1. Manuals
  2. Brands
  3. ROVEMA Manuals
  4. Industrial Equipment
  5. VPR Series
  6. Operator's manual

ROVEMA VPR Series Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Introduction .......................................................................................................... 1-1
Safety Instructions ............................................................................................... 2-1
Machine Safety Devices ........................................................................................................... 2-1
EMERGENCY STOP Push-Button ..................................................................................... 2-2
Machine Safety Devices ..................................................................................................... 2-3
Guard Doors ........................................................................................................................ 2-3
Safety Labels ...................................................................................................................... 2-4
Component Safety .................................................................................................................... 2-5
Operator Safety ......................................................................................................................... 2-6
Operator Safety Guidelines ............................................................................................... 2-6
Machine Lock-out Procedure ................................................................................................... 2-7
Parts and Functions ............................................................................................. 3-1
Film Carriage ............................................................................................................................. 3-2
Film Spindle ........................................................................................................................ 3-3
Dancer Assembly ............................................................................................................... 3-4
Film Unwind Device ............................................................................................................ 3-5
Film Tracking Assembly ..................................................................................................... 3-6
Touchscreen Controls ................................................................................................. 3-7
Out of Film Sensor Assembly ............................................................................................ 3-8
Guide Rollers ...................................................................................................................... 3-9
Film Feeding Device ............................................................................................................... 3-10
Belts Assemblies .............................................................................................................. 3-11
Drive System ..................................................................................................................... 3-12
Engage/Retract Device..................................................................................................... 3-13
Touchscreen Controls ............................................................................................... 3-14
Forming Set ............................................................................................................................. 3-15
Vertical Sealing Device ........................................................................................................... 3-16
Hot Air Gun ....................................................................................................................... 3-17
Heat Shield ........................................................................................................................ 3-18
Engage/Retract Device..................................................................................................... 3-19
Touchscreen Controls ............................................................................................... 3-20
Support Frame .................................................................................................................. 3-21
Horizontal Sealing Device ...................................................................................................... 3-22
Sealing Jaws ..................................................................................................................... 3-23
Jaw Body .................................................................................................................... 3-24
C-Frames, Jaw Carriers and Jaw Springs ................................................................ 3-25
Seal Pressure ............................................................................................................. 3-26
Drive System ..................................................................................................................... 3-27
Touchscreen Controls ............................................................................................... 3-28
Knife Assembly ................................................................................................................. 3-29
Touchscreen Controls ............................................................................................... 3-30
Impulse Temperature Controllers .................................................................................... 3-31
Touchscreen Controls ............................................................................................... 3-32
Registration Sensor ................................................................................................................ 3-33
Touchscreen Controls ...................................................................................................... 3-34
Pneumatics System ................................................................................................................ 3-36

Table of Contents

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the VPR Series and is the answer not in the manual?

Questions and answers

Related Manuals for ROVEMA VPR Series

Summary of Contents for ROVEMA VPR Series

  • Page 1: Table Of Contents

    Table of Contents Introduction ......................1-1 Safety Instructions ....................2-1 Machine Safety Devices ......................2-1 EMERGENCY STOP Push-Button ..................2-2 Machine Safety Devices ..................... 2-3 Guard Doors ........................2-3 Safety Labels ........................2-4 Component Safety ........................2-5 Operator Safety ......................... 2-6 Operator Safety Guidelines ....................
  • Page 2 Table of Contents (continued) Primary Manifold ......................3-36 Horizontal and Vertical Cooling Devices ..............3-37 Vacuum System ......................3-38 Pressure Switch ......................3-39 Secondary Manifold ......................3-40 Electronics System ......................... 3-41 Touchscreen Display ......................3-42 Programmable Logic Controller ..................3-43 Motion Controller ......................
  • Page 3 Table of Contents (continued) Horizontal Seal Setup Screen ................... 5-15 AUTO PROFILE MODE Switch ................5-15 AUTO SEAL MODE Switch .................. 5-15 Seal Angle and Seal Time Settings ..............5-16 Postseal Angle and Postseal Time Settings ............5-16 Preseal Time Setting .................... 5-16 Bulge Factor Setting....................
  • Page 4 Table of Contents (continued) Operating Procedures ..................7-1 Starting a Production Run ....................... 7-1 Producing Empty Bags ...................... 7-2 Checking an Empty Bag ....................7-3 Making Filled Bags ......................7-4 Checking a Filled Bag ......................7-5 Stopping a Production Run ......................7-7 Emergency Stop .........................

  • Page 5: Introduction

    Rovema VPR Operator’s Manual Introduction Introduction The Rovema VPR is a continuous motion form-fill-seal vertical bag- maker that packs a variety of products into bags. It forms, fills, and seals bags by forming flat packaging material into a tube, sealing the edges and bottom of the tube, filling the tube with product, cutting the tube to length, and sealing the top of the tube.

  • Page 6: Safety Instructions

    Rovema VPR Operator’s Manual Safety Instructions Safety Instructions This chapter contains information on: machine safety devices, component safety, operator safety, and the machine lockout procedure. Machine Safety Devices The machine safety devices include an EMERGENCY STOP push- button, guard doors, and safety labels.

  • Page 7: Emergency Stop Push-Button

    Rovema VPR Operator’s Manual Safety Instructions Machine Safety Devices EMERGENCY STOP Push-Button The EMERGENCY STOP push-button immediately stops all moving parts of the bagmaker. Press this button whenever there is perceived or actual damage occurring to the bagmaker or to an operator.

  • Page 8: Guard Doors

    Rovema VPR Operator’s Manual Safety Instructions Machine Safety Devices Guard Doors The guard doors isolate the operator from the forming and sealing area of the bagmaker. The doors are equipped with a switch. When either door is opened, the switch disables the servo drive motors.

  • Page 9: Safety Labels

    Rovema VPR Operator’s Manual Safety Instructions Machine Safety Devices Safety Labels Safety labels alert an operator to a particular hazard. These labels appear near hazardous areas of the bagmaker. When you see these labels, read them, and follow their instructions.

  • Page 10: Component Safety

    Rovema VPR Operator’s Manual Safety Instructions Component Safety Rovema does not allow any electrical or mechanical modifications to the VPR bagmaker without explicit authorization. Only original Rovema spare parts and accessories should be used on the bagmaker; This ensures that the machine will perform safely and as designed.

  • Page 11: Operator Safety

    Rovema VPR Operator’s Manual Safety Instructions Operator Safety Only properly trained personnel can operate the bagmaker. The operator is responsible for following the operator safety guidelines presented in this section as well as any employer safety guidelines. Operator Safety Guidelines Use the following safety guidelines for safe operation of the bagmaker.

  • Page 12: Machine Lockout Procedure

    Rovema VPR Operator’s Manual Safety Instructions Machine Lockout Procedure The bagmaker must be properly locked-out before any repair or maintenance tasks can be performed on it. Use the following procedures to lockout the bagmaker. To lockout the bagmaker: 1. Press the STOP push-button to halt the machine.

  • Page 13: Parts And Functions

    Rovema VPR Operator’s Manual Parts and Functions Parts and Functions This section describes the major parts and functions of the Rovema VPR bagmaker. These parts include: the film carriage, the film feeding device, the forming set, the vertical sealing device, the horizontal sealing device, the registration sensor, the pneumatics system, and the electronics system.

  • Page 14: Film Carriage

    Rovema VPR Operator’s Manual Parts and Functions Film Carriage The film carriage controls the supply of packaging material. It consists of: a film spindle, a dancer assembly, a film unwind device, a film tracking device, an out of film sensor assembly, and guide rollers.

  • Page 15: Film Spindle

    Rovema VPR Operator’s Manual Parts and Functions Film Carriage Film Spindle The film spindle supports the packaging material on the film carriage. It consists of an air bladder that is partly enclosed within a metal housing. The housing has slots that allow sections of the air bladder to protrude through it.

  • Page 16: Dancer Assembly

    Rovema VPR Operator’s Manual Parts and Functions Film Carriage Dancer Assembly The dancer assembly maintains tension on the film web. It includes one fixed roller and a dancer arm assembly. When film is threaded through the bagmaker, a film loop forms between the fixed roller and the arm rollers.

  • Page 17: Film Unwind Device

    Rovema VPR Operator’s Manual Parts and Functions Film Carriage Film Unwind Device The film unwind device unwinds the film roll. It consists of an unwind motor, an unwind stop sensor, a stop flag, and a linear potentiometer. As film is pulled out of the film loop, the dancer arms rise. At a certain point, the rising dancer arms rotate the stop flag away from the unwind stop sensor;...

  • Page 18: Film Tracking Assembly

    Rovema VPR Operator’s Manual Parts and Functions Film Carriage Film Tracking Assembly The film tracking assembly controls the position of the film carriage relative to the forming collar. The assembly includes a DC drive motor and two limit switches. The drive motor moves the upper and lower sections of the film carriage towards the left and right-hand sides of the forming collar.

  • Page 19: Touchscreen Controls

    Rovema VPR Operator’s Manual Parts and Functions Film Carriage > Film Tracking Assembly Touchscreen Controls The left and right-hand film carriage movements are controlled by two switches on the touchscreen display. Whenever the bagmaker is turned on, pressing either of these switches will cause the film carriage to move (except when the E-STOP button is depressed).

  • Page 20: Out Of Film Sensor Assembly

    Rovema VPR Operator’s Manual Parts and Functions Film Carriage Out of Film Sensor Assembly The out of film sensor assembly causes the bagmaker to stop forming bags when the film roll is exhausted or when the film tension is too high. It consists of a proximity sensor and two metal flags that are connected to the dancer arms.

  • Page 21: Guide Rollers

    Rovema VPR Operator’s Manual Parts and Functions Film Carriage Guide Rollers The guide rollers provide an almost frictionless path for the film to travel along up to the forming collar. The last roller before the forming collar (setup rollers) is adjustable. This roller changes the angle of the film web to match the angle of the forming collar.

  • Page 22: Film Feeding Device

    Rovema VPR Operator’s Manual Parts and Functions Film Feeding Device The film feeding device pulls film from the film carriage and pushes it down the forming tube for sealing. The device consists of two belts assemblies, a drive system, and an engage/retract device.

  • Page 23: Belts Assemblies

    Rovema VPR Operator’s Manual Parts and Functions Film Feeding Device Belts Assemblies The belt assemblies suction the film tube and push it down the forming tube. Within each assembly is a vacuum chamber that directs vacuum through holes in the feeding belts. The suction produced by the vacuum increases the friction between the belts and the film tube while reducing the friction between the film tube and the forming tube.

  • Page 24: Drive System

    Rovema VPR Operator’s Manual Parts and Functions Film Feeding Device Drive System The drive system turns the film feed belts to push the film down the forming tube. The system includes one servo motor and a gear box. The servo motor turns the gear box and the gear box turns both belt assemblies in synchronization with one another.

  • Page 25: Engage/Retract Device

    Rovema VPR Operator’s Manual Parts and Functions Film Feeding Device Engage/Retract Device The engage/retract device moves the film feeding belts against and away from the forming tube. It also maintains belt pressure against the tube. The device consists of two pneumatic cylinders, a pressure regulator, and a pressure gauge.

  • Page 26: Touchscreen Controls

    Rovema VPR Operator’s Manual Parts and Functions Film Feeding Device Touchscreen Controls The engage/retract device is controlled by the BELTS OPEN/CLOSED switch on the bagmaker’s main menu screen. When you touch the OPEN switch, the belts will move away from the forming tube. When you touch the CLOSED switch, the belts will move against the tube.

