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Advanced Poly-Packaging Advanced Poly-Bagger T-1000-S18H Operation Manual

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T-1000
™
Advanced Poly-Bagger
(Model T-1000-S14)
___________________________________________________________________________
Operation Manual, Version 9 Revision G
0

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Summary of Contents for Advanced Poly-Packaging Advanced Poly-Bagger T-1000-S18H

  • Page 1 T-1000 ™ Advanced Poly-Bagger (Model T-1000-S14) ___________________________________________________________________________ Operation Manual, Version 9 Revision G...
  • Page 2 Nov 2018 (Ver 9G) Apr 2018 (Ver. 9F) Jan 2018 (Ver. 9E) Nov 2017 (Ver. 9D), 2014 (Ver. 8), 2010 (Ver. 7) 2009 (Ver. 6), 2007 (Ver. 5), 2006 (Ver. 4), 2003 (Ver. 3), 2001 (Ver. 2), 1995 (Ver. 1), Advanced Poly-Packaging, Inc. (APPI). All rights reserved.

  • Page 3: Table Of Contents

    Table of Contents Chapter 1: Introduction Welcome .......................... 7 Overview .......................... 7 Standard Features ......................7 System Integration ......................8 Available Options ......................9 Using this Manual - Typographical Conventions ............11 Contact Information ....................... 11 Warranty Registration ....................13 Chapter 2: Safety, Getting Started Chapter Summary ......................
  • Page 4 Air Pulse......................... 29 Seal Point ........................29 Seal Time ........................29 Reverse ........................... 30 Blow Off ........................30 Index Speed ........................30 Seal Temperature ......................30 Options Menu......................... 30 LS-10 Load Shelf ......................31 3.10 FS-10 Flat Seal Assembly ....................31 3.11 FS-30 Heavy-Duty Flat Seal Assembly .................
  • Page 5 3.35 Temperature Calibration Screen ..................43 3.36 Technical Assistance & Troubleshooting Screens ............44 3.37 Bagger Auxiliary Options ....................44 3.38 Pass Code Setup Screen ....................44 3.39 Bagger Factory Settings ....................45 3.40 Bag Registration......................47 3.41 Job Save and Recipe Management ................48 Internal Memory (PLC) ....................
  • Page 6 4.17 Preventative Maintenance Chart ..................77 4.18 Spare Parts Kits ......................78 4.19 Troubleshooting Guide ....................80 4.20 Troubleshooting Checklist ..................... 80 4.21 PLC IO Listing ....................... 82 4.22 Schematics ........................86 Electrical Drawings ......................86 Pneumatic Piping Diagrams ................... 99 Chapter 5: Parts and Drawings T-1000-S14 Advanced Poly-Bagger ................

  • Page 7: Chapter 1: Introduction

    Chapter 1: Introduction Welcome Overview Standard Features System Integration Available Options Using this Manual - Typographical Conventions Contact Information Warranty Registration...
  • Page 8 Now that you have decided to upgrade your packaging facilities with the T-1000-S14 Advanced Poly- Bagger™ from Advanced Poly-Packaging, Inc., we thank you for selecting our equipment, materials, and service. Where labor reduction and fast changeover are important, the T-1000-S14 uses Advanced Poly- Bags (pre-opened bags on rolls) manufactured by Advanced Poly-Packaging, Inc.
  • Page 9 Continuous Strip Option: Leave bags connected in an "endless" strip or a predetermined number of strips of sealed bags. Counters – Preset, Total and Maintenance counters are provided. Energy Conservation and Component Saver: To extend its life and conserve energy in your plant, the T-1000-S14 is programmed to sequentially shut down components when not in use for extended periods of time.
  • Page 10 Although the T-1000-S14 is equipped with many "built-in" options, various auxiliary options and equipment can easily be added for special purpose packaging. The following options may be purchased from Advanced Poly-Packaging, Inc: AF-10 Accumulating Funnel: A special purpose funnel that collects and holds product until it is ready to be dropped.

  • Page 11: Using This Manual - Typographical Conventions

    E-Stop: This option can be used to stop the cycle operation of the T-1000-S14 and possibly other auxiliary infeed or outfeed equipment purchased with the T-1000-S14. FS-10 Flat Seal Assembly: Helps decrease/eliminate wrinkles in the seal by pulling the sides of the bag. Increases bag integrity.

  • Page 12: Contact Information

    UC-2400 Vibratory Parts Counter: Automatic parts counter feeds fasteners, electronic components, injected molded parts and many other types of product, then drops the final count into the bag, carton, or infeed conveyor. UF-2000 Takeaway Conveyor: Removes packaged product to a packing station or directly feeds a carton or table, conveying the product from floor level.

  • Page 13: Warranty Registration

    1.8 Warranty Registration This section must be completed and returned to Advanced Poly-Packaging, Inc. to register the T-1000 Bagger for Warranty Protection. Serial Number: (Serial Number located on the back panel) Company Name and Address Contact Name(s) / Title(s) / Phone Number...

  • Page 14: Chapter 2: Safety, Getting Started

    Chapter 2: Safety, Getting Started Chapter Summary Safety, Risks Installation Procedures Note on Adjustments to the T-1000-S14 Air and Power Requirements Assembly Instructions Air and Power Hookup Main Power Bag Threading Cycle Operation of the T-1000-S14 Quick Setup Procedures...

  • Page 15: Chapter Summary

    2.1 Chapter Summary This chapter describes procedures to receive and set up the T-1000-S14, including uncrating instructions, environmental, air and power requirements, risks, required safety precautions, quick start procedures assembly instructions and height adjustments. Additionally, this chapter describes safety precautions, how to power on the T-1000-S14 and how to properly thread bags through the machine.

  • Page 16: Installation Procedures

    CAUTION: Ensure that any height adjustments allow for sufficient movement of the operator. Improper height adjustments could negatively affect operator movement, causing strain, added stress, discomfort, and fatigue. CAUTION: Be careful when opening the seal frame as it may drop suddenly causing injury or damage to the equipment.

