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HayssenSandiacre Ultima SV 12-19HR Instruction Manual

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Instruction Manual
Panel View 1000
Model: 12-19HR
Rev: 15
Ultima SV
Certis USA
M334U88011

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Summary of Contents for HayssenSandiacre Ultima SV 12-19HR

  • Page 1 Instruction Manual Panel View 1000 Model: 12-19HR Rev: 15 Ultima SV Certis USA M334U88011...
  • Page 3 This manual provides personnel with the information needed to safely operate and maintain the HayssenSandiacre machine. It has been designed and written to be used as an instruction tool, as well as a reference tool, for everyday work. To improve understanding by all levels of users, step- by-step instructions are provided wherever possible.
  • Page 4 Introduction © Copyright 2002 - 2008 by HayssenSandiacre, A Barry-Wehmiller Company ALL RIGHTS RESERVED. THE REPRODUCTION OR UTILIZATION OF THIS WORK IN ANY FORM IS FORBIDDEN WITHOUT THE PERMISSION OF THE PUBLISHER...
  • Page 5 USING THE PARTS MANUAL TO ORDER REPLACEMENT PARTS Parts Identification MPORTANT Do not order parts from the Instruction Manual or Training Man- ual. The part needed may be part of an assembly or an entire assembly. The Description of each major assembly, located in the Table of Contents in the Parts Manual, can help identify the specific bill of material required.
  • Page 6 If the part required does not look like the illustration or is not shown in the Parts Manual, check the original part for a cast or stamped number. All HayssenSandiacre part numbers have 10 digits. If a number is not visible, completely describe the part. Draw an illus- tration with dimensions.
  • Page 7 Abbreviation Meaning B/M NBR Bill of Material number Revision letter ASSY NBR Assembly drawing number Code for HayssenSandiacre use PARTS BOOK NR Parts book number Numerical listing of parts found ITEM on the Bill of Material DRWG NBR Drawing/Part number...
  • Page 8 Machine down, rush and emergency orders are shipped Air Freight, and an “Emergency Handling” charge may be added. • If parts are to be exported, advise HayssenSandiacre about any special documents the government may require. • When confirming a telephone order by mail, indicate in BOLD PRINT that this order confirms the phone order.
  • Page 9 Replacement Parts Request Form Please print the following information clearly. Company Information Machine Serial Number Date Company Name Billing Information Address Telephone Number City State Zip Code Fax Number Contact E-Mail Address Company Name Ship To Information Address Telephone Number City State Zip Code...
  • Page 10 Using the Parts Manual to Order Replacement Parts P a g e 6...

  • Page 11: Table Of Contents

    Table of Contents Chapter 1: Machine Overview Component Identification..............1-1 Operation Overview ................. 1-2 Chapter 2: Safety Safety Overview ................2-1 Safety Signals ................. 2-1 Basic Danger and Warning Notices ..........2-1 Installation ................2-1 Guards..................2-1 Machine Location ..............2-2 Burn, Nip, and Pinch Points ............
  • Page 12 ......................3-9 Chapter 4: Maintenance Lubrication Chart ..............4-2 General Maintenance ...............4-2 Rollers..................4-2 Belts..................4-2 Applying LocTite®................4-2 Rust Colored Stain On Stainless Steel - Causes and Solutions ..4-3 Guidelines For Washdown Environments ........4-4 Infeed System................4-4 Chapter 5: Operator Interface Allen Bradley PanelView 1000............5-1 Allen Bradley PanelView 1000 Screens..........5-3 Screen Layout................5-3 Password Protection..............5-46...
  • Page 13 Chapter 6: Unwind Assembly Unwind Assembly Setup and Operation Procedures ....6-4 Unwind Operation Overview............ 6-4 Loading a Roll of Film.............. 6-5 Threading Film ................ 6-6 Motorized Unwind Adjustment..........6-8 Removing a Depleted Film Roll..........6-8 Dancer Roller and Brake Adjustment ........6-9 Replacing the Bladder in a Pneumatic Spindle......
  • Page 14 Registration scanner system components: ....7-11 Scanner Control Unit Components ......7-12 Registration Mark Sensor Setup..........7-13 Opaque (non-foil) Material ..........7-13 Foil Material ..............7-13 Transparent Material...........7-14 Mechanical Bag Length Setup..........7-14 Film with an eyespot (Printed Film)......7-15 Film without an eyespot (Plain Film) ......7-15 Motorized Printer Take-Up (Option)..........7-16 Chapter 8: Forming Tube Assembly Former ....................8-1...
  • Page 15 Clean pull belts................ 9-1 Pull Belt Removal and Installation........... 9-3 Drive Pulley Replacement ............9-3 Pull Belt Pressure Adjustment..........9-4 Servo Pull Belt Drive Assembly............9-4 Continuous Motion Pull Belt ............9-5 l....................9-5 Pull Belt Pressure..............9-5 Pull Belt Centering..............9-6 Pull Belt Alignment ..............
  • Page 16 Standard Pillow Bag Or Flat Bottom Bag Operation .10-15 Quad Seal to Standard Flat Bottom Bag Operation..10-16 Standard Flat Bottom Bag to Quad Seal Operation..10-16 Quad Seal to Pillow Bag Operation ......10-16 Pillow Bag to Quad Seal Operation ......10-17 Flat Bottom Bag to Pillow Bag Operation....10-17 Pillow Bag to Flat Bottom bag Operation ....10-17 Direct Drive Platen with Offset ............10-18 Chapter 11: End Seal Assembly...
  • Page 17 Setup ................... 11-18 Quali-Seal Setup- Standard Jaw ..........11-19 Quali-Seal - ESP Jaw ..............11-28 Carrier Alignment ..............11-28 Gripper Alignment ............... 11-28 Jaw Face Alignment ............11-29 Jaw Pressure Adjustment............ 11-30 How To Change End Seal Systems ..........11-31 Changing from Quali-Seal to Resistance ......
  • Page 18 Filter Regulator with Gauge ...........13-1 Lubricator ..............13-1 Shut-Off and Pressure Relief Valve ......13-2 Air Pressure Switch ...............13-2 Flow Control Valves...............13-2 Slow Start Adjustment - Norgren System ......13-2 Pressure Switch Setting - Norgren ........13-3 Air Valve and Manifold Assembly ..........13-3 Exhaust Silencer/Separator ...........13-4 Optional Maintenance Alert and Prevention System (MAPS)13-4 Convert a Dry Air Valve to a Wet Air Valve ........13-5 Air System Maintenance ..............13-6...
  • Page 19 Bag Tucking.................. 14-14 Bag Tucking Dimensions............. 14-15 Tucker Flat Bottom Bag Option ........... 14-15 Film Splicer................... 14-16 Splicing Film ................ 14-16 Flat Bottom Bag ................14-18 Forming Tube Assembly ............. 14-18 Corner Creasing Assembly ..........14-18 Tucking Assembly ............... 14-19 Setup and Adjustment ............
  • Page 20 Stripper Cylinder Pneumatic Speed Adjustment....14-34 Stripper Proximity Switch Adjustment........14-35 Stripper Linkage Adjustment..........14-36 Product Stripper (Cam Operated) ..........14-37 Stripper Bar Gap Adjustment..........14-38 Stripper Cylinder Pneumatic Speed Adjustment....14-39 Stripper Proximity Switch Adjustment........14-39 Mini Product Stripper (Small Bag) ..........14-41 Reverse Strip ................14-41 Pneumatic Printer Backup............14-42 Setup ...................14-42 Removing the Backup............14-43 Shaker Jaw Assembly..............14-43...
  • Page 21 Dump Sensor............14-58 Preliminary Dump Sensor Adjustment...... 14-59 Volume Cup Adjustment........... 14-59 Trap Door Adjustment ..........14-60 Coordination Of Drop Timing........14-60 Brush/Scraper Adjustment........14-60 Changing Sets of Cups..........14-61 Dump Plate Height Adjustment ........ 14-61 Drive Motor Clutch Slip Adjustment (6-Cup and 9-Cup) ..14-62 Take Up Spring Pressure Adjustment (5-Cup) ..
  • Page 22 Machine Synchronization ............14-78 Synchronization Electrical Cabinet Front Panel....14-79 Synchronization Electrical Cabinet ........14-80 Chapter 15: Troubleshooting Troubleshooting Guidelines............15-1 Machine Overview ................15-2 Packaging Material Feed System ..........15-3 Print Registration ..............15-5 Platen..................15-5 End Seal System ..............15-6 Bag Cutoff................15-8 Quad Seal................15-8 Pneumatic System..............15-9 Ethernet Module Diagnostics ............15-11 Using Diagnostic Information..........15-11 Encapsulation Statistics............15-13 Servo ...................15-14...

  • Page 23: Chapter 1: Machine Overview

    CHAPTER 1: MACHINE OVERVIEW COMPONENT IDENTIFICATION Unwind Stand Registration Roller Assembly Forming Tube Assembly Pull Belts Platen Assembly End Seal Jaws and Knife Figure 1: Component Identification Component Overview The unwind stand removes film from NWIND SSEMBLY the spindle and supplies it to the reg- istration roller assembly.

  • Page 24: Operation Overview

    Operation Overview OPERATION OVERVIEW Registration Roller Forming Shoulder Pull Belts End Seal Film Figure 2: Film Measure, Form and Pull The bagger forms plain or printed film into a tube, adds product then seals and ejects the filled bag. Pre-programmed bag Registration rollers pull the film length pulled by from the unwind stand as the pull...

  • Page 25: Chapter 2: Safety

    Personnel should not operate this machine until trained on its function and purpose. MPORTANT HayssenSandiacre’s liability is limited to operation using the orig- inal program. Machines are shown without guards for illustration purposes only. The following signal words are used to inform about potential hazards...

  • Page 26: Machine Location

    Basic Danger and Warning Notices Side Door Guard Front Door Guard Figure 1: Machine Guards Safety switches are located on each guard. If a guard is opened while the machine is running, the machine stops and the operator interface indicates which door is open. Guard design is based on level machine footings that are even with the work area.

  • Page 27: Electrical

    BURN POINTS NIP POINTS PINCH POINTS KNIFE BELTS ELECTRICAL Figure 2: Safety Symbols Be extremely careful when working near nip points and pinch points. Keep body parts, hair, neckties, clothing, and tools away from these hazards to prevent serious injury or death. Do not wear rings, watches, or necklaces near the machine.

  • Page 28: Replacement Parts

    Basic Danger and Warning Notices MPORTANT Any changes not authorized by HayssenSandiacre may void the machine warranty. If there are any question or a need for modifi- cation, contact HayssenSandiacre. Parts should be replaced by maintenance personnel familiar with the Replacement Parts machine.

  • Page 29: Chapter 3: Installation

    CHAPTER 3: INSTALLATION MACHINE DELIVERY When the machine arrives, inspect the entire shipment for damage. If there is damage, photograph for verification and immediately file a claim with the carrier. • Provide competent machinery movers when the machine arrives • Note the gross weight of the machine shown on machine order acknowledgement and on the bill of lading •...

  • Page 30: Installing Electrical Devices

    Machines are prewired to the Order Acknowledgement. Check the name plate on the electrical cabinet for the exact power requirements. A labeled terminal is provided in the electrical enclosure for this con- nection. If further assistance is needed, contact the HayssenSandiacre Service Department. ARNING Ground the machine using an earth permanent device.

  • Page 31: Ground Fault Circuit Interrupter (Gfci)

    Current can flow through a person if electrically hot lines are touched Ground Fault while an individual is also touching the machine. The GFCI acts as an Circuit Interrupter (GFCI) overload device that senses ground currents which can be caused by wet wiring in equipment or contact with hot lines.

  • Page 32: To Lift Machine From Skid

    To Lift Machine from Skid TO LIFT MACHINE FROM SKID The machine should remain on the platform or skid until it has been moved to the installation site. ARNING When lifting or moving the machine adhere to the following guidelines to prevent harm to personnel or machinery: •...
  • Page 33 Forks Fork Lift Front Straps Rear Straps Figure 1: Lift Points MPORTANT When lifting the machine, carefully secure slings to the four top outside corners of the machine frame. To lift the machine, a fork lift or other suitable lifting device and four hoist straps are required.

  • Page 34: Product Feed Interface Installation And Operation

    Product Feed Interface Installation and Operation PRODUCT FEED INTERFACE INSTALLATION AND OPERATION Use the interface schematic provided to connect the bagger to the feed Feed System system. The schematic is included in the panel set of drawing shipped Electrical with the machine and in the parts manual. MPORTANT Follow electrical requirements outlined in the feed system instruction manual.

  • Page 35: Double Dumping

    The usual mechanical interface is a transition chute between the end of Mechanical the feed system discharge and the entrance to the forming tube assem- Interface bly funnel. 1. Poker 2. Product Shield A. Width of Poker B. Height of C.

  • Page 36: Mezzanine Installation

    Mezzanine Installation MEZZANINE INSTALLATION ARNING To prevent injury to personnel and equipment damage, use proper lifting, and equipment moving techniques. Restrict per- sonnel from walking, crawling, or reaching under equipment while it is supported. Platform Railing Deck Assembly Front & Rear Railing Platform Left Hand...
  • Page 37 If the scale does not rest on all four pads, shim the corners to support the scale before tightening the mounting bolts. If the mezzanine has a stairway and platform instead of a ladder: a. Install the railing which is adjacent to the stairway. b.
  • Page 38 H A Y S S E NSA N D I AC R E ® 3 - 1 0 / R e v 1 5 U l t i m a S V...

  • Page 39: Chapter 4: Maintenance

    ARNING Turn all power to the machine off before doing any lubrication, cleaning, adjustments or maintenance. Use HayssenSandiacre Lubri-Can™ food grade lubricants to properly maintain the machine. A full line of H1 approved oil and grease is available. Figure 1: HayssenSandiacre Lubri-Can Food Lubricants...

  • Page 40: Lubrication Chart

    160 hours of operation. Inspect screws, bolts and setscrews. Retighten where necessary. APPLYING LOCTITE ® MPORTANT HayssenSandiacre uses only USDA approved LocTite. • When using LocTite, do not use lock washers. • DO NOT use LocTite on any adjustment screws.

  • Page 41: Rust Colored Stain On Stainless Steel - Causes And Solutions

    RUST COLORED STAIN ON STAINLESS STEEL - CAUSES AND SOLUTIONS AUTION This procedure is for WASHDOWN RATED MACHINES ONLY! Figure 2: Examples of rust color stain Causes Solutions 1.Using a cleaning solution that is alkaline 1.Use neutral cleaning solution (pH 6-8) (higher than pH 11) a.If the customer insists on using an alkaline solution, rinse the detergent completely off...

  • Page 42: Guidelines For Washdown Environments

    Guidelines For Washdown Environments GUIDELINES FOR WASHDOWN ENVIRONMENTS These recommendations should be followed to help prevent problems from occurring in environments where machinery is exposed to water during clean-up. AUTION DO NOT use this procedure on painted machines; it will cause •...

  • Page 43: Chapter 5: Operator Interface

    CHAPTER 5: OPERATOR INTERFACE ALLEN BRADLEY PANELVIEW 1000 The Ultima SV has an operating interface that utilizes a touch screen, and most operator functions are activated through this touch screen. To activate a function, touch a finger on the appropriate touchpad. MPORTANT Applying too much pressure on the touchpad may •...
  • Page 44 Allen Bradley PanelView 1000 When the machine is in single cycle mode, a single bag is produced each INGLE YCLE time the Start pad is touched. When the machine is in continuous cycle mode, empty bags are produced ONTINUOUS YCLE continuously when the Start pad is touched until the Stop pad is touched.

  • Page 45: Allen Bradley Panelview 1000 Screens

    ALLEN BRADLEY PANELVIEW 1000 SCREENS Screen Layout Power Up Main Menu Program Program Manual Empty Bags Filled Bags Diagnostic Setup Select Machine Alarm Setup 1 Recipe Save IO Monitor History Machine Setup 2 System Temperature Installation Tuning Options Options 2 Auger Zipper Volumetric...
  • Page 46 Allen Bradley PanelView 1000 Screens MPORTANT These screens include information/typical values for optional • equipment that may not be on every machine. Functions must be enabled before entering a value. • Functions should be disabled when not in use. • Some screen names may differ slightly from the name on the •...
  • Page 47 MAIN MENU The Main Menu screen is used to access the Manual, Empty Bags, Filled Bags, Program Setup, Program Select and Diagnostics screens. H A Y S S E NSA N D I AC R E ® U l t i m a S V 5 - 5 / R e v 1 5...
  • Page 48 Allen Bradley PanelView 1000 Screens MANUAL FUNCTIONS Use this screen to manually activate various machine functions and to access the Diagnostic screen. Enables the platen. The function is ON until the pad is touched a sec- NGAGE LATEN ond time. Advances the film manually without performing sealing operations.
  • Page 49 EMPTY BAGS Use this screen to produce empty bags in either a single or continuous cycle with either regis- tered or plain film. Empty bags mode is used for verifying placement, seam seal quality, and for troubleshooting. The Empty Bags screen provides access to the Machine Setup 1, Machine Setup 2, Options, and Temperature Control screens.
  • Page 50 Allen Bradley PanelView 1000 Screens FILLED BAGS Use this screen to produce filled bags in continuous cycle only. The Filled Bags screen provides access to these screens. Sets the desired speed for filled bags mode, measured in ILLED PEED bags-per-minute (bpm). ETPOINT Displays the number of filled bags since the last bag count reset.
  • Page 51 MACHINE SETUP 1 Use this screen to set up machine timed function parameters and states. Start delay is the amount of delay between the receipt of the dump sig- TART ELAY nal from the scale and the start of the next bag making cycle. Start delay is required to allow the product to fall completely before the jaws close.
  • Page 52 Allen Bradley PanelView 1000 Screens Sets the bag length in millimeters (mm). If running in Plain Film mode ENGTH this is the desired bag length. If running in Printed Film mode, this is the distance from the leading edge of one eyespot to the leading edge of the next eyespot, plus 3/8"...
  • Page 53 If the machine is not registered, the machine will automatically register the film. Changing the registration rollers changes the time needed to pull the EGISTRATION length of film entered as the bag length. OLLER The FROM setting determines the start of the pull in machine degrees, and the TO value determines the stopping point of the pull in machine degrees.
  • Page 54 Allen Bradley PanelView 1000 Screens MACHINE SETUP 2 Use this screen to set up machine timed function parameters and states. Displays the actual machine degree when the jaws are fully closed and LOSE EGREE the end of the measuring roller film pull. Many other machine func- tions are timed relative to the degree when the film pull stops or the jaws close.
  • Page 55 Move the FROM and TO settings later in the cycle if the film requires some sealing time before the knife cuts the film. YPICAL ETTING FROM setting is about 20° before the jaw close point TO setting is the jaw closed point plus 50° The platen function must be turned ON in all applications and can LATEN occur any time the film is not moving.
  • Page 56 Allen Bradley PanelView 1000 Screens ically 50-100 ms, depending on the product and the delay in the scale. The TO value is the time required to make the full poker stroke. If adjusted too high, the poker will not retract before the next dump, catching product.
  • Page 57 OPTIONS Use this screen to set up and view parameters for installed options, and to access the Auger, Zip- per, Options 2 and Volumetric screens. Displays the seal time in milliseconds (ms). Enable or disable auxiliaries 1-5. FROM and TO values are entered in 1 - A machine degrees.* Aux.
  • Page 58 Allen Bradley PanelView 1000 Screens When using this option, the film is overpulled by the length set on this EVERSE screen. The jaws close to a fixed gap. The reverse strip length of film (overpull) is then pulled back. The pancake cylinders fire to make the seal.
  • Page 59 OPTIONS 2 Use this screen to set up and view parameters for installed options. mmmmmp A printer is normally turned on when the film is stopped and remains RINTER on for a duration required by the printer. The FROM and TO values are adjusted to suit the application.
  • Page 60 Allen Bradley PanelView 1000 Screens AUGER Use this screen to view auger settings and access the Auger Calibration screen. Enter the actual needed weight for the final filled bag. ARGET EIGHT Displays the actual weight distributed. CTUAL EIGHT Displays the number of turns the auger will make in one machine URNS cycle.
  • Page 61 Sets the number of seconds before the vibrator stops after filling a bag. IBRATOR ELAY With Fill toggles between On and Off. With Fill on means the vibrator is on during a fill and stays on after the fill is complete as specified by the Off Delay.
  • Page 62 Allen Bradley PanelView 1000 Screens AUGER CALIBRATION Use this screen to calibrate the auger. The Auger Calibration screen provides access to the Auger Feedback screen. Set the target (required) weight of the final filled bag. Any units may ARGET EIGHT be used.
  • Page 63 AUGER FEEDBACK Use this screen to set the feedback parameters. Enables/disables feedback adjustments. If the feedback function is dis- NABLE EEDBACK abled, the filler PLC will ignore any feedback signals sent from the checkweigher. Sets the number of required fill cycles to be completed before any weight feedback adjustments will be made by the filler PLC.
  • Page 64 Allen Bradley PanelView 1000 Screens A set period of time that the feedback pulse from the checkweigher must exceed before any corrections are made. If the duration of the feedback pulse exceeds the duration of the dead band, adjustments will be made to the auger turns setting.
  • Page 65 ZIPPER (TOP ZIP) Use this screen to set parameters for Top Zip applications. Sets the length of the zipper tape to be welded to a bag in millimeters IPPER ENGTH (mm). ETPOINT Sets the amount of time the zipper is sealed (welded) to the packaging IPPER material in real time milliseconds (ms).
  • Page 66 Allen Bradley PanelView 1000 Screens A start value (FROM) is entered in the From Deg field. This function LTRASONIC NVIL flattens the zipper material in preparation for the knife to make a cut and also provides a good sealing surface with the film. The Made Deg is a display of the degree when the action is completed.
  • Page 67 ZIPPER (WEB DIRECTIONAL) Use this screen to set parameters for Web Directional applications. Sets the actual zipper seal time. IPPER ETPOINT Sets the actual ultrasonic anvil time. LTRASONIC ETPOINT Activates/deactivates the ultrasonic anvil. LTRASONIC NVIL Activates/deactivates the zipper seal. EALER Sets the point in the machine cycle where the ultrasonic anvil, zipper EGREE cutter (knife), and zipper seal start.
  • Page 68 This screen is not available for stand-alone RecPro zipper applica- tors. This screen is used only for RecPro systems integrated with the HayssenSandiacre bagger system. Stand-alone units have their own control system. Sets the length of the zipper tape to be welded to a bag in millimeters...
  • Page 69 A start value (FROM) is entered in the From Deg field. This function NIFE cuts the zipper material in preparation for the sealer to seal the zipper to the film. The Made Deg is a display of the degree when the action is completed.
  • Page 70 Allen Bradley PanelView 1000 Screens VOLUMETRIC Use this screen to control volumetric infeed cup size. Increases or Decreases is touched to change the volumetric height. OLUMETRIC EIGHT Enter the number of cups for a volumetric filler. OLUMETRIC H A Y S S E NSA N D I AC R E ®...
  • Page 71 TEMPERATURE Use this screen to enable or disable heat zones and to enter heat zone setpoints. MPORTANT Once the temperature zones are named on the Name Heat Zones screen, the names will display on this screen. Earlier versions of this software may display Platen Heater, Front Jaw Heater, Rear Jaw Heater, Aux.
  • Page 72 Allen Bradley PanelView 1000 Screens Warn on Temp. Alarm allows the machine to continue to run after receiving an alarm that the temperature falls outside the set range. Fault on Temp Out of Range stops the operation at the end of the current bag cycle when the temperature falls outside the set range.
  • Page 73 EXTENDED HEAT ZONES This screen is available when the Quad Seal option is installed, and is used to enable or disable the named heat zones and enter a temperature setpoint. H A Y S S E NSA N D I AC R E ®...
  • Page 74 Allen Bradley PanelView 1000 Screens NAME HEAT ZONES This screen is used to label the eight heat zones. When the names are entered on this screen, they will automatically display on the Empty Bags screen, the Filled Bags screen, the Temperature Tuning 1 and 2 screens, and the Temperature Control screen.
  • Page 75 PROGRAM SETUP Use this screen to initialize common functions of the machine. Accesses the Alarm History screen. LARM ISTORY Resets both total bags count and total filled bags count to zero (0). ESET OUNT Enables or disables the accessory. CCESSORY UTPUT Enables or disables the external machine pause function.
  • Page 76 Allen Bradley PanelView 1000 Screens This sets the type of electrical connection between the remote machine AUSE LOSED and the PLC. ONTACT TOGGLE Closed allows the bagger to run as long as the external signal is applied and to stop when the signal is suspended. Open allows the bagger to run as long as there is no external signal applied and to stop when the signal is suspended.
  • Page 77 ALARM HISTORY Use this screen to assess machine performance over time by displaying a record of machine faults recorded since the last clear alarms command. Navigates through recorded alarms. LARM ISTORY ONTROLS Deletes the alarm history. LEAR LARMS H A Y S S E NSA N D I AC R E ®...
  • Page 78 Allen Bradley PanelView 1000 Screens PROGRAM SELECT Use these screens to access recipes from the memory. There are four program selection screens on the machine with a total of 59 namable recipes and 50 auger recipes. Changes the access level when a password is entered. ASSWORD NTRY TO Displays the number (1-59) of the currently selected program for the...
  • Page 79 RECIPE SAVE Use this screen to save a new recipe, change a password or edit auger settings. Sets the current bagger recipe. AGGER URRENT ECIPE Sets the number of an empty slot or of a filled slot to be replaced. The URRENT new recipe will be saved at this location.
  • Page 80 System Installation screen. AUTION Do not use the HayssenSandiacre Integrated Zipper, the RecPro Side Zipper, or the RecPro Integrated Zipper touchpad if the option is not installed on the bagger. Using the touchpad with a stand-alone zipper applicator causes a PLC fault and requires HayssenSandiacre Engineering assistance.
  • Page 81 TEMPERATURE TUNING Use this screen to set temperature parameters for the platen, front and rear jaws, and auxiliary temperature zone 1. AUTION Only qualified personnel should use this screen to • adjust temperature loop tuning parameters for the platen, jaws, and auxiliary heat zone. Once the temperature zones are named on the Name •...
  • Page 82 Allen Bradley PanelView 1000 Screens DIAGNOSTIC monitor machine states, Use this screen for troubleshooting and accessing I/O monitor screens. discrete logic controller inputs/outputs, and part numbers for installed software. Displays the software part number and revision letter for the program- PLC S OFTWARE mable logic controller (PLC).
  • Page 83 I/O MONITOR All I/O Monitor Slot screens provide feedback about the status of the logic controller inputs and outputs. H A Y S S E NSA N D I AC R E ® U l t i m a S V 5 - 4 1 / R e v 1 5...
  • Page 84 Allen Bradley PanelView 1000 Screens I/O MONITOR All I/O Monitor Slot screens provide feedback about the status of the logic controller inputs and outputs. H A Y S S E NSA N D I AC R E ® 5 - 4 2 / R e v 1 5 U l t i m a S V...
  • Page 85 I/O MONITOR All I/O Monitor Slot screens provide feedback about the status of the logic controller inputs and outputs. H A Y S S E NSA N D I AC R E ® U l t i m a S V 5 - 4 3 / R e v 1 5...
  • Page 86 Allen Bradley PanelView 1000 Screens I/O MONITOR All I/O Monitor Slot screens provide feedback about the status of the logic controller inputs and outputs. H A Y S S E NSA N D I AC R E ® 5 - 4 4 / R e v 1 5 U l t i m a S V...
  • Page 87 Sandiacre Technical Service with the malfunction. MPORTANT Faults indicated on the PLC Fault screen are not user serviceable. If a fault occurs, contact HayssenSandiacre Technical Services or Engineering for assistance. H A Y S S E NSA N D I AC R E ®...

  • Page 88: Password Protection

    Password Protection PASSWORD PROTECTION A password is required to save a recipe or access the System Installa- tion screen. The option to enter a password is on the Password Mainte- nance screen. The password system is divided into three levels: •...

  • Page 89: Change Password

    At the Main screen, touch Program Select. Change Password The Program Select screen displays. Touch Password Entry to Save #. Key in the current password, touch ↵. The Program Save screen displays. Touch the empty square next to Change Password. Key a new password, touch ↵.

  • Page 90: Recipe Setup Description

    Recipe Setup Description RECIPE SETUP DESCRIPTION Because many of the parameters in a recipe are product or speed dependent, it is difficult to suggest specific values for every parameter. Typical values are suggested where possible. To make developing a recipe easier, it is recommended to edit an existing recipe. For our cus- tomers’...

  • Page 91: Load A Recipe

    LOAD A RECIPE MPORTANT The machine must be reset before completing this procedure. • The machine must be stopped before selecting a recipe to • modify or save a new recipe. It is not possible to enter a recipe from nothing. Modify an •...

  • Page 92: Test A Recipe

    Test a Recipe TEST A RECIPE Touch Empty Bags The Empty Bags screen displays. Touch Single Cycle or Continuous Cycle Single Cycle Continuous Cycle Select Continuous Cycle to run product or produce Select Single Cycle to produce one bag each empty bags.

  • Page 93: Double Pull Recipe

    Touch the Save As pad. The recipe is loaded and saved to the appropriate location DOUBLE PULL RECIPE Double pull mode is required when the bag length exceeds the length of the platen. These instructions apply to the Ultima ST, Ultima SV and the Ultima SU.

  • Page 94: Name Heat Zones

    Name Heat Zones Touch Password Entry to Save. The keypad displays. Key in the password and touch The Save screen displays. Touch Mechanical Setup. A blank screen displays. Touch the hidden button. The Configuration screen displays. Use the up and down arrow keys to highlight Date/Time. Touch The Date/Time screen displays.

  • Page 95: Upgrading Panelview 1000 Software

    UPGRADING PANELVIEW 1000 SOFTWARE Turn power to the touchscreen Off. Insert the flashcard and adapter into the memory card slot located in the back of the touchscreen. Turn power to the touchscreen On. Touch the square prompt that appears in the lower right corner of the touchscreen.

