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PackLab MODULE 40 User Manual

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GENERAL AND SAFETY
INFORMATION
LABELING UNIT
MODULE 40/60/90/120
Complete or partial reproduction of this manual is forbidden without the manufacturer's prior written consent. The manufacturer implements a policy of continuous improvement and reserves the right to make changes that do not affect safety to this document without prior notice. © 2003 - Text,
illustrations and layout by IDM esperti in comunicazione tecnica - Forlì. The text in this manual is copyright and the intellectual property of IDM. It may be quoted in full or in part provided reference to the author is made.
Sede legale: Via A.Volta, 16 - 6030 S.Giorgio (MN) ITALY
Tel. 0376 372300 Fax 0376 372445
www.packlab.com - E-mail tech@packlab.it
IMPORTANT
Keep this service manual to hand during the machine/
equipment's working life
MODULE
40/60/90/120
user manual
Serial number
INDEX
Section
1
Section
5
ENGLISH
0
Edition
09-2003
1

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Summary of Contents for PackLab MODULE 40

  • Page 1 IDM esperti in comunicazione tecnica - Forlì. The text in this manual is copyright and the intellectual property of IDM. It may be quoted in full or in part provided reference to the author is made. Sede legale: Via A.Volta, 16 - 6030 S.Giorgio (MN) ITALY Tel. 0376 372300 Fax 0376 372445 www.packlab.com - E-mail tech@packlab.it...
  • Page 3 Section 1 GENERAL AND SAFETY INFORMATION PURPOSE OF THE MANUAL........2 IDENTIFICATION OF MANUFACTURER AND MACHINE ............. 2 GLOSSARY AND TERMINOLOGY ......3 METHODS FOR REQUESTING ASSISTANCE ... 3 ACCOMPANYING DOCUMENTATION ......3 SAFETY REGULATIONS..........3 English Ed. 0 (05-2003) - 1 -...
  • Page 4 Section 1 GENERAL AND SAFETY INFORMATION PURPOSE OF THE MANUAL The manufacturer has developed this manual, which is advance notice. an integral part of the machine, to provide the Several symbols, whose meaning will be described necessary information to those who are authorized to below, have been adopted to emphasize some interact with it during the course of its expected life.
  • Page 5 Section 1 GENERAL AND SAFETY INFORMATION GLOSSARY AND TERMINOLOGY We describe several recurring terms in the manual so operations necessary for maintaining the machine at as to provide a more complete understanding on their the appropriate level of functionality and efficiency. meaning.
  • Page 6 Section 1 GENERAL AND SAFETY INFORMATION – Do not tamper with, circumvent, remove or bypass involved from injury and to rigorously apply all the the installed safety devices. Failure to observe this laws, with particular reference to those regarding requirement can cause series risks to the safety and mobile job sites.
  • Page 7 Section 1 GENERAL AND SAFETY INFORMATION Rules for adjustment and maintenance – Maintain the machine in perfect working order, performing the scheduled maintenance required by the manufacturer. Good maintenance will allow you to achieve better performance, longer working life and constant observance of safety standards. –...

  • Page 9: Table Of Contents

    Section 5 LABELING UNIT version: Module 40/60/90/120 TECHNICAL INFORMATION MAINTENANCE INSTRUCTIONS page page DESCRIPTION OF THE MACHINE ......2 CLEANING OPERATIONS.......... 29 DIFFERENT CONFIGURATIONS (VERSIONS)... 3 CLEANING THE PAPER BRAKING PAD ....29 TECHNICAL SPECIFICATIONS ........4 CLEANING THE STOP PHOTOCELL ....... 30 CLEANING THE DIVERTER ROLLERS .....

  • Page 10: Labeling Unit

    Winding dandy roller: controls the speed of the winding motor Winding roller: it is a powered paper feedback roller (MODULE 40 with clutch) Deviation rollers: they deviate the paper tape and support it with special rings Reel carrier disk...

  • Page 11: Different Configurations (Versions)

    MODULE"60": rated surface speed 60 m/min; high reels MODULE"90": rated surface speed 90 m/min; “E” VERSION with simplified control push-button MODULE"120":rated surface speed 120 m/min; panel(only for MODULE 40) "DX" VERSION:carousel clockwise rotation; "SX" VERSION:carousel anticlockwise rotation; Important "150" SIZE:...

  • Page 12: Technical Specifications

    Section 5 LABELING UNIT version: Module 40/60/90/120 TECHNICAL SPECIFICATIONS Rated surface speed ....40/60/90/120 m/min See technical details on the small plate stuck onto the Idling noise ..........<75 dB(A) machine body. Example of configuration: Module 60 SX 150 Single-phase electric supply IDM-412006003.tif...
  • