Page 1 T-1000 Advanced Poly-Bagger ______________________________________________________________________________ Operation Guide Setup, Operation and Parts Manual (Version 2)
Page 3 T-1000 Advanced Poly-Bagger ______________________________________________________________________________ Operation Guide Setup, Operation and Parts Manual Advanced Poly-Packaging, Inc. 1331 Emmitt Road, Akron, Ohio 44306 Phone (800) 754-4403 Fax (330) 785-4010...
Page 4 Poly Packaging, Inc. Unauthorized duplication, distribution, or disclosure to third parties without the expresses permission of Advanced Poly-Packaging, Inc. is strictly prohibited. Trademarks T-1000 Advanced Poly-Bagger is a trademark of Advanced Poly-Packaging, Inc. Advanced Poly-Packaging, Inc. owns also the following trademarks: Advanced Poly-Bags, Twin-Seal, Advanced Poly-Pack, Advanced Poly-Bag, Blist-a-Bag. Limited Warranty & Disclaimer Warranty period is 12 months or 1,000,000 cycles whichever comes first.
Page 5: Table Of Contents
Contents ______________________________________________________________________________ Chapter 1, Introduction Welcome Overview Special Features System Integration Options Available Using This Manual Registration Information Chapter 2, Getting Started Installation Procedures Air & Power Requirements Assembly Air & Power Hookup Main Power Bag Threading Cycle Operation Note on Adjustments Energy Conservation &...
Page 6 3.22 Insert Funnel 3.23 Diverting Funnel 3.24 Palm Buttons 3.25 Light Curtain 3.26 Trim Seal 3.27 Flat Seal Assembly 3.28 Twin Seal Assembly 3.29 Compartment Seal 3.30 Auxiliary Options Setup 3.31 Graphs Screen 3.32 Job Save / Recall 3.33 Technical Assistance 3.34 Timers 3.35 Passwords 3.36 Inputs / Outputs (PLC)
Page 7 5.7 Upper Roller Finger Assembly 5.8 Air Knife Assembly 5.9 Outer Main Frame Assembly 5.10 Pneumatics Mntg. Valve 5.11 Electrical Panel Assembly 5.12 Sealer Frame Assembly 5.13 Seal Frame Manifold Sub-Assembly 5.14 Pressure Bar Sub-Assembly 5.15 Heater Bar Sub-Assembly 5.16 PTFE Anti-Stick Guide Sub-Assembly 5.17 Grooved Roller Mounting Sub-Assembly 5.18 Bag Finger Grounding Assembly 5.19 Stand Assembly...
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Page 9: Chapter 1, Introduction
Operation Guide __________________________________________________________________ Chapter 1, Introduction Welcome Overview Special Features System Integration Options Available Using This Manual Registration Information...
Page 10 With a wide range of bag sizes (2" x 3" to 14" x 30") and mil thickness (1 mil to 5 mil), we hope the T-1000 will meet all of your bagging needs.
Page 11 CF-10 Counting Funnel - Preprogrammed, the T-1000 Counting Funnel counts product entering the funnel or bag and signals the T-1000 to seal the bag when the preset quantity has been reached. The Counting Funnel may operate in conjunction with the Accumulating Funnel...
Page 12 The conveyor perfectly fits underneath the T-1000 and takes the product away. Small, lightweight and equipped with castors, use this conveyor anywhere in the plant. Designed for 24 hour / 7 days a week operation.
Page 13: Registration Information
1.6 Using this Manual - Typographical Conventions The following manual conventions are frequently used to assist in understanding important information, alerting the operator of potentially dangerous or damaging practices, and the normal functions of the T-1000 Advanced Poly-Bagger text Normal text <ENTER>...
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Page 15 Operation Guide __________________________________________________________________ Chapter 2, Getting Started Installation Procedures Assembly Instructions Height Adjustment Air & Power Hookup Bag Threading...
Page 16: Chapter 2, Getting Started
2.1 Installation Procedures The T-1000 is transported as a single unit in a custom crate designed to protect the machine during shipment. It is shipped completely assembled except for a few items which are easily attached during installation with final adjustment for proper placement of touch screen, dancer assembly, foot switch, funnel and guards.
Page 18: Assembly
Dancer Assembly : The dancer assembly, located on the stand at the rear of the T-1000, is secured with tape strapping during shipment. After the removal of the strapping, the dancer should be checked to make sure that it will rotate freely in a semicircular path.