  • Page 96: Timing Chart - Ultima Sv Panelview 1000

    Timing Chart - Ultima SV PanelView 1000 TIMING CHART - ULTIMA SV PANELVIEW 1000 Customer ______________________________ Program # _____________ Model # _______________ Product _______________________________ Machine # _____________ Weight ________ Bag Size _______ Eye Location: Front _____ Rear ______ Platen Distance ________ Former Assembly 03032A_________ Set the distance between the Cutoff Knife and Bag Eject to _____________ Auxiliary #1 ____________________...
  • Page 97 CHAPTER 6: UNWIND ASSEMBLY The unwind system stores a film roll for use in making a bag. The unwind stand contains a combination of fixed and moveable rollers that aid the registration rollers in removing film from the roll. The dancer rollers ensure film is pulled smoothly into the bagger by con- trolling brake pressure.
  • Page 98 Stationary Rollers Dancer Roller Assembly Brake Release Lever Low Film Detect Tension Adjust Spring Roll Brake Zipper Applicator Material Depletion Detector (low film) Roll Brake Mechanism Spindle Spindle Support Plates Stationary Rollers Brake Tension Release Dancer Rollers Side view with top mounted zipper Figure 2: Additional Unwind Stands The stand consists of the following components: •...
  • Page 99 • Stationary Rollers - Rollers rotate in fixed position and work with the dancer rollers to unwind additional film from the roll after the registration rollers stop. • Dancer Rollers - Rollers rotate and pivot position to reduce brake pad pressure, releasing and stopping film movement. Dancer pivot is controlled by two tension assist springs that work with the stationary rollers to stage film for the regis- tration rollers.
  • Page 100 Unwind Assembly Setup and Operation Procedures Film Roll Latch Protective Barrier Spindle Figure 3: Spindle Safety Lock (unlocked) - Ultra Machines Only UNWIND ASSEMBLY SETUP AND OPERATION PROCEDURES AUTION Always ensure the safety lock is engaged before starting the machine. The registration rollers pull the film for a length of time determined by Unwind Operation the programmed bag length.
  • Page 101 This procedure may also be used to re-position a roll of film on a spin- Loading a Roll of dle or after completing the Removing a Depleted Film Roll procedure. Film AUTION Always use proper lifting techniques when moving or lifting rolls of film.
  • Page 102 Unwind Assembly Setup and Operation Procedures If spindle safety locks are installed, engage the locks on each side Splice the new film to old film with tape, or thread film through machine Engage the brake Reset the machine This procedure assumes the machine is completely empty of film. Threading Film MPORTANT Machine threading may vary.
  • Page 103 Inner Tube Film Film Direction Bottom Plate Film Dual Rollers Figure 5: Threading the Forming Tube Assembly b. to make threading the film through the forming shoul- der easier, cut the film in one of the methods shown in the illustration below Leading Film Edge...
  • Page 104 Unwind Assembly Setup and Operation Procedures c. insert the film edge around the opening between the inner tube and the forming shoulder d. gently ease the film back-and-forth, working it down- ward until the edge of the film appears beneath the bottom plate of the forming shoulder Grasp the film edge and pull it through the forming shoul- der until the film covers the length of the forming tube.
  • Page 105 Lift the spindle and roll from the machine. Pneumatic Mechanical Depressurize the spindle bladder Turn the hand wheel counterclock- wise to loosen the roll on the spin- ARNING If the spindle has a pneumatic bladder, be sure to depressurize it AFTER the spindle and roll are removed from the film unwind to prevent the roll from slipping off and causing injury.
  • Page 106 Unwind Assembly Setup and Operation Procedures Lock the brake release rod jam nut. Reset the tension springs or air pressure of pneumatic sys- tem: Without Air Cylinders With Air Cylinders Reattach the tension assist Return the air pressure to the air springs cylinder and set at 30-40 psi Verify the dancer arm is in the level position.
  • Page 107 REPLACING THE BLADDER IN A PNEUMATIC SPINDLE A core slipping on a pneumatic spindle or a bladder that does not remain inflated indicates the bladder needs replacing. Remove the Bladder Remove the end caps. Remove the lugs. Tap the sealing caps out on Remove the bladder.
  • Page 108 Replacing the Bladder in a Pneumatic Spindle Install Bladder Install shim. Pull the bladder out. Tap sealing cap into place Insert another plug Stretch back in and slide in lug. At other end, trim bladder Install shim at other end. flush Tap sealing cap in place.
  • Page 109 H A Y S S E NSA N D I AC R E ® U l t i m a S V 6 - 1 3 / R e v 1 5...
  • Page 110 Replacing the Bladder in a Pneumatic Spindle H A Y S S E NSA N D I AC R E ® 6 - 1 4 / R e v 1 5 U l t i m a S V...
  • Page 111 CHAPTER 7: REGISTRATION ROLLERS The registration roller assembly is responsible for measuring the fin- ished bag length and providing the appropriate amount of film to the forming tube assembly. It is also responsible for maintaining film tracking throughout the machine. REGISTRATION ROLLER ASSEMBLY COMPO- NENTS •...
  • Page 112 Registration Roller Assembly Components It is extremely important for proper operation of the machine that the Cleaning measuring roller and upper feed roller assembly be clean and free of dirt and contamination. The rollers should be cleaned frequently with soap and water. Any worn rollers should be replaced. No lubrication is required.
  • Page 113 CANTILEVER PRESSURE ROLLER ADJUSTMENT When pressure rollers are repositioned or replaced, the pressure must be reset. All springs must be adjusted to the same setting. MPORTANT This is a factory setting. Minor adjustments may need to be made to the distance setting depending on film. Top Mounted 1-5/16"...
  • Page 114 Advanced Measure, Form, and Pull (MFP) Registration Roller Assembly (Optional) ADVANCED MEASURE, FORM, AND PULL (MFP) REGISTRATION ROLLER ASSEMBLY (OPTIONAL) Applications requiring zippers and thicker film may use the advance MFP registration roller assembly. The design of the advanced MFP assembly allows for more contact between the feed rollers, registration roller, and the film.
  • Page 115 The roller subassemblies are modular and can be easily repositioned, added, or removed. MFP feed rollers are more flexible, allowing them to contact the registration roller and the film in more places. Because of flexible bushings, the feed rollers can contour themselves to the reg- istration roller.
  • Page 116 Advanced Measure, Form, and Pull (MFP) Registration Roller Assembly (Optional) Pressure Rollers with Pneumatic Weighting Positioning Hand Knob Figure 5: Registration Rollers with Pneumatic Weighting The pressure rollers with pneumatic weighting contour over the driven roller for more contact over the film. The cylinders that tighten the pressure rollers are controlled by the pressure regulator.
  • Page 117 USDA REGISTRATION ROLLERS Figure 6: USDA Registration Rollers MAINTENANCE When loading film or performing maintenance on the registration roll- Pressure Roller ers, it may be necessary to release the pressure roller. Adjustment Turn the valve control to the far right to close the pressure roller.
  • Page 118 Advanced Measure, Form, and Pull Registration Roller Assembly (AMFP) for USDA applications ADVANCED MEASURE, FORM, AND PULL REGIS- TRATION ROLLER ASSEMBLY (AMFP) FOR USDA APPLICATIONS MPORTANT This roller is currently available only on the Ultima SU. This registration roller is designed specifically for USDA use on Hays- senSandiacre Ultima SU machines.
  • Page 119 MPORTANT Springs can collapse from too much pressure being • applied. Pressure settings too high will cause premature wear on • the rollers and bearings. Pressure settings too high on several, but not all, rollers • could warp the shaft and possibly cause film tracking problems.
  • Page 120 Print Registration For proper operation of the bagmaking machine, the registration roller Cleaning and upper feed roller assembly must be clean and free of dirt and con- tamination. Clean the rollers frequently with soap and water. Install new rollers when wear is evident. PRINT REGISTRATION The film pull is synchronized by registration marks (eyespots) on the succession of bags.
  • Page 121 The registration scanner system detect registration marks on the fol- lowing materials: • Transparent Material • Foil • Opaque, Non-foil Material EGISTRATION SCANNER SYSTEM COMPONENTS • Registration Scanner Control Unit - mounted to the machine frame inside the front door. •...
  • Page 122 Print Registration CANNER ONTROL OMPONENTS Offset Adjustment Pot The offset adjustment pot calibrates the registration scanner to the reflected light level from the packaging material background. Eye Spot Indicator The eye spot indicator illuminates when the registration scanner detects a registration mark. Background Selector Switch The background selector switch sets the scanner unit to look for either light or dark background.
  • Page 123 Registration Mark PAQUE FOIL ATERIAL Sensor Setup Before proceeding, verify the machine is in plain film mode. Position the background sensor to view the film from a straight on position. Registration Mark Sensor Film Backup 1/4” Minimum Gap Film 90° Fiber Optic Cable Figure 11: Registration Mark Sensor Positioned “Straight On”...
  • Page 124 Print Registration Position the registration mark sensor: a. for a black or dark registration mark, position the sen- sor straight to the film. b. for a white or light registration mark, position the sen- sor at a 45 angle. Move the film to reflect light off the background. Adjust the offset as follows: a.
  • Page 125 ILM WITH AN EYESPOT RINTED At the Main Menu screen, touch Empty Bags or Filled Bags. The selected screen displays. Touch Printed Film to enable. Using a metric ruler, measure the distance from the lead- ing edge of one eyespot to the leading edge of the next eyespot.
  • Page 126 Motorized Printer Take-Up (Option) MOTORIZED PRINTER TAKE-UP (OPTION) The motorized printer take-up allows the operator to adjust the position of printed information on the bag. Adjustments to this option are per- formed on the Options screen from the Operator Interface. From the Options screen, locate Printer Position, which includes up and down touchpads.
  • Page 127 CHAPTER 8: FORMING TUBE ASSEMBLY The FTA converts a roll of film into a tube by pulling the film over a forming shoulder. The edges are overlapped in position to create a ver- tical seal. The FTA consists of: • Forming Shoulder •...
  • Page 128 Last Roller Reset and restart the machine. LAST ROLLER The last roller is mounted on the back of the FTA and guides the film onto the forming shoulder. Adjust the last roller parallel to the rear edge and the bottom surface of the shoulder. The last roller needs to be tangent to the rear slope of the shoulder.
  • Page 129 Dusty products dropping through the forming tube create a cloud of Air Displacement contaminants that can settle onto operating components of the bagger. System The contaminants can cause the machine to jam, damage moving parts, or interfere with the sealing process. To eliminate the effects of prod- uct dust, a vacuum pump is attached to the forming tube to draw the dust cloud away from the effected areas.
  • Page 130 Pneumatic Tube Stop Adjust the tube stop as close to the tube as possible with- out touching the film (1/16" to 1/32" or 3/16" for zipper). Tighten the lock nut. Close the platen. Restore machine power. PNEUMATIC TUBE STOP Machines running film with zipper tape often have pneumatic tube stops installed.
  • Page 131 Figure 3: Pneumatic Tube Stop (side view) H A Y S S E NSA N D I AC R E ® U l t i m a S V 8 - 5 / R e v 1 5...
  • Page 132 Pneumatic Tube Stop To fine adjust the position of the pneumatic tube stop, use the centering Pneumatic Tube starwheel directly behind the tube stop. Stop Fine Adjustment AUTION Platen is HOT! Use caution to prevent burns. Remove machine power. Open the front guard doors. Swing the platen out of the way.
  • Page 133 FORMING TUBE INSERTS Forming tube inserts help maintain proper film tension. Without inserts, the pull belts may slip on the film and cause tension loss on the film. This leads to looping and poor tracking on the forming tube and shoulder.
  • Page 134 FTA Tube / Collar Clearance adjustment Bolts Clearance Figure 5: Film Clearance Tighten the bolts. If the tube moves as the bolts are tightened, place wedges (card- board, screwdriver blades, etc.) between the tube and bottom plate to hold the tube stationary as the bolts are tightened. Check for interference.
  • Page 135 QUAD SEAL FORMING TUBE ASSEMBLY (FTA) MPORTANT Quad Seal is currently only available on Ultima SV machines. There are several film guide adjustments on the forming tube that will help ensure proper forming of the quad seal. Before machine operation, foam and Teflon tape must be applied to Prepare Film these locations on the FTA -See Quad Seal Platen Assembly - Front Guides and...
  • Page 136 Quad Seal Forming Tube Assembly (FTA) Verify all fasteners are tightened. Some re-adjustment may be necessary to ensure proper forming of the quad seal shape along with free sliding of the film. MPORTANT Threading the film is easier if the side plates are temporarily backed away from the forming tube.
  • Page 137 While ensuring enough of a gap to reduce stress and drag on the film remains, adjust the guides as close to the cor- ner as possible in order to draw the film into the correct profile. Verify all fasteners are tightened. MPORTANT It is normal for the corner seals to have slight variations in width.
  • Page 138 Square Forming Tube Assembly (FTA) H A Y S S E NSA N D I AC R E ® 8 - 1 2 / R e v 1 5 U l t i m a S V...
  • Page 139 CHAPTER 9: PULL BELT ASSEMBLY Pull belts advance a predetermined length of packaging material from the registration rollers over the former and into the jaw area. Overpull increases the speed of the pull belts beyond that of the registration roller to maintain tension. The pull belt assembly consists of a drive shaft, drive pulley, idler pul- ley and pull belts.
  • Page 140 Pull Belt Care SELF-CENTERING PULL BELTS Idler Pulleys Self-centering pull belts automatically align both pull belts at the same time with the forming tube. The air cylinders compensate Pull Belt for varying sizes of forming tubes and pull belt wear without the need for a manual or mechanical adjustment.
  • Page 141 Pull Belt Removal and Installation MPORTANT Replace both pull belts at the same time because unequal pull • belts may cause problems with packaging material tracking. DO NOT use screwdrivers or other tools to remove pull belts • because of possible damage to the pull belt drive. Bring the machine to a controlled stop.
  • Page 142 Servo Pull Belt Drive Assembly The pull belt air pressure is factory set Pull Belt Pressure to 30 psi. If this needs to be changed, Adjustment turn the pressure adjusting knob on the pull belt regulator located to the rear of the electrical cabinet.
  • Page 143 CONTINUOUS MOTION PULL BELT CMB pull belts are turned by a transmission through drive shafts. CMB machine drive shafts turn continuously at a rate determined by the bagger speed. Figure 2: Continuous Motion 1. Belt Actuating Roller Assemblies 7. Brake Lockout Knobs 2.
  • Page 144 Continuous Motion Pull Belt To center the pull belts: Pull Belt Centering Loosen the pressure handwheel locking disk and turn the pressure adjustment handwheel counterclockwise to pro- vide clearance for the FTA. With both front doors Open, press Reset. The belts will be extended. Turn the pressure handwheel clockwise to move the belts toward the FTA.
  • Page 145 NON CMB PULL BELTS Non CMB pull belts are turned by a transmission through drive shafts, and only turn when a signal is received from the clutch/brake drive board. Pressure Pressure Washers Washers Open the front doors. Pull Belt Centering Non CMB Turn the pressure handwheel counter-clockwise to move belts away from the former.
  • Page 146 Quad Seal Pull Belts QUAD SEAL PULL BELTS MPORTANT Quad Seal is currently only available on Ultima SV machines. Pull Belt Tilt Front View Adjustment bolts (2) Side seal adjustment bracket (upper) Side seal Foam strips (4) (Teflon Tape - not shown) Side seal adjustment bracket (lower) Rear View...
