display the current appl icating roller speed. Press the number to change the setting.

3 .0 HZ

: Display the current speed of the wipe-down system/brushes. Press the number to change

setting.

· · ENABLE

GUIDEf3F.:LT 38.0 HZ

: Display the current speed of the guiding belts. Press the number to change setting.

QUANTITY : 1 29

: Display the current accumulated production volume

� lR�) IFULl� �� co - �- -- ~ - - - -

' including any error messages if any

3. Manual Mode Page

: d isplay the current status of the system,

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: NEW SOLID INTERNATIONAL CORPORATION 3-1-201 4

1 4:24

ENAOI f ,JOG MODI:.

MAN UAL MODE

CUllER Sl:.l�VO

MAIN PAGE

ENABLE ONCE MOD[

FILM FF:1:D S DNO •

NOW ! PRINTED LABEL

CYCLE ONCE ' I

MAIN PAGE

.. . ... . . . .


C ENABLE . - JOG MODE

. .. . . , � . � . -· �.

ENABLE ONCE MODE

: Press to activate and de-activate jogging mode (button change to green color when in-use)

: Press to activate and de-activate the lx cycle mode in slow motion (button change to green color when in-use)

: Press to control the jogging or lx cycle of the cutter seNo (button change to green color when pressed)

26


SENSOR

UP

-. . � '

· SENSOR DOWN

MACHINE

UP

MACHINE

DOWN

CYCLE ONCE

NOW I PRINTED LABEL!

• -- -. . --_I

: Press to control the jogging or lx cycle of the film feed servo (button change to green color when pressed)

: Press to move up the Printed Label PE Sensor

: Press to move down the Printed Label PE Sensor

: Press to move up the appl icator head

: Press to move down the appl icator head

: Press to complete lx full sleeving cycle of film feeding and cutting action in slow motion

: Press to choose between using Clear Film (Non-Registration Mark) or Printed Label with registration referenc

� .. {K(@ �fl� �� ·-· � -��-- - ---�---- -- - - -- -- - . -

including any error messages if any

4. Parameters Page

: d isplay the current status of the system,

27

; NEW SOLID INTERNATIONAL CORPORATION 3-1 -2014

1 4:24 PARAMETERS

ENTER PASSWORD

1 1 1 1

MAIN PAGE


ENTER PASSWORD

1 1 1

___:J _J

28

MAIN PAGE

RECIPE PAGE

PARAMETERS

PAGE

: NEW SOLID INTERNATIONAL CORPORATION : Enter password to reveal the recipe page button and parameter page button

PARAMETERS

PAGE

: Press to enter recipe selection and storage page

: Press to enter parameters settings

29

�NEW SOLID INTERNATIONAL CORPORATION 5. Making changes to parameters

3-1-2014

14 :24 PARAMETERS MAI N PAGE

MAIN PAGE

NEXT PAGE

FILM FEED

OFFSET (mm)

'�-CUTTER POSITION

(CIRCLE)

u

FILM LENGTH

(mm)

u


BOTTLE SENSOR DELAY TIME (ms)

OU

FILM DELAY TIME (ms)

4u

NEXT PAGE

· : Press to enter the next page of parameters

FILM FEED OFFSET (mm)

: Display the current film feed offset for Printed Label. This is the length that Printed Label PE Sensor signals will be ignored within the set label length. Press the number to change setting.

30

; NEW SOLID INTERNATIONAL CORPORATION BOTTLE SENSOR DELAY T IME (ms)

50 : Display the current delay time for product sensor. This is

the time that Product PE Sensor signals wi l l be delayed before initiating a ful l sleeving cycle.

Press the number to change setting.

CUTTER POSITION (CIRCLE)

--�

. 4 : Display the current setting for blade position/angle relative

to the mandrel. Press the number to change setting.