Page 21: Air & Power Hookup
VAC and properly grounded before hooking up the power. The air supply should be fed to the T-1000 with 3/8 ID flexible tubing; this tubing affixes to the coupler adapter (quick disconnect not provided). Connect the air to the regulator by holding the regulator firmly in one hand and pushing the air line connector on the male regulator connector.
Page 28: Cycle Operation
Note: If bags were delivered with the T-1000 or the size of the bags were known to APPI, the T-1000 may be ready to run. Therefore, few changes to BAG SET UP may be required.
Page 29: Chapter 3, Touch Screen Operation
Operation Guide ______________________________________________________________________________ Chapter 3, Touch Screen Operation Touch Screen Part Names Specifications Contrast Adjustment Touch Screen Program...
Page 30 3. Touch Screen Operation This section describes in detail, the identification, operation and adjustments of the Touch Screen Program. 3.1 Touch Screen Part Names - Front Panel (See Fig. 1) 1 System Button (See Section 3.4) 2 F1 (Help Screen) 3 F2 Increase Brightness (when system button is pressed) 4 F3 Midpoint Brightness (when system button is pressed) 5 F4 Decrease Brightness (when system button is pressed)
Page 33: Main Menu
: Stop functions or warning messages. 3.6 Introductory Screen When the T-1000 is turned on, an Introductory screen is displayed (Fig. 3-1). The Introduction screen is a welcome screen and has a button to take you to the Main Menu.
Page 34: Bag Setup Menu
The bag set up menu is the menu where most entries and machine operation setting will occur. When a new bag size or thickness is introduced, the T-1000 must be set up to properly run the bags 3.9 Seal Time Displays, in seconds, the time the pressure (rubber) bar will remain touching the surface of the bag for proper sealing.
Page 35: Seal Point
will change to Ready. From a "cold" start, it takes approximately four minutes to reach the set temperature. 3.11 Seal Point Seal point is a reference point. Increasing this number raising the seal point on the bag. Each increment adjusts the position approximately 1/8" up or down. To adjust the value, press the button labeled <Seal Point>...
Page 36: Blower
1) In the Manual mode with NO accumulating funnel, Fill Time will do nothing. However, when the T-1000 is equipped with an accumulating funnel, Fill Time will affect the delay time before sealing, after the door has closed on the accumulating funnel.
Page 38 APPI for pass codes. Options which have been purchased separately must be installed by APPI or by qualified maintenance personnel. The following sections describe how to setup optional equipment on the T-1000. If your T-1000 is not equipped with these options, please disregard these sections.
Page 39: Accumulating Funnel
3.18 Accumulating Funnel The Accumulating Funnel Option is not included in the standard T-1000 package and must be purchased separately. This special purpose funnel has several functions: 1) to collect (accumulate) a product before dropping the full contents of the Accumulator into the bag, 2) to...
Page 40: Inline Printer
3.20 Inline Printer A Printer option is not included in the standard T-1000 package and must be purchased separately. Used for product identification, a Printer option prints information, graphic images or bar codes directly to the surface of the film.
Page 41: Insert Funnel
The Diverting Funnel option (DF-10) is used to signal a diverting mechanism, located either beneath the seal bar of the T-1000 or at the end of a conveyor, to direct product one way or another (or into Box A or Box B) To turn the option ON, press the toggle button.
Page 42: Light Curtain
A minimum ON timer is provided so that false signals do not cycle the bagger when the Auto Cycle option is turned ON. Additionally, a Load Time delay is provided which delays the T-1000 from cycling immediately after the light curtain field obstruction is removed. See Fig. 3-26 3.26 Trim Seal...
Page 43: Twin Seal Tm Assembly
ON the ON/OFF button. Use the <Setup> button to make it easier to mechanically adjust the fingers along the front plate slots on the T-1000. See Fig. 3-24. Once the mechanical adjustment is complete, press <ON> and <AUTO> for normal operation of the flat seal assembly.
Page 44: Graphs Screen
"talk" to each other is essential to a fully automatic packaging system. Rarely will reprogramming be necessary to interface auxiliary (infeed) equipment. Additional cabling, however will be required which will transfer the signals between the T-1000 and your existing equipment. Three auxiliary signals are provided with the T-1000 so that no additional modifications or wiring is required for the integration.
Page 45: Job Save / Recall
The T-1000 is able to store 32 machine settings, called jobs, including BAG SETTINGS, OPTIONS SETTINGS and AUXILIARY SETTINGS. Each time a setting is changed on the T-1000, the settings are immediately saved in memory so that if power is lost, the T-1000 will power on with the job that was running before power was lost.
