Wexxar WF30T Operation And Service Manual
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Wexxar WF30T Operation And Service Manual

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WF30T Case Former
WEXXAR WF30T CASE FORMER
Operation and Service Manual
10101 Nordel Court, Delta, B.C. V4G 1J8 Canada
Telephone (604) 930-9300, Fax (604) 930-9368
WF30T; Rev. 1.15

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Questions and answers

Keith Cianci
March 1, 2025

My question is your machine the wax 30 what is the maximum width of a box using the small hand of the machine or does the width not matter when you're talking about changing the hands it's only the height that matters with regard to when to change the big hand please advise where this is in the manual or just tell me the answer

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1 comments:
Mr. Anderson
May 14, 2025

The maximum box width (Dimension ‘D’) for the Wexxar WF30T machine is 17.00 inches. There is no mention of a "small hand" or "big hand" affecting the width, so the width does not change based on that.

This answer is automatically generated

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Keith Cianci
March 1, 2025

I have a question about your machine don't know if it's in the operations manual or not what is the maximum length a box can be before you have to change the arm plate that opens the Box and sticks it can be before you have to go to the larger plate a very small box or the standard plate

0
1 comments:
Mr. Anderson
May 14, 2025

The maximum box length for the Wexxar WF30T before needing to change the arm plate is 42 inches.

This answer is automatically generated

0
Keith Cianci
March 1, 2025

The company I work for newlywed Foods buys a lot of equipment from you and they won't give me an answer on this question so I came to you yes I work for newlywed Foods can you give me the answer to my question

0
MIke Hurt
February 3, 2025

adjustments for gap/joint variation, still within FBA/PMMI specifications.

0

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Summary of Contents for Wexxar WF30T

  • Page 1 WF30T Case Former WEXXAR WF30T CASE FORMER Operation and Service Manual 10101 Nordel Court, Delta, B.C. V4G 1J8 Canada Telephone (604) 930-9300, Fax (604) 930-9368 WF30T; Rev. 1.15...
  • Page 2 WF30T Case Former...

  • Page 3: Table Of Contents

    WF30T Case Former Table of Contents Table of Contents LIST OF TABLES ..........................IV TABLE OF FIGURES ..........................VI PREFACE ..............................IX About this manual ........................... x How to use this manual........................xi SAFETY ............................1-1 ......................1-2 AFETY ONSIDERATIONS ......................1-2 AFETY TANDARDS ......................1-2 ENERAL RECAUTIONS ......................1-3...
  • Page 4 WF30T Case Former Table of Contents ......................5-27 ONTROLS ESCRIPTION HIGH SPEED SERVO SETTINGS ....................5-45 LOW SPEED SERVO SETTINGS .....................5-45 OPERATING PROCEDURES ....................6-46 ..........................6-46 AFETY ..........................6-47 TART 6.2.1 Preliminary Checks ....................6-47 6.2.2 Start-up Procedures ....................6-48 6.2.3 ‘CYCLE’ Operation ....................6-50 6.2.4 ‘JOG’ Operation......................6-50 ........................6-50...
  • Page 5 WF30T Case Former Table of Contents ..................9-90 NEUMATIC YSTEM AINTENANCE 9.5.1 Pneumatic Supply Adjustments.................9-90 9.5.2 Valve Bank ........................9-90 9.5.3 Filter-Regulator......................9-90 9.5.4 General Pneumatics....................9-91 ..................9-91 LECTRICAL YSTEM AINTENANCE 9.6.1 Safety Circuit ......................9-91 9.6.2 Electrical Enclosure....................9-91 ....................9-92 ECHANICAL AINTENANCE 9.7.1 Vertical Alignment Procedures ..................9-92 ....................9-93...

  • Page 6: List Of Tables

    WF30T Case Former List of Tables List of Tables Table 1: Optical Proximity Sensors ................... 4-19 Table 2: Inductive Sensors ......................4-19 Table 3: Sensor Cables ......................4-19 Table 4: Remote Demand Sensor ..................... 4-20 Table 5: Magazine Management Sensors................. 4-20 Table 6: Interlock Switches......................
  • Page 7 WF30T Case Former List of Tables Table 53: Both forming head and jaw too slow ..............10-104 Table 54: Jaw too slow; forming head speed normal ............10-105 Table 55: Forming head not moving..................10-105 Table 56: Jaw not moving...................... 10-106 Table 57: PLC Input LED Status Table for Jog Step Sequence ...........
  • Page 8 WF30T Case Former Table of Figures Table of Figures Figure 1-1: Locked Out Electrical Disconnect and Filter-Regulator Assembly ......1-3 Figure 1-2: Safety Guard Doors ....................1-3 Figure 1-3: Examples of Safety Interlocks................... 1-4 Figure 2-1: Main Disconnect Switch .................... 2-9 Figure 3-1: Component Overview....................
  • Page 9 WF30T Case Former Table of Figures Figure 5-40: 'PLC Outputs’ Screen.................... 5-38 Figure 5-41: Illuminated ‘PLC OUTPUT STATUS’ Indicator ............. 5-39 Figure 5-42: 'SETUP GUIDE’ Button..................5-39 Figure 5-43: 'SETUP GUIDE/HELP’ Screen ................5-39 Figure 5-44: Setup Guide Detail Screen Button ................ 5-40 Figure 5-45: Sample Setup Guide Detail Screen ..............
  • Page 10 WF30T Case Former Table of Figures Figure 8-4: Flap Folders ......................8-75 Figure 8-5: Minor Flap Folder Top Plates.................. 8-78 Figure 9-1: Conveyor Belt Tensioning..................9-87 Figure 9-2: Inductive Sensor Adjustment Range............... 9-89 Figure 9-3: Mast Assembly Showing Guide Wheels ..............9-93 Figure 9-4: Discharge Pusher Sealed Guide Wheels..............

  • Page 11: Preface

    Due to technical advances and improvements, some of the information contained in this manual may be changed or modified without prior notice. The WF30T Case Former Operation and Service Manual was written to assist you in installing, operating, troubleshooting, maintaining, repairing, and training others to operate the machines properly.

  • Page 12: About This Manual

    Chapter 12 is intended for users who train others how to operate and maintain the WF30 Series machines. It includes a training outline, instructor data sheets, and performance checklists. Chapter 13 explains the WEXXAR product support policies and practices, as well as important warranty information.

  • Page 13: How To Use This Manual

    WF30T Case Former Preface How to use this manual Please note that some of the pictures in this manual may differ slightly from your machine. This symbol alerts you to a risk of personal injury due to mechanical or pneumatic operation.

  • Page 14: Safety

    WEXXAR. The WF30T has safety features to prevent you from injury while the machine is operating. Sliding and bi-folding guard doors equipped with interlock switches prevent you from entering the work cell while the case formation is in progress;...

  • Page 15: Safety Considerations

    NEMA 12 UL listed standard electrical control 1.3 General Precautions Your WEXXAR packaging machine is a rugged piece of industrial machinery. It is equipped with various guards and other safety features, but it must be treated with respect at all times to avoid the possibility of personal injury.

  • Page 16: Lock-Out Compliance

    To safely carry out service or repair work on the machine, a lockable shutoff valve is located on all WEXXAR machines upstream of the filter regulator unit. Padlock this valve in the OFF position for absolute safety during service work. Always follow local lock-out/tag-out regulations.