  • Page 147 Side seal foam strips (4) teflon tape not shown Side seal backup brackets Side seal adjustment brackets (2) Keep with side seal backup brackets. Side seal adj. brackets (2) Keep with pull belt. Double pull belt Upper Pulley Push down to change Pull belt drive servomotors belts Figure 4: Assembly # 03044E0733 - Quad Seal Pull Belts and Side Seam Film...
  • Page 148 Quad Seal Pull Belts The restrictor should be reset to the restricted position when full travel is no longer required. Otherwise interferences may occur in the assem- bly, causing malfunctions and possible damage. Unwind Pull belts Slide Remove screw Slide restrictor block to the back position Insert and tighten screw in back hole...
  • Page 149 Make this adjustment in small increments until satisfactory results are obtained. Loosen one fastener then tighten the opposing fastener Re-tighten the first fastener. XAMPLE To tilt the top of the pull belt toward the front of the machine, 1) loosen the top bolt a little, 2) then tighten the bottom bolt, 3) retighten the top bolt.
  • Page 150 Quad Seal Pull Belts Forming Tube (overhead cross section) Side Seal Guide Forming tube (with foam strips) Correct Incorrect Incorrect Offset Angular Gap guide firmly against forming tube with no offset 1/16" NOTE 1/16" Actual distance may vary. Figure 7: Side Seal Film Guide Alignment While holding the film guide against the tube, tighten the two fasteners that connect each adjustment block to a pivot shaft on the film guide - See Figure 3:...
  • Page 151 CHAPTER 10: PLATEN ASSEMBLY The platen assembly makes the vertical seam seal (also known as a back seal) that seals the edges of the packaging material together to produce a continuous tube. The platen assembly consists of a heater body, cartridge heater, temperature probe, air cylinder, and a centering hand wheel.
  • Page 152 Platen Operation PLATEN OPERATION When making adjustments for normal platen operation, there are four sealing factors to consider: • Time • Temperature • Pressure • Seam seal cooling Adjust these factors until the correct seal quality is achieved. It is rec- ommended to operate with the minimum sealing temperature required to make acceptable seals.
  • Page 153 Platen Distance Adjustment Lock Nut Distance Handwheel MPORTANT If the gap is too small, overheated film sticks to the • back-up sponge tape and does not pass smoothly down the forming tube. If the gap is too large, the seam seal is weak or non-existent.
  • Page 154 Double Platen Fin Seal Assembly (optional) DOUBLE PLATEN FIN SEAL ASSEMBLY (OPTIONAL) MPORTANT May also be referred to as "true fin" or "pinch platen". The fin seal requires a special platen assembly with two opposing platen bars. The film edges are perpendicular to the forming tube between the platen bars.
  • Page 155 Inline Zipper Platen Figure 3: Inline Zipper Platen The inline zipper platen appears on machines with the inline zipper applicator and follows the same principle of operation as the double platen fin seal assembly; however, the front platen has two sealing sur- faces that seal the zipper, and the rear platen creates the back seal.
  • Page 156 Double Platen Fin Seal Assembly (optional) While supporting the platen assembly, pull out the pivot pin. MPORTANT When removing the pivot pin, do not allow the bronze thrust washers to fall. This may cause damage to the washers. Remove the platen assembly. Place the new platen in position.
  • Page 157 The front platen assembly components are contained in the platen housing and the rear platen assembly components are contained just behind the forming tube. Flow control valves on the air cylinder control sealer speed. To adjust Front Platen the speed of the front platen seal bar: Assembly Speed Adjustment Turn OFF all power to the machine.
  • Page 158 Double Platen Fin Seal Assembly (optional) Leave a close gap between the platen and the forming tube. To adjust: a. move the air cylinder to the fully retracted position b. loosen the distance handwheel jam disk Figure 8: Front Platen Distance Knob c.
  • Page 159 Loosen the two lock handles on the rear platen. Rear Platen Centering and Slide the platen to center position. Distance Tighten the locking handles. Adjustment Leave a close gap between the platen and the forming tube. To set the gap, adjust the rear adjusting knob. Adjusting Knob Lock Handles Figure 9: Rear Platen Assembly...
  • Page 160 Quad Seal Platen Assembly QUAD SEAL PLATEN ASSEMBLY MPORTANT Quad Seal is currently only available on Ultima SV machines. The quad seal makes a special type of flat bottom bag with the four corners sealed. This allows for thinner films to be used while still maintaining package stiffness and strength.
  • Page 161 Center Platen Forming Tube Support Bar-cover Upper tilt/position slot - center with foam & teflon tape platen (Lower slot not shown) Side Platens 2 Front, 2 Rear Rear Arm Front Arm Tilt/position lock knobs- In/out adjustment - push/ pull Side seal platens Front platen actuator (8 on front platen and (rear is similar)
  • Page 162 Quad Seal Platen Assembly Unlock the actuator. Make adjustments left and right by turning the adjustment knob. Lock down the position using the actuator lock handles. RONT CTUATOR OSITION This adjustment does not involve an adjustment knob; it is a manual push/pull adjustment.
  • Page 163 MPORTANT The side platen position/tilt adjustment is easier to perform when no film is on the former. To position and/or tilt a platen: Unlock the appropriate knobs. Spin the knobs to the desired position. Visually align the platen edge with the side seal film guide. Rulers are on the assembly to aid in setup, also See Figure 10:Quad Seal Platen Assembly - Front View and See Figure 12:Side Platen Alignment.
  • Page 164 Quad Seal Platen Assembly initial setup, the center platen position is adjusted moving the whole actuator left or right. The center platen and forming tube support bar should be reset to a cen- tered, straight-up position whenever beginning set up on a new forming tube.
  • Page 165 TANDARD ILLOW OTTOM PERATION The quad seal platen may be run in a standard pillow bag or flat bottom bag configuration. Side Platen Deactivation Options: 1.Turn Off heat to the side platens. 2.Adjust side platens out of the way. Option 1 This is to ensure the side platens do not strike anything while running.
  • Page 166 Quad Seal Platen Assembly EAL TO TANDARD OTTOM PERATION Refer to Option 1 and Option 2 for the side platen deactivation Remove the side seal film guides along with the two adjustment brackets for each guide. Loosen the two fasteners holding the center platen just enough to slide the center platen to the lowest possible position.
  • Page 167 Loosen the two fasteners holding the center platen just enough to slide the center platen to the lowest possible position. Retighten the two center platen fasteners. Set the platen air pressure to 40 psi at the back of the machine. ILLOW AG TO PERATION...
  • Page 168 Direct Drive Platen with Offset DIRECT DRIVE PLATEN WITH OFFSET Standard Adj. Handle Adjustment Bolts Platen Figure 15: Direct Drive Platen with Offset Adjustments The direct drive platen with offset is used on machines with a rectangu- lar FTA. The platen works the same as the standard platen by forming a seal against the FTA.
  • Page 169 CHAPTER 11: END SEAL ASSEMBLY ARNING Be extremely careful when working near the end seal assembly to avoid crushing injuries and painful cuts and burns. END SEAL OPERATION The end seal assembly creates the end (top and bottom) seals on a bag. It seals the top of the previous bag and the bottom of the next bag at one time.
  • Page 170 End Seal Operation 1 = Jaw Actuator 7 = Knife Linkage 2 = Rear Carrier 8 = Carrier Shaft 3 = Knife 9 = Compression Spring 4 = Deflection Collar 10 = Actuator Shaft 5 = Pressure Adjust Nut 11 = Crank Linkage 6 = Front Jaw Carrier Figure 1: End Seal Assembly H A Y S S E...
  • Page 171 SEALING METHODS Resistance and Quali-Seal are the two sealing methods used on end seal systems. Resistance is used to seal laminated films and oriented polypropylene. Quali-Seal is a precise, temperature-controlled end sealing system designed specifically for polyethylene sealing. Resistance seals are the most common method of creating an end seal Resistance and are identified by wide seals (½"...
  • Page 172 Sealing Methods The Quali-Seal is an exclusive sealing system that differs from conven- Quali-Seal tional polyethylene sealing systems. Sealing ribbons, backup rubbers, and water channels, or coolers, are not required. Instead, constant heat is applied to both sides of the bag to be sealed and an air blast is used to quickly cool and set the seal.
  • Page 173 DRIVE LINKAGE AND SHAFTS One of three types of drive links connects the jaw cylinder clevis to the jaw pivot assembly shaft. Early vertical machines contained an unpinned clevis link clamped around the pivot assembly shaft with two bolts. Later model jaw cylinders with a pneumatic cushion contained a pin installed through the drive link into the pivot assembly shaft to pre- vent the drive link from shifting.
  • Page 174 Drive Linkage and Shafts 1 = Cylinder 4 = Pivot Assembly Drive Shaft 2 = Saddle Clamp 5 = Clevis 3 = Drive Link Figure 3: Four Bolt Drive Link The four bolt drive link is machined from a single block of aluminum. Once the angles are cut and the pivot assembly shaft hole is bored, the block is sawed into two sections.
  • Page 175 JAW CLEANING AUTION NEVER use a brass brush on EZseal jaws. Use a clean soft cloth to clean jaw faces. Standard Jaw EZseal Jaw Clean the jaws at the end of each Clean the jaws at the end of each operating shift with a brass bristle operating shift with a clean, soft brush...
  • Page 176 End Seal Adjustments and Procedures MPORTANT The following procedure requires heat sink compound. • Heaters purchased after August 2006 are manufactured • with a sealant to eliminate moisture wicking into the heater. This will eliminate GFCI trips and down time waiting for heaters to dry out.
  • Page 177 Jaw Closed Proximity Switch ARNING Adjustment Do not touch Start. Serious personal injury or damage to the machine may occur. MPORTANT The proximity switch is set at the factory and does not • require adjustment unless the original setup is altered. Machine power must be On for this procedure.
  • Page 178 End Seal Adjustments and Procedures Verify Empty Bag Speed is below 100. Must be below 100 in order to set Jaw Open Percent to 100. Set Jaw Open Percent to 100. Open and close the jaws and verify: a. crank linkage is vertical/crank (jaw) linkage is level b.
  • Page 179 Set the jaw open cushion. a. close the jaw open cushion completely b. open the jaw open cushion ¼ turn Set the jaw close cushion at the 0 position. Restore machine power. Adjust machine parameters using the operator interface. a. set the jaw close timing FROM 150° TO 330° b.
  • Page 180 End Seal Adjustments and Procedures EPLACING AND ETTING YDRAULIC HOCK BSORBERS Hydraulic shock absorbers are used to control the jaw cushion while operating. The shock absorber fits into the end of the jaw actuator. To install a hydraulic shock absorber: 1 = Hydraulic Shock Absorber 2 = Cushion Adjustment 3 = Length 3 Inches...
  • Page 181 RESISTANCE END SEAL ADJUSTMENTS AND PROCEDURES Front and Rear EMOVAL Jaw Faces Remove all power from the machine. Remove the knife. Remove the nuts and slide the jaw faces out of their hous- ings. NSTALLATION Remove all power from the machine. Slide the jaw face into its housing and tighten the nuts.
  • Page 182 Resistance End Seal Adjustments and Procedures Spring washers, located between the jaw mounting blocks and the jaw housings, and adjusting screws are used to make alignment adjust- ments. • Turn the adjusting screws clockwise or counterclockwise to expand or compress the spring washers. •...
  • Page 183 Loosen jaw components: Unpinned 2 and 4 Bolt Pinned 2 Bolt a. loosen the drive link on the drive a. loosen the pressure adjustment shaft nuts until the compression springs spin freely b. loosen the pressure adjustment nuts until the compression b.
  • Page 184 Resistance End Seal Adjustments and Procedures Turn the pressure adjusting nuts clockwise and compress springs to: Red Springs Blue Springs 1 9/16" (40mm) 1 3/8" (35 mm) Tighten the jam nuts. Reinstall the hydraulic cylinder cushion. MPORTANT Replacing the jaw cylinder cushion requires threading the •...
  • Page 185 If adjustment is necessary, turn the appropriate adjust- ment screw to eliminate the gap between the jaw faces. Re-tighten the setscrews. Replace and re-tighten the guard screws. CEREAL JAW The cereal jaw is a resistance jaw with a wider center band that is not heated.
  • Page 186 ESP End Seal Assembly ESP END SEAL ASSEMBLY The enhanced sealing pressure (ESP) jaw assembly uses sealing pres- sure from the jaw lock air cylinders. The jaw actuator closes the jaw into position. The jaw close position produces a gap between the front and rear jaw face of 1/8 inch. The gap is necessary for reverse stripping.
  • Page 187 QUALI-SEAL SETUP- STANDARD JAW (4) RIB SEAL 2X Full Size 1 = Spring Adjusting Screw 14 = Jack Screws 27 = Gripper Mounting Bolt 2 = Actuator Rod 15 = Setscrew B 28 = Upper Adjusting Screws 3 = Jam Nut 16 = Setscrew A 29 = Lower Adjusting Screws 4 = Spring Housings...
  • Page 188 Quali-Seal Setup- Standard Jaw Remove power to the machine; perform plant Lock- out/Tag out procedure. Remove the knife. a. Follow the Knife Blade Replacement proce- dure in this chapter, but do not reinstall the knife at this point. b. Inspect the Teflon tape on the jaws for nicks, cuts, tears, loose fit, and cleanliness and clean or replace as needed.
  • Page 189 Remove the front grippers a. Loosen the two gripper mounting bolts on the top front gripper. b. Slide the top front gripper off. c. Loosen the two gripper mounting bolts on the bottom front gripper. d. Slide the bottom front gripper off. Loosen the jaw mounting plate.
  • Page 190 Quali-Seal Setup- Standard Jaw Unload the spring tension on the jaw carriers (left and right: see the following drawing). 1 = Deflection Collar 4 = Jam Nut 2 = Spring Length 5 = Spring 3 = Pressure Adjusting Nut Figure 14: Left Side of Jaw Carrier a.
  • Page 191 Adjust the deflection collars. Adjustment with Alignment Adjustment without Alignment Spacer Spacer a. Insert spacers between the machined a. Set the gap between the machined surfaces on each side of the front and surfaces on the inside of the front rear jaw carrier.
  • Page 192 Quali-Seal Setup- Standard Jaw Apply load to the jaw face springs. a. Using a 3/16" Allen wrench, loosen both spring adjust- ing screws at the back of the rear carrier. Turn the screw until there is no contact between the spring plunger and the screw.
  • Page 193 i. Tighten the bolts (locking) on the spring housing clamping blocks until the housings are tight. j. Push the jaws closed until the front and rear jaw faces touch. k. While observing the rear jaw, push the jaw linkage to the final closed position.
  • Page 194 Quali-Seal Setup- Standard Jaw c. Check the seal impression with TIPI paper. d. If pressure is not even, repeat adjustments after each 1/8 turn until even pressure is obtained. e. Once even pressure has been obtained, retighten set screws A. f.
  • Page 195 Tighten the gripper mounting bolts a. Lock down all four gripper jack screws by turning the jam nuts until contact is made with the jaw face backup plate. b. Tighten the two gripper mounting screws on the top and bottom of the gripper plate. Remove the jaw linkage clamp block.
  • Page 196 Quali-Seal - ESP Jaw QUALI-SEAL - ESP JAW Correct Quali-Seal jaw setup is required to produce strong seals. The setup procedure includes several parts. Incorrect set-up of any or all of these can result in bags with seals that leak, are deformed, or break open easily.
  • Page 197 Tighten the gripper mounting bolts and re-install the front gripper rubber. Hold a folded piece of film in the jaws and manually close the jaws. Lock the link arm level, clamping the film with the grip- per. Verify the film is clamped tightly between the grippers, if not, repeat this procedure.
  • Page 198 Quali-Seal - ESP Jaw Touch Start. The machine makes a cycle and the jaws close on the paper leaving an imprint, showing areas where there is insufficient contact. If the test shows correct contact, see the procedure for installing grippers. A good impression is uniform and even top to bottom and left to right.