FILM LENGTH

(mm)

1 0

to change setting. : Display the current setting for film length. Press the number

31

: NEW SOLID INTERNATIONAL tORPORATION 3-1 -201 4

1 4:24 PARAMETERS MAIN PAGE

BAN K-UP SENSOR

DELAY TIME (ms)

2

LOW PRODUCT SENSOR DELAY T IME (ms)

2

PREV. PAGE

BANK-UP SENSOR DELAY TIME (ms)

2

BAN K-UP SENSOR

R ESET DELAY T IME (ms)

2

LOW PRODUCT SENSOR

RESET DELAY TIME (ms)

2

NEXT PAGE

: Display the current sensitivity setting for bank-up sensor

delay time. Press the number to change setting.

BANK-UP SENSOR RESET DELAY TI M E (ms)

: Display the current reset sensitivity setting for

bank-up sensor. Press the number to change setting.

32

: NEW SOLID INTERNATIONAL CORPORATION LOW PRODUCT SENSOR

DELAY T IME (ms)

2 Display the current sensitivity setting for low

product sensor delay time. Press the number to change setting.

LOW PRODUCT SENSOR

R ESET DELAY T IME (ms)

2 : Display the current reset sensitivity setting for

1 1ow-product sensor. Press the number to change setting

PREV. PAGE

: Press to go to previous page

NEXT PAGE

: Press to go to next page

6. Changing the password

33

---- ·- - -

C NEW SOLID INTERNATIONAL CORPORATION

3-1-201 4 1 4:24 PARAMETERS MAI N PAGE

CHANGE PASSWORD

1 1 1 1

MACHINE TOTAL

67

I MACHINE TOTAL I 67

Clear All Alarms

Goto Conf1g

PREV. PAGE

: Display the whole accumulated production volume

record of this appl icator

Clear All Alarms : Press to clear all alarms and error messages

Goto Conf1g , : Press to enter the configuration of the PanelView HMI

PREV. PAGE

: Press to go to previous page

7. Alarm List/Error Log

34


Alarrri kle�SaJ'=' Ol c urro?nc.e T,rne Oc cu--re·-,,_·>? [ ate

Alarm Message Occurrence Time Occurrence Date

a a a MAIN PAGE

: Move up to the above record

: Move down to the below record

: Enter

MAIN PAGE


8. Recipe Selection

35

� NEW SOLID INTERNATIONAL CORPORATION 3-1 -201 4

1 4:24 RECI PE

CHOOSE RECIPE NUMBER

RECIPE - 1 - R ECIPE - 4 -

RECIPE - 2 RECIPE - 5 -

RECIPE - 3 - RECIPE - 6 -

MAIN PAGE


PARAMETERS

PAGE

MAIN PAGE

PARAMETERS

PAGE

: Press to enter parameters settings

RECIPE - 1 RECIPE - 2 -

: Press to enter Recipe 1 : Press to enter Recipe 2





36

:; NEW SOLID INTERNATIONAL CORPORATION 9. Recipe amendments and storage

R EC I P E

3-1-2014 1 4:24

SPEED :

APPLICATING

ROLLER :

BRUSHES :

GUIDBELT :

FILM LENGTH

RECIPE - 1

200 B.P.M.

40.0 HZ

30. 0 HZ

38.0 HZ

1 00.0 mm

: Press to return to Recipe Selection

NOW I

RECIPE

NOW : PRINTED LABEL'.

I

LOADING

PRI NTED LABEL ! - -� . � � �.• : Display recipe film type. Press to choose between using Clear Film

(Non-Registration Mark) or Printed Label with registration reference.

SPEED : 200 B.P.M.

: Display recipe production speed. Press the number to change the setting.

APPLICATING ROLLER :

40.0 HZ

: Display recipe appl icating roller speed. Press the number to change the setting.

BRUSHES : 30.0 HZ

: Display recipe wipe-down system/brushes speed. Press the number to change the setting. 37

----- -- --

: NEW SOLID INTERNATIONAL CORPORATION GUI DBELT : 38. 0 HZ

: Display recipe guiding belt speed. Press the number to change the setting.