  • Page 17: Safety Interlocks

    Examples of cautionary labels are shown below. 1.11 Touchscreen Cautionary Alerts The WF30T also features cautionary alerts on the Human-Machine Interface (HMI) touchscreen. 1.12 Lubricants, etc. Read the attached Material Safety Data Sheets (Appendices A and B), which fully describe the...

  • Page 18: Installation

    WF30T Case Former Installation 2 INSTALLATION 2.1 Prerequisites To install the WEXXAR WF30T Case Former you will require: • A forklift truck and four (4”x4”) wooden blocks to remove the machine from the skid. • A spirit level to level the machine.

  • Page 19: Removal From Crate

    Removal of the machine from the shipping base must be done carefully. The lifting equipment that is used must be sufficiently strong to support the weight of the machine (≈ 1,300 lbs./590 kg). 2.4 Mechanical Assembly The Model WF30T Case Former is shipped in a fully assembled ‘ready-to-run’ condition.

  • Page 20: Location, Leveling And Conveyors

    WF30T Case Former Installation 2.5 Location, Leveling and Conveyors 2.5.1 Location When selecting the machine location, carefully consider the following points: • Adequate access around the machine for correct operation and service. • Sufficient room to open the bi-fold and access doors (including control enclosure).

  • Page 21: Discharge Conveyor

    WF30T Case Former Installation 2.5.3 Discharge Conveyor The discharge conveyor is customer supplied and may be a gravity-fed or powered type. If the discharge conveyor is powered, a smooth top surface is preferred. It is important to note that the case discharge mechanism is designed to discharge the case against zero restraint.

  • Page 22: Electrical Power

    Before attempting any electrical connections, check the machine’s set-up voltage. This is listed on a label on the inside of the access panel of the electrical enclosure. The standard WEXXAR voltage is 230V 60Hz single-phase, but alternate voltages are accommodated to meet specific customer requests.

  • Page 23: Component Identification

    WF30T Case Former Component Identification Management 3 COMPONENT IDENTIFICATION Beacon (optional) Operator Side Guard Doors Drive Motors Tape Head Assembly Mast Guide Track Pinblocks Sliding Collar Guard Doors Jawplates Main Frame Stabilizer Bars Sliding Frame Mast Case Separator Figure 3-1: Component Overview...

  • Page 24: Figure 3-2: Operator's Side View

    WF30T Case Former Component Identification Filter / Regulator Forming Head Control Panel (Electrical Enclosure) Magazine Assembly Discharge Pusher Guide Track Leveler Side-belt Flap Injector (typical) Discharge Conveyors Folders Pusher Figure 3-2: Operator's Side View Safety Interlocks Magazine Pusher Feedbelts Figure 3-3: Left Hand (Infeed) View...

  • Page 25: Major Components (Alphabetized)

    WF30T Case Former Component Identification 3.1 Major Components (Alphabetized) 1) Caliper Located at the discharge end of the magazine, just behind the injector, the Caliper forms a slot to permit the separation of one case only. The width of the caliper slot must be adjusted to suit the thickness of the corrugated material of the case.
  • Page 26 WF30T Case Former Component Identification 13) Flap Folders The Flap Folders fold the bottom case flaps prior to sealing. There are two minor and two major flap folders, one for each case flap. See ‘Major Flap Folders’ and ‘Minor Flap Folders’ for detailed descriptions.
  • Page 27 WF30T Case Former Component Identification 26) Low Pressure Switch The Low Pressure Switch, located at the bottom of the control panel, features an adjustable low pressure switch, which immediately stops the machine when the pneumatic pressure drops below 75 PSI. This switch is not meant to be adjusted by the machine operator.
  • Page 28 WF30T Case Former Component Identification 38) Pneumatic Valve Bank The Pneumatic Valve Bank controls the movements of the machine by converting electrical signals from the PLC into airflow to the pneumatic cylinders that control machine movements. 39) Programmable Logic Controller The Programmable Logic Controller (PLC) is used to control the machine's operating sequence.

  • Page 29: Pin And Dome Technology

    Component Identification 3.2 Pin and Dome Technology WEXXAR’s ultra-reliable Pin and Dome case forming technology has been proven to surpass all other forms of case opening technologies in its ability to provide continuous and repeatable output regardless of corrugated case quality. Unlike case formers that use vacuum for gripping and opening case blanks, Pin and Dome is a simple maintenance-free mechanical case gripping system that ensures maximum uptime.

  • Page 30: Theory Of Operation

    WF20T Case Former Installation THEORY OF OPERATION All motions of the WF30T Case Former are controlled by the PLC (Programmable Logic Controller), which is located in the main electrical control enclosure. Inductive and optical proximity sensors are used to detect the position of the machine’s components and the cases being formed.
  • Page 31 ° The case opening action now occurs, which opens the case 90 to the fully OPEN position while still held securely by the pins. WEXXAR does not use a vacuum system on its case formers. 5) Minor Flap Folding: After opening the case, the forming head moves it to the DOWN position. During this descent, the case bottom’s minor (widthwise) flaps contact a pair of angled minor flap...

  • Page 32: Sensors

    WF20T Case Former Installation 4.2 Sensors 4.2.1 Optical Proximity Sensors These infrared sensors are used to detect the position of the cases being formed as they proceed through the machine. They help in timing the machine, and detect any faults in the process. Table 1: Optical Proximity Sensors Sensor Name Status...

  • Page 33: Remote Demand Sensor

    WF20T Case Former Installation 4.2.4 Remote Demand Sensor The ‘REMOTE DEMAND’ sensor optically detects if there is a jam at the discharge end, and halts production of additional cases until the jam has been cleared. It can also be used to control ‘case on demand’...

  • Page 34: Tape Management System

    WF20T Case Former Installation 4.4 Tape Management System This optional system on the WF20T monitors the pressure-sensitive adhesive tape application, and detects faulty conditions. A set of optical and inductive sensors monitors the condition of the tape applicator. Table 7: Tape Management System Sensors Sensor Name Status Part #...

  • Page 35: Sensor Locations

    WF20T Case Former Component Identification 4.5 Sensor Locations LS-12 / LS-15 / LS-16 (optional) LS-3 LS-18 LS-1 LS-2 LS-4 LS-6 LS-17 Figure 4-1: Sensor Locations, Part 1 4-22...
  • Page 36 WF20T Case Former Component Identification LS-9 LS-5 LS-14 (optional) LS-11 LS-13 LS-8 LS-7 Figure 4-2: Sensor Locations, Part 2 4-23...

  • Page 37: Pneumatic Valve Operation

    WF30T Case Former Controls 4.6 Pneumatic Valve Operation The WF30T Case Former utilizes both solenoid valves and servo- pneumatic valves for precise component motion control. Note that case corrugate thickness (especially double or triple wall corrugate) will cause cycle times to change. Case size and weight will also change the speed...

  • Page 38: Factors Influencing Pneumatic Speeds

    4.6.4 Non-Lube Pneumatic System Wexxar’s non-lube pneumatic system features a coalescing-type mist separator that effectively removes 99.9% of oil mist from incoming air. Combined with pre-lubricated air cylinders and valves, this option will provide reliable pneumatic operation without the hassle of keeping the lubricator filled.