  • Page 199 HOW TO CHANGE END SEAL SYSTEMS To change sealing systems, the front and rear sealing jaw assemblies must be removed from the carriers. Turn all power to machine Off. Changing from Quali-Seal to Carefully remove the cutoff knife. Resistance Remove the wires from the Unplug the electrical disconnect for terminal strip in the jaw carrier the sealing jaw.
  • Page 200 How To Change End Seal Systems Turn all power to machine Off. Changing from Resistance to Quali-Seal Remove the wires from the Unplug the electrical disconnect for terminal strip in the jaw carrier the sealing jaw. terminator box. Loosen guard mounting screws and remove guards. Remove cutoff knife.
  • Page 201 TETRA JAW MPORTANT This option is currently available only on Ultima SV machines; however, some jaw combinations may include Tetra and standard jaw assemblies. The tetra jaw is a resistance jaw used to make a tetrahedron package. The assembly is made for quick installation and disconnect. With the stager removed, the tetra jaw mounts over the existing jaw using the stager mounts.
  • Page 202 Tetra Jaw Installation MPORTANT If the Tetra and standard jaw assembly are both • installed on the machine the only setup changes required to switch jam systems is the heater electrical disconnects, the jaw air lines and the jaw proximity switch.
  • Page 203 Bolt the tetra air assembly onto the machine on the actua- tor casting. Power the machine On. Install the tetra jaw option at the System Installation Setup screen. Activate/deactivate the tetra jaw function from the pro- gram setup screen. Follow normal temperature and timing for jaw setup. ECOVERY ROM AN TOP OR...
  • Page 204 Knife Assembly Knife Blade Replacement 1 = Knife Retainer 6 = Flow Control 2 = Knife 7 = Knife Air Cylinder 3 = Rear Jaw 8 = Jam Nut 4 = Knife Linkage 9 = Rod End 5 = Front Jaw Remove machine power and lockout the machine.
  • Page 205 Knife Speed Adjustment MPORTANT The jaws must be CLOSED for this procedure. ARNING Exercise extreme caution while working with the power ON. Press the Reset button, but do not cycle the machine. With the jaws closed, press the manual operator on the knife control valve to actuate the knife.
  • Page 206 Knife Assembly The linear plunge knife is housed in the front jaw assembly. Operating Linear Plunge in a forward and back motion, it plunges from the jaw area, cuts Knife (Optional) through the film, and passes into a recess in the rear jaw. At the end of the dwell time, the knife retracts back into the front jaw.
  • Page 207 Partially loosen the right hand 10/24" screw. Slide the knife out of the recess. Slide in the new knife blade. Tighten the right hand screw. Replace the left hand screw. Restore power. INEAR LUNGE NIFE OSITION DJUSTMENT Remove machine power and lockout the machine. Verify the knife is fully retracted and the air cylinder is fully extended.
  • Page 208 Types of Seal Openability/Failure TYPES OF SEAL OPENABILITY/FAILURE Delamination Film Break/Tear Interfacial Peel Seal • Composition of seal layer • Tensile strength of film • Thickness of seal layer or lamination • Tensile strength of seal • Temperature, Dwell, Pres- sure layer Seal strength is...
  • Page 209 Figure 20: Servo-driven Jaw Motor There are several advantages to servo-driven jaws as opposed to con- ventional pneumatic jaw actuators. • The timing belt and pulley designed has been made with common components and is more reliable over time. • Since the actuator is not pneumatic, there is reduced com- pressed air consumption.
  • Page 210 Servo-Driven Jaw Actuator Figure 21: Servo Jaw Actuator Bolt-In Mounting H A Y S S E NSA N D I AC R E ® 1 1 - 4 2 / R e v 1 5 U l t i m a S V...
  • Page 211 SERVO ACTUATOR JAW Some machines may not have a sevo actuated jaw system. Refer to the bill of materials and drawings for the machine to determine if the servo actuator jaw procedures apply. 1 = Actuator, Belt Drive 5 = Shaft, Carrier 2 = Support 6 = Link Arm 3 = Shaft...
  • Page 212 Servo Actuator Jaw 1 = Support Plate 5 = Rear Drive Link Assembly 2 = Support Bracket, Output Shaft 6 = Front Drive Link Assembly 3 = Output Shaft 7 = Link Bar 4 = Drive Motor Figure 23: Major Components Actuator Belt Drive Assembly Drive Alignment MPORTANT Servo actuator drive alignment procedures require the use of spe-...
  • Page 213 2 Each Fixtures Required Figure 24: Shaft Alignment Fixture Place two (2) fixtures on to the shafts as shown below. Adjust the output shaft position as needed to fit the fixtures on to the shafts. 1 = Actuator, Belt Drive Assembly 3 = Shaft 2 = Output Shaft 4 = Shaft Alignment Fixture (2 required)
  • Page 214 Servo Actuator Jaw 5.Assemble the Drive Link Assembly and Link Bar per bill of material drawing. 6.Loose assemble the Drive Link Assemblies to the shafts per bill of material drawing. Do not tighten to the shafts at this time. 7.Square the Rear Drive Link Assemblies using the Drive Link Square Fixture 2 Each Fixtures Required 2 = Drive Link Square Fixture (2 required)
  • Page 215 8.Set the Front Drive Link Assembly angle position using the Drive Link Angle Fixture. (1) Fixture Required 1 = Front Drive Link Assembly 2 = Drive Link Angle Fixture (1 required) Figure 27: Servo Jaw Drive Link Angle Fixture Setup Manually close the jaws to place the drive linkage in the horizontal position.
  • Page 216 Servo Actuator Jaw 1. Loosen the hex nut to open the fixture. 2. Place the bottom half of the fixture under the carrier shaft and the drive link. 3. Place the top half of the fixture on top of the carrier shaft and the drive link.
  • Page 217 Servo Actuator Drive Jaw Setup 1 = Actuator, Belt Drive 6 = Collar Clamp 2 = Support 7 = Link Arm 3 = Shaft 8 = Assembly Pivot Arm 4 = Fixed Shaft 9 = Proximity Switch Housing 5 = Shaft, Carrier 10 = Proximity Switch Figure 29: Servo Actuator Drive Jaw Setup MPORTANT...
  • Page 218 Servo Actuator Jaw E-Stop the machine. 2.Check the tension of the three (3) servo jaw drive belts (approximately 1/8" deflection). If the belt tension is good proceed to Jaw Linkage Resistance Adjustment section, if not complete the below steps. 1 = Gear Mounting Bracket 4 = Tension Bolt 2 = Hex Nut 5 = Drive Belts (3) each...
  • Page 219 3.Adjust Jaw Linkage Resistance Manually close the jaws by turning the drive belt. As the jaws approach the closed position, observe the link arm position and the resistance feeling on the drive linkage. 1 = Drive Gear/Belts 2 = Link Arm 3 = Assembly Pivot Arm Figure 31: Jaw Linkage 1.
  • Page 220 Servo Actuator Jaw Note: Carriers and Jaws Not Shown 1 = Collar Clamp 2 = Compression Spring Figure 32: Jaw Linkage Resistance Adjustment Verify the resistance so it is felt only when linkage is in the horizontal position. Repeat Steps 2-3 as necessary. MPORTANT Make small adjustments to the spring tension 1/8 turn •...
  • Page 221 Ensure the jaws are closed and the linkage is in the horizontal position. Remove the proximity switch housing. Loosen the two (2) hex nuts on the proximity switch. One (1) hex nut outside the housing and one (1) hex nut inside the hous- ing.
  • Page 222 Servo Actuator Jaw From the Empty Bags screen: 1. Set Bag Speed to 60 bpm. 2. Press Continuous mode 3. Press Start and note the linkage and proximity switch during operation. Linkage should be in the horizontal position. Proximity switch LED should be ON when the jaws are closed.
  • Page 223 The servo jaw drive assembly consists of three (3) drive belts. Drive Belt Replacement H A Y S S E NSA N D I AC R E ® U l t i m a S V 1 1 - 5 5 / R e v 1 5...
  • Page 224 Servo Actuator Jaw = Support Plate 11 = Tension Bolt 20 = Output Shaft Support Bracket 2 = Drive Motor 12 = Drive Belt 1 21 = Support Bracket Assembly Mounting Bolts 3 = Tension Block Assembly 1 13 = Drive Belt 2 22 = Drive Motor Pulley 4 = Hex Nut 14 = Drive Belt 3...
  • Page 225 3.Remove the bag eject assembly from the machine. 1 = Mounting Bolts Figure 36: Bag Eject Mounting Remove two (2) air hoses from the bag eject assembly. Support the bag eject assembly from underneath using a suitable lift jack. Remove four (4) bag eject mounting bolts from under- neath the servo drive assembly.
  • Page 226 Servo Actuator Jaw 5.Release tension from the drive belts. Drive Belt 1 Drive Belt 2 and 3 a. Loosen the hex nut # 4 on tension block assembly a. Loosen the hex nut # 7 on tension block assembly 1, # 3. 2, # 8.
  • Page 227 10.Remove the guard standoff. Remove one (1) guard support standoff from the sup- port plate #1. It is in front of the rear drive link assembly #25A on the non-motor side of the assembly. 1 = Drive Motor 2 = Rear Drive Link Assembly 3 = Standoff Figure 38: Guard Standoff Removal 11.Remove the three (3) drive belts.
  • Page 228 Servo Actuator Jaw 13.Assemble the support bracket assembly. Place the top half of the support bracket assembly # 9 on the bottom half of the support bracket assembly #20. Assemble four (4) support bracket assembly mounting bolts # 21 on top of the support bracket assembly # 9. Tighten.
  • Page 229 17.Assemble the output shaft drive assembly. Install two (2) output shaft support bracket mounting bolts # 19A. Tighten. Tighten two (2) output shaft support bracket mounting bolts # 19B. 18.Set the tension for the drive belts per the Drive Belt Tension Adjustment section of this procedure.
  • Page 230 Servo Actuator Jaw H A Y S S E NSA N D I AC R E ® 1 1 - 6 2 / R e v 1 5 U l t i m a S V...
  • Page 231 CHAPTER 12: ELECTRICAL SERVO A servo system uses feedback to force the output (position or speed) to match the input. The Ultima SV utilizes two servomotors to drive the film pull. One motor is used to drive the registration rollers to measure and register film and the second is used to drive the pull belts to pull the film over the forming tube and ensure constant film tension.
  • Page 232 Servo Heater #1 RTD #1 Heater #1 RTD #2 Heater #1 RTD #3 Heater #1 A-B SLC/500 PLC RTD #4 16 pt 16 pt 16 pt 16 pt 16 pt signal Power Input Input Output Output Cond. Input Supply SLC 5\04 SLC 500 1746- 1746-...
  • Page 233 AXIS ORGANIZATION In this system, two (2) servo axes control the film pull. The primary axis or master axis is designated as the registration roller. The purpose of this axis is to drive the registration rollers, which pull the film from the supply roll, register the pull to the eye mark, and meter the pull to establish the correct pull length and maintain registration of the eye spot to the cutoff.
  • Page 234 Side Mount Electrical Cabinet SIDE MOUNT ELECTRICAL CABINET Most Ultima SV machines have a side mounted electrical cabinet for all machine wiring and circuit boards. Side cabinets can either be per- manently mounted or may have a swing-away option which allows operators and maintenance personnel access through the side of the machine.
  • Page 235 CHAPTER 13: PNEUMATICS The pneumatic system provides clean, dry air for seal cooling and lubricated air for the valves and air cylinders. The air supplied to the machine must be clean, dry and a minimum of 65 PSI. MPORTANT Refer to the manufacturer’s literature for specific information on the pneumatic components.
  • Page 236 System Components FF AND RESSURE ELIEF ALVE The shut-off and pressure relief valve is solenoid operated. When ener- gized, it allows air to flow to the machine functions. When de-ener- gized, it stops the air flow and removes air pressure from the cylinders. AUTION This valve does not control the air to the pull belts.
  • Page 237 Apply the desired switching air pressure to the pressure Pressure Switch switch. Setting - Norgren Turn the adjusting screw with a 0.125" (3mm) hex wrench until the contacts close. MPORTANT One complete revolution of the adjusting screw covers the com- plete adjustment range of 30 to 150psi.
  • Page 238 Air Valve and Manifold Assembly Valves 1, 2 and 3 pass clean non-lubricated air. The other valves pass clean lubricated air. The functions performed by the valves are listed on the function decal on the side of the manifold. Exhaust Silencer/Separator Drain Exhaust Silencer/Separator Drain...
  • Page 239 CONVERT A DRY AIR VALVE TO A WET AIR VALVE Figure 4: Air Valve System If an accessory is added to the bagger that utilizes an air cylinder, a dry air valve must be converted to a wet air valve. To accomplish this: Loosen the two nuts (1).
  • Page 240 Air System Maintenance AIR SYSTEM MAINTENANCE Check the water level and empty as needed. The air supply needs to be Filter Regulator turned OFF to remove the bowl. Do not install the plastic bowl without the metal guard. The lubricator maintains a constant oil-to-air ratio once the oil rate is Lubricator set, regardless of the changes in airflow.
  • Page 241 All options are not available for all machine models and with some machine sizes. Please contact HayssenSandiacre Engi- neering with questions concerning the availability of options. Options must be activated/deactivated via the System Installa- •...
  • Page 242 Accu-Track Film Tracking System Unwind Manual - Allows the operator to control the direction and dis- tance the unwind moves. Touching the Accu-Track right or left touch- pads moves the unwind and film in the corresponding direction. The amplifier receives signals from the eyes and sends signals to the Eye Amplifier machine controller to make film corrections.
  • Page 243 Eyespot on left side of film Switch set to Accu-Track Eye Left Eyespot NORMAL Unwind won’t move ACCU-TRACK BOTH CLEAR Eyes Unwind moves left BOTH COVERED Unwind moves right ABNORMAL If ACCU-TRACK location switch is set to left but eyes are on wrong side, the computer generates a web guide sensor error Figure 2: Accu-Track Eyes...
  • Page 244 Bag Deflator BAG DEFLATOR Bag deflation removes air from the package just before the end seal jaws close and form the seal. This produces a more attractive bag with- out wrinkles and allows smaller cases to be used. Bag deflation is available in several configurations, depending upon product and film.
  • Page 245 BAG SPACER The bag spacer allows the operator to separate the packaged product into groups, which are spaced according to the setup. Bag spacer controls are found on the operator interface. Screen loca- tion varies with the operating system. • the bag spacer can be activated or deactivated by touching the Bag Spacer pad •...
  • Page 246 Bag Spreader BAG SPREADER Spreader Fingers Figure 6: Bag Spreader Fingers The bag spreader fingers grips and spread the bag flat as the stager closes. This reduces wrinkles in the end seals of the package. The spreader fingers shown below are pictured with the fixed rotated jaw assembly.
  • Page 247 Slide the spring loader finger assembly into place. Tighten the two bolts. Restore power and air to the machine. Cycle the machine to verify the adjustment is correct. Repeat steps 1-4 if necessary. SMALL BAG SQUEEZER The small bag squeezer forces air out of the package and flattens it prior to sealing the top of the package.The removal of excess air from the bag allows for better shipping and a prolonged shelf-life for the product.
  • Page 248 Bag Squeezer Removing excess air from the bag is accomplished by plates mounted on cylinder rods in the front and rear of the bag. These cylinders are activated by a signal at the correct time. When the pull belts almost complete their cycle, the cylinders press the bag from both directions to remove air from the bag, creating a thinner bag.
  • Page 249 Place the squeezer in the same position as the jaws in the drop-jaw position. MPORTANT Holes are already drilled and tapped for the squeezer feature in the machine frame. BAG SUPPORT AND EJECT The bag support and eject assembly supports the filled bag and ejects it horizontally onto a takeaway conveyor.
  • Page 250 Motorized Bag Support and Eject Turn Off machine power. Assembly Adjustment Loosen the locking handle and position the support plate 3/4" (19 mm) less than one bag length from the cutoff knife. The unit may be lifted and lowered on its support shafts once the lock- ing handle is loosened.
  • Page 251 The bag support and eject assembly is powered by an AC motor (115v) which enables the operator to fine-tune adjustments. The motor holds its position through an electric clutch. The eject assembly has position limit proximity switches. These switches restrict the range of movement of the support plate. The limits are factory set.
  • Page 252 Slide Chute For proper delrin guide operation, after replacing any part in this area Delrin Guide ensure the following: • The block should be level from side-to-side • With the air removed, the pusher block can be pushed in and out with minimal force. •...