FILM LENGTH 1 00 .0 mm

: Display recipe film length. Press the number to change the setting.

CHANGE PARAMETERS OF RECIPE - 1 - TO SYSTEM ?

CANCEL

: Pop-up page to confirm if user choose to load the recipe parameters into the appl icator

setttngs. Press OK to proceed or CANCEL to exit.

3 8

C NEW SOLID INTERNATIONAL CORPORATION 4.2 Operation

• This section contains instructions for day to day running of the system once the machine has been set up and adjusted as in Section 3

• The System should only be used by fully trained operating and maintenance personnel. Management must ensure that operators and service technicians are fully conversant with the contents of this m_anual BEFORE being allowed to work with the equipment.

4.2.1 Setting up the film

1. Fil l the film spool unit with fresh rolls of film.

2. Thread the material between the nip rollers prior to the film slack d river. Lift the film nip roller assembly by pulling down the lever against the applied spring pressure, and inserting the material between two nip film rollers. Refer to Figure 4.2.1

3. Continue threading the material all over the film slack roller and the film dancer assembly, which is positioned on top of the machine with a level

sensor. The PE sensor is placed below the unit to detect the height/level of the film dancer assembly position. Continue threading the material between the metal rol lers in film slack reservoir. Refer to Figure 4.2.1

0 0

39

: NEW SOLID INTERNATIONAL CORPORATION Figure 4.2.1

4. Thread the material over the mandrel and into material feed roller and the cutting unit.

5. IMPORTANT ! ' Loosen the mandrel support roller and feeding driver roller just enough to thread the cutting unit WITHOUT DROPPING the mandrel. Make sure all blades are facing away from the mandrel to preventjamming.

6. Ensure the mandrel is firmly supported by checking al l supports and rol lers. If the mandrel can be moved left and right by hand, that means it is not properly instal led. Make sure the mandrel is a l igned with film sensor and should be straight vertical ly.

4.2.2 HMI Screen Operation

1. Turn on the isolating switch to energise the system. Press the green Power On button and on the screen:

Press " SYSTEM READY" button -+ Press " Enable POWER" Now the appl iator has complete activation.

2. First time setup requires manual confirmation before production, on the screen: Press "MANUAL MODE" -+ "ENABLE ONCE MODE" -+ "CYCLE ONCE" This will confirm the correct label length and blade position

3. The preset password is "1111" . To change this setting requires entering PARAMETERS PAGE: "PARAMETERS PAGE" -+Enter Password-+ "Next Page" -+ "Next

Page" -+ change Password-+Enter New Password-+ "MAIN PAGE" Now your new password has been set.

4. Before entering into production, please store or load your parameters from the Recipe Page:

(1) Enter " PARAMETERS PAGE" -+ Enter Password -+ Set your parameters in those pages

40

S NEW SOLID INTERNATIONAL CORPORATION (2) Enter " RECIPE PAGE" ➔Choose Recipe Number-+ Eneter

Parameters in each field After completing, press " LOADING" to load the parameters ��* into applicator settings.

5. In Normal Production, use " AUTO MODE" by pressing

" ENABLE AUTO MODE" ➔ II START"

Turn on " ENABLE BRUSHES" ," ENABLE GUIDEBEL T" , " ENABLE JAM

SENSOR" , " ENABLE LOW PRODUCT SENSOR" , " ENABLE BANK-UP SENSOR" as required Now the machine will activate automatically with products infeeding.