Page 46: Passwords
Outputs and Inputs. PLC I/O screen(s) are also used to assist APPI Service Technicians, working with your Maintenance Personnel to troubleshoot the T-1000 in the field. See Fig. 3-15. To determine the function of each Input / Output, press the LED to display a brief description.
Page 47: Input / Outputs (Expansion Card)
LED to display an information screen describing the function. See Fig. 3-16. 3.38 UF-5000 Operation Screen The T-1000 is programmed to also control the UF-5000 Infeed Conveyor if equipped with the Expansion PLC Card. This screen allows the operator to setup the conveyor to run standalone, with the T-1000 or with parts counters.
Page 48: Uf-5000 Settings Screen
Press the UF-5000 Mode button to return to the UF-5000 Operation Screen. 3.40 Information Screens The T-1000 touch screen program provides for many informational screens that provides descriptions of functions or screens. See Fig. 3-19 for an example of an information screen.
Page 49: Message Screens
3.41 Message Screens Message screens provide functional messages that describe errors or the status of equipment. Fig. 3-20 is an example of a message screen. Other message screens include: Open Frame, Printer Fault, Open Thermocouple, Job Run Error, Out of Bags, Predetermined Count Reached, Perf Sensor not Activated, Light Curtain Reset, Seal Bar not Engaging, UF-5000 Estop Engaged, UF-5000 Password not Entered.
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Page 51: Chapter 4, Operation, Settings & Adjustments
Operation Guide ______________________________________________________________________________ Chapter 4, Settings & Adjustments Machine Adjustments Component Replacement...
Page 52: Machine Adjustments
Then "snug" the upper block bolts and recheck the alignment. Note (TIP): A light source (lamp) positioned to the rear of the T-1000 showing light in the gap of the rollers will assist in judging whether the upper and lower roller are parallel.
Page 55: Dancer Assembly
The roller shaft must be parallel to the upper and lower guide rollers to allow proper tracking through the center of the T-1000. If the roller shaft is not parallel, the web of bags may track to the left or right.
Page 57: Ptfe Anti-Stick Adjustment
NOTE: If bags have an air relief hole or hanger hole, shift the bag to the right or left of center to avoid having the hole pass directly under the perf sensor. NOTE: Use the web guides for minor adjustments only. Major adjustment of the guides requires relocation of the bag roll on the bag roll shaft.
Page 59: Drive Belt Tension
Note: Pressure bar adjustment should only be necessary after rod or bushing replacement. 4.10 Drive Belt Tension Adjustment The T-1000 has two belts, one of which will periodically require adjustment. The drive belts (Fig. 4-18) will require adjustment if it becomes loose during normal operation.
Page 63: Anti-Jam Adjustment
To avoid personal injury, do not place fingers or hands into the seal area of the T-1000 while power is ON or air is attached. Do not test the anti-jam device with hands or fingers. Ensure the poly tube which is used for testing is long enough to keep fingers or hands away from the seal area of the T-1000.
Page 67: Heater Cartridge Replacement
Screen Front Cabinet, beneath the Touch Screen (if installed on the T-1000). Press the <START> key if the T-1000 is in the Stop mode. If "Y0" illuminates in long pulses without increasing the Temperature on the Bag Setup Screen (page 32, Fig. 3-3) proceed to step two. 2) Check the heater fuse (F5), on the Interface Board (Fig.
Page 70 Note: If you do not have an Ohms meter, replace the heater cartridge after step three. To replace the heater cartridge, turn the main power to the OFF position, unplug the power cord and disconnect the air line. Disconnect the heater cartridge wire at the connector. From underneath the inner frame, loosen and remove the screws which holds the wire clamp and lower heater bar plate to the upper heater bar plate (Fig.
Page 72: Brake Gap Adjustment
1. Ensure the T-1000 power is turned OFF. 2. Remove the right side (as you are facing the front of the T-1000) cover by first removing the bolt then pulling the cover outwards on bottom and then lifting upwards to remove.
Page 75 10. The BAUD RATE switch and MEMORY SELECTOR should be facing upwards. 11. You have now finished downloading the new program. PLC EPROM INSTALLATION INSTRUCTIONS For TOUCH SCREEN Version T-1000 1. Complete steps 1-9. 2. Turn power OFF. 3. The BAUD RATE switch should be facing DOWN, and the MEMORY SELECTOR switch should be UP.
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Page 77: Chapter 5, Parts
Operation Guide ______________________________________________________________________________ Chapter 5 Parts Dwgs Spare Parts Kits...
Page 78 5.1 Main Assembly => T-T1000 T-1000 Advanced Poly-Bagger See Dwg #T-T1000 TA-T10100 Head Assembly, T-1000 TA-T10199 Stand Assembly, T-1000 TA-T10240 Touch Screen Control Case Assembly...
Page 80: Head Assembly
5.2 Assembly => TA-T10100 Head Assembly, T-1000 See Dwg #TA-T10100 TA-T10018 Flat Load Shelf Sub-Assembly TA-T10110 Main Frame Assembly, T-1000 TA-T10280 Sealer Frame Assembly S/F TO-T1-FU-MISC Additional Funnel for T-1000 TP-T1MD00044 Top Cover TP-T1MD00045 Cover, Electronics Side TP-T1MD00046 Cover, Pneumatics Side...
Page 82: Flat Load Shelf Sub-Assembly
5.3 Assembly => TA-T10018 Flat Load Shelf Sub-Assembly See Dwg #TA-T10018 TP-T1MB00074-1 Load Shelf Bracket (Left) TP-T1MB00074-2 Load Shelf Bracket (Right) TP-T1MB00075 Fixed Load Shelf 9" (Fixed) TP-T1MB00076 Fixed Load Shelf Rod TP-101102 Nut, 6-32 Hex Mach Screw TP-102152 Washer, #6 Med Split Lock TP-102155 Washer, 1/4 Med Split Lock TP-103137...
Page 84 5.4 Assembly => TA-T10110 Main Frame Assembly,T-1000 See Dwg # TA-T10110 TA-T10230 Main Frame Assembly TA-T10250 Inner Main Frame Assembly TA-T10255 Outer Main Frame Assembly TA-T10275 Electrical Panel Assembly...
Page 86: Main Frame Assembly
5.5 Assembly => TA-T10230 Main Frame Assembly See Dwg #TA-T10230 TP-T1MC00001-1 Main Frame Plate (left) TP-T1MC00001-2 Main Frame Plate (right) TP-T1MC00017 Vulcanized Rubber Roller TP-T1MC00042 Face Plate TP-T1MC00056 Belt Drive Rear Support Shelf TP-T1MC00079 Shaft, Cylinder Pivot TP-504113 Bearing, 7612 DLG (2/M) TP-504114 Bearing, 7608 DLG...
Page 88: Inner Main Frame Assembly
Compression Spring, Guide TP-111010 Collars, Spring Closure TP-111142 Clamp Collar, 2 pc Split TP-214373 Clamp, 1/4" #10 Screw TP-401291 Elbow, 1/4" Tube X 1/4" Tube TP-406181 Filter, 4 micron (air knife) TP-501127 Motor 1/9 HP 1700 RPM 115 TP-501130 Capacitor, (T-1000 Motor)
Page 90: Upper Roller Finger Assembly
5.7 Assembly => TA-T10002 Upper Roller Finger Assembly See Dwg# TA-T10002 TP-T1MC00014 Support Brace (Sensor) TP-T1MC00020-1 Upper Finger (Left) TP-T1MC00020-2 Upper Finger (Right) TP-T1MC00083 Insulator, High Volt Sensor TP-T1MC00118-1 Film Web Roller Bracket (Left) TP-T1MC00118-2 Film Web Roller Bracket (Right) TP-T1MC00119 Film Web Roller TP-T1MC00120...
Page 92: Air Knife Assembly
5.8 Assembly => TA-T10001 Air Knife Assembly See Dwg# TA-T10001 TP-T1MC00080 Venturi / Air Pulse Bracket TP-T1MC00108 Air Pulse Manifold Assembly TP-102154 Washer, #10 Med Split Lock TP-103129 Screw, SHCS 10-32 x 1/2 TP-401134 Hex Plug, 1/8"x 3/4 Brass TP-401258 Straight, 1/4"...
Page 94: Outer Main Frame Assembly
5.9 Assembly => TA-T10255 Outer Main Frame Assembly See Dwg# TA-T10255 TA-T10025 Pneumatic Mntg. Valve Assembly TA-T10702 Clutch-Timing Belt Pulley TA-T10703 Tear Off Clutch Assembly TP-T1MC00054 Cover Support Clamp (4/M) TP-T1MC00058 Latch Adjuster Block (2/M) TP-T1MC00059 Latch Lock Block (2/M) TP-T1MC00082 Cover Stand-off (2/M) TP-T1MC00084...
Page 96 5.10 Assembly => TA-T10025 Pneumatic Mounting Valve Assemblyy See Dwg# TA-T10025 TP-401134 Hex Plug, 1/8"x 3/4 Brass TP-401275 Elbow, 3/8" tube x 1/8" np TP-401288 2 Pin SY S.ValveCon.Housin TP-402252 5 Station Manifolds Assembly TP-404262 Muffler, Sintered Bronze 1...
Page 97: Electrical Panel Assembly
Wiring Harness, T-1000 TP-T1MD00113 Electronics Back Plate TP-T1MD00149 Electronics Mtg Panel Assembly TP-T1ME00301 PCB, High Voltage Board Figure TP-200348 PCB, T-1000 IF Bd. Comp. TP-202116 6,000uF 40V Comp Capacitor TP-206146 Triac, 400v, 25amp, Q4025P TP-207216 Fuse Holder(110v/220v) TP-211384 Transformer, High Volt W/RF TP-211391 Triad Dual Pri.
Page 99: Sealer Frame Assembly
5.12 Assembly => TA-T10280 Sealer Frame Assembly (Standard Frame) See Dwg# TA-T10280 TA-T10003 Seal Frame Manifold Sub-Assembly TA-T10004 Main Seal Cylinder Sub-Assembly TA-T10005 Pressure Bar Sub-Assembly TA-T10006 Heater Bar Sub-Assembly TA-T10009 PTFE Anti-Stick Guide Sub-Assembly TA-T10012 Grooved Roller Mounting Sub-Assembly TA-T10013 Heater Bar Cylinder Sub-Assembly TA-T10017...
Page 101: Seal Frame Manifold Sub-Assembly
5.13 Assembly => TA-T10003 Seal Frame Manifold Sub-Assembly See Dwg# TA-T10003 TP-T1MB00021 Valve Manifold Mtg Bracket TP-101103 Nut,8-32 Hex Mach Screw Plate TP-102103 Lockwasher,#8 Int Tooth Plate TP-103118 Screw, SHCS 8-32 x 1 TP-401134 Hex Plug,1/8"x 3/4 Brass TP-401275 Elbow, 3/8" tube x 1/8" np TP-401288 2 Pin SY S.ValveCon.Housin TP-402253...
Page 103: Pressure Bar Sub-Assembly
5.14 Assembly => TA-T10005 Pressure Bar Sub-Assembly See Dwg# TA-T10005 TP-T1MB00029 Anti-Jam Pressure Housing TP-T1MB00030 Anti-jam Contact Center TP-T1MB00031 Anti-jam Pressure Pad TP-T1MB00068 Anti-jam Contact Strip TP-T1MB00111 Rubber Strip Holder TP-101131 Nut, Acorn Brass Nickel Plate TP-103138 Screw, SHCS 1/4-20 x 5/8 TP-103408 Screw, FHCS 8-32 x 3/8 TP-106093...
Page 105: Heater Bar Sub-Assembly
5.15 Assembly => TA-T10006 Heater Bar Sub-Assembly See Dwg# TA-T10006 TP-T1MB00008 Heater Bar Mtg Plate TP-T1MB00009 Heater Seal Bar TP-T1MB00024 Heater Cartridge Bracket TP-T1MB00145 Thermocouple Wire Tie Down TP-T1MB00159 Heater Cartridge Wire Lead TP-101126 Nut, Hex Jam SS 10-32 TP-102150 Washer, #10 Flat SS TP-103025 Screw, SHCS 10-32 x 1 SS...
Page 107 5.16 Assembly => TA-T10009 PTFE Guide Sub-Assembly See Dwg# TA-T10009 TP-T1MB00034 Bracket Plate Finger (PTFE) TP-T1MB00040 Rod, PTFE (2/M) TP-108156 Extension Spring, PTFE Roll TP-300500 PTFE Sheet (T-1000)
Page 109: Grooved Roller Mounting Sub-Assembly
5.17 Assembly => TA-T10012 Grooved Roller Mounting Sub-Assembly See Dwg# TA-T10012 TP-T1MB00004 Grooved Metal Roller Mount TP-T1MB00012 Grooved Lower Roller (Steel) TP-T1MB00013 Grooved Lower Roller Shaft TP-T1MB00155 S Frame Film Web Tension Roll TP-T1MB00156 S Frame Film Web Tension Roll TP-101143 Locknut, Hex Nylon Insert TP-102153...
Page 111: Bag Finger Grounding Assembly
5.18 Assembly => TA-T10017 Bag Finger Grounding Assembly See Dwg# TA-T10017 TA-T100124-1 High Voltage Sensor TP-T1MB00028 Grooved Metal Roller Finger TP-T1ME00325 Grounding Sensor Wire Assembly TP-101102 Nut, 6-32 Hex Mach Screw Pltd TP-102102 Lockwasher, #6 Int Tooth Pltd TP-102132 Washer, #6 SAE Flat Zinc TP-103207 Screw, BHCS 6-32 x 3/8 Blk...
Page 113: Stand Assembly
5.19 Assembly => TA-T10199 Stand Assembly, T-1000 See Dwg# TA-T10199 TA-T10200 Base Assembly TA-T10210 Upper Column Assembly TA-T10220 Dancer Assembly...
Page 115: Base Assembly
5.20 Assembly => TA-T10200 Base Assembly See Dwg# TA-T10200 TP-T1MA00051 Lower Base Weldment TP-T1MA00051-1 Lower Column TP-T1MA00102 Floor Leveler, Base Assembly TP-102156 Washer, 5/16 Med Split Lock TP-102157 Washer, 3/8 Med Split Lock TP-103161 Screw, SHCS 5/16-18 x 5/8 TP-103165 Screw, SHCS 3/8-16 x 7/8 TP-110756 Swivel Caster...
Page 117: Upper Column Assembly
5.21 Assembly => TA-T10210 Upper Column Assembly See Dwg# TA-T10210 TP-T1MA00087 Cross Pipe Weldment TP-T1MC00019-1 Base Clamp Block (Left) TP-T1MC00019-2 Base Clamp Block (right) TP-102154 Washer, #10 Med Split Lock TP-102156 Washer, 5/16 Med Split Lock TP-103012 Screw, SHCS 5/16-18 x 2-1/2 TP-103129 Screw, SHCS 10-32 x 1/2 BLK TP-103137...
Page 119: Dancer Assembly
Film Tension Hub Sub-Assembly TA-T10011 Dancer Guide Sub-Assembly TP-T1MA00069-1 Dancer Side Frame Plate (Left) TP-T1MA00069-2 Dancer Side Frame Plate (Right) TP-T1MA00073 Shaft, Bag Roll (T-1000) TP-T1MA00115 Brake Tension Strap (Dance) TP-101141 Locknut, Hex Nylon Insert TP-102143 Washer, SAE Flat Zinc 5/16 TP-102156...
Page 121: Dancer Guide Sub-Assembly
5.23 Assembly => TA-T10011 Dancer Guide Sub-Assembly See Dwg# TA-T10011 TP-T1MA00072 Dancer Tension Bar TP-T1MA00081 Dancer Tension Bar Cross B TP-T1MA00089 Dancer Roller 1.101.A21.00 TP-T1MA00090 Dancer Guide Roller Shaft TP-T1MA00186 Tension Adjuster & Spacer TP-101144 Nut, Hex Mach Screw TP-102153 Washer, #8 Med Split Lock Z TP-102154 Washer, #10 Med Split Lock...
Page 123 5.24 Assembly => TA-T10240 Touch Screen Control Case Assembly See Dwg# TA-T10240 TP-T1MA00088 Base Clamp Pipe Insert TP-T1MD00039 Control Case Touch Screen TP-T1MD00039-1 Control Case Touch Screen Back Plate TP-T1MD00039-3 Touch Screen Front Plate, Plain TP-T1MD00094 Touch Screen Tube Short TP-T1MD00109 Mounting Bar, Touch Screen TP-T10MA0041...
Page 125: Spare Parts Kit (Level 1)
5.25 SP-10 Spare Parts Kit (Level 1) (P/N T-SP-10) APPI Part Number Quantity Description TP-T1MA00115 Brake Tension Strap TP-T1MC00124-1 High Voltage Sensor TP-180155 Compression Spring, Pressure bar TP111010 Spring Closure Collars (Web Guides) TP-207206 Fuse, (2.5 Amp) TP-207225 Fuse, Fast Act (1 Amp) TP-207226 Fuse, (3.15 Amp) TP-207227...
Page 126: Spare Parts Kit
5.26 SP-20 Spare Parts Kit (Level 2) (P/N T-SP-20) APPI P/N Qty Description APPI P/N Qty Description TP-T1MA00115 2 Brake Tension Strap TP-300500 PTFE Sheet TP-T1MN00041 1 Main Seal Cylinder TP-306002 Anti-Jam Seal Rubber TP-T1MC00055 1 Brake Bushing TP-401254 Tee Fitting 1/4 Poly TP-T1MC00124-1 1 High Voltage Sensor (Top) TP-401255...
Page 127 APPI P/N Qty Description APPI P/N Qty Description TP-217116 1 Cartridge Heater TP-503102 Clutch/Brake Bearing TP-220367 1 PLC Controller TP-503182 Belt, Brake TP-220368 1 Touch Screen TP-503108 Bearing TP-221416 2 Thermocouple Wire TP-504113 Roller Bearings TP-504132 2 Cam Follower (CYR 1S) TP-504114 Clutch/Brake Bearing...
Page 128: Chapter 6, Preventive Maintenance & Scheduled Maintenance
Operation Guide ______________________________________________________________________________ Chapter 6, Preventive Maintenance & Scheduled Maintenance PM Checklist Schedule Maintenance (CHART)
Page 129 6.1 Preventative Maintenance & Scheduled Maintenance To extend the life of the T-1000, qualified maintenance personnel must perform all required maintenance tasks. Failure to perform scheduled and preventative maintenance may cause excessive wear to components and will void the warranty. For the purpose of this manual, preventative maintenance (PM) tasks are considered periodic tasks which should be performed on a daily, weekly or monthly basis.
Page 130: Scheduled Maintenance Chart
6.3 Scheduled Maintenance Chart CHART ITEM DESCRIPTION Drive belt Adjust/Inspect for wear (right panel) replace when necessary Drive belt Inspect for wear, replace when (left panel) necessary Heater element & Inspect for fraying, cuts, wiring loose connections Pressure bar Disassemble, clean, inspect assembly springs for wear, breakage (frequency dependent on...
Page 131 6.3 Preventative Maintenance (PM) Chart, Continued... (Options / Auxiliary Equipment) CHART ITEM DESCRIPTION Inspected by: (Initials) (Note: Each chart change represents 1MM cycles)
Page 132: Troubleshooting Checklist
The items included in this section cover the common causes of trouble which an operator might encounter during the operation of the T-1000. When operating difficulties occur, the best procedure is to observe what is happening; then search out the causes; and effect the correction.
Page 133 2. Web dragging foreign objects prematurely in 2. Remove obstructions 3. Bag roll side-plates bent machine 3. Repair / remove side-plates inward 7.3 Interface PCB Voltage Table by Terminal Number The following chart is provided to assist in further trouble shooting the T-1000.
Page 134 Operation Guide ______________________________________________________________________________ Chapter 7 Trouble Shooting...
Page 135 All voltage measurements are made with the machine in MANUAL MODE with all options which might impede the operation of the machine shut off. All measurements are made with these settings unless specified otherwise. All inputs that are listed as current sinking can be grounded to force the circuit on. Note: Component saver timers should be turned to the highest setting prior to testing voltages to ensure accuracy of readings.
Page 136 J2-5 Not Used Unused interface diode circuit anode (E12). J2-6 Not Used Unused interface diode circuit cathode (E12) J2-7 J1-3,4 0 V. D.C. to Bagger Run/Stop command to auxiliary 24V. D.C. equipment. E11 on indicates run. Voltage max. determined by auxiliary equipment voltage on Aux.
Page 137 J3-4 J1-3,4 0 V. D.C. or Optical Touch (Palm) Button 1 (right side) 24 V. D.C. inverting input (current source) to inverting input on I.F. Board. 0 bolts indicates an input from touch button. 24 volts indicates an input and lights E-7. Available on Palm Button Plug 1-2 under right side cover of machine.
Page 138 is on when the triac is off if the circuit has voltage applied, even though the machine may be shut off. This is the only neon which lights when its circuit is off! J4-1 J1-3,4 0 V. D.C. or 24 volts D.C. to all the control circuits on the 24 V.
Page 139 neutral 1 on 120 volt A.C. (Not jumpered on 230 volt machines.) J5-6 J5-8 (9th terminal) 90 to 100 V. +90 to +100 volts D.C. clutch drive voltage. D.C. Lights N1 neon (two electrodes) and N7 neon (one electrode) when voltage is applied while machine is advancing bags.
Page 140 Optional parallel contact with J5-13 for heater terminal) power. 7.4 Wiring Tab (Point to Point) The following point to point listing is provided to further assist is trouble shooting the wiring of the T-1000. SEAL BAR IN (2 PIN MOLEX) WHT/BLK/BL PLC INPUT PIN 23...
Page 141 MOTOR (5 PIN MOLEX) BLACK IF/BD-J5 PIN-14 BLACK JUMPED TO PIN-1 WHITE IF/BD-J5 PIN-2 MOTOR STARTER CAP. PIN-1 MOTOR STARTER CAP. PIN-3 GRN / GREEN CHASSIS GROUND SOLENOID AIR VALVES (2 PIN MOLEX) SAV-1 (MAIN SEAL PRES.) IF/BD-J4 PIN-1 WHT/BLK/RED PLC OUTPUT-PIN-27 SAV-2 (HEATER SEAL BOARD) IF/BD-J4 PIN-1...