  • Page 39: Low Pressure Switch

    WF30T Case Former Controls 4.6.5 Low Pressure Switch The WF30 is equipped with an adjustable low pressure switch, which immediately shuts down the machine when the pneumatic pressure has dropped below 75 PSI. This feature is intended to reduce case jam frequency by alleviating conditions which are conducive to case jams and irregular machine function.

  • Page 40: Controls

    ‘pushbuttons’ displayed on the screen. It also provides instructions on machine operation and displays error messages. This section lists the standard controls on a WF30T. Actual control functions may vary depending on options installed on your machine.

  • Page 41: Figure 5-5: 'Service' Screen

    WF30T Case Former Controls 4) Touchscreen Display The following control descriptions refer to the software ‘buttons’ or ‘switches’ that appear on the display screen, and which act as though they were hardware equivalents. Touching the ‘Service’ screen anywhere will activate the ‘Main Control’ screen. Normal machine-status messages are shown in the top of the ‘Main Control’...

  • Page 42: Figure 5-7: 'Main Control' Screen

    WF30T Case Former Controls Figure 5-7: 'Main Control' Screen 6) ‘START’ Button The ‘START’ button starts the CYCLE of the machine to form cases continually. If the ‘REMOTE DEMAND’ sensor is ON, automatic case forming will stop when formed cases block the sensor on the outfeed conveyor, and will resume when they move downstream away from the sensor.

  • Page 43: Figure 5-10: 'Touch-Sensitive Displays

    WF30T Case Former Controls 8) Touch-sensitive Displays On the ‘Main Control’ screen to the right of the ‘START’ button are several touch-sensitive displays - the ‘Total Number of Cases’ value, and three box dimension buttons. The ‘Actual CPM’ value is not touch-sensitive, but it changes to 0 when the ‘Total Number of Cases’...

  • Page 44: Table 8: Case Measurement Dimensions

    WF30T Case Former Controls 13) ‘Box Settings’ Keypad On the resulting ‘Box Settings’ screen, press any of the values to the right of the case dimensions that you wish to change (C, D, or E Dimensions). A keypad will appear on the left of the screen showing the maximum and minimum dimensions available for the selected measurement.

  • Page 45: Figure 5-16: 'Jog Control' Screen

    WF30T Case Former Controls 16) ‘Jog Control’ Screen Along the bottom of the ‘Jog Control’ screen, 18 sensor LS status indicators show which sensors are activated during each jog step. An illuminated status indicator shows that there is no response from a particular sensor. Touching the sensor status indicator will change the display to show a photo of the sensor location on the machine.

  • Page 46: Figure 5-19: 'Machine Cycle Jog' Button

    WF30T Case Former Controls 17) ‘MACHINE CYCLE JOG’ Button Each time that the ‘MACHINE CYCLE JOG’ button is pressed, the machine moves through a single step of the forming process. The ‘Next Jogging Step’ display shows what the next step will be when the ‘MACHINE CYCLE JOG’...

  • Page 47: Figure 5-22: 'Dry Cycle On' Toggle Switch

    WF30T Case Former Controls 20) ‘DRY CYCLE’ Operation purposes troubleshooting, machine operators may choose to operate the machine without any cases loaded. This function is called ‘DRY CYCLE’, and is available in both JOG mode and AUTOMATIC CYCLE mode. To enable DRY CYCLE operation, press the ‘DRY CYCLE OFF’...

  • Page 48: Figure 5-31: 'Machine Feedback' Button

    WF30T Case Former Controls 23) ‘ALARM HISTORY’ Button The ‘Alarm History’ screen displays the time and date of each alarm condition that the machine has experienced. The ‘Alarm History’ screen can be Figure 5-28: 'ALARM accessed by pressing the ‘ALARM HISTORY’ button in HISTORY' Button the upper left-hand corner of the ‘Setup’...

  • Page 49: Figure 5-34: 'Troubleshooting' Screen

    WF30T Case Former Controls 25) ‘Machine Feedback’ Screen The ‘Machine Feedback’ screen displays data related to the performance of nine machine components. This ‘Real Time Sequence’ display shows in blue bars the actual time in milliseconds of the operation of each component within the machine cycle. To the right of the real time sequence display are the Start Time, End Time, and Duration Time of each of the nine machine components.

  • Page 50: Figure 5-36: Plc Inputs Screen

    WF30T Case Former Controls 29) ‘PLC Inputs’ Screen The ‘PLC Inputs’ screen displays 24 function indicators which are related to machine functions. If one of the machine components is not functioning, the corresponding indicator will be illuminated. Note: not all of the function indicators are active.

  • Page 51: Figure 5-39: 'Plc Outputs' Button

    WF30T Case Former Controls 30) Alarm Diagnostic Detail Screen To see a photo screen of any of the inputs, press any of the 24 touch-sensitive function indicator buttons. Touch the photo to be returned to the ‘PLC Inputs’ screen. If the related function indicator is illuminated, inspect and repair the related component.

  • Page 52: Figure 5-41: Illuminated 'Plc Output Status' Indicator

    WF30T Case Former Controls The ‘PLC Outputs’ screen displays 12 buttons. Each of these output buttons control a PLC output directly. To test these functions, stop the machine, and remove any unformed cases from the magazine. Then touch each button.

  • Page 53: Figure 5-44: Setup Guide Detail Screen Button

    WF30T Case Former Controls For an example of how to change the machine setup, touch the ‘STEP 1 DIMENSION B’ button. This action will bring up a title screen for the Step 1 adjustment. Touch the ‘FORWARD’ button in the lower right-hand corner of the screen to access screens which provide written and illustrated steps for the completion of that adjustment.

  • Page 54: Figure 5-48: 'Parameters' Screen

    WF30T Case Former Controls Touching the ‘PARAMETERS’ button prompts the operator for a password. Touch the blank field in the ‘Password’ window to bring up an ‘Alphanumeric Keypad’ window. Type the required password. To enter the password into the ‘Password’ window, touch the ‘ENTER’ key. Then touch the ‘OK’...

  • Page 55: Figure 5-50: 'Homing Value' Button

    WF30T Case Former Controls 38) ‘High and Low Speed Servo Settings’ Screens Figure 5-49: ‘Servo High and Low Speed Settings’ Screens On either the high or low speed settings screens, you can alter the following values, described in detail below, for the Jaws and Forming Head servo speeds:...

  • Page 56: Figure 5-53: 'Ramp Rate' Button

    WF30T Case Former Controls To alter the jaws’ initial closing speed, touch the blue numerals of the ‘INITIAL SPEED (CLOSE)’ button. Touching this value will bring up a TENKEY keyboard which can be used to change the value. Touch ENTER to set the new initial closing speed value.

  • Page 57: Figure 5-58: 'Actual Cpm' Button

    WF30T Case Former Controls 46) ‘RAMP RATE (UP/DOWN)’ Button To alter the forming head’s upward ramp rate, touch the blue numerals of the ‘RAMP RATE (UP)’ button. Figure 5-57: Touching this value will bring up a TENKEY keyboard ‘RAMP RATE’...

  • Page 58: High Speed Servo Settings

    WF30T Case Former Controls 49) ‘Dry Cycle’ Function Toggle Button Users can also toggle the DRY CYCLE function ON or OFF by pressing the black ‘DRY CYCLE OFF’ button on the bottom of the screen. This will activate the DRY CYCLE function, and the button will be replaced with a blue ‘DRY CYCLE ON’...