  • Page 17: Note On Adjustments To The T-1000-S14

    Operating Environment: The T-1000-S14 should be placed in an area free of excessive heat, moisture, dirt, and dust. Operating room temperature should range from 50°F to 100°F (10°C to 87.77°C). 2.4 Note on Adjustments to the T-1000-S14 Upon receipt, it is not unusual for the T-1000-S14 to be out of alignment due to shipping and excessive handling.

  • Page 18: Air And Power Hookup

    CAUTION: The seal bar should not come in contact with the funnel during sealing. Raise the funnel to avoid contact. CAUTION: To avoid injury, do not operate the T-1000-S14 without a funnel, guard or covers properly positioned. APPI offers a variety of funnels and chutes. Guarding may need to be added to prevent operators from reaching in, around or under the guard or funnels.
  • Page 19 Figure 2-1 Loosen for clockwise/counterclockwise adjustment and tilt adjustment Loosen for up/down adjustment Loosen for in/out adjustment...
  • Page 20 Figure 2-2 CAUTION: Carefully loosen for up/down adjustment while two other people support the T-1000-S14. CAUTION: If the bagger is not held in position by two people, the weight of the machine may cause it to drop suddenly, causing severe injury.
  • Page 21 Figure 2-3 Power Modem Switch Network DB25 Fuse Footswitch Main Power Switch Line Out Aux 3 Aux 1 Aux 2...

  • Page 22: Main Power

    2.8 Main Power The main power switch is located on the side cover of the machine. See Figure 2-3. To turn the T-1000-S14 on, turn the switch counterclockwise from its vertical OFF position to its horizontal ON position. The green Power light on the touch screen will illuminate and the Introduction screen will be displayed.

  • Page 23: Quick Setup Procedures

    Locate the foot switch and plug it into the rear foot switch connector. See Figure 2-3. Press the foot switch to index one bag through the “nip” rollers. If a foot switch is not being used, press the Manual Cycle button. One bag should index, blow open and stop between the pressure bar and the heater bar.
  • Page 24 Threading Diagram, Standard Vertical, Single Dancer Figure 2-4...
  • Page 25 Threading Diagram: Standard Vertical, Single Dancer, with Ti-1000 “Z” Printer Figure 2-5...

  • Page 26: Chapter 3: Touch Screen Operation

    Chapter 3: Touch Screen Operation Touch Screen Operation Touch Screen Specifications / Features Touch Screen Program, Overview Introductory Screen Operation Screen Main Menu Settings Screen Options Menu Ti-1000 Inline Printer Counters Screen Continuous Strip Screen Technical Assistance & Troubleshooting Screens Bagger Auxiliary Options Pass Code Setup Screen Bagger Factory Settings...

  • Page 27: Touch Screen Operation

    3.1 Touch Screen Operation This section describes in detail, the identification, operation, and adjustments of the Touch Screen Program. 3.2 Touch Screen Specifications / Features Screen, Resolution 7", 800 x 480 pixels, 65,536 TFT Colors Features Real time clock, recipes, USB 65,536 colors, TFT Memory 11.6 MB...

  • Page 28: Operation Screen

    3.5 Operation Screen Operation Screen is provided to function with Pass Code Protection function of the machine. If the pass code function is enabled in the Technical Assistance Screen, the touch screen will default to the Operation Screen after a preset time has elapsed.

  • Page 29: Fill Time

    Fill Time The <Fill Time> button functions differently dependent upon the MODE in which the T-1000 is operating: MANUAL, AUTOMATIC (AUTO) mode or AUXILIARY mode. In the Manual mode with NO accumulating funnel, Fill Time will delay the operation from starting until this time has passed.

  • Page 30: Reverse

    affect the required seal time. If adjusting pressure or temperature, test various seal times until satisfied with the seal quality. Reverse The distance the bag reverses can be set to cause the perforation to break between the bags. For wider bags, the reverse distance may need to be increased.

  • Page 31: Load Shelf

    3.9 LS-10 Load Shelf This option is used as a support shelf for the product to avoid the bag from prematurely tearing off at the perforation when the product is inserted in the bag. The Load Shelf allows the product to drop onto the shelf relieving the pressure on the bottom of the bag.

  • Page 32: Compartment Seal

    3.12 CS-10 Compartment Seal Seal the bag a second time to create a separate compartment in the bag. This option is useful to segregate different parts or protect damage caused from part contact. See Figure 3 - To start, set the First Seal Point by pressing the <Seal Point>...

  • Page 33: Counting Funnel

    3.15 CF-10 Counting Funnel This option is useful to automatically cycle the bagger when a preset number of parts have fallen through the funnel. See Figure 3 - 13. To turn ON the option, press the toggle button to ON. Press the <Reset> button to reset the count to the pre-set value.

  • Page 34: Bag Opening Device

    3.16 BO-30 Bag Opening Device This device enters the bag with one or more “fingers” and then pulls and holds the bag open. Air can also be shut off at this point. See Figure 3 - 15. To turn ON this option, press the Toggle button to <ON>. Down Delay is a delay time before the finger will attempt to enter the bag, after it is initially blown open.
  • Page 35 To enable the Light Curtain option, press the button labeled <Press to Enable>. Once enabled, you will not be able to disable the option without knowing the correct pass code. This prevents unauthorized personnel from enabling / disabling the option. Please refer to 3.38 Pass Code Setup Screen”...

  • Page 36: Bag Open Detector

    3.18 BO-20 Bag Open Detector This photo optic, closed contact sensor detects the opening or presence of bag material. This option will detect whether or not a bag is blown open or whether or not a funnel is inserted into the bag for validation that the bag is ready to receive product.