  • Page 27: Forming Set

    Rovema VPR Operator’s Manual Parts and Functions Forming Set The forming set folds the flat film into a tube. It includes a forming collar, a forming tube, a head plate, a collar mount, securing knobs, and adjustment bolts. The forming collar folds the film into a tube while the forming tube maintains its shape;...

  • Page 28: Vertical Sealing Device

    Rovema VPR Operator’s Manual Parts and Functions Vertical Sealing Device The vertical sealing device joins the edges of the film tube together. It includes a hot air gun, a heat shield, an engage/retract device, and a support frame. Support Heat Shield...

  • Page 29: Hot Air Gun

    Rovema VPR Operator’s Manual Parts and Functions Vertical Sealing Device Hot Air Gun The hot air gun joins the edges of the film tube by melting them together. It accomplishes this by directing a hot air stream onto the film. The air stream is created when compressed air is released over a heating element inside of the gun.

  • Page 30: Heat Shield

    Rovema VPR Operator’s Manual Parts and Functions Vertical Sealing Device Heat Shield The heat shield confines the welding area and applies pressure to the melted film. It includes cooling elements, a compression roller, a heat deflector, and a locking lever.

  • Page 31: Engage/Retract Device

    Rovema VPR Operator’s Manual Parts and Functions Vertical Sealing Device Engage/Retract Device The engage/retract device moves the hot air gun in and out of the welding area. The device rotates the gun and moves it forward just before the film feeding cycle starts. Once film feeding stops, the device pulls the gun backwards and rotates it towards the heat deflector.

  • Page 32: Touchscreen Controls

    Rovema VPR Operator’s Manual Parts and Functions Vertical Sealing Device Touchscreen Controls The timing of the engage/retract movements is controlled by a switch on the touchscreen display. The device is timed to engage the film before the film feeding device begins advancing film. It retracts the device just after the film stops moving;...

  • Page 33: Support Frame

    Rovema VPR Operator’s Manual Parts and Functions Vertical Sealing Device Support Frame The support frame positions the vertical sealing device. It includes three sets of locking levers; position locking levers, pivot locking levers, and a gun locking lever. Use the position locking levers to adjust the distance between the...

  • Page 34: Horizontal Sealing Device

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device The horizontal sealing device creates the top and bottom seals in a bag and cuts the bag from the film tube. Top and bottom seals (horizontal seals) are created in the same manner as the vertical seal;...

  • Page 35: Sealing Jaws

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device Sealing Jaws The sealing jaws create horizontal seals in the film tube. Seals are created when the front and back sides of the film tube are pressed together and heated for a period of time. The heat causes the film to melt and the pressure causes the two sides of the film tube to mix into one.

  • Page 36: Jaw Body

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device > Sealing Jaws Jaw Body The jaw body creates the heat needed to melt the film. Each jaw has two thin metal bands (sealing bands) that stretch across the length of the jaw.

  • Page 37: C-Frames, Jaw Carriers And Jaw Springs

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device > Sealing Jaws C-Frames, Jaw Carriers and Jaw Springs The c-frames, the jaw carriers, and the jaw springs work in conjunction to create the pressure needed to mix the two sides of the film tube.

  • Page 38: Seal Pressure

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device > Sealing Jaws Seal Pressure The sealing pressure is determined by the amount of jaw spring compression. The amount of compression is determined by the distance between the jaw springs and the c-frames. As this distance increases, so does the sealing pressure.

  • Page 39: Drive System

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device Drive System The drive system shapes the motion of the sealing jaws (“D-Motion”). It is this motion that causes the sealing jaws to open and close around a bag. The system includes a servo motor, a servo amplifier, gearing, and crank arms.

  • Page 40: Touchscreen Controls

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device Touchscreen Controls Sealing time is determined by the speed of the horizontal sealing device. Settings on the touchscreen display control the speed of the device. These settings affect the jaw profile. The jaw profile describes the speed of the sealing jaws at various points in the “D-Motion”.

  • Page 41: Knife Assembly

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Jaws Knife Assembly The knife assembly cuts the bags from the film tube. It is housed between the upper and lower sections of the rear jaw body. When the sealing jaws close, the knife extends and cuts through the film. It is powered by a pneumatic cylinder.

  • Page 42: Touchscreen Controls

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device > Knife Assembly Touchscreen Controls The touchscreen has a switch that controls the knife assembly. This switch determines when the knife can extend and cut a bag from the film tube and whether the knife will be used during bag production.

  • Page 43: Impulse Temperature Controllers

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device Impulse Temperature Controllers The impulse temperature controllers supply a very strong current pulse to the sealing bands just before the sealing jaws close; causing them to become very hot, very quickly. After the jaws open, the controllers supply constant lower voltage across the bands to keep them warm.

  • Page 44: Touchscreen Controls

    Rovema VPR Operator’s Manual Parts and Functions Horizontal Sealing Device > Temp. Controllers Touchscreen Controls The temperature controls for the vertical and horizontal sealing device have a common control on the touchscreen display; the JAW HEAT switch. The JAW HEAT switch turns on or off the power to all temperature controllers.

  • Page 45: Registration Sensor

    Rovema VPR Operator’s Manual Parts and Functions Registration Sensor The registration sensor allows the bagmaker to use registered film. Because registered film has artwork printed at evenly spaced intervals, the bagmaker must cut and seal the film between the printed sections.

  • Page 46: Touchscreen Controls

    Rovema VPR Operator’s Manual Parts and Functions Registration Sensor Touchscreen Controls The registration sensor has three switches that control its operation; the PHOTOEYE WINDOW switch, the PHOTOEYE CORRECTION switch, and the PHOTOEYE ENABLE/DISABLE switch. PHOTOEYE WINDOW switch determines when the bagmaker will examine the signal from the sensor.