  • Page 59: Operating Procedures

    6.1 Safety Equipment Safety The WF30T has safety features to prevent you from injury while the machine is operating. Sliding and bi-folding guard doors, equipped with interlock switches, are in place to prevent you from entering the work cell while the case forming is in progress; the machine will not run if these doors are open.

  • Page 60: Start-Up

    • Is the tape applicator on the WF30T properly installed, loaded with a tape roll, and ready to go? The end of the tape should be on the front roller, with the sticky side facing the incoming case. For complete tape installation instructions, see the separate Dekka Tape Head Manual that is supplied with this machine.

  • Page 61: Start-Up Procedures

    WF30T Case Former Operating Procedures Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 11: Preliminary Start-up Checklist Machine Start-up Preliminary checks Check if the machine is set up for the right case size. Check if the machine is properly loaded, with the first case pushed into the caliper slot.

  • Page 62: Table 13: Machine Start-Up Procedures

    WF30T Case Former Operating Procedures 5) Check that the magazine pusher valve is ON and the pressure is set to between 20 and 35 PSI. Note that a pressure lower than 20 PSI places a lesser load on the pneumatic system.

  • Page 63: Cycle' Operation

    ‘Jog Control’ screen will cycle through each machine sequence, one step at a time for each push of the button. 6.3 Monitoring 6.3.1 Monitoring Machine Operation The WEXXAR WF30T is completely automated. It requires very little monitoring once it is running. Monitoring the machine involves: •...

  • Page 64: Loading The Magazine

    WF30T Case Former Operating Procedures 6.3.2 Loading the Magazine The case magazine must contain an adequate number of cases for proper operation. In addition, note the following points: • Every case that is loaded The cases must be right way up and properly folded.

  • Page 65: Clearing A Case Jam

    6.4 Clearing a Case Jam The WEXXAR Model WF30T Case Formers will provide reliable, trouble-free performance on a wide variety of case sizes. Occasional jams are not uncommon, but frequent jamming can usually be traced to a particular reason, such as incorrectly set machine adjustment, and corrected.
  • Page 66 WF30T Case Former Operating Procedures 3. If required by local regulations or company policy, lock out the electrical power and air supply before proceeding. WARNING! Never attempt to remove a jammed case by reaching in from the discharge end of the machine or around a guard with the air pressure still switched on.

  • Page 67: Shutdown

    WF30T Case Former Operating Procedures 6.5 Shutdown There are several options to stop the machine: 1. ‘STOP’ Button: Pushing the ‘STOP’ button is the proper way to stop the machine in a non-emergency situation. When the ‘STOP’ button is pressed in CYCLE mode operation, the case in process is completed, and the mechanisms return to their HOME positions unless the machine is in REMOTE DEMAND pause.

  • Page 68: Case Size Adjustments

    7.1 Safety Equipment Safety The WF30T has safety features to prevent you from injury while case size adjustments are being performed. Sliding and bi-folding guard doors, equipped with interlock switches, are in place to prevent you from entering the work cell while the case forming is in progress; the machine will not run if these doors are open.

  • Page 69: Table 17: Case Size Range

    WF30T Case Former Case Size Adjustments Table 17: Case Size Range Case Size Range Inches Figure 7-1: Dimensions on Left and Right Hand Cases The case size adjustment sequence described in the following pages and as shown on the machine itself is ordered so that the adjustments occur in a logical ‘walk around’...

  • Page 70: Figure 7-3: Mast Assembly Components

    WF30T Case Former Case Size Adjustments ‘B’ Dimension Adjustment Scale Collar ‘B’ Adjust ‘E’ Adjust Locking Knob Handles ‘E’ Adjust Locking Handles Head-Up Latch ‘E’ Dimension Adjustment ‘B’ Adjust Scale Hand Crank Mast Assembly Figure 7-3: Mast Assembly Components 7-57...

  • Page 71: Flat Case Height (Dimension 'B')

    WF30T Case Former Case Size Adjustments 7.2 Flat Case Height (Dimension ‘B’) Figure 7-4: Dimension ‘B’ To adjust the machine to the correct Dimension 'B' setting: 1. Loosen the two light blue quick-adjust locking handles that secure the collar assembly on the mast.

  • Page 72: Table 18: Dimension 'B' Adjustments

    WF30T Case Former Case Size Adjustments Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 18: Dimension ‘B’ Adjustments Size Adjustments Flat Height Adjustment (Dimension ‘B’) Measure Dimension ‘B’ against the scale. Unlock the two quick-adjust handles that secure the collar assembly.

  • Page 73: Formed Case Height (Dimension 'E')

    WF30T Case Former Case Size Adjustments 7.3 Formed Case Height (Dimension ‘E’) Figure 7-7: Dimension ‘E’ Measure the height of the formed case with the bottom minor flaps folded. The machine must be adjusted so that the vertical distance between the top of the minor flap folders (DOWN position)

  • Page 74: Table 19: Dimension 'E' Adjustments

    WF30T Case Former Case Size Adjustments 5. Check the setting with a case. a. Push the case, with the bottom minor flaps folded, up onto the pins until the top flap makes contact with bottom of the pinblocks. b. Hold the forming head fully DOWN.

  • Page 75: Case Width (Dimension 'D')

    WF30T Case Former Case Size Adjustments 7.4 Case Width (Dimension ‘D’) Figure 7-11: Dimension ‘D’ Use the two blue side handwheels, ‘D1’ and ‘D2’, to adjust the machine for the case width dimension. The adjustments should approach their final position in a decreasing direction (counterclockwise rotation) to eliminate the effects of backlash in the leadscrews.

  • Page 76: Table 20: Dimension 'D' Adjustments

    6) Adjust the second handwheel marked ‘D2’, which is located at the discharge end. This adjustment sets the width of the conveyor assembly in the tape application section of the WF30T. The scale is located on the outfeed end of the machine frame. Figure 7-14: ‘D2’ Adjustments Check the ‘S’...

  • Page 77: Case Length (Dimension 'C')

    WF30T Case Former Case Size Adjustments 7.5 Case Length (Dimension ‘C’) Figure 7-15: Dimension ‘C’ Magazine Pusher Assembly Feedbelts Magazine Pusher Regulator ‘C’ Scale Pointer ‘A’ Quick Adjust Handles ‘C’ Length Adjustment Handwheel Feedbelt Locking Handles Figure 7-16: Main Magazine Assembly Components...

  • Page 78: Table 21: Dimension 'C' Adjustments

    WF30T Case Former Case Size Adjustments 2) Adjust the handwheel to the indicated scale setting. There is no locking device for this adjustment. Figure 7-17: Dimension ‘C’ Adjustments 3) Check the setting by measuring the distance between the leading and trailing minor flap folder cylinder rod centers.

  • Page 79: Flat Case Width (Dimension 'A')

    WF30T Case Former Case Size Adjustments 7.6 Flat Case Width (Dimension ‘A’) Figure 7-19: Dimension ‘A’ The magazine must be adjusted to suit the width of the flat case (Dimension ‘A’). To do this, 1) Adjust telescoping side magazine assembly by loosening the two...