6. To adjust the height of appl icator head, enter Manual Mode and

" MANUAL MODE " ➔ "ENABLE JOG MODE" ➔ "MACHINE UP" or

"MACHINE DOWN" df 7. To adjust the printed registed label cutting position, enter Manual Mode

and " MANUAL MODE " ➔ "ENABLE JOG MODE" ➔ "SENSOR U P" or "SENSOR DOWN"

8. To reset the accumulated production volume, press "RESET QUANTITY" to go back to zero.

9. If a door was opened or emergency stop was activated, the unit needs to be

have a safety reset. Press "Close" to acknoledge error message ➔

press "SAFETY RESET" ➔ press "POWER" 10. To view the alarm list or error log, enter the page by pressing "FAULT

QUEUE"

11. To clear the alarm list or error log, enter Parameters Page by :

" PARAMETERS PAGE" ➔ enter password➔" NEXT PAGE" _. ,, NEXT

PAGE" ➔" Clear Al l Alarms" 12. To make changes to HMI settings, eneter Parameter Page by:

" PARAMETERS PAGE" ➔enter password➔ " NEXT PAGE" _.,, N EXT

PAGE" _.,, Goto Config"

13.Any of the following conditions will trigger an alarm and causing the machine

to stop: • Guard/Door opened

41

� NEW SOLID INTERNATIONAL CORPORATION • Inverter Error • Film Feed or Cutter Servo Error • Emergency Stop activated • Film Jam • Film Reservoir (if optioned) reached reserve l imit • Film Reservoir (if optioned) missing another spare roll in reserve

14. The fol lowing message will be notified on the running message bar but the machine will continue to function: • Low-product infeed • Product bank-up • Film low • Film Reservoir (if optioned) door opened during change

15.If the Film Reservoir (if optioned) requires resetting, press the Reset Button on the unit "SAFETY RESET"

I

RESET

42

: NEW SOLID INTERNATIONAL CORPORATION 5 . M A I N T E N A N C E

To maintain the machine in good working order and to g ive maximum performance it is

important to carry out basic servicing on a regular basis.

Before commencing any maintenance program ensures the main power i nput is switched off.

5.1 MAIN MACHINE 5.1.l_Daily

1. Clean the material spool tray with a lint free cloth.

2. Clean the anvil shaft of the perforator (if optioned) and the perforator wheel and l ightly coat with a sil icone spray (RS part number 5 56-531 or similar) .

3. Clean the face of the sensor controlling the full spool unwinds with a l int free cloth.

4. Check and clean the film feed drive roller using a di lute detergent and dry thoroughly.

5. Clean the wheel face of all rubber rollers with dry clothes or di lute detergent. DO NOT use any lubricant, oil or solvent based liquid in order to maintain surface friction. Fi lm residue can be removed with a light scrub or sand paper.

6. Clean film dust inside the cutter assembly with compressed air blower. The clear protection cover can be wiped with dry clothes if necessary.

5.1.2 Weekly 1. Clean the rubber drive of the material full spool feed system with di lute detergent

and dry thoroughly.

2. Check all material guide spools for free rotation.

3. Grease the leadscrew of the head vertical adjustment system with White Food Quality Grease.

4. Check that all mandrel support rollers and feed rollers rotate freely. Lubricate the bearings l ightly with silicone spray if necessary.

43

Z NEW SOLID INTERNATIONAL CORPORATION 5. Check the cutting unit by unscrew and take off the plastic cover, clean a l l debris

and dirt on the plastic and blade. Check if blade is still sharp, change blade if necessary.

5.1 .3_Monthly

1. Clean the vertical head adjustment guide bars and lubricate l ightly with silicone spray.

2. Clean and check al l bearings, including the mandrel to ensure smooth rotation. Replace damage or worn bearings.

3. Clean and check guiding belt tension and rotation speed. Both belts should berunning at the same speed.

4. Clean and check wipe-down system/brushes rotation speed. Both sides should be running at the same speed.

44

1:1 NEW SOLID INTERNATIONAL CORPORATION 6 . T R O U B L E SH O O TI N G

When encountering machine malfunctioning, please check al l the parameter checking first, before proceeding to tuning the machine.

The following l ist is a guide to identifying the cause of the more common problems encountered in banding/sleeving products.