  • Page 37: 5000 / Us-5500 Semiautomatic Net Weigh Scale

    3.21 US-5000 / US-5500 Semiautomatic Net Weigh Scale The US-5000 and US-5500 Net Weigh systems are versatile semiautomatic bagging systems which provides for fast bagging of kits or one type of part per bag, in counts up to 10,000 pieces. If your company bags a wide variety of parts with multiple parts of various counts in bags, the US-5000 and US- 5500 Kit Packaging systems are an excellent solution.

  • Page 38: Adjustable Stand Screen

    3.25 Adjustable Stand Screen Operating height can be adjusted through the touch screen controlling a telescopic lift screw mechanism. To adjust the height, toggle the Option ON and press the UP Arrow or the DOWN Arrow. See Figure 3 - 24. 3.26 DF-20 Part Diverter (Diverting Funnel) This feature is used to count bags and divert them from the...

  • Page 39: Seal Validation

    Eye / Count Toggle button: When toggled to COUNT, the diverter flips to divert bags after a preset quantity have been cycled. When toggled to EYE, the diverter flips and diverts every bag. To ensure the accuracy of the count, an eye test must be performed. Press the <Eye Test> button to display the DF-20 Eye Test screen and perform an eye test.

  • Page 40: Medical Flat Seal

    Bar applying heat. If ‘Cool Time’ is used, Total Time is 'Seal Time' plus 'Cool Time'. Add ‘Total Time’ on ‘Seal Validation’ screen and use it for validation. Range: When the range is set, it allows a variance (+/- seconds) from the set seal time. 3.

  • Page 41: Uf-5000 Infeed Conveyor Operation Screen

    Seal Time: The amount of time, in seconds, the heater bar will remain touching the surface of the bag for proper sealing. To adjust this setting, press the <Seal Time> button, enter a value on the numeric keypad and then press the <ENT>...

  • Page 42: Ti-1000 Inline Printer

    3.32 Ti-1000 Inline Printer The Thermal Inline Transfer Printer - prints text, graphics and bar codes, formatted in a separate software program. The label formats are "downloaded" to the printer from a To enable Printer operation on the Thermal Transfer (TT) Printer, press the highlighted <Printer Ti-1000>...

  • Page 43: Temperature Calibration Screen

    3.35 Temperature Calibration Screen This calibrated temperature screen will allow for temperature calibration of the heater bar. A typical temperature setting is 400°F or 204°C. The maximum temperature setting is 600°F or 260°C. The operator will have the option of choosing between two thermocouples (TC 1 and TC 2). Since variables such as position and age of the thermocouples may affect the actual reading, a calibrated readout will provide for more consistency in sealing.

  • Page 44: Technical Assistance & Troubleshooting Screens

    Figure 3 - 36 3.38 Pass Code Setup Screen Advanced Poly-Packaging, Inc. (APPI) has included a pass code function in all touch screen equipment to prevent operators from changing settings. There are two pass code levels described as follows: 1.

  • Page 45: Bagger Factory Settings

    Level 2: This level pass code, when the pass code function is enabled, prevents the operator from accessing settings screens that affect the operation of the equipment. See Figure 3 - 38. Pass codes prevent unauthorized individuals from tampering with settings. When equipment is shipped, APPI uses the following codes which should be changed prior to putting the T-1000 into operation.
  • Page 46 Blower OFF: To preserve compressed air, the blower (air knife) will turn off after this preset amount of time has passed. The value is set in minutes and fractions of a minute. For instance, a setting of 5.1 would turn the air off if the machine is not in use for a period of five minutes and six seconds.

  • Page 47: Bag Registration

    Air Pulse Delay: The amount of time, in seconds, before the air pulse operation begins. This delay setting allows the bag to get into position before blowing it open. To change this setting, press the <Air Pulse Delay> button, enter a value on the numeric keypad and press the <ENT> button. Brightness Control.

  • Page 48: Job Save And Recipe Management

    3.41 Job Save and Recipe Management From the Main Menu touch <Technical Assist> and enter the Level 1 Pass Code. Touch the <Bagger Factory> button to access the Bagger Factory screen. From there touch the <Bag Registration> button located along the right-hand side of the screen.

  • Page 49: Internal Memory (Plc)

    A. Internal Memory (PLC) Saving a job to Internal Memory: Select <PLC> in the Bag Registration screen (as described above) and exit to the Main Menu. Go to Settings and set the specifications for your job. Once the job is set, touch <Job Save> on the right side of the screen to access the Bagger Job Save screen, see Figure 3 - 43.

  • Page 50: Memory Files And Data Structures

    <Enter> to continue or <Exit> to cancel. Touching the QTY box will access a green numeric keypad where the operator can enter the number of products that will go into each bag. For instance, if three items go into the bag before it is sealed, the number 3 can be entered into that field.
  • Page 51 PLC Memory The Program File contains the system files, user-created instructions (Ladder Logic), and sub-routines. Contains the information required for operation of the Program File, organized by data type. Figure 3 - 49 External Storage The Memory Stick contains several types of data from the machine. The Bagger Settings are stored, similar to the information in PLC Storage.
  • Page 52 BITMAP, CARD, DISP, FONT, HDCOPY, JPEG, LADDER, MEMO, MSG, OPELOG, SCRN, SNAP, SRAM, WAV, and WEBSERV are folders used by the touch screen software and will appear empty on the PC. This is because the files are hidden to prevent damage, and therefore do not show up in Windows Explorer. Do not store any information in these files as it will alter the program and will not function when the memory stick is re-inserted in the touch screen.
  • Page 53 This data can be used to provide information about the machine, including number of parts per month. However, these files must be saved (copied) to a PC without the original file changed. Then, the files can be used and saved as MS Excel files for full use of the MS Excel formulas.
  • Page 54 SMP0004.CSV Production Time Log – records the length of time the machine has been in production and gives details on the length of time the machine has been in the modes listed below. (See Figure 3 - 52) The data recorded in each column is as follows: A.

  • Page 55: Plc Info

    Figure 3 - 53 Manual Backup: Data is recorded and saved automatically as described above. It can also be done manually using buttons on Log screens: • 'Write' - overwrite (save) the same file • 'Backup' - create new file (save as) •...

  • Page 56: License Activation

    Figure 3 - 56 3.45 License Activation The License Activation Screen controls access to Advanced Poly-Packaging’s proprietary software for controlling the T-1000 Bagger, and must be activated in order to operate the machine. When shipped from the factory, a 60-day trial activation is included. After full payment for the software is received, a full software license will be granted.

  • Page 57: Production Graph And Temperature Graphs

    3.46 Production Graph and Temperature Graphs Simple production and temperature graphs are provided to chart production and temperature throughout the day. The Detail Temperature Graph allows greater resolution of temperature to one decimal point. See Figure 3 - 58, Figure 3 - 60 Figure 3 - 59, and Press the <Reset>...

  • Page 58: Bagger Machine Info

    3.48 Bagger Machine Info Model Number, Serial Number, Part Number and Line Figure 3 Number will be displayed; set at the factory. See - 63 Figure 3 - 63 3.49 Warning and Message Screens Normal operating message and fault messages will be displayed automatically to alert the operator of situations Figure 3 - 64 Figure 3 - 72 on the machine.
  • Page 59 Figure 3 - 69 Figure 3 - 68 Figure 3 - 70 Figure 3 - 71 Figure 3 - 72...

  • Page 60: Chapter 4: Adjustments Maintenance, Troubleshooting

    Chapter 4: Adjustments Maintenance, Troubleshooting Machine Adjustments Compression (Nip) Roller Adjustment Dancer Assembly Adjustments (Roller Shaft) Dancer Bar and Brake Strap Adjustment Upper Roller Guides PTFE Adjustment PTFE Replacement Pressure Bar Adjustment Sealer Cylinders Adjustment Pressure Bar (Rubber) Replacement Anti-Jam Adjustment Heater Cartridge Replacement Replace Thermocouple Wire Preventative Maintenance and Scheduled Maintenance...

  • Page 61: Machine Adjustments

    4.1 Machine Adjustments Periodically, the T-1000-S14 will require readjustments or realignments of components to ensure proper operation. Adjustments may be required after transportation, excessive handling or due to normal wear and tear. The following chapter includes extensive information on how to make these adjustments. “How To” documents for many machine adjustments, replacements or troubleshooting techniques are in the Help Function of our website: www.advancedpoly.com.
  • Page 62 LEFT SIDE PANEL COMPRESSION NIP ROLLER ADJUSTMENT Figure 4-1...
  • Page 63 RIGHT SIDE PANEL COMPRESSION NIP ROLLER ADJUSTMENT Figure 4-2...

  • Page 64: Dancer Assembly Adjustments (Roller Shaft)

    4.3 Dancer Assembly Adjustments (Roller Shaft) Dancer Assembly Please refer to 5.6 when using these instructions. A roller shaft, holding in position a roll of bags, will rest on the side plates of the dancer assembly. The roller shaft must be parallel to the upper and lower guide rollers to allow proper tracking through the center of the T-1000-S14.
  • Page 65 LEFT SIDE PLATE PTFE ADJUSTMENT Figure 4-3...

  • Page 66: Ptfe Adjustment

    4.6 PTFE Adjustment A non-stick PTFE sheet that prevents the bag from sticking to heater bar surfaces is located immediately behind the front plate. The PTFE should periodically be inspected for wear or damage. If holes or tears exist, the rolls can be turned (rotated) to cover the contact surfaces with fresh material. If an adjustment of PTFE is required, turn the main power OFF and unplug the power cord.

  • Page 67: Pressure Bar Adjustment

    19. Slide the Front Gripper Plate back into position. 20. Place Front Plate Spacers behind Front Plate, insert button head screws, then tighten. 4.8 Pressure Bar Adjustment The pressure bar, when actuated by the seal cylinder, is forced against the front plate. The pressure bar must be parallel to the front plate to avoid excessive wear of components.
  • Page 68 SEAL CYLINDER ADJUSTMENT Figure 4-4...
  • Page 69 PRESSURE BAR REPLACEMENT Figure 4-5...
  • Page 70 PRESSURE BAR REPLACEMENT Figure 4-6 Note: There is a 1/8"gap between the pressure rubber and front gripper plate.

  • Page 71: Anti-Jam Adjustment

    4.11 Anti-Jam Adjustment The anti-jam device is designed to protect the T-1000-S14 from damage when an obstruction is encountered in the seal area, between the pressure bar and front gripper plate. If properly adjusted, the pressure bar will retract if an obstruction is encountered in the seal area. The pressure bar houses springs that cause the rubber and holder to compress.
  • Page 72 ANTI-JAM OVERRIDE ADJUSTMENT Figure 4-7...

  • Page 73: Heater Cartridge Replacement

    Part 2: Other Anti-Jam Testing Next, locate the "X4" LED on the PLC Info Screen (under Technical Assist) and ensure the light is illuminated (ON). Then, compress the rubber and holder into the pressure bar (nylon holder). As soon as the rubber is pressed into the nylon holder, the "X4"...
  • Page 74 HEATER BAR CARTRIDGE REPLACEMENT Figure 4-8 VIEW FROM UNDERNEATH THE INNER FRAME Note: Heater cartridge wires must make a sharp 90° bend at the end of heater bar. Wires should not extend past the end of the heater bar. Note: If the wires rub on the bagger when the heater bar is in or out, the heater cartridge will fall prematurely.

  • Page 75: Replace Thermocouple Wire

    4.13 Replace Thermocouple Wire A thermocouple wire, brazed to a ring terminal and secured to the bottom of the heater bar, detects the amount of heat the heater bar is emitting. The thermocouple wire is considered a normal wear item and will infrequently fail, requiring replacement.