Page 142 PIN-4 NOT USED PIN-5 TO CORCOM GROUND AND T-2XFMR GROUND PIN-6 IF/BD-J5 PIN-2 J-2 (3 PIN CONN) PIN-1 NOT USED PIN-2 NOT USED PIN-3 PLC INPUT-PIN-21 J-3 (2 PIN CONN) PIN-1 NOT USED PIN-2 TO H.V. SENSOR J-4 (4 PIN CONN) PIN-1 T-2XFMR PIN-2...
Page 143 PIN-3 WHT/BLK/ORG AUX-3 PIN-I PIN-4 AUX-3 PIN-H PIN-5 WHT/VIO IF/BD J-2-PIN-11 PIN-6 WHT/BL IF/BD J-2 PIN-9 PIN-7 NOT USED PIN-8 NOT USED PIN-9 NOT USED PIN-10 NOT USED PIN-11 WHT/GRN SEE NOTE:1 PIN-12 WHT/GRN IF/BD J1-PIN-3 OR 4 PIN-13 WHT/GRN JAM DETECT PIN-2 PIN-14 WHT/GRN...
Page 144 PIN-11 WHT/VIO PLC INPUT PIN-5, OPT. PART SENSE PIN-3 PIN-12 OPTICAL PART SENSE PIN-2 J-3 (10 PIN CONN) PIN-1 WHT/BLK/BRN PLC INPUT PIN-18, TOUCH BUTTON-2 PIN-3 PIN-2 OPT. TOUCH BUTTON-2 PIN-2 PIN-3 WHT/BLK/GRY PLC INPUT PIN-17, TOUCH BUTTON-1 PIN-3 PIN-4 OPT.
Page 145 PIN-F GREEN AUX-3 PIN-C, AUX-2 PIN-F, IF/BD J1 PIN-3 OR 4 AUX-2 (6 PIN CONN) PIN-A WHT/GRY PLC INPUT PIN-20 PIN-B WHT/GRN IF/BD J1-PIN-3 OR 4, FOOT SW. PIN-3 PIN-C WHT/BU IF/BD J4-PIN-7 PIN-D NOT USED PIN-E BLUE IF/BD J4-PIN-6 PIN-F GREEN IF/BD J1 PIN-3 OR 4, AUX-1 PIN-F, AUX-3 PIN-C...
Page 146: Circuit Boards
7.5 Circuit Boards PLC (Fig. 4-8) Output Indicators (LEDs) Y Heater Circuit Auxiliary Output Motor Run / Standby (IF27) Pressure Bar (SAV1) Flat Seal Assembly (SAV7) Heater Bar (SAV2) Bag Tear Off (SAV6) Trim Seal Blow Off (SAV5) Clutch / Perf Sensor Circuit Air Pulse (SAV10) Blower (SAV9) Load Shelf (SAV3)
Page 148 Input Indicators (LEDs) X Heater Bar Temperature Readout (Thermocouple) Reserved Reserved Anti-Jam Sensor (Pressure Bar) Foot Switch Perf Sensor Position (P.S. Board) Auxiliary Input Signal (Dump product) Anti-Jam Over-ride Sensor (Pressure Bar) Palm Button (Left) Palm Button (Right) Inner Frame Open Sensor Open Thermocouple Alarm (Caution: Should never be lit) Printer (No Foil) Alarm Counting-Funnel Sensor (Auto Detect)
Page 151: Pneumatic Valves / Cylinders
I.F. Board Connectors (Fig. 4-11) See wiring diagram for connectors identification (J1 - J5) Perf Sensor (P.S.) Board (Fig. 4-12) Armed Sensor Light Green Perf Detected Light Perf Sensor Sensitivity Adjustment Factory set only Jumper Settings Jumper 1 / 2 (normal) J1 - J4 Connectors See wiring diagram...
Page 156: Notes
7.8 NOTES Date Notes...

Advanced Poly-Packaging T-1000 Operation Manual

Chapter 1, Introduction

Chapter 2, Getting Started

Chapter 3, Touch Screen Operation

Chapter 4, Operation, Settings & Adjustments

Chapter 5, Parts

Chapter 6, Preventive Maintenance & Scheduled Maintenance

Chapter 7 , Trouble-Shooting

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