  • Page 80: Feedbelt Horizontal Adjustments (Dimension 'H')

    WF30T Case Former Case Size Adjustments 7.7 Feedbelt Horizontal Adjustments (Dimension ‘H’) Loosen the red clamp handles and adjust the red feedbelts so that they support the case evenly. The most typical position for the feedbelts is in the center of each minor panel of the flat case blank to ensure that the weight of the flat case blank is balanced on the two belts.

  • Page 81: Case Separator Horizontal Adjustment (Dimension 'G')

    WF30T Case Former Case Size Adjustments 7.8 Case Separator Horizontal Adjustment (Dimension ‘G’) After Dimensions ‘A’ and ‘H’ have been correctly adjusted, the case separator may need to be adjusted so that it rests in the center of the case width. If it is not...

  • Page 82: Jawplate 'F' Adjustment

    WF30T Case Former Case Size Adjustments 7.9.1 Jawplate ‘F’ Adjustment The jawplates must be set so that the gap between them, when fully CLOSED, is (1 mm) " more than the thickness of the flat case. See Figure 7-25. If adjustment is required, proceed as...

  • Page 83: Caliper 'F' Adjustment

    WF30T Case Former Case Size Adjustments 7.9.2 Caliper ‘F’ Adjustment The caliper at the inboard end of each bottom feed drivebelt must be set to provide a sliding fit for a single flat case. See Figure 7-26. Caliper clearance: case thickness + 1/16”...

  • Page 84: Table 25: Dimension 'F' Adjustments

    WF30T Case Former Case Size Adjustments Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 25: Dimension 'F' Adjustments Size Adjustments Corrugate Thickness Adjustment (Dimension 'F') Adjust the caliper to provide a sliding fit for a single flat case: Loosen the two orange quick-adjust handles on the calipers.

  • Page 85: Other Machine Adjustments

    8.1 Safety Equipment Safety The WF30T has safety features to prevent you from injury while machine adjustments are being performed. Sliding and bi-folding guard doors, equipped with interlock switches, are in place to prevent you from entering the work cell while the case forming is in progress; the machine will not run if these doors are open.

  • Page 86: Stabilizer Bars And Pinblocks

    WF30T Case Former Other Machine Adjustments 8.2 Stabilizer Bars and Pinblocks The stabilizer bars are used to support the outside corner of the case as it descends into the minor and major flap folders. See Figure 8-1. A standard set of 3 fixed bars will cover most case sizes.

  • Page 87: Magazine

    WF30T Case Former Other Machine Adjustments 8.3 Magazine Pusher The magazine pusher holds the stacked cases vertically and provides a moderate force to help move the cases towards the separator end of the magazine. 1) Place some flat case blanks in the magazine.

  • Page 88: Sensor Ls-7 Adjustment

    WF30T Case Former Other Machine Adjustments 8.4 Sensor LS-7 Adjustment Sensor LS-7 signals the presence of the major flap through or below the major flap folders. It mounts on an adjustable bracket and must be set to sense the arrival of the major flap. If the case size change involves a significantly different length of the flap, then adjust the position of LS-7 accordingly.

  • Page 89: Table 27: Mechanism Home Positions

    WF30T Case Former Other Machine Adjustments Table 27: Mechanism HOME Positions Mechanism HOME Positions Forming Head Jaws Minor Flap Folder OPEN DOWN Injector Major Flap Folders DOWN OPEN Forming Head Assembly Discharge Pusher BACK Case Separator 7) From the ‘Main Control’ screen of the touchscreen, press the ‘JOG CONTROL’...

  • Page 90: Quick Size Change Guide

    WF30T Case Former Other Machine Adjustments 8.7 Quick Size Change Guide The case size change table (Table 30) in this section is used to make case size changeover simpler and faster. For each case, the optimum set-up parameters can be determined and entered into Table 30.

  • Page 91: Table 30: Dimension Adjustment Reference

    Other Machine Adjustments Indicate in Table 30 which top plates are used. Figure 8-5: Minor Flap Folder Top Plates Table 30: Dimension Adjustment Reference WEXXAR CASE FORMER CASE SIZE S/N CASE IDENTIFICATION OR PRODUCT COUNT Refer to Section 7: ‘Case Size Adjustments’...

  • Page 92: Machine Maintenance

    9.1 Safety Equipment Safety The WF30T has safety features to prevent you from injury while maintenance is in progress. Sliding and bi-folding guard doors, equipped with interlock switches, are in place to prevent you from entering the work cell while the case forming is in progress; the machine will not run if these doors are open.

  • Page 93: Maintenance

    WF30T Case Former Machine Maintenance 9.2 Maintenance WARNING! The tape knife blade is sharp, and can cause serious injury. 9.2.1 Inspections On a daily basis, the operators should inspect for: 1) Leaks at: • Pneumatic system (air supply). • Filter bottle drain.

  • Page 94: Cleaning

    WF30T Case Former Machine Maintenance 9.2.2 Cleaning Tools and Materials • Soapy water • Rag or paper towel • Filter replacements (if necessary) Instructions • Inspect the machine daily and remove any corrugated fragment deposits that may have accumulated. •...

  • Page 95: Preventative Maintenance Schedule

    Visually inspect the machine for loose fasteners and leaks in the pneumatic system, reducer lubricant, and drain bottle overflow. • Clean the tape knife on the WF30T Dekka Tape Head with WD-40 or a similar low- toxicity cleaner and lubricate the blade guard pad with silicone. Weekly •...

  • Page 96: Typical Maintenance Adjustments

    The sensor must be located at least 4 feet (1.2 meters) downstream from the discharge end of the WEXXAR case former for proper operation. Make sure there are no false targets in the sensor’s sensing range. No other adjustments are required.

  • Page 97: Magazine Pusher

    WF30T Case Former Machine Maintenance 9.4.3 Magazine Pusher The magazine pusher is fitted with a pressure regulator, a shutoff valve, and a flow control. The flow control is set to almost fully CLOSED, as the speed is very slow. Verify the following items on the magazine pusher: 1) Verify that all components are accounted for (i.e., pusher arm, knob, spacer, etc).

  • Page 98: Injector Assembly

    WF30T Case Former Machine Maintenance 9.4.5 Injector Assembly Verify the following items on the magazine injector assembly: 1) Examine cylinder for wear or damage. 2) Examine linear guide rods for wear or damage. 3) Examine shock absorbers and mechanical stops for function and proper position.

  • Page 99: Forming Head

    WF30T Case Former Machine Maintenance 9.4.7 Forming Head It is important to note that changes in the speed of the descent of the case onto the minor flap folders can make it necessary to change the position the ‘FORMING HEAD PARTLY DOWN’...

  • Page 100: Conveyor Belt Tension & Tracking

    WF30T Case Former Machine Maintenance forces generated. A rotating collar on the shock absorber is used to make this adjustment. Adjustable shock absorbers are adjusted after the desired speed of the mechanism has been set. The measurements are marked on a rotating collar on the bottom of the shock absorber.

  • Page 101: Discharge Conveyor Assemblies

    Ensure that all conditions are represented on the beacon. Check sensors LS13/14/15/16/12 and their cables for any damage. 9.4.13 Tape Head Adjustments For adjustments and set-up of the adhesive system on the WF30T, refer to the separate Dekka Tape Head Manual supplied with this machine. - 9-88 -...

  • Page 102: Proximity Sensors

    WF30T Case Former Machine Maintenance 9.4.14 Proximity Sensors Two types of proximity sensors are used on the WF30T case former: inductive and infrared photo-type. The majority is of the inductive type; they sense the presence of a steel component by...

  • Page 103: Pneumatic System Maintenance

    WF30T Case Former Machine Maintenance 9.5 Pneumatic System Maintenance 9.5.1 Pneumatic Supply Adjustments Little adjustment is necessary. The black knob on the top of each regulator unit adjusts the pneumatic supply pressure. The main regulator should be set to give a pressure of 90 PSI. If the main supply pressure regularly drops by 15 PSI while running, a larger supply air-line may be required.

  • Page 104: General Pneumatics

    WF30T Case Former Machine Maintenance 9.5.4 General Pneumatics Verify the following general pneumatic items: Check all tubing and fittings for damage and leaks. Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 44: General Pneumatic Maintenance Pneumatics Check all tubing and fittings for damage and leaks.

  • Page 105: Mechanical Maintenance

    WF30T Case Former Machine Maintenance 9.7 Mechanical Maintenance • Observe the machine in operation, looking particularly for any uneven or excessively noisy motions and abnormal air leaks. • With the machine stopped and the air OFF, check for smooth action without excessive bearing wear or abnormal looseness of all moving parts.

  • Page 106: Maintenance Parts List

    Use Keystone Pennwalt ‘Nevastane HT-2’ grease or equivalent. 9.9.2 Ball Bearings All ball bearings used on WEXXAR packaging machines sealed-for-life, regular lubrication is not required. Figure 9-3: Mast Assembly Showing Guide Wheels 9.9.3 Sealed Guide Wheels...

  • Page 107: Table 47: Lubricants

    WF30T Case Former Machine Maintenance CAUTION! DO NOT use any automotive oils (engine oil, transmission fluid, power steering oil, or brake fluid), detergent oil, or any synthetic oil incompatible with Buna N, PVC, Polyethylene, or nylon. Figure 9-4: Discharge Pusher...

  • Page 108: Troubleshooting & Repairs

    To safely work on the machine, disconnect the compressed air supply and power supply. The guard doors around the WF30T will ensure that you do not accidentally enter the machine’s working cell while its components are energized. Never attempt to disable any of the safety features or enter in through the discharge end while the machine is still powered.

  • Page 109: General Troubleshooting

    WF30T Case Former Troubleshooting & Repairs 10.2 General Troubleshooting The most common error in troubleshooting packaging machinery problems is an incorrect diagnosis of the problem. Errors cause much lost time and needless expense and are avoided by a careful analytical approach before attempting corrective action. Always start by ensuring that all case size adjustments have been made correctly.

  • Page 110: Table 48: General Troubleshooting Reference

    WF30T Case Former Troubleshooting & Repairs Table 48: General Troubleshooting Reference Problem Possible Cause Solution Bottom caliper set too Adjust caliper to sliding fit. tight Check magazine pusher air switch is ON, regulator at 20-35 PSI. Check magazine width setting.
  • Page 111 WF30T Case Former Troubleshooting & Repairs Problem Possible Cause Solution Check injector stroke. Poor injector stroke, case not fully UP onto Refer to Section 9.6.1: ‘Vertical pins Alignment Procedures’. Dimension 'E' set too Readjust Dimension 'E'. Refer to Section 7.3: ‘Formed Case Height’.

  • Page 112: Machine Sequence Troubleshooting

    WF30T Case Former Troubleshooting & Repairs 10.3 Machine Sequence Troubleshooting The machine sequence is controlled by a PLC located inside the electrical enclosure. The controller responds to inputs from the panel buttons and various sensors on the machine mechanisms, and it provides outputs that control the solenoid valves in the pneumatic system.

  • Page 113: Table 50: Error Codes

    WF30T Case Former Troubleshooting & Repairs Table 50: Error Codes Error Error Error Condition Condition Condition Code Code Code Tape Disengaged – F001 E-Stop Activated F006 Servo Fault F032 Push ‘E-STOP’ & Check Tape Routing Box Jam Detected Tape Running – Push Aux.

  • Page 114: Electrical Troubleshooting

    ON. In the unlikely event that these LEDs are still illuminated improperly, and you do not have the appropriate PLC interface, or training, contact WEXXAR's service department. Without the appropriate equipment and training to correct this status, there is nothing else that you can do.
  • Page 115 WF30T Case Former Troubleshooting & Repairs NOTE: Many of the input signals to the PLC originate from inductive or optical sensors as noted on the electrical control circuit. Without a target, they are similar to a normally open (‘NO’) switch. With a target in their sensing range, they turn ON and connect the load to positive through an PNP output transistor.

  • Page 116: Tape Applicator Troubleshooting

    10.5 Tape Applicator Troubleshooting Comprehensive information on the set-up, operation, and maintenance of the adhesive system on the WF30T is contained in the separate Dekka Tape Head Manual supplied with this machine. 10.6 Pneumatic Troubleshooting The pneumatic system of your WEXXAR Case Former is designed to give long, trouble-free service.

  • Page 117: Table 53: Both Forming Head And Jaw Too Slow

    WF30T Case Former Troubleshooting & Repairs Table 53: Both forming head and jaw too slow Problem Possible Cause Solution Adjust the regulator’s set point. Mast cylinder: 70 PSI. Regulator set point too Jaw cylinder: 70 PSI. Other actuators: 90 PSI.

  • Page 118: Table 54: Jaw Too Slow; Forming Head Speed Normal

    WF30T Case Former Troubleshooting & Repairs Table 54: Jaw too slow; forming head speed normal Problem Possible Cause Solution Adjust the regulator’s set point. Mast cylinder: 70 PSI. Low Air Pressure Regulator set point too low Air pressure at machine’s main regulator: 90 PSI.

  • Page 119: Other Typical Pneumatic Issues

    WF30T Case Former Troubleshooting & Repairs Table 56: Jaw not moving Problem Possible Cause Solution Compressed air not Connect air supply. connected Mechanical Clear mechanical jam. Socket loose Tighten socket. Open Circuit Cable broken Replace cable. Valve head against surface...

  • Page 120: Led Status Tables

    WF30T Case Former Troubleshooting & Repairs 10.7 LED Status Tables Table 57: PLC Input LED Status Table for Jog Step Sequence STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 8 STEP 9 SENSOR STEP 7...

  • Page 121: Table 58: Plc Output Led Status Table For Jog Step Sequence

    WF30T Case Former Troubleshooting & Repairs Table 58: PLC Output LED Status Table for Jog Step Sequence OUTPUT STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 8 STEP 9 STEP 7 FUNCTION LOAD PLC/ HOME...

  • Page 122: Repair Procedures

    Troubleshooting & Repairs 10.8 Repair Procedures The operating time before significant wear will occur with WEXXAR packaging machines depends upon the service duty to which the machine is subjected, and can vary widely between different customers. Many wear points are quite simple (bushings, rod ends, etc.), and the corrective action is self-evident.

  • Page 123: Magazine Repairs

    WF30T Case Former Troubleshooting & Repairs 10.8.2 Magazine Repairs Remove all cases from the magazine before commencing any repair work. Feedbelt Repairs All feedbelts run on sealed ball bearings, which are lubricated for life. Should bearing failure occur, the entire bearing and housing should be replaced.