  • Page 76: Preventative Maintenance Checklist

    4.15 Preventative Maintenance Checklist CHART ITEM DESCRIPTION PERIOD Filter / Air regulator Drain water from filter Air regulator Adjust pressure to 60 PSI Anti-jam device Check operation, adjust as needed (section 4.11) Pressure bar (rubber) Clean with alcohol Perforation sensor Clean sensor assembly with alcohol Upper (rubber) roller Inspect for nicks or cuts;...

  • Page 77: Scheduled Maintenance Chart

    4.16 Scheduled Maintenance Chart ITEM DESCRIPTION Drive belt Adjust/Inspect for wear (right panel) replace when necessary Heater element Inspect for fraying, cuts, and wiring loose connections Pressure bar Disassemble, clean, inspect assembly springs for wear, breakage (frequency dependent on environment and product) Guide rollers Inspect for free movement Roller bearings...

  • Page 78: Spare Parts Kits

    4.18 Spare Parts Kits This section provides two lists of common wear items that may require occasional replacement. Level One Spare Parts Kit P/N: TO-T1-SP10-S14 ITEM ITEM NO. DESCRIPTION TP-215200 SWITCH, MAGNETIC (THREADED BOLT & NUT) TP-T1MA00115 BRAKE TENSION STRAP (DANCER) TP-108155 COMPRESSION SPRING, PRESSURE BAR TP-111010...
  • Page 79 Level Two Spare Parts Kit P/N: TO-T1-SP20-S14 ITEM ITEM NO. DESCRIPTION TP-101131 NUT, ACORN BRASS NICKEL PLATED TP-108155 COMPRESSION SPRING, PRESSURE BAR TP-108156 EXTENSION SPRING, PTFE ROD ASSEMBLY TP-111010 COLLARS, SPRING CLOSURE (WEB GUIDE) TP-207344 FUSE, 12 AMP, TIME DELAY TP-215200 SWITCH, MAGNETIC (THREADED BOLT &...

  • Page 80: Troubleshooting Guide

    4.19 Troubleshooting Guide The items included in this section cover the common causes of trouble that an operator might encounter during the operation of the T-1000-S14. When operating difficulties occur, the best procedure is to observe what is happening, identify the causes and effect the correction. Make only one adjustment at a time, checking the results of each adjustment.
  • Page 81 PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 1. Seal time too low 1. Increase in Settings screen 2. Heat (temperature) too low 2. Increase in Settings screen 3. Heater cartridge bad 3. Replace heater cartridge 4. Insufficient air pressure 4. Increase air pressure Pressure bar presses against 5.

  • Page 82: Plc Io Listing

    4.21 PLC IO Listing Main PLC and Expansion PLC IO (Inputs and Outputs) listing is provided to assist in troubleshooting the T-1000-S14. Card: Address Description Normal State Inputs Main PLC Reserved for Stepper control Main PLC Perf Sensor Main PLC Not Used - Available Main PLC AF10 Home Sensor...
  • Page 83 PLC Exp1 Light Curtain signal PLC Exp1 DF-20 Eye PLC Exp1 Barcode 'Quality Error' PLC Exp1 US50: Tray Home sensor PLC Exp1 US50: Tray Out sensor PLC Exp1 MV10 Temperature alarm PLC Exp1 MV10 Pressure alarm PLC Exp1 Barcode 'GOOD READ' PLC Exp1 BO-30 Bag Open sensor PLC Exp1...
  • Page 84 Main PLC TIZ NBO Print request Main PLC Station #5 solenoid Main PLC H/V Armed (for 220V) Main PLC LC-10 Power relay Main PLC TIZ INL Print request Main PLC Auxiliary Out Main PLC Not Used - Not Available Main PLC Not Used - Not Available Main PLC Not Used - Not Available...
  • Page 85 PLC Exp1 Not Used - Not Available PLC Exp1 Not Used - Not Available PLC Exp1 Not Used - Not Available PLC Exp1 Not Used - Not Available PLC Exp1 Not Used - Not Available PLC Exp1 Not Used - Not Available PLC Exp1 Not Used - Not Available PLC Exp1...

  • Page 86: Schematics

    4.22 Schematics Electrical and Pneumatic drawings are provided along with descriptions to assist in troubleshooting the T- 1000-S14. A. Electrical Drawings 110V Circuit Circuit drawings are provided to assist in troubleshooting the functionality of the T-1000 and the interface signaling with auxiliary infeed equipment. A circuit diagram of the 110V circuit is comprised of main power to the T-1000, through the fuse, Corcom filter, motor controller, solid state relay, heater element, line out, and into the power supply printed circuit board.
  • Page 87 Barcode Verifier The T-1000-S14 has the option of a Barcode Verifier installed to scan labels. See T1kST- E35_BCV_Keyence SR.
  • Page 88 110V Circuit T1kST-E1-110VAC...
  • Page 89 Analog Card, Temperature Controller, Heater Circuit T1kST-E56_TC4...
  • Page 90 Analog Output Card T1kST-E57_FP0RDA4...
  • Page 91 Stepper Motor Circuit T1kST-E4...
  • Page 92 High Voltage Board Assembly...
  • Page 93 Aux Interface T1kST-E7...
  • Page 94 Solenoid Valve Circuit Diagram T1kST-E8...
  • Page 95 PLC Expansion T1kST-E10_EXP-IO...
  • Page 96 DB Connector Pin T1kST-E14_DBCon...
  • Page 97 Panasonic Light Curtain T1kST-E34_LC_Panasonic SF4C...
  • Page 98 Barcode Verifier T1kST-E35_BCV_Keyence SR...

  • Page 99: Pneumatic Piping Diagrams

    Pneumatic Piping Diagrams APPI offers a piping diagram to assist in troubleshooting the T-1000 bagger. Piping from Solenoid Valve Stations 5 through 11 will change based on the configuration of the T-1000 and the options ordered by the customer. See Dwgs T- 1000 PNE 1 through 7.
  • Page 100 T-1000-S14 Pneumatic System Layout Diagram T-1000 PNE 1...
  • Page 101 Printer Pneumatic Layout T-1000 PNE 2...
  • Page 102 Accumulator Funnel Pneumatic Layout T-1000 PNE 3...
  • Page 103 Load Shelf Pneumatic Layout T-1000 PNE 4...
  • Page 104 Flat Seal Pneumatic Layout T-1000 PNE 5:...
  • Page 105 Bag Opener Pneumatic Layout T-1000 PNE 6...
  • Page 106 Trim Seal Pneumatic Layout T-1000 PNE 7...
  • Page 107 This page intentionally left blank...

  • Page 108: Chapter 5: Parts And Drawings

    Chapter 5: Parts and Drawings T-1000-S14 Advanced Poly-Bagger Base Assembly Upper Column Assembly Covers and Guarding Flat Load Shelf Assembly Dancer Assembly Touch Screen Assembly Main Frame Assembly Air Knife Assembly Sealer Frame Assembly: Drop Frame NBO Wide Sealer Frame Assembly: Drop Frame Electrical Panel Bag Blow Off (Optional) Bag Deflator (Optional)

  • Page 109: T-1000-S14 Advanced Poly-Bagger

    5.1 T-1000-S14 Advanced Poly-Bagger T-T1000-S14 ITEM QTY. PART NO DESCRIPTION TA-T10200 BASE ASSEMBLY TA-T10210 UPPER COLUMN ASSEMBLY TA-T10018 FLAT LOAD SHELF ASSEMBLY TA-T10220 DANCER ASSEMBLY TA-T10240 IOP (TOUCH SCREEN) SEE ASSEMBLY BAGGER W/OUT PRINTER TA-T10250-S14 MAIN FRAME ASSEMBLY TA-T10001-S14 AIR KNIFE ASSEMBLY TA-T10280-S14 NBO SEAL DROP FRAME TA-T10002-S14...
  • Page 110 VIEW FROM INSIDE BAGGER T-1000-S14 SYSTEM LAYOUT P/N: T-T1000-S14...

  • Page 111: Base Assembly

    5.2 Base Assembly P/N: TA-T10200 ITEM QTY. PART NO DESCRIPTION TP-T1MA00051 LOWER BASE WELDMENT TP-T1MA00051-1 LOWER COLUMN TP-106094 STUD, FLOOR LEVELER TP-106119 SPRING PIN TP-109148 HAND KNOB TP-110756 CASTER, SWIVEL TP-110763 CASTER, RIGID...

  • Page 112: Upper Column Assembly

    5.3 Upper Column Assembly P/N: TA-T10210 ITEM QTY. PART NO DESCRIPTION TP-T1MC00019-1 BASE CLAMP (L. H.) TP-T1MC00019-2 BASE CLAMP (R. H.) TP-T1MC00019-3 BRACKET, MOUNTING TP-T1MA00087 CROSS PIPE TP-401267 ELBOW, DOUBLE UNIVERSAL TP-406260 FILTER/DRYER/REG. ASSEMBLY TP-401222 HEX NIPPLE...

  • Page 113: Covers And Guarding

    5.4 Covers and Guarding P/N: TA-T1-S14NOPRINT ITEM PART NO. DESCRIPTION TP-T1MD00004S14 ELECTRONICS COVER TP-T1MD00005S14 RIGHT SIDE COVER TP-T1MD00044 TOP COVER TP-111241 SNAP BUTTON PLUG TP-T1MO00226-4 LEXAN GUARD BRACKET (RIGHT) TP-T1MD00116-2 LEXAN GUARD 5.25" PASS THROUGH TP-T1MO00226-3 LEXAN GUARD BRACKET (LEFT)

  • Page 114: Flat Load Shelf Assembly

    5.5 Flat Load Shelf Assembly P/N: TA-T10018 ITEM PART NO. DESCRIPTION TP-T1MB00074-2 LOAD SHELF BRACKET (RIGHT) TP-T1MB00074-1 LOAD SHELF BRACKET (LEFT) TP-T1MB00075 9" FIXED LOAD SHELF TP-T1MB00076 LOAD SHELF ROD...

  • Page 115: Dancer Assembly

    5.6 Dancer Assembly P/N: TA-T10220 ITEM QTY. PART NO DESCRIPTION TP-T1MA00069-1 DANCER SIDE PLATE TP-C1MA00069-2 DANCER SIDE PLATE TA-T10011 DANCER GUIDE SUB-ASSEMBLY TP-T1MA00073 BAG ROLL SHAFT TP-504132 CAM FOLLOWER TP-T1MA00115 BELT TENSION STRAP & SPRING TP-104148 SPACER TP-101141 LOCKNUT, HEX #10-24 TP-T1MA00049 FILM TENSION HUB TP-103307...
  • Page 116 Dancer Guide Subassembly P/N: TA-T10011 ITEM QTY. PART NO DESCRIPTION TP-T1MA00081 DANCER TENSION BAR CROSS BRACE TP-109212 KNOB TP-T1MA00072 DANCER TENSION BAR TP-T1MA00186 TENSION ADJUSTER ASSEMBLY GUIDE ROLLER ASSEMBLY Guide Roller Assembly ITEM QTY. PART NO DESCRIPTION TP-T1MA00089 DANCER GUIDE ROLLER TP-T1MA00090 DANCER GUIDE ROLLER SHAFT...
  • Page 117 Dancer Guide Subassembly Guide Roller Assembly DANCER GUIDE SUBASSEMBLY P/N: TA-T10011...

  • Page 118: Touch Screen Assembly

    5.7 Touch Screen Assembly P/N: TA-T10240 ITEM QTY. PART No DESCRIPTION TA-T10240-IOP SEVEN INCH TOUCH SCREEN TP-T1MD00109 MOUNTING BAR TP-111215 JOINING TEE TP-T1MD00094 BASE TELESCOPE TP-111104 COLLAR CLAMP TP-T1MA00088 BASE CLAMP PIPE...

  • Page 119: Seven Inch Touch Screen

    5.8 Seven Inch Touch Screen TA-T10240IOP ITEM QTY. PART No DESCRIPTION TP-T1MD00040 TOUCH SCREEN HOUSING TP-T1MD00040-1 BACK COVER TP-111131 BALL GRIP POSITIONING ARM TP-111125-2 SOCKET ARM PART OF TP-220363 SCREEN STUD PART OF TP-220363 SCREEN CLIP TP-220363 TOUCH SCREEN TP-IOPBOLT-L MODIFIED BOLT TP-102147 WASHER, 5/8 FLAT...
  • Page 120 SEVEN INCH TOUCH SCREEN P/N: TA-T10240IOP...

  • Page 121: Main Frame Assembly

    5.9 Main Frame Assembly P/N: TA-T10250-S14 ITEM QTY. PART NO DESCRIPTION TP-T1MC00001S14NB SIDE FRAME TP-T1MC00044 FACE PLATE BLOCK TP-T1MC00042NB FACE PLATE TP-T1MC00079 CYLINDER PIVOT SHAFT TP-T1MC00056 REAR CROSS SUPPORT SHAFT TP-T100054 COVER SUPPORT CLAMP TP-T1MC00099 REAR COVER SUPPORT TP-T1MC00058 LATCH ADJUSTER BLOCK TP-T1MC00059 LATCH LOCK BLOCK TP-T1MC00163-2...
  • Page 122 MAIN FRAME ASSEMBLY P/N: TA-T10250-S14...

  • Page 123: Upper Roller Assembly

    5.10 Upper Roller Assembly P/N: TA-T10002-S14 ITEM PART NO. DESCRIPTION TP-T1MC00119 FILM WEB ROLLER TP-T1MC00120 FILM WEB ROLLER SHAFT 1/4” ID, 3/8” OD, 0.375” LONG BUSHING TP-107177 TP-T1MC00018-S14 ROLLER MOUNT TP-T1MC00118-1 FILM WEB ROLLER BRACKET LEFT TP-T1MC00118-2 FILM WEB ROLLER BRACKET RIGHT...

  • Page 124: Air Knife Assembly

    5.11 Air Knife Assembly P/N: TA-T10001-S14 ITEM PART NO. DESCRIPTION TP-BP-1013-S14 MOUNTING BAR TP-BP-1015-S14 AIR NOZZLE TP-T1MC00020NB FINGER PLATE TP-T1MC00125S14 SENSOR MOUNTING BAR TP-T1MC00083 HIGH VOLTAGE SENSOR INSULATOR TA-T100124-1 HIGH VOLTAGE SENSOR TP-405268 AIR KNIFE TP-401277 ELBOW, ¼ TUBE TP-401292 STRAIGHT, ¼...

  • Page 126: Sealer Frame Assembly: Drop Frame

    5.12 Sealer Frame Assembly Drop Frame P/N: TA-T10280-S14 ITEM QTY. PART NO DESCRIPTION TP-T1MB00200 SEALER FRAME NBO INTERNAL GUARD (4.25” PASS-THROUGH) TP-T1MD000276 NBO INTERNAL GUARD (5.25” PASS-THROUGH) TP-T1MD00276NB-1 NBO INTERNAL GUARD (6.25” PASS-THROUGH) TP-T1MD000276-2 NBO INTERNAL GUARD (7.25” PASS-THROUGH) TP-T1MD000276-3 BOTTOM INTERNAL GUARD (4.25”...
  • Page 127 TP-T1MB00022 GUARD ROD MOUNTING BLOCK SHIELD MOUNTING ROD (4.25” Pass-Through) TP-T1MB00144 SHIELD MOUNTING ROD (5.25” Pass-Through) TP-T1MB00144-1 SHIELD MOUNTING ROD (6.25” Pass-Through) TP-T1MB00144-2 SHIELD MOUNTING ROD (7.25” Pass-Through) TP-T1MB00144-3 TP-104210 SPACER, 3/8LG,1/2 DIA.,.252 HOLE TP-T1MO00129 DROP FRAME FACE PLATE TP-T1MO00023 DROP FRAME SPACER TA-T10017 BAG FINGER GROUNDING ASSY...
  • Page 128 Note: The hardware that goes with item # 16 is stacked in the order of Bushing Thrust Nylon (item# 16), 3/8 Flat Washer (item# 53), 3/8 Internal Toothed Lock Washer (item# 54), then 3/8-16 Hex Jam Nut. *Note: If you purchased the T-1000-S14 with a Standard Frame instead of a Drop Frame, your part numbers for the Standard Sealer Frame Assembly are the same as those listed above with the exception of Item 30 TP-104210 Spacer, Item 31 TP-T1MO00129 Drop Frame Face Plate and Item 32 TP-T1MB00023 Drop Frame Spacer.

  • Page 129: Nbo Wide Seal Frame Assembly

    5.13 NBO Wide Seal Frame Assembly P/N: TA-T10280-S18NB ITEM QTY. PART NO DESCRIPTION TP-T1-00200S18 SEALER FRAME TP-T1MB00010-W18 SEALER ROD TIE BAR TP-T1MB00016-S18 SEAL CYLINDER MOUNTING BLOCK TP-T1MB00005-W18 FRONT GRIPPER PLATE SEAL GUIDE ROD (5.25” Pass Through) TP-T1MB00033-W18-1 SEAL GUIDE ROD (6.25” Pass Through) TP-T1MB00033-W18-2 SEAL GUIDE ROD (7.25”...
  • Page 130 TP-402186 FLOW CONTROL, #10-32 TP-211374 MAGNET, ROUND TP-T1MB00027-1 GRIPPER SPACER (W) TP-104210 SPACER, 3/8LG,1/2 DIA.,.252 HOLE TP-T1MD00275NB-S18-2 BOTTOM INTERNAL GUARD TP-107127-1 BRONZE BUSHING TP-T1MBO0129-W18 DROP FRAME FACE PLATE (WIDE) TP-107228 BUSHING, NYLON FLANGE TP-107160-1 PTFE COATED BUSHING TP-104124 SPACER TP-T1ME00209 SEAL BAR COIL CABLE TP-403508 GAS SPRING...
  • Page 131 *Note: Items 5, 7, and 21 will vary depending upon the Pass-Through size of the Bagger. Please note this when ordering parts from the Bill of Materials shown above. For example, a Bagger with a 6.25” Pass-Through will use Seal Guide Rod TP-T1MB00033-W18-2, Shield Mounting Rod TP-T1MB00144-2, and Main Cylinder TP-403242.