FAULT CAUSE REMEDY

Sleeves not 1.Mandrel not straight 1.Make sure that the mandrel is feeding properly properly installed, with all support 2.Material unwind not functioning. and feed rollers adequately 3.Product sensor not functioning. tightened.

2.Check the film roller is properly secured onto the film driver, and the film is being unwound.

Check product sensor for obstruction, cleanliness and function.

Cut sleeve too 1.Material unwind under tension. 1.Check full spool unwind system short after initial for obstruction or excessive setting 2.Layflat material too tight on the friction. Check for correct slack mandrel web in material full spool

3.Sensor adjustment reservoir.

2.Check film sizes and tolerances and retry cut/feed further along reel OR replace reel.

Adjust film sensor; make sure the photo eye is positioned in places where the printing and clear area of the film is clearly visible.

45

SNEW SOLID INTERNATIONAL CORPORATION

FAULT CAUSE REMEDY

Cut sleeve too long 1 . Sensor adjustment. 1 .Adjust film sensor, make sure photo OR keeps feeding eye is not positioned in area where

2.Sensor malfunctioning. there is no printing

3.P.L.C error signaling. 2.Reset sensor, if faulty, replace with a new one.

4.Logic card faulty. 3.Check input signal.

If necessary, replace a new logic card.

Cutter are not able to 1 . Fault in cutting servo supply 1 .Check complete circuit for function cut the sleeve circuit. and any component for failure. -

appropriately 2.Cutting blades blunt or 2. Inspect cutter blade and replace blade damaged . . if necessary.

Material jam above,. 1 .Material jammed caused by 1 . Check the cutter blade for damages or inside cutting blade incomplete cutting. and replace blade if necessary.

2.Material jammed caused by Reposition the blade position; please blade not turning away from refer to section 4.4. Please note that this the mandrel after cutting is the cause of the jam up before

adjusting the blade position.

Sleeve or long band 1 . Soft rubber flails not 1 .Adjust flail wipedown to contact sleeve wipedown incorrect. contacting sleeve correctly. properly. See section 2.5

-

2.Contamination of flails. 2.Clean flails with mild detergent solution.

3.Contamination on product. 3.Ensure clean, dry product delivered to

applicator.

46

ii NEW SOLID INTERNATIONAL CORPORATION

FAULT CAUSE REMEDY

Material splits when 1 .Material too heavily creased 1 . Remove material and open flat and passing through the during manufacture. check for damage on crease indicated film by opaque witness marks along spreader/mandrel. 2. Mandrel damaged or has crease.

sharp edges.

3.Film spreader too tight a fit to 2.Check for damage and replace if

necessary. material.

3.Check material size and tolerances 4.Perforator damaging with reference to film spreader. material.

4.Check perforator wheel for free 5.Material not welded on seam rotation and lubricate if necessary. I correctly.

This fault sometimes occurs at end of reel - replace reel.

Sleeve not being 1 .Shooting Head set too 1 .Set vertical adjustment system to fitted to product high/low to product. correct height.

2.Product not central in 2.Adjust conveyor guide rails and scroll relationship to centre line of to centralize product. See section 2.9 material feed. Pitching Scroll.

3.Sleeve fed too early. 3.Adjust product sensor in direction of

4.Sleeve fed too late. product flow.

Adjust product sensor against direction of product flow.

Incorrect amount of 1 .Film registration sensor 1 .Refer to the Photo Sensor manual to film is being fed into setting went off. re-set the sensor. the Cutting Unit.

47

-- - -

� NEW SOLID INTERNATIONAL CORPORATION Appendix 1 Electric Circuit Diagram

48


Appendix 2 Spare Parts List Main Applicator

w g, --(0

Ch � (J) 0

I

rt if•

.....