  • Page 124: Solenoid Valve Repairs

    WF30T Case Former Troubleshooting & Repairs 10.8.5 Solenoid Valve Repairs The valves are designed for easy replacement. 1) Lock the air OFF at the manual shutoff valve upstream of the filter/regulator unit. Adhere to the lockout/tagout procedure in Section 1: ‘Safety’.

  • Page 125: Engineering Specifications

    WF30T Case Former Engineering Specifications 11 ENGINEERING SPECIFICATIONS 11.1 Operating Parameters Table 59: Operating Parameters Operating Parameters Integrated safety guarding with keyed interlock switches. Safety Guarding Aluminum, stainless steel and plated steel. Machine Construction Discharge at absolute minimum 23” (584 mm). With leveling pads, the range is 24”...

  • Page 126: Training Guide

    WF30T Case Former Training Guide 12 TRAINING GUIDE 12.1 Instructor Data Sheet Knowledge of basic mechanical Trainee prerequisites: operations and reading skills 30 minutes Classroom time: 2 hours Hands-on training: 2.5 hours Total training hours: 10 in classroom training sessions...

  • Page 127: Training Outlines

    Length Details Number This lesson familiarizes trainees with the operation of a WF30T machine. It may be carried out either in a classroom or at a workshop. A classroom presentation would require slides or a video showing the parts and Description of sequence of operations.
  • Page 128 Shutdown 5 minutes A hands-on tutorial is best. Refer to Section 6.5: ‘Shutdown’. This lesson trains users to properly maintain and clean the WF30T. Maintenance 40 minutes and Cleaning A hands-on tutorial is best. Refer to Section 9.2.2: ‘Cleaning’.

  • Page 129: Performance Checklists

    WF30T Case Former Training Guide 12.3 Performance Checklists To instruct trainees in the performance and operation of the machine, use the Performance Checklists found throughout this manual, notably in Section 6: ‘Operating Procedures’, Section 7: ‘Case Size Adjustments’, Section 8: ‘Other Machine Adjustments’, and Section 9: ‘Machine Maintenance’.
  • Page 130 WF30T Case Former Training Guide Instructions for Assessing Performance Before the Performance Assessment 1. Verify that the work area conforms to all safety standards. 2. Verify that tools, equipment, and material needed to perform the task are on hand. During the Performance Assessment 1.

  • Page 131: Service & Warranty

    To order parts or arrange for service, please call or fax us. Warranty Machinery and parts manufactured by WEXXAR are warranted for a period of one year from date of shipment against failure or defective workmanship. Components purchased from other manufacturers by WEXXAR are warranted for the duration of the manufacturer’s warranty.

  • Page 132: Options

    WF30T Case Former Options 14 OPTIONS 14.1 Machine Management System 14.1.1 Tape Monitoring The tape monitoring system alerts the machine attendant when a taping fault occurs, and when it is time to replace the tape roll. A tape-roll-follower arm is fitted to the machine. A small wheel mounted on the end of the follower arm makes contact with the tape roll.

  • Page 133: Normal Operation

    WF30T Case Former Options 14.1.3 Normal Operation The Green beacon is ON steady when the machine is in ‘CYCLE’ mode, running or paused on ‘REMOTE DEMAND’. The Green beacon goes out when the Red beacon is activated, except if the machine is restarted with an almost empty tape roll. A machine management shutdown will allow the machine cycle to be completed;...

  • Page 134: Index

    WF30T Case Former Appendix A: MSDS Geralyn FMG 387 INDEX Stop ..........5-29, 6-54 Adhesive Adjustments ........9-88 Adhesive System .......... 4-21 Caliper............3-12 Adjustments Case Injection ..........4-18 Adhesive........... 9-88 Case Length..........7-64 Caliper ............7-70 Case Measurement Dimensions ....5-31 Case Size ..........
  • Page 135 WF30T Case Former Appendix A: MSDS Geralyn FMG 387 Electrical Disconnect........3-12 LED Status Tables ........10-107 Electrical Enclosure ........9-91 Left Hand Cases ........... 7-56 Electrical Panel ..........3-12 Leveling............2-7 Electrical Power ........1-3, 2-9 Location ............2-7 Emergency Stop ........
  • Page 136 WF30T Case Former Appendix A: MSDS Geralyn FMG 387 Parts Servo Settings .......... 5-42 Components ..........3-12 Sealed Guide Wheels ........9-93 Maintenance ..........9-93 Sensors ..........4-19, 8-77 Wear Parts..........9-93 Adhesive System ........4-21 Performance Checklists ......12-116 Adjustments ..........8-77 Pin and Dome ..........

  • Page 137: Material Safety Data Sheets: Fuchs Lubricants - Geralyn Fmg 387

    WF30T Case Former Appendix A: MSDS Geralyn FMG 387 Wear Parts ............ 9-93 APPENDIX A Material Safety Data Sheets: Fuchs Lubricants – Geralyn FMG...
  • Page 138 WF30T Case Former Appendix A: MSDS Geralyn FMG 387 FUCHS LUBRICANTS CANADA LTD. PACIFIC DIVISION Material Safety Data Sheet WHMIS Not controlled...
  • Page 139 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
  • Page 140 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
  • Page 141 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
  • Page 142 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
  • Page 143 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
  • Page 144 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...

  • Page 145: Material Safety Data Sheets: Keystone Lubricants - Nevastane Ht-2

    WF30T Case Former Appendix B: MSDS Keystone Nevastane HT-2 APPENDIX B Material Safety Data Sheets: Keystone Lubricants – Nevastane HT-2...
  • Page 146 WF30T Case Former Appendix B: MSDS Keystone Nevastane HT-2...
  • Page 147 WF30T Case Former Appendix B: MSDS Keystone Nevastane HT-2...
  • Page 148 WF30T Case Former Appendix B: MSDS Keystone Nevastane HT-2...
  • Page 149 WF30T Case Former Appendix B: MSDS Keystone Nevastane HT-2...
  • Page 150 WF30T Case Former Appendix B: MSDS Keystone Nevastane HT-2...
  • Page 151 & S PERATION ERVICE ANUAL 65-35-1 Effective June 17, 2009 BEL 290 ULLY UTOMATIC OP AND OTTOM EALER Wexxar Packaging Inc. Phone (604) 930-9300 • Fax (604) 930-9368 E-mail: sales@wexxar.com...
  • Page 152 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R SAFETY CAUTION Make sure machine is disconnected from power sources, air and electric, before undertaking any maintenance or service procedures.
  • Page 153 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R ABLE OF ONTENTS INSTALLING THE BEL 290.............................4 ............................4 EVELING THE ACHINE ...........................5 NSTALLING THE...

  • Page 154: Installing The Bel 290

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Control Panel Case Height Crank Case Width Crank (position) BEL 290 fully automatic top and bottom taper Installing the BEL 290 1.

  • Page 155: Installing The Tape Heads

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R NSTALLING THE EADS Tape dispensing heads are mounted using the pins on their sides. These pins fit into corresponding slots in the upper and lower tape head mounting brackets.

  • Page 156: Machine Adjustments

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Machine Adjustments Safety: Disconnect machine electrics and compressed air before making any machine adjustments. There are only two main quick adjustments required in setting up the BEL 290 to run a particular case size: Case width adjustment ‘D’-...

  • Page 157: Case Height Adjustment

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R EIGHT DJUSTMENT Case Dimension ‘E’ Adjustment Use the case height crank and scale on the side of the arch to adjust the case height to Dimension ‘E’. CASE HEIGHT SCALE ‘E’...