  • Page 47: Pneumatics System

    Rovema VPR Operator’s Manual Parts and Functions Pneumatics System The pneumatics system controls the compressed air supply to the bagmaker. The system distributes compressed air to the bagmaker’s pneumatic cylinders, vacuum generator, and cooling devices (optional equipment). The system includes a primary manifold, a secondary manifold, and an air filter/regulator.

  • Page 48: Primary Manifold

    Rovema VPR Operator’s Manual Parts and Functions Pneumatics System Primary Manifold The primary manifold distributes compressed air to the horizontal and vertical cooling devices, and, the vacuum system. A pressure switch is also connected to the primary manifold. Pressure Switch...

  • Page 49: Horizontal And Vertical Cooling Devices

    Rovema VPR Operator’s Manual Parts and Functions Pneumatics System > Primary Manifold Horizontal and Vertical Cooling Devices The horizontal and vertical cooling devices release compressed air onto the horizontal and vertical seals. These devices direct compressed air from the primary manifold, through valves, through air lines, to cooling wands.

  • Page 50: Vacuum System

    Rovema VPR Operator’s Manual Parts and Functions Pneumatic System > Primary Manifold Vacuum System The vacuum system creates the suction for the film feeding belt assemblies. The system includes a vacuum generator, an air filter, and a vacuum gauge. The vacuum generator uses the compressed air to generate a vacuum.

  • Page 51: Pressure Switch

    Rovema VPR Operator’s Manual Parts and Functions Pneumatics System Pressure Switch The pressure switch monitors the available air pressure in the primary manifold. If the pressure falls below the preset limit, the switch signals the bagmaker to stop forming bags and to display the “LOW AIR PRESSURE”...

  • Page 52: Secondary Manifold

    Rovema VPR Operator’s Manual Parts and Functions Pneumatics System Secondary Manifold The secondary manifold supplies compressed air to the solenoid valves that power the engage/retract devices and optional equipment (splice table, bag ejectors, and etc.). Solenoid Valve Secondary Manifold Figure 3.40 Shows the secondary manifold and a bank of solenoid valves.

  • Page 53: Electronics System

    Rovema VPR Operator’s Manual Parts and Functions Electronics System The electronics system controls all of the forming operations. It includes a touchscreen display, a programmable logic controller, a motion controller, servo amplifiers, and a speed controller. 3-41 6/9/99 VPR01 REV A...

  • Page 54: Touchscreen Display

    Rovema VPR Operator’s Manual Parts and Functions Electronics System Touchscreen Display The touchscreen display collects and displays information. It relays this information to the motion controller or to the programmable logic controller (PLC). Forming parameters are relayed to the motion controller.

  • Page 55: Programmable Logic Controller

    Rovema VPR Operator’s Manual Parts and Functions Electronics System Programmable Logic Controller The PLC executes commands from the touchscreen display and from the motion controller. Commands from the touchscreen tell it when to move the film carriage or; open or close the film feeding belts.

  • Page 56: Motion Controller

    Rovema VPR Operator’s Manual Parts and Functions Electronics System Motion Controller The motion controller determines when the PLC will activate the various forming operations. It also performs film registration, and, commands the servo amplifiers. It tells the PLC when to: Activate optional equipment (printers, vibrators, and etc.)

  • Page 57: Servo Amplifiers

    Rovema VPR Operator’s Manual Parts and Functions Electronics System Servo Amplifiers The servo amplifiers operate the servo motors for the film feeding device and the horizontal sealing device. They receive motion commands from the motion controller and send out the appropriate voltages to execute the commands.

  • Page 58: Speed Controller

    Rovema VPR Operator’s Manual Parts and Functions Electronics System Speed Controller The speed controller operates the motor for the film unwind device. It has an input from the film unwind sensor which tells it when to start and stop the unwind motor and an input from the linear potentiometer which tells it how fast to run the motor.

  • Page 59: Theory Of Operations

    Rovema VPR Operator’s Manual Theory of Operations Theory of Operations This section describes the theory behind the forming cycle, the vertical sealing device, the horizontal sealing device, and film registration. Forming Cycle The forming cycle is based on a 360 degree encoder count (film drive encoder count).
  • Page 60 Rovema VPR Operator’s Manual Theory of Operations 6/27/99 VPR01 REV A...

  • Page 61: Impulse Sealing

    Rovema VPR Operator’s Manual Theory of Operations Impulse Sealing Impulse sealing is the process of joining two layers of polyethylene film into one layer. The union of the two layers is achieved by applying heat and pressure for a certain amount of time. During impulse sealing, the film layers are liquefied by the heat, mixed together by the pressure, and solidified by cool air.

  • Page 62: Vertical Sealing Device

    Rovema VPR Operator’s Manual Theory of Operations Vertical Sealing Device The vertical sealing device joins the edges of the film tube. When film is threaded down the forming tube, the forming collar directs the right film edge over the left film edge. The forming ridge pushes the center of the overlapping sections upwards while the cooling elements push the surrounding areas away form the hot air stream;...

  • Page 63: Horizontal Sealing Devicew

    Rovema VPR Operator’s Manual Theory of Operations Horizontal Sealing Device The horizontal sealing device joins the front and backsides of the film tube together to create top and bottom seals. When it seals, it creates the top seal of the bag below the jaws and the bottom seal of the bag above the jaws.

  • Page 64: Film Registration

    Rovema VPR Operator’s Manual Theory of Operations Film Registration Registered film has artwork printed at evenly spaced intervals. When the bagmaker forms bags out of this material, it must create horizontal seals around the artwork. In order to create the seals around the artwork, the bagmaker must have some means of detecting where the artwork is located.

  • Page 65: Operator Controls

    Rovema VPR Operator’s Manual Operator Controls Operator Controls This section describes the controls used to operate the bagmaker. These controls include a touchscreen display, temperature controllers, a MAIN DISCONNECT switch, an AIR DISCONNECT lever, several push-buttons, and a selector switch.
  • Page 66 Rovema VPR Operator’s Manual Operator Controls Touchscreen The touchscreen display is used to load, run, or modify a product recipe; and to monitor bag production. The display is composed of screens. Each screen is a collection of touch sensitive cells (switches) that initiate machine functions, change recipe parameters, activate additional screens, or display information.

  • Page 67: Main Menu Screen

    Rovema VPR Operator’s Manual Operator Controls Touchscreen Main Menu Screen The main menu screen displays the most commonly used cells and provides access to all other screens. MOVE FILM CARRIAGE JOGGING MODE SELECT LEFT RIGHT LEFT RIGHT FILM JAWS FWD...

  • Page 68: Jogging Mode Select Switch

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Main Menu MOVE FILM CARRIAGE Switch Use this switch to move the film carriage (and the film web) towards the left or right-hand side of the forming collar. Press the LEFT switch to move the film carriage towards the left-hand side of the forming collar.

  • Page 69: Jaw Heat Enable Switch

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Main Menu JAW HEAT ENABLE Switch Use this switch to toggle the power to the temperature controllers on or off. When this switch is set to ENABLE, the temperature controllers turns on and the heating element inside of the hot air gun heats. When this switch is set to DISABLE, the temperature controller turns off and the heating element inside of hot air gun stops heating.

  • Page 70: Funnel Jam Switch

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Main Menu FUNNEL JAM Switch This switch enables or disables the funnel jam sensor. When this switch is set to ENABLE, the sensor will cause the bagmaker to stop forming bags if a product dump does not clear the forming tube within a certain period of time (indicating that the dump is jammed in the funnel).

  • Page 71: Warning Display

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Main Menu WARNING Display This cell displays messages about the machine’s operating condition that the operator should be aware of, but, that will not stop bag production. ALARM Display This cell displays the most recent machine fault. If there are no faults, the message “NO ACTIVE ALARMS”...

  • Page 72: View Active Alarms Switch

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Main Menu VIEW ACTIVE ALARMS Switch This switch displays the alarms screen. The alarms screen displays all of the current warning and alarm conditions that have not been cleared. Once an alarm or warning condition is corrected and the ALARM RESET cell is touched, the alarm or warning message will disappear from the screen.

  • Page 73: Settings Menu

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu The settings menu screen contains switches that control froming operations, recipe management, and data monitoring. MACHINE SETTINGS MENU H. SEAL KNIFE FEEDER H. COOL V. SEAL SETUP FILM FILM BLOW OFF...

  • Page 74: Cam Settings

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu Cam Settings Many of the touch cells on the settings menu screen control cam settings. Cam settings determine when forming operations will occur based on the film feeding encoder count. When the encoder count is between the cam values set for a forming operation, the motion controller signals the PLC to initiate that operation.

  • Page 75: Horiz. Cooling Settings

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu > Cam Settings Horiz. Cooling Settings These settings determines when the horizontal cooling device can be activated to cool horizontal seals. When the film feed encoder count is between these settings, the motion controller will signal the PLC to energize the horizontal cooling solenoid valve.

  • Page 76: Cutting Knife Settings

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu > Cam Settings Cutting Knife Settings These settings determine when the knife can be extended to cut a bag from the film tube. When the film feed encoder count is between these settings, the motion controller will signal the PLC to energize the knife solenoid valve.

  • Page 77: Impulse Seal Cam Settings

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu > Cam Settings H. Impulse Seal Cam Settings These settings determine when the impulse temperature controllers will change from the preheat temperature level to the sealing temperature level. When the film feed encoder count is between these settings, the motion controller will signal the impulse temperature controllers to heat the sealing bands to the sealing temperature.

  • Page 78: Seal Screen

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu V. Seal Screen This screen controls the timing of the vertical seal engage/retract device. The V. SEAL ADVANCE and the V. SEAL RETARD switches determine when the hot air gun will move into and out of the sealing position.

  • Page 79: Horizontal Seal Setup Screen

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu Horizontal Seal Setup Screen The horizontal seal setup screen controls the motion of the horizontal sealing jaws. The settings on this screen determine how fast the sealing jaws will move through the various portions of the “D-Motion”.

  • Page 80: Seal Angle And Seal Time Settings

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu > H. Seal Setup Seal Angle and Seal Time Settings The seal angle is the angle that the sealing jaws travel through while creating a horizontal seal. The seal time is the amount of time that the jaws have to move through the seal angle.

  • Page 81: Bulge Factor Setting

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu > H. Seal Setup Bulge Factor Setting Bulge factor sets the speed of the film feeding device as a percentage of the jaw speed. Bulge factors between 80% and 100% cause the bags to stretch during filling.

  • Page 82: Feeder Screen

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu Feeder Screen The feeder screen synchronizes the product dump with the closing of the horizontal sealing jaws. The motion controller signals the PLC to request a product dump ### ms before the horizontal sealing jaws close.

  • Page 83: Bagger Synchronization Adjustment Screen

    Touchscreen > Settings Menu Bagger Synchronization Adjustment Screen The settings on this screen synchronizes the bagmaker to the takeaway conveyor. Note: These settings are used by Rovema engineers. Please contact the Rovema Service Department before changing any of these settings. BAGGER SYNCHRONIZATION ADJUSTMENT...

  • Page 84: Bag Synchronization

    Bag Synchronization The settings on this screen are used to prevent twin bagmakers from dropping bags on top of one another. Note: These settings are used by Rovema engineers. Please contact the Rovema Service Department before changing any of these settings.

  • Page 85: Recipe Menu Screen

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Menu Recipe Menu Screen The recipe menu screen includes cells that allow you to load or save a product recipe. Product recipes contain all of the settings required to form a particular bag style.

  • Page 86: Recipe Load Selection Screen

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Recipe Menu Screen Recipe Load Selection Screen This screen is used to load a product recipe. Loading a recipe removes all of the current settings and replaces them with the new settings. To load a recipe, use the UP and DOWN arrow keys to scroll through and select a product recipe from the list.

  • Page 87: Recipe Save Selection Screen

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Recipe Menu Screen Recipe Save Selection Screen This screen is used to save the current machine settings under a previously saved recipe name. Use the UP and DOWN arrow keys to scroll through and select a previously saved product recipe. Press the ENTER key to save the current machine settings under the selected program recipe name.

  • Page 88: Film Splice Settings

    Rovema VPR Operator’s Manual Operator Controls Touchscreen > Settings Film Splice Settings The film splice settings control the heating of the splice table impulse splicing band. The seal intensity parameter sets the sealing temperature as a percentage of the total current. The pulse duration determines how long the sealing band will be heated.

  • Page 89: Temperature Controllers

    Rovema VPR Operator’s Manual Operator Controls Temperature Controllers There are two types of temperature controllers used on the bagmaker; impulse controllers and heatseal controllers. Impulse Temperature Controllers The impulse temperature controllers control the heating of all impulse sealing bands; impulse bands are located on the horizontal sealing jaws and on the film splice bar.

  • Page 90: Heatseal Temperature Controller

    Rovema VPR Operator’s Manual Operator Controls Temperature Controllers Heatseal Temperature Controller The heatseal temperature controller controls the temperature of the hot air gun. The controller powers the heating element inside of the gun. It is also connected to the temperature probe located on top of the gun.

  • Page 91: Main Disconnect Switch

    Rovema VPR Operator’s Manual Operator Controls MAIN DISCONNECT Switch The MAIN DISCONNECT switch turns on or off all electrical power to the VPR bagmaker. Turn this switch to the “I” or ON position to connect power to the bagmaker. Turn this switch to the “O” or OFF position to disconnect power to the bagmaker.

  • Page 92: Push-Buttons And Selector Switch

    Rovema VPR Operator’s Manual Operator Controls Push-Buttons and Selector Switch The push-buttons and selector switch control the operating mode of the bagmaker. They include the SYSTEM READY lighted push-button, the JOG/AUTO selector switch, the JOG/RUN push-button, the STOP push-button, the CLAMP/UNCLAMP push-button, the FILM SPLICE push-button, and the EMERGENCY STOP push-button.

  • Page 93: Jog/Run Push-Button

    Rovema VPR Operator’s Manual Operator Controls JOG/RUN Push-Button The JOG/RUN push-button runs the bagmaker in the selected operating mode. When the JOG/AUTO selector switch is set to JOG, press and hold the JOG/RUN button to jog the film drive or the jaw drive.

  • Page 94: Film Splice Push-Button

    Rovema VPR Operator’s Manual Operator Controls FILM SPLICE Push-Button The film splice push-button activates the film splice bar. Once the two pieces of film are aligned with one another, press and release this switch to weld them together. FILM SPLICE Figure 5.30.1...

  • Page 95: Machine Setup Procedures

    Rovema VPR Operator’s Manual Machine Setup Procedures Machine Setup Procedures This section describes how to prepare the bagmaker to form bags. These procedures include: Starting the Bagmaker Turing on the Water Chiller Loading a Product Recipe Setting the Machine Speed and the Bag Length...

  • Page 96: Starting The Bagmaker

    Rovema VPR Operator’s Manual Machine Setup Procedures Starting the Bagmaker To start the bagmaker you must activate the electrical and pneumatic supplies. The following procedures describe how to activate these supplies. Turning on the Electrical and Pneumatic Supplies To turn on the electrical supply, turn the MAIN DISCONNECT switch to the ON position.

  • Page 97: Turning On The Water Chiller

    Rovema VPR Operator’s Manual Machine Setup Procedures Turning On the Water Chiller The water chiller circulates cool water through the horizontal sealing jaws and the cooling elements of the heat shield. As soon as the bagmaker is turned on, the water chiller should be turned on.

  • Page 98: Loading A Product Recipe

    Rovema VPR Operator’s Manual Machine Setup Procedures Loading a Product Recipe The product recipe contains all of the forming parameters that the bagmaker needs to form bags. When the machine is first turned on, the last product recipe that was used on the machine is automatically loaded.

  • Page 99: Setting The Machine Speed And The Bag Length

    Rovema VPR Operator’s Manual Machine Setup Procedures Setting the Machine Speed and the Bag Length The bagmaker needs to know the machine operating speed and the bag length before it can create the jaw profile. When the bagmaker is first turned on, the machine speed and the bag length settings from the last production run are loaded.

  • Page 100: Loading A Film Roll

    Rovema VPR Operator’s Manual Machine Setup Procedures Loading a Film Roll To load a film roll: 1. Remove the film spindle from the film carriage. 2. Slide the spindle through a new roll of film. 3. Inflate the spindle so that it securely holds the film roll.

  • Page 101: Threading A Film Roll

    Rovema VPR Operator’s Manual Machine Setup Procedures Threading a Film Roll To thread a roll of film: 1. Cut the film at a 45 Degree angle. 2. Use the film routing label on the side of the bagmaker to pull the film through the lower and upper sections of the film carriage to the forming collar.

  • Page 102: Setting Up The Vertical Sealing Device

    Rovema VPR Operator’s Manual Machine Setup Procedures Setting Up the Vertical Sealing Device Setting up the vertical seal device includes positioning the device and starting the hot air gun. To position the vertical sealing device: 1. Loosen the position locking levers on both sides of the vertical sealing device.

  • Page 103: Starting The Hot Air Gun

    Rovema VPR Operator’s Manual Machine Setup Procedures Setting Up the Vertical Sealing Device Starting the Hot Air Gun Starting the hot air gun requires that you enable the hot air gun temperature controller and that you input the sealing temperature.

  • Page 104: Operating Procedures

    Rovema VPR Operator’s Manual Operating Procedures Operating Procedures This section describes procedures that can be used to operate the bagmaker. It describes how to start a production run, how to stop a production run, how to restart a production run after and emergency stop, and how to jog the machine.

  • Page 105: Producing Empty Bags

    Rovema VPR Operator’s Manual Operating Procedures Starting a Production Run Producing Empty Bags The first step in starting a production run is to produce empty bags. Empty bag production will indicate whether adjustments need to be made to the sealing devices, to the film tracking, or to film feeding.

  • Page 106: Checking An Empty Bag

    Rovema VPR Operator’s Manual Operating Procedures Starting a Production Run Checking an Empty Bag Use the following procedure to check an empty bag. 1. Check that the vertical seal is formed in the center of the bag. If the vertical seal is not formed in the center of the bag: a.

  • Page 107: Making Filled Bags

    Rovema VPR Operator’s Manual Operating Procedures Starting a Production Run Making Filled Bags Once the bagmaker is producing empty bags, it is ready to produce filled bags. Filled bag productions will indicate whether adjustments need to be made to the product drop timing or product drop quantity.

  • Page 108: Checking A Filled Bag

    Rovema VPR Operator’s Manual Operating Procedures Starting a Production Run Checking a Filled Bag Use the following procedure to check a filled bag: 1. Check that there is no product trapped in the horizontal seals. If there is product trapped in the horizontal seals: a.
  • Page 109 Rovema VPR Operator’s Manual Operating Procedures Starting a Production Run Once the bagmaker is producing quality filled bags, start the normal production run. To start the normal production run: 1. From the bagmaker control panel, set the JOG/AUTO selector switch to AUTO.

  • Page 110: Stopping A Production Run

    Rovema VPR Operator’s Manual Operating Procedures Stopping a Production Run Use the following procedures to stop or shut down the bagmaker in normal and emergency situations. Emergency Stop Press the EMERGENCY STOP push-button to stop the bagmaker in an emergency situation.

  • Page 111: Restarting After An Emergency Stop

    Rovema VPR Operator’s Manual Operating Procedures Restarting After an EMERGENCY STOP Use the following procedure to restart the bagmaker after an EMERGENCY STOP. 1. Use the alarms screen to help resolve the problems that caused the emergency stop. 2. Pull out the EMERGENCY STOP push-button.

  • Page 112: Machine Jogging Procedure

    Rovema VPR Operator’s Manual Operating Procedures Machine Jogging Procedure Jogging the machine means to operate it at a slow steady pace. Both the film feeding device and the horizontal sealing device can be jogged independent of one another. Use film feed jogging to advance film down the forming tube.

  • Page 113: Working With Components

    Rovema VPR Operator’s Manual Working with Components Working With Components This section describes procedures that can be used to restore bagmaker performance or to resolve forming problems. These procedures include: Adjusting the Film Tension Adjusting the Film Tracking Adjusting Automatic Film Tracking Sensors...

  • Page 114: Adjusting The Film Tension

    Rovema VPR Operator’s Manual Working with Components Adjusting the Film Tension The dancer assembly controls the film tension. Film tension is adjusted by changing the amount of spring pre-compression in the arm springs. This procedure describes how to adjust the arm spring pre- compression so that the desired film tension is easier to obtain.

  • Page 115: Adjusting The Film Tracking

    Rovema VPR Operator’s Manual Working with Components Adjusting the Film Tracking Film tracking controls the alignment of the vertical seal. Ideally, you want the film tracking to be such that the center of the overlapping sections of the film tube is centered on the forming ridge. This procedure describes how to adjust the film tracking (or establishing the film tracking path).

  • Page 116: Adjusting Automatic Film Tracking Sensors

    Rovema VPR Operator’s Manual Working with Components Adjusting Automatic Film Tracking Sensors Automatic film tracking automatically moves the film carriage to keep the film centered on the forming ridge. This procedure describes how to adjust the position of the film tracking sensors so that automatic film tracking will keep the film tracking along the correct path.

  • Page 117: Aligning The Belt Assemblies

    Rovema VPR Operator’s Manual Working with Components Aligning the Belt Assemblies To gain maximum tracking against the film tube, the belt assemblies must be parallel to the flat surfaces on the side of the forming tube. To align the belt assemblies: 1.

  • Page 118: Aligning The Forming Collar

    Rovema VPR Operator’s Manual Working with Components Aligning the Forming Collar The forming collar affects the alignment of the vertical seal. It must be positioned relative to the forming tube. The collar should be positioned so that there is equal clearance around the forming tube (on all sides).

  • Page 119: Aligning The Sealing Jaws

    Rovema VPR Operator’s Manual Working with Components Aligning the Sealing Jaws The jaw alignment procedure positions the front jaw parallel to the rear jaw so that the sealing pressure is evenly distributed between them. The alignment is performed whenever a jaw body is removed from its carrier.

  • Page 120: Performing A Carbon Paper Test

    Rovema VPR Operator’s Manual Working with Components Aligning the Sealing Jaws Performing a Carbon Paper Test The carbon paper test shows how the sealing pressure is distributed between the sealing bands. You perform the test by placing a piece of carbon paper between the sealing jaws and closing them on the paper.

  • Page 121: Evaluating The Results Of The Carbon Paper Test

    Rovema VPR Operator’s Manual Working with Components Aligning the Sealing Jaws Evaluating the Results of the Carbon Paper Test The impression that is left in the paper shows how the sealing pressure is distributed between the sealing bands. The darker areas of the impression show where the sealing pressure is the greatest.
  • Page 122 Rovema VPR Operator’s Manual Working with Components Aligning the Sealing Jaws Evaluating the Results of the Carbon Paper Test Looking at figure 8.10 (view 1), the right side of the top impression is lighter than the left side. This indicates that the sealing pressure is greater on the left side of the top sealing band than it is on the right side of the band.