  • Page 132: Pressure Bar Subassembly

    A. Pressure Bar Subassembly P/N: TA-T10005 ITEM QTY. PART NO DESCRIPTION TP-T1MB00029 ANTI-JAM PRESSURE HOUSING TP-T1MB00030 ANTI-JAM CONTACT STRIP TP-T1MB00031 ANTI-JAM PRESSURE PAD TP-T1MB00068 ANTI-JAM CONTACT STRIP TP-T1MB00111 RUBBER STRIP HOLDER TP-306002 RUBBER SEAL TP-300001 RUBBER BUMPER TP-106093 1/4-20 x 2" STUD TP-108155 COMPRESSION SPRING TP-101130...

  • Page 133: Heater Bar Subassembly

    Heater Bar Subassembly P/N: TA-T10006 ITEM PART NO. DESCRIPTION TP-T1MB00008 HEATER BAR MOUNTING PLATE TP-T1MB00009-1 1/8" SEAL BAR* TP-T1MB00006 HEATER BAR CLAMP TP-T1MB00024 HEATER CARTRIDGE CORNER HANGER TP-T1MB00145 WIRE TIE-DOWN TP-109096 HEATER CARTRIDGE WIRE LEAD CLAMP TP-104124 SPACER TP-217116 CARTRIDGE, HEATER TP-221416 THERMOCOUPLE WIRE *Note: Depending on your order, Item 2 could also be TP-T1MB00009 Heater Seal Bar, TP-T1MB00009-2 1/4"...

  • Page 134: Ptfe Guide Subassembly

    PTFE Guide Subassembly P/N: TA-T10009 ITEM PART NO. DESCRIPTION TP-T1MB00034 PTFE FINGER TP-T1MB00040 PTFE ROD TP-108089 EXTENSION SPRING TP-300500 PTFE SHEET...

  • Page 135: Grooved Roller Mounting Subassembly

    Grooved Roller Mounting Subassembly P/N: TA-T10012 ITEM PART NO. DESCRIPTION TP-T1MB00013 ALUMINUM ROLLER SHAFT TP-T1MB00004NB ROLLER MOUNTING BLOCK TP-T1MB00012 ROLLER TP-107227 BUSHING, THRUST NYLON TP-504107 BEARING, 0.500 BORE, 1.125 0D, 9/32 WIDE TP-T1MB00155 FILM WEB TENSION ROLL TP-T1MB00156 FILM WEB TENSION SHAFT TP-T1MC00121 REAR ROLLER CLIP 1/4”...

  • Page 136: Bag Finger Grounding Subassembly

    Bag Finger Grounding Subassembly P/N: TA-T10017 ITEM PART NO. DESCRIPTION TA-T100124-3 GROUNDING SENSOR TP-T1MB00028 GROOVED METAL ROLLER FINGER TP-T1ME00325 GROUNDING SENSOR WIRE ASSEMBLY...

  • Page 137: Latch Subassembly

    Latch Subassembly P/N: TA-T10019 ITEM PART NO. DESCRIPTION TP-T1MB00060 LATCH LOCK TP-T1MB00061 LATCH CAM TP-106135 DOWEL PIN...

  • Page 138: Manifold Assembly

    Manifold Assembly P/N: TA-T1-10020-S14 ITEM PART NO. DESCRIPTION TP-T1MC00015S14 MANIFOLD BRACKET TP-402104 IN-LINE FLOW CONTROL, AS2051F-07 TA-T1-10025-S14 PNEUMATIC VALVE ASSEMBLY Note: Valves with one button (Single Valves) are part # TP-402266. Valves with two buttons (Dual Valves) are part # TP-402267.

  • Page 139: Electrical Panel

    5.14 Electrical Panel P/N: TA-T10270-S14 ITEM QTY. PART NO DESCRIPTION TP-T1MC00006-S14 ELECTRONICS MOUNTING PANEL TP-205108 EMI FILTER, CORCOM TP-207216, TP-207344 FUSE HOLDER & FUSE TP-212167 6-PIN CIRCULAR FEMALE TP-212247 9-PIN D-SUB FEMALE TP-212410 AC OUTLET TP-213361 24VDC, 3AMP POWER SUPPLY TP-215000A COVER TP-215000...
  • Page 140 ELECTRICAL PANEL P/N: TA-T10270-S14...

  • Page 141: Bag Blow Off (Optional)

    5.15 Bag Blow Off (Optional) TO-T1-BB10 ITEM QTY. PART NO DESCRIPTION TP-TS10-106 TRIM SEAL BLOW-OFF TP-404002 NOZZLE, SAFETY BLOW GUN TP-401258 MALE CONNECTOR...

  • Page 142: Bag Deflator (Optional)

    5.16 Bag Deflator (Optional) TO-T1-BF10-2 ITEM QTY. PART NO DESCRIPTION TP-BF10-160 BACK PLATE TP-BF10-157 PLATE CLAMP HP-35027A1 SPONGE REPLACEMENT...

  • Page 143: Notes

    5.17 Notes Date Note...

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