  • Page 158: Case Width Adjustment

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R IDTH DJUSTMENT Case Dimension ‘D1’ (Conveyor Adjustment) Use the case width crank and the scale at the front of the conveyor to set Dimension ‘D1’. The case width crank can be connected to the case width leadscrew on either side of the machine frame.

  • Page 159: Case Dimension 'D2' (Major Flap-Folding Rods)

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Case Dimension ‘D2’ (Major Flap-folding Rods) If necessary, loosen the bolts that lock the top major flap folding rods in position and adjust their position so that they capture the top case flaps and fold them down ahead of the top tape head as the case passes under them.

  • Page 160: Case Dimension 'D3' (Case Side Compression)

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Case Dimension ‘D3’ (Case Side Compression) Adjust the side-compression rollers to control the tendency of the upper sides of the case to expand due to incorrect top flap folding and perhaps case overfilling.

  • Page 161: Top Ski Flap Width Adjustment

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R IDTH DJUSTMENT The top ski, used to fold down the front minor flap, is mounted on a slotted bracket that permits the ski to be adjusted towards or away from the machine infeed.

  • Page 162: Starting The Machine

    To carry out service or repair work safely on the machine, the manual air ‘ON/OFF’ valve is located on all WEXXAR machines upstream of the filter-regulator unit. Padlock this valve in the OFF position for absolute safety during service work. Always follow local lock-out/tag-out regulations.

  • Page 163: Electrical Switching

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Electrical Switching A ‘MAIN DISCONNECT’ switch is located on the lower control panel Switch on the electrical supply to power the machine programmable logic controller [PLC] and control screen [HMI].

  • Page 164: Controls

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Controls Control Panel with Touchscreen Interface ONTROLS VERVIEW The control system consists of a touchscreen interface and a Programmable Logic Controller (PLC), which interact with each other and make the machine operate.

  • Page 165: Controls Description

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R ONTROLS ESCRIPTION 1) ‘MAIN DISCONNECT’ Switch The ‘MAIN DISCONNECT’ switch turns the main electrical power to the machine ON or OFF;...
  • Page 166 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 4) Touchscreen Display The following control descriptions refer to the software ‘buttons’ or ‘switches’ which appear on the display screen, and which act as though they were their hardware equivalents.
  • Page 167 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 6) ‘START’ Button The ‘START’ button starts the cycle of the machine. Once pressed, the ‘START’...
  • Page 168 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 10) ‘SELECTED CPM’ Button and Display The ‘SELECTED CPM’ display indicates the total number of cases per minute that the operator wishes to seal.
  • Page 169 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 13) ‘ALARM HISTORY’ Button and Screen The ‘Alarm History’ screen displays the time and date of each alarm condition that the machine has experienced.
  • Page 170 16) ‘SERVICE’ Button The ‘SERVICE’ button is located in the upper right-hand corner of the screen. Touch the ‘SERVICE’ button to bring up the ‘Service’ screen. On the ‘Service’ screen are the phone and fax numbers for Wexxar/BEL. ‘SERVICE’ Button...
  • Page 171 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R ‘TOP/BOTTOM HEAD MANAGE’ Toggle Switches The ‘TOP/BOTTOM HEAD MANAGE’ toggle switches control the status of the machine’s Tape Management System, activating or deactivating sensors PHS-03, PRS-04, PRS-05, PHS-06, PRS-07 and PRS-08.
  • Page 172 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 21) ‘Parameters’ Screen The ‘Parameters’ screen displays touch-sensitive values for the KICKER DOWN TIME, CONVEYOR RUN TIME, STOP GATE DOWN TIME and REMOTE DEMAND TIME parameters.
  • Page 173 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 23) ‘CONVEYOR RUN TIME’ Button To change the CONVEYOR RUN TIME, touch the blue numerals of this value.
  • Page 174 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 27) ‘PLC INPUTS’ Button In the center-left side of the ‘Troubleshooting’ screen is the ‘PLC INPUTS’...
  • Page 175 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 29) ‘PLC OUTPUTS’ Button In the center-right side of the ‘Troubleshooting’ screen is the ‘PLC OUTPUTS’ button.

  • Page 176: Feeding Cases Into The Machine

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Feeding Cases into the Machine A powered infeed conveyor belt is the preferred method of feeding cases to the BEL 250 although gravity or manual feed may also be used.

  • Page 177: Service And Maintenance Procedures

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Service and Maintenance Procedures QUIPMENT AFETY The BEL 290 has safety features to prevent you from injury while maintenance is in progress. Sliding and bi-folding guard doors, equipped with interlock switches, are in place to prevent you from entering the work cell while the case forming is in progress;...

  • Page 178: Preventive Maintenance

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R REVENTIVE AINTENANCE A regular program of preventative maintenance will help to avoid unnecessary downtime due to premature component failures.
  • Page 179 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Daily Inspection Inspect all pneumatic motions for smooth action and belt wear. As the machine processes a case, listen for air leakage or other abnormal noises.

  • Page 180: Weekly Inspection

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Maintenance and Cleaning Cleaning Remove any corrugated fragment deposits that have accumulated. Check the pneumatic filter bowl filter for debris.

  • Page 181: Side - Belt Conveyor System

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R BELT ONVEYOR YSTEM The side-belt conveyor system is designed to keep the case square during sealing. This results in a stronger seal and a better finished appearance.

  • Page 182: Chain Drive

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Chain Drive Chain tension is preset at the factory, but if adjustment is needed, tighten the idler sprocket, as shown in the preceding illustration.
  • Page 183 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Conveyor Belt Replacement The belts are replaced by removing the top cover assemblies from each side unit. We recommend replacing both belts at the same time.
  • Page 184 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 4. Remove the stainless steel cover guard. 5. Remove the belt and replace it with a new one. Finger-splice belts can move in either direction. 6.

  • Page 185: Troubleshooting Guide

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Troubleshooting Guide 1 - C & S ECTION ORRUGATED UALITY PECIFICATIONS Corrugated case quality is a major contributor to smooth efficient running and quality output 1.

  • Page 186: Section 2 - Case Drive Belt System

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 2 - C ECTION RIVE YSTEM The side-belt conveyor system is designed to keep the case square during sealing, resulting in a technically stronger seal and a better finished appearance.
  • Page 187 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Problem: Machine Jams Frequently. Turn off the machine as soon as a jam occurs and prior to clearing the jam. Open the belts and raise the head.

  • Page 188: Section 3 - General Taping Conditions

    B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R 3 - G ECTION ENERAL APING ONDITIONS Problem: Tape Does Not Stick To Case Surface. •...
  • Page 189 B E L 2 9 0 F U L L Y U T O M A T I C A S E A P E E A L E R Problem: Tape Falls Forward on Bottom Head. This can be caused by a lack of static on the bottom wipe-down roller. •...

  • Page 190: Section 4 - Case Infeed And Indexing

    ACHINE ONTROLS For controls troubleshooting, see the ‘TROUBLESHOOTING’ Button and the ‘Troubleshooting’ Screen in the Control Section of the manual. For additional assistance, contact us at: Wexxar Packaging Inc. Phone (604) 930-9300, Fax 604-930-9368 E-mail: sales@wexxar.com 65-35-1 06/17/09...

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