  • Page 123: Performing The Alignment

    Rovema VPR Operator’s Manual Working with Components Aligning the Sealing Jaws Performing the Alignment Once you have determined where the sealing pressure needs to be changed, you can make the adjustment(s). You should make your adjustments in small increments. You should also perform a carbon paper test after each adjustment.
  • Page 124 Rovema VPR Operator’s Manual Working with Components Performing the Alignment (continued) 7. Turn the set screw(s) to make the pressure adjustment indicated by the carbon paper test. 8. Re-install the front jaw body. 9. Tighten the adjustment plate securing bolts.

  • Page 125: Replacing The Impulse Components

    Rovema VPR Operator’s Manual Working with Components Replacing the Impulse Components Periodically the impulse components must be replaced to maintain quality horizontal seals. These components include the Teflon tape, the Teflon strips, the rubber cords, and the sealing bands. The Teflon strips and the rubber cords are replaced most frequently.
  • Page 126 Rovema VPR Operator’s Manual Working with Components Replacing the Impulse Components The following procedure describes how to replace one sealing band and its Teflon tape, its Teflon strip, and its rubber cords. Use the same procedure to replace all of the sealing bands and their components.
  • Page 127 Rovema VPR Operator’s Manual Working with Components Replacing the Impulse Components 7. Center the tape on the jaw body and push the excess behind the isolation plates. Figure 8.15 Shows how to place the Teflon tape for the lower sealing band.
  • Page 128 Rovema VPR Operator’s Manual Working with Components Replacing the Impulse Components 8. Insert a mounting tool into both sides of the jaw body. Figure 8.16 Shows how to insert the mounting tool in the jaw body. 9. Slide one end of the sealing band into the sealing band clamp until it touches the screw (the beveled side must face upwards).
  • Page 129 Rovema VPR Operator’s Manual Working with Components Replacing the Impulse Components 10. Tighten the screw to hold the sealing band. 11. Slide the other end of the sealing band into the opposite sealing band clamp. 12. Check that there is no slack in the band and tighten the securing screw.
  • Page 130 Rovema VPR Operator’s Manual Working with Components Replacing the Impulse Components 17. Fold the Teflon strip over the sealing band and work it into the opposite crevice. 18. Work the second piece of rubber cord along the side of the Teflon strip.

  • Page 131: Changeover Procedure

    Rovema VPR Operator’s Manual Changeover Procedure Changeover Procedure This procedure describes how to changeover the bagmaker to form a different style of bag. To changeover the bagmaker: 1. Remove the existing forming set. 2. Install the appropriate forming set. 3. If the bag style you want to form requires a different vertical sealing device, remove the existing vertical sealing device and install the appropriate vertical sealing device.

  • Page 132: Maintenance Procedures

    Maintenance Procedures The following procedures describe how to clean and maintain the Rovema VPR vertical bagmaker. The scheduling of the procedures is based on the bagmaker running one shift per day (8 hours per shift). If the bagmaker is operating for more or fewer shifts, adjust the cleaning and maintenance schedules accordingly.

  • Page 133: Daily Maintenance

    Rovema VPR Operator’s Manual Maintenance Procedures Daily Maintenance Each day, use the following procedure to maintain the bagmaker. 1. Check that the guard door switch and the EMERGENCY STOP switch are working properly. 2. Remove any condensed water from the air filter/regulator bowl.

  • Page 134: Weekly Maintenance

    Rovema VPR Operator’s Manual Maintenance Procedures Weekly Maintenance Each week, use the following procedure to maintain the bagmaker. 1. Lockout the bagmaker, remove the jaw drive covers and inspect the timing belts for wear and proper tensioning. 2. Check that all of the film guide rollers are moving freely.

  • Page 135: Troubleshooting Guide

    Rovema VPR Operator’s Manual Troubleshoot Guide Troubleshooting Guide This chapter contains a list of fault messages, their possible cause(s), and corrective actions that may resolve them. EMERGENCY STOP PUSH-BUTTON POSSIBLE CAUSE CORRECTIVE ACTION 1) The E-STOP push-button is 1) Reset the E-STOP push-button.
  • Page 136 Rovema VPR Operator’s Manual Troubleshoot Guide JOGGING MODE CORRECTIVE ACTION POSSIBLE CAUSE 1) The JOG/AUTO selector switch is set 1) Set the selector switch to AUTO. to JOG. TEMPERATURE OUT OF RANGE CORRECTIVE ACTION POSSIBLE CAUSE 1) The temperature controller is not 1) Set the JAW HEAT ENABLE cell to turned on.
  • Page 137 Rovema VPR Operator’s Manual Troubleshoot Guide SCALE NOT READY/FEEDER NOT READY POSSIBLE CAUSE CORRECTIVE ACTION 1) The SCALE or FEEDER ENABLE 1) Set the switch to "DISABLE". switch is set to ENABLE but the scale 2) Wait for the scale or feeder to send a or feeder has not sent its ready signal.
  • Page 138 Rovema VPR Operator’s Manual Troubleshoot Guide TOP IMPULSE CONTROLLER FAULT CORRECTIVE ACTION POSSIBLE CAUSE 1) Replace the broken band. 1) One of the top impulse bands is 2) Check the electrical connections for broken. the top impulse band. 2) One of the electrical connections for 3) Check that the impulse controller is the top impulse band is loose.
  • Page 139 Rovema VPR Operator’s Manual Troubleshoot Guide MOTION CONTROLLER AND SERVO AXIS MODULE ERROR MESSAGES ERROR MESSAGE CORRECTIVE ACTION Jaw Resolver Loss Refer to the 1394 Controller User Manual Film Resolver Loss to resolve motion controller and axis Jaw Axis Module HDWR Fault module errors.

This manual is also suitable for:

Vpr-320

Table of Contents

Save PDF