  • Page 253 Fixed Shaft Chute Tilt Angle Adj. Handle Vertical Position & Horizontal Angle Adj. Handle Horizontal Position and Vertical Angle Adj. Handle Figure 10: Slide Chute The slide chute angle and adjustments will vary with bag size. The chute may be adjusted as needed by using the appropriate locking han- dle.
  • Page 254 Bag Tucking BAG TUCKING Bag tucking is used to create a bag of equal width throughout the length of the bag. This is done by four tucker fingers that fold in excess film on the side of the bag at both the top and bottom. Tucked bags have straight edges that are easier to insert into cartons or boxes.
  • Page 255 Bag Tucking Dimensions Flat Bag Widths Minimum Depth Maximum Depth (without tuck) Not Available Not Available in. - 3½ in. (52 mm - 88 mm) ½ in. ½ in. in. - 5 in. (92 mm - 127 mm) (12 mm) (12 mm) ½...
  • Page 256 Film Splicer FILM SPLICER The film splicer assembly makes replacing film quicker and easier. Handle Gripper Pad Clamp Collar Actuator Shaft Splicer Plate Gripper Bar Link Block Tape Pivot Block Dispenser Ruler Figure 13: Film Splicer Components E-Stop machine. Splicing Film Raise and lock the dancer roller in the up position.
  • Page 257 Lift the old film, while it is still clamped under clamp bar #2 and run new film underneath to clamp bar #2. The new film now lies under the old film. Clamp in position. Clamp bar Clamp bar Slot Slot Rear of Machine To Measuring...
  • Page 258 Flat Bottom Bag FLAT BOTTOM BAG The flat bottom bag accessory is used to produce a bag that has a gusseted flat bottom seal and a gabled top seal. A rectangular forming tube is used to form the flat bottom of the bag. Top and bottom tuckers form gussets in the bag as the end seal jaws close.
  • Page 259 Tube Tube Film Forming Shoulder Adj. Top Plate Corner Creaser Forming Tube Mounting Plate Adj. Top Plate Adjusting Block Figure 17: Forming Tube with Corner Creasing Assembly The creasing assemblies must be aligned with the corner of the tube and with the two film guides on the tube above and below the rollers. The tube is vertically adjustable in the forming shoulder to align the rollers with the film guides.
  • Page 260 Flat Bottom Bag Top Tuckers Figure 18: Tucking Assembly Adjustments To setup the machine to produce a flat bottom bag: Setup and Adjustment Turn Off machine power. Remove the end seal knife. AUTION Removing the end seal knife will help prevent injuries. Remove the forming tube.
  • Page 261 Adjust the depth of the top tuckers so the leading edge is even with the side of the forming tube and lock in place. Top View Clearance on all sides] 8” Top Tuckers Figure 19: Bag Tucking Device Pull the jaws and tuckers open. Thread film through the machine and over the forming tube.
  • Page 262 Hole Punch Assemblies The standard flat bottom bag machine has fixed tuckers that actuate Movable Bottom with the jaw close. To prevent bags from hanging on the bottom tuck- Tuckers ers, they need to be out of the way before the jaw opens. To do this, an optional air cylinder on the bottom tuckers allows the tucker blades to extend before the jaw closes and to retract before the jaw opens.
  • Page 263 EATER OSITION DJUSTMENT The tip of the heater should protrude approximately " (2.4mm) beyond the front sealing jaw face. To adjust the heater position, per- form the following procedure: Heater Front Jaw 5/8" Lock Nut Adjusting Nut Clamp Screws Turn Off machine power. Loosen the lock nut, turn the adjusting nut to compress the spring to 5/8"...
  • Page 264 Hole Punch Assemblies DJUSTING ONTROL Open the electrical enclosure. Turn the temperature controller On. Turn the potentiometer to the correct temperature. Close the electrical enclosure. After a few minutes, use a pyrometer to check the temper- ature. Run product on the machine when the required tempera- ture is achieved.
  • Page 265 Adjusting Adjusting Screw Screw Side Mounting Plate Cylinder Jaw Housing Mounting Plate Lower View Back-up Cross Section Screw Screws Jam Nut Guide Bars Setscrew Figure 21: Resistance Round Hole Punch UNCH LIGNMENT The punch rod must slide freely through the guide bushings in both the front and rear jaw face.
  • Page 266 Hole Punch Assemblies Turn Off machine power. Loosen the adjusting screws. Screws are located on the hole punch assembly attached to the rear jaw carriage. Manually extend the punch rod to its maximum extended position. Slide the cylinder mounting plate until the punch rod extends beyond the rear jaw face to a location that pro- duces the correct hole size.
  • Page 267 UNNING ITHOUT UNCH To run bags without the round hole punch, turn the cylinder timing Off on the operator interface and perform the following: Turn Off machine power. Loosen the adjusting screws. Slide the punch assembly back until the punch rod is inside the jaw housing.
  • Page 268 Hole Punch Assemblies Quali-Seal Round Hole Punch Punch Alignment Adjustment Screws Back-up Block (Spring loaded) Punch Cylinder Depth Adjustment Slot Figure 22: Quali-Seal Jaws and Hole Punch The Quali-Seal hole punch assembly uses a serrated tooth punch rod actuated by an air cylinder. As the hole is punched, film is gripped between the punch guide block on the rear jaw and spring loaded back-up block on the front jaw.
  • Page 269 Turn the adjusting screws to provide only enough pressure to adequately grip the film while the hole is being punched. MPORTANT For sealed punches, adequate pressure must be obtained to seal film in the area around the hole. Use Teflon tape on the sealing surfaces of the guide block and back-up block.
  • Page 270 Motorized Film Unwind Slide the punch assembly off the glide bars. Loosen the two gripper mounting bolts on the bottom rear gripper. Slide the bottom rear gripper off with the hole punch parts attached. Loosen the two gripper mounting bolts on the bottom front gripper.
  • Page 271 This is accomplished with a motor mounted on the side of the unwind stand that is activated from the front panel by switches designated either for the right or left direction. If the film drifts off center, the operator can activate the correct switch and allow the film to center itself again.
  • Page 272 Poker punches and placement of the punches is determined by each applica- tions requirements. The punch location is adjustable along the width of the assembly. The pneumatic web punch requires timing entries (FROM/TO) to set the point during the bag cycle the punches will fire. The timing is simi- lar to that of a printer after the film pull cycle has stopped.
  • Page 273 Turn the flow control adjustment screws on the cylinder inward to decrease and outward to increase the speed. Fine adjustment may be required for smooth operation. Press Reset. Check operation, and repeat as needed. PRODUCT STRIPPER (LINKAGE OPERATED) The product stripper removes any product in the end seal area before the stager closes.
  • Page 274 Product Stripper (Linkage Operated) The gap between the stripper bars must be at 0.062" - 0.093". If adjust- Stripper Bar Gap ment is necessary: Adjustment Turn Off machine power. Pull down on the clevis until both air cylinder rods are fully retracted.
  • Page 275 Turn the jaws On. Set the jaw timing from 150 to 330 . Press Reset. Cycle the machine and observe the action of the stripper bars. E-Stop the machine. Fine adjust the open stripper speed controls. If the stripper bars contact the cams when opening, turn the speed controls clockwise to correct.
  • Page 276 Product Stripper (Linkage Operated) MPORTANT Setting the proximity switch too far toward the rear of the machine may cause damage to the stripper bars and the jaw assembly. If the proximity switch is set too far toward the front of the machine, bags catch on the stripper bars.
  • Page 277 Tighten the two outside pinch clamps to the stripper actu- ator shaft. Tighten each bolt the same amount to ensure an even gap on each side of the pinch clamp. Turn the jaw actuator pinch clamp and adjust so the actua- tor link is at a 30 angle from the floor.
  • Page 278 Product Stripper (Cam Operated) Gap between stripper bars (0.035" - 0.9mm) Proximity Switch for Stripper Bar (2) Cam (4) End Seal Jaws Hold-down Bar (4) Stripper Arm (4) Clevis Cam (2) Proximity Switch Cam Follower (2) for Stripper Roller Jam Nuts Clamp Collar (12) Flow...
  • Page 279 Move the adjusting screws on both sides of the clevis. The stripper bars should be level on top and parallel with each other. They must also be centered with the jaws or wrinkles in the end seal may occur. Tighten the jam nuts. Restore power.
  • Page 280 Product Stripper (Cam Operated) Turn the strippers On from the touch screen Enter 358 for the TO setting • The strippers open at the end of the bag making • cycle Completely open the external flow controls and internal cushions (counterclockwise). Verify the main pressure regulator is set to 65 PSI.
  • Page 281 MINI PRODUCT STRIPPER (SMALL BAG) This option provides a small burst of air at jaw open, to help remove the sealed bag from the jaw area. This is a timed function and can be set using the Aux 2 parameter. Stripper Figure 27: Mini Product Stripper REVERSE STRIP...
  • Page 282 Pneumatic Printer Backup PNEUMATIC PRINTER BACKUP The pneumatic printer backup option is a pneumatically operated plate that moves the printer backup pad in and out to create more space for film travel. This is commonly used with zipper to allow enough space for the zipper to clear the printer backup pad.
  • Page 283 If the backup must be adjusted side-to-side, loosen the handknob. Slide the backup until it is in the correct position. Tighten the handknob. If the backup must be removed for maintenance or repair: Removing the Backup Remove power and air from the machine. Loosen the 5/18"...
  • Page 284 Shaker Jaw Assembly Shaker action starts automatically when the shaker jaw proximity switch signals that the shaker jaws have closed on the bag. The vibra- tion clears any product out of the sealing area and settles it toward the bottom of the bag. The vibration stops when the jaw close proximity switch is detected.
  • Page 285 HAKER MOOTHNESS UNING The smoothness flow controls adjust the exhaust air flow from the vibrator piston of the actuator. The valves are located on the shaker assembly. Observe and listen to the action of the vibrator cylinders to verify they operate smoothly without hammering.
  • Page 286 Stager STAGER The stager is mounted immediately above the end seal jaws, and the purpose is to support the product while the seals are cooling. This allows for optimum strength seals. Currently, there are two styles of stagers: Flow Control for Cooling Air Air Cylinder Stager Open Speed Control Stager Close Speed Control...
  • Page 287 Clam Shell Linear Adjust the flow control fittings by Open the flow controls completely turning the adjustment screws all and then close 1 turn the way in (clockwise) and then If fine adjustment is required, turn back out four (4) turns. the controls in or out until the Fine adjust screws in or out until stager plates open and close...
  • Page 288 Stager Linear Stager Cable MPORTANT Replacement Contact your HayssenSandiacre Parts Representative to • identify the correct alignment blocks. Portions of this procedure may also be used for correct • setup when replacing the air cylinder. Turn Off all air and electrical power to the machine and follow company Lock Out/Tag Out policies and proce- dures.
  • Page 289 Stager Orientation: Upside down with cylinder facing you. Left Right Figure 32: Air Cylinder Install the cable. a. Insert the end with the short screw into the right end of the air cylinder. b. Thread cable around pulleys. c. Bring the loose end of the cable around to the left side of the air cylinder.
  • Page 290 Stager MPORTANT When using off -set spacer blocks make sure the arrow is pointing toward the air cylinder. Figure 34: Off-set Spacer Block e. Push the stager carriers together against the spacer blocks. f. Reinstall the cable clamp blocks using the hardware retained earlier in the procedure.
  • Page 291 STATIC ELIMINATOR Static charges cause product to stick to the film. Static eliminators are used to reduce the amount of static created by pulling certain types of film. Static eliminators can be mounted near the measuring roller and above the jaws to help reduce static on the film. The static eliminator near the jaws also controls static in the product.
  • Page 292 Static Eliminator ABLE UPPORTS Supports are used to guide the high voltage cables from the bars along the frame of the machine to the power unit. AUTION Cables should always be kept at least ¼" away from the machine frame, walls, and ceiling. If it must touch the machine, it should be encased in plastic tubing.
  • Page 293 Remove the plastic plug from the power supply with an insulated screwdriver. Plug the cable into the receptacle the plastic plug was in. Screw in the knurled plug on the cable. MPORTANT Finger tighten the plug into the power supply. Do not use exces- sive force.
  • Page 294 Static Eliminator The power supply does not require any special maintenance proce- dures. Periodically check the ground connection to ensure the static bars are operating at maximum capability. Turn ON the power supply. Touch the emitter points with a static bar checker (avail- able from most static eliminator manufacturers.) The round display on the static bar check glows orange when high voltage is present at the emitter points.
  • Page 295 If no spark occurs nor any arcing is heard, the power supply is faulty. If a spark and arcing sound does occur, the bar is faulty. If either are faulty, contact HayssenSandiacre Customer Service to order new parts.
  • Page 296 Tube Air TUBE AIR Tube air is used primarily when packaging snack foods, and it does several things: it adds air to the bag which acts as a cushion to protect the product, it gently pushes the product down into the bag, and it pre- vents wrinkles in the seals.
  • Page 297 VOLUMETRIC FEED SYSTEM The volumetric product feed system measures product by volume and feeds by gravity. The labeled drawing below shows the various compo- nents in the volumetric. Hopper Servo Motor Handwheel Volume Adjustment Motor Trap Doors Upper Plate Telescoping Cups Lower Plate Cam Follower...
  • Page 298 Volumetric Feed System The height and diameter of the cups determines the volume of the prod- uct delivered. The height is controlled by a small DC motor or by a manual hand crank. The motor provides motorized volume adjustment by raising or lowering the upper plate without stopping the machine. The volumetric feed system consists of a volumetric filler which is driven by a DC drive motor through a motor control module.
  • Page 299 When running product the bottom cups always overlap the upper cups by at least 1/4" (7 mm) or product is likely to spill. Cups can be designed for special applications. Contact HayssenSandiacre for more information. H A Y S S E NSA N D I AC R E ®...
  • Page 300 Volumetric Feed System AUTION Decrease volume adjustment only while product is being run. The mass of product in the cups can restrict movement of the feed plate. This can cause the motor to bind and possible be damaged. The volume can be increased at any time. DJUSTMENT Horizontally opening trap doors, operated by the cam follower in a closed track, assure high speed opening and controlled closing.
  • Page 301 HANGING ETS OF The volumetric feed may have several sets of cups for running various packages and weights. MPORTANT Rubber retaining rings are provided on each half set of cups, top • and bottom to lock the cup into position. The same rings are used for any size cups.
  • Page 302 Volumetric Feed System (6-C RIVE OTOR LUTCH DJUSTMENT UP AND Collar Turn the Volumetric Off. Turn the collar until the 1/4-20 socket head bolt is easily accessible. Loosen the 1/4-20 bolt so the collar can be turned. Use a 3/16 Allen wrench or T-handle. Turn the collar clockwise or counterclockwise to adjust slip: Clockwise...
  • Page 303 (5-C PRING RESSURE DJUSTMENT For proper operation, the take-up spring pressure should be adjusted to 1/4". The spring is located inside the volumetric overhead. (5-C RIVE HAIN DJUSTMENTS UP AND Adjust the two drive chains to 1/4" deflection to reduce or eliminate slippage.
  • Page 304 Integrated Auger Feed System Setup INTEGRATED AUGER FEED SYSTEM SETUP MPORTANT Any unit of measure can be used for the auger; the measure- • ments do not have to be entered in grams. Weight values need to be consistent. Weight units have to be between 0 and 999.9. Convert the •...