-

1f I � \ ��:..__J, +- �

E • �

'. . � \ ' l�_ �

l

;--,-

(I) � / '\ � �

�

49

I

..... n g ..... < Q) (1) -en (I) ::, (J) Q ....

---- � -- - -

: NEW SOLID INTERNATIONAL CORPORATION ......

Ol ::, en 3

0 Cl) ::, I;/) 0-

co 0 "ir) (I) ::,

OJ � (1) -··

g

� u

I.O

0 ' ,- p ;'}

I ,.. v, -.... (I)

<t> -.:; =:I ... U) {,!)

/JJ 0 � tr.)

.... u, c; 0 ,..... ro -. 0 "'

50

S NEW SOLID INTERNATIONAL CORPORATION Item Item Name Model Supplier Quantity

1 Color Contrast Sensor KTSW-2N1116 Sick 1

2 Cutter Unit M2KFW000SPM SPM 1

3 Bottle/Product PE Sensor WL9G-3N1132 Sick 1

4 Appl icating Motor M8MX2SSK4YGA Panasonic 2

5 Jam PE Sensor WT2S-N131S10 Sick 1

6 Slack/Tension PE Sensor DTl0-Nl0BS Sick 1

\ ] TRANSMISSION BELT M2TBT000SPM-BTSS10 SPM 1

(Cutter)

8 TRANSMISSION BELT M2TBT000SPM-BTS260 SPM 1

(Film Feed)

9 Cutter Position PE Sensor WLL180T-N432 Sick 1

10 Contrast Sensor Motor 4IK25GA-ST VGS 1

11 Proximity Switches D4V-8108Z OMRON 1

12 Machine Height Motor SIK60GU-ST VGS 1

51

--- -- --

,,.,.. • NEW SOLID INTERNATIONAL CORPORATION

Electrical Components within the cabinet

Item Item Name Model Supplier Quantity

1 Inverter/VSD 22BB5P0N104 ROCKWELL 3

2 Inverter /VSD 22BB2P3N104 ROCKWELL 4

3 Circuit Breaker 25019 LEGRAND 1 14 Leakage Detector 411723 LEGRAND 2

5 Circuit Protector 604833 LEGRAND 1





10 Power Supply DR-75-24 MEAN WELL 1

11 Contactor LC1D09M7 SCHNEIDER 4

112 Reversing Contactor LC2-D09M7 SCHNEIDER 2

13 Relay RXM2AB2P7 SCHNEIDER 1

14 Relay RXM4AB2BD SCHNEIDER 4

15 Relay RXM2AB2BD SCHNEIDER 16

16 Safety Relay 440R-M23147 ROCKWELL 1

17 PLC 1766-L32BXB ROCKWELL 1

18 PLC Output Module 1762-OB16 ROCKWELL 1

19 PLC Input Module 1762-IQ16 ROCKWELL 1

20 PLC Analogue 1762IF2OF2 ROCKWELL 1

52

: NEW SOLID INTERNATIONAL CORPORATION Module

21 Servo Motor Driver 2097-V34PRS ROCKWELL

22 Servo Motor MPL-8330P-HJ72M ROCKWELL

23 Overload Relay LR3-D04 TELEMECANIQUE

24 Overload Relay LR3-D02 TE LEM ECANIQU E

1 . Inverter/VSD 2. Inverter/VSD 3. Circuit Breaker 4.Leakage

• • • ( -...,. _, -

6. Circuit Protector



Protector

• •


2

2

1

1

I

I

5. Circuit Protec

10. Power Suppl

1 1 . Contactor 12. Reversing 13. AC 240V 14. DC 24V Relay 15. DC 24V Re1

53

: NEW SOLID INTERNATIONAL CORPORATION Contactor Relay

•

16. Safety Relay 17. PLC 18. PLC Output 19. PLC Input 20. PLC Analogt Module Module

21. Servo Motor 22. Servo Motor 23. Overload Driver Relay

54

Module

24. Overload Relay

62/,' 35( c,6,21

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