  • Page 305 ETERMINING AMPLE EIGHT Select the approximate number of auger revolutions needed to produce the weight of the package (1-10) and enter the value by touching the Auger Revs pad. Touch the Make Sample Bag and Reset Trim Value pad to produce a filled bag. Repeat Step 2 four additional times for a total of five (5) sample bags.
  • Page 306 Integrated Auger Feed System Setup a. Auger Start Degree The beginning of the auger cycle relative to the bag making cycle. The auger feedscrew revolves and dis- penses product.The bagger jaws need to close before the product drops to prevent contaminated seals or jammed jaws.
  • Page 307 UGER TAGER LOSE ELAY On the Auger Setup screen, touch the Close Delay pad. The numeric keypad displays. Enter the close delay time (dwell) in milliseconds for the auger stager and touch Return to save. Close Delay value is the amount of time (ms) from the end of the auger feed cycle until the auger stager closes.
  • Page 308 Integrated Auger Feed System Setup Touch Auger Screen. Auger Setup screen displays. Touch Auger Calibration. Auger Calibration screen displays. Touch Checkweigh Feedback Rate O/I pad to enable the option. The pad illuminates when the option is active. Enter the trim value on the external checkweigher as the feedback rate.
  • Page 309 AUGER/BAGGER TOGGLE INTERFACE This section applies to a bagger/auger system where both the bagger and the auger screens are viewed and controlled through the bagger operator interface. Toggle touchpads have been added to switch between the bagger control system and the auger control system. Refer to the bagger instruction manual in the operator interface chapter for bagger control instructions.
  • Page 310 Remote Machine Control REMOTE MACHINE CONTROL Some bagmakers have the capability of interfacing with remote machines. The interface allows an external machine such as a conveyor or cartoner to pause or stop the bagger when it stops and restarts. The settings of the touchpads are stored in the recipe.
  • Page 311 SCALE DUMP-TIMING The Yamato scale is usually interfaced in the master mode. Yamato Feed Bucket Weigh Bucket Collating Chute Dump signal discharge delay Collating Funnel Forming Tube Start Delay Stager Default Setting - 500ms Signal delay from the time the product leaves the weigh bucket. This Dump Signal Delay allows the product to fall to the discharge of the collating funnel before the dump signal is sent to the bagger.
  • Page 312 Scale Dump-Timing Because the scale controls the system speed, the scale speed must be Master Mode slower than the empty bag rate in the bagger. This allows the bagger to finish the cycle and be ready for the next scale discharge. When in slave mode, the bagger sends a solid ready signal when, in filled bag mode, the Start pad is touched.
  • Page 313 The pacer controls the system speed. Slave Mode • scale speed must be faster than the pacer speed in the bag- ger. • the bagger must also be faster that the pacer speed in the bagger. • the pacer runs at exactly the needed BPM. •...
  • Page 314 Gas Flush (Modified Atmosphere Packaging) GAS FLUSH (MODIFIED ATMOSPHERE PACKAG- ING) Gas flush is an optional system that has the capability to produce a vac- uum, partial vacuum or inert gas atmosphere in flexible packages of high barrier construction. The purpose of gas flush is to extend the shelf life of many foods.
  • Page 315 Pressure Regulator Pressure Gauge Gas Flow Solenoid Gas flow is enabled/disabled by the gas flow solenoid. The gas travels from the solenoid to the adjustable pressure regulator where the pressure is set. A gauge is connected to the pressure regula- tors to allow monitoring of the operating pressure.
  • Page 316 Spinach Agitator SPINACH AGITATOR The agitator engages product as it drops from the infeed system. There are two fingers that continuously rotate to disperse product and prevent clogging on the main feeder. The motor is connected to an 18:1 gear reducer and a motor speed controller that drives and controls the agita- tor.
  • Page 317 Assembly Motor Components A 1/8HP, 115/230 VAC, motor drives the agitator. Gearhead 18:1 ratio gearhead is used to reduce and control the motor speed. Speed Controller A potentiometer allows change of speed settings from low to high as desired to control product disbursement. Drive Shaft Connects the drive assembly to the agitator fingers.
  • Page 318 Machine Synchronization Motor Settings Speed Potentiometer Run/Stand-by Switch OTOR TART Open flip cover on motor controller box. To start, set Run/Stand-by switch to run. Motor will start running at speed set on the potentiometer. To stop, set Run/Stand-by switch to stand-by. OTOR PEED DJUSTMENT...
  • Page 319 Synchronization Electrical Cabinet Front Panel Figure 42: Front Panel Synchronization Electrical Cabinet 1 = Display 3 = Power Switch 2 = Fill Enable Lights 4 = Synchronization Enable Switch Used to view and set synchronization parameters. ISPLAY When display lights are ON synchronization fill is enabled. NABLE IGHTS Turns the main power to the synchronization cabinet ON/OFF.
  • Page 320 Machine Synchronization Synchronization Electrical Cabinet Figure 43: Synchronization Electrical Cabinet Components 1 = Fuse 7 = CPU 13 = Master Bagger Terminal Block 2 = Power Switch 8 = 120VAC Outlet 14 = Auger Relay Slave #1 3 = 24VDC Power Supply 9 = Power Terminal Block 15 = Slave #1 Terminal Block 4 = Terminal Block...
  • Page 321 H A Y S S E NSA N D I AC R E ® U l t i m a S V 1 4 - 8 1 / R e v 1 5...
  • Page 322 Machine Synchronization H A Y S S E NSA N D I AC R E ® 1 4 - 8 2 / R e v 1 5 U l t i m a S V...
  • Page 323 Machine serial number Call HayssenSandiacre’s Technical Support at (864) 486-4111 and select Option 3. Other HayssenSandiacre contact information is listed in the How to Use the Parts Manual to Order Replacement Parts section of the Instruction Manual and the Parts Manual.
  • Page 324 Machine Overview MACHINE OVERVIEW The packaging machine is divided into two sections for easier trouble- shooting. The back half of the machine consists of the unwind stand to the registration rollers. The front half of the machine consists of the registration rollers to the end seal jaws.
  • Page 325 Packaging Material Feed System PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Clean the roll brake and drum with solvent Roll brake and drum are dirty brake cleaner. Roll is not tight on spindle Tighten the roll. See Chapter: Unwind Reposition the roll. Roll is misplaced on spindle Assembly Roll is unevenly wound or...
  • Page 326 Machine Overview PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Check settings on machine controller. Adjust overpull percentage to higher value. Incorrect timing Some films can cause excessive pull belt wear. To remedy this, decrease over Packaging material is pull percentage, but not to the point where not tracking properly the film begins to loop.
  • Page 327 Print Registration PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Dirty pull belts or registration roll- Clean with soap and water; dry completely. Machine is not in Registered Turn registered film ON via touch screen. Film mode Adjust the placement value until in registra- Placement value is set too high tion..
  • Page 328 Machine Overview Problem Cause Corrective Action Check the width of the film and the diame- Insufficient lap ter of the tube. Film is too narrow Replace with roll of proper width film. Older Machines: Adjust the pull belt overpull setting until Back seal is too narrow looping occurs, then increase approxi- Pull belts are running too long...
  • Page 329 PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Spreaders too close together Re-adjust the spreaders. Bag eject platform height is too Lower the bag eject platform. high Bag eject platform height is too Raise the bag eject platform. Stager/shaker jaws closing too Delay the start of the stager close. Wrinkles in end seals early Too little head space...
  • Page 330 Machine Overview PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Jaws not properly aligned Re-align jaws. Sharp edge on leading/trailing Repair or replace jaw. edge of jaw Film tears at seal Temperature setting too high Reduce temperature. Dull knife Sharpen or replace knife. Excesive flow fluctuations Adjust flow control Excessive jam jaw mes-...
  • Page 331 PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Incorrect setup of the guide Follow the procedures provided in this plates and/or fingers on the FTA manual for correct setup. Incorrect overpull setup Set the overpull high enough to remove all slack in the film between the measuring roller and the pull belts Film bulging out on the front or rear of the tube...
  • Page 332 Machine Overview PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Filter is dirty Clean or replace filter. Defective diaphragm Replace. No air from regulator Defective adjusting screw Replace. Defective seals Replace. Check voltage and Hertz at the coil lead ter- Solenoid valve coil minals.
  • Page 333 PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Loose packing gland Tighten packing. Air cylinder leaks at piston Worn piston rod Repair or replace piston rod. O-rings worn Replace. Piston cup worn Replace piston cup. Piston rod nut is loose Tighten nut. Dirt or rust in cylinder Clean or replace cylinder.
  • Page 334 Ethernet Module Diagnostics Although information can be found in the Backplane and Connection Manager or Network Statistics sections, the most useful diagnostic information on your 1756-ENBT module is located under the Miscella- neous section. The Miscellaneous section accesses: Section Information Encapsulation Statistics General information about TCP connections, such as active incoming or outgoing connections and the total...
  • Page 335 The Encapsulation Statistics screen offers general information about Encapsulation TCP connection coming into and going out of the 1756-ENBT module. Statistics The table below lists the most useful fields on the Encapsulation Statis- tics screen: Field Definition Cumulative Encap (TCP) Connections The total number of incoming and outgoing module con- nections since powering up.
  • Page 336 Ethernet Module Diagnostics Servo PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Servomotor does not Check for supply voltage at drive terminals No Power start. L1 and L2 on CLC indramat only. Loose connection Check all cables (refer to schematic(s). Check that all pull-belts and registration No position reference input rollers are turned on at touch-screen.
  • Page 337 SERCOS DRIVE ERROR CODES The following list of problematic symptoms (no error code shown) and problems with assigned error codes is designed to help you resolve problems. When a fault is detected, the 7-segment LED will display an E, fol- lowed by the flashing of the two-digit error code, one digit at a time.
  • Page 338 Sercos Drive Error Codes Error Problem Probable Cause Corrective Action Code • Operate within (not above) Motor Overtemperature Motor thermostat trips due to: the continuous torque rating • High motor ambient tempera- for the ambient temperature ture and/or (40°C max) •...
  • Page 339 Error Problem Probable Cause Corrective Action Code • Verify voltage level of the Bus Undervoltage Low AC line/AC power input incoming AC power • Check AC power source for glitches or line drop • Install an uninterruptible power supply (UPS) on your AC input •...
  • Page 340 Sercos Drive Error Codes Error Problem Probable Cause Corrective Action Code • Replace motor/encoder Motor Encoder State Error The motor encoder encoun- tered an illegal transition • Use shielded cables with twisted pair wires • Route the feedback away from potential noise sources •...
  • Page 341 Error Problem Probable Cause Corrective Action Code • Reduce acceleration rates IPM Thermal Protection Fault The internal filter protecting the drive from overheating has • Reduce duty cycle (ON/OFF) tripped of commanded motion • Increase time permitted for motion • Use larger Ultra3000 and motor •...
  • Page 342 Sercos Drive Error Codes Error Problem Probable Cause Corrective Action Code Absolute Position Exceeds Motion is commanded to a Set motion command to a posi- Position Rollover position outside the position tion within the position rollover rollover range. range • An absolute index is initiated that specifies a position out- side the position rollover range...
  • Page 343 Error Problem Probable Cause Corrective Action Code • Verify that there are no Self-sensing Commutation Motion required for self-sensing impediments to motion at Startup Error startup commutation was startup, such as hard limits obstructed • Increase self-sensing current if high friction or load condi- tions exist •...
  • Page 344 Sercos Module Status LED SERCOS MODULE STATUS LED SERCOS LED Status Probable Cause Corrective Action Steady Green Communication ready No faults or failures Flashing Green Establishing communica- System is still in the pro- Wait for steady greed LED tion cess of establishing SER- status COS communication Node address setting on...
  • Page 345 SERCOS COMMUNICATION PHASE STATUS CP LED Display Module Status Solid Orange In Phase -1: Autobaud detection in progress. In Phase 0: Looking for a closed ring Flashing Red In Phase 1: Looking for active nodes Alternating Red and Green In Phase 2: Configuring nodes for communication Flashing Green In Phase 3: Configuring device specific parameters Solid Green...
  • Page 346 SERCOS Ring Status SERCOS RING STATUS SERCOS Ring LED Ring Status Action Solid Green The ring, drive, and axes are con- None figured and are actively communi- cating through to the nodes on the ring Flashing Red The module has detected a setup Check your system ssetup and configura- or configuration fault with the ring tion as follows:...
  • Page 347 installation 14-8 Bag Support and Eject Accu-Track 7-16, 14-1 assembly adjust 14-10 enable 14-1 ejector plate eye amplifier 14-2 adjust 14-10 eye gap 14-3 changeover 14-10 setup 14-2 Adjustments accu-track 6-8 bag support & eject 14-10 changing 8-7 dancer roller 6-9 Checkweigh feedback rate 14-67 dancer roller &...
  • Page 348 knife position 11-36 Former 8-1 knife speed 11-37 last roller 8-2 change end seal replacing 8-1 Quali to resistance 11-31 Sponge Tape 8-3 resistance to Quali 11-32 Square 8-11 drive linkage/shafts 11-5 Tube 8-2 ESP assembly 11-18 Tube Inserts 8-7 setup 11-18 Four-Side Seal 10-6 False header 11-17...
  • Page 349 Product Spacing 3-6 Blade Replacement 11-38 Timing 3-6 Position Adjustment 11-39 Installation Linear Stager Air Devices 3-1 air cylinder replacement 14-48 Electrical Devices 3-2 cable replacement 14-48 Ground Fault Circuit Interrupter 3-3 plate adjust 14-47 Feed System 3-6 speed adjust 14-46 Lifting machine 3-4 LocTite 4-2 Product Feed Interface...
  • Page 350 Film splicer 14-16 bladder installation 6-12 Flat bottom bag 14-18 bladder removal 6-11 Linear Stager 14-46 Pneumatic System Components 13-1 Motorized bag support and eject 14-10 Pneumatics Motorized film unwind 14-30 Air Pressure Switch 13-2 Pneumatic printer backup 14-42 Air Valve and Manifold 13-3 Poker 14-32 Dry Air Valve to a Wet Air Valve 13-5 Quali-Seal round hole punch 14-28...
  • Page 351 FTA Front and Rear Film Plates 8-10 bag length 5-10 FTA Side Plates 8-9 bag spacer 5-17 Platen Actuator Adjustments 10-11 description 5-48 Front Actuator In/Out Position 10-12 empty bag speed 5-11 Front Actuator Left/Right Position 10-11 end seal air 5-14 Rear Actuator In/Out Position 10-12 hole punch 5-17 Rear Actuator Left/Right Position 10-11...
  • Page 352 Registration mark setup (Transparent) 7-14 Scale Remote Machine Control 14-70 dump timing 14-71 Replacement Parts Ishida 14-72 Contacting Hayssen® 0-3 Yamato Delivery Of Parts 0-4 master mode 14-72 How to Order Parts 0-1 Yamator Parts Identification 0-1 dump signal delay 14-71 Resistance Seal 11-3 Screen bottom sealing pressure 11-16...
  • Page 353 cable supports 14-52 grounding 14-53 Unwind Assembly power supply brake adjustment 6-9 testing 14-53 components 6-2 power unit 14-52 brake release lever 6-3 static bar 14-51 dancer rollers 6-3 maintenance 14-54 low film/no film detector 6-3 troubleshooting 14-54 roll brake mechanism 6-3 Stripper roll spindle 6-3 cam 14-37...
  • Page 354 H A Y S S E NSA N D I AC R E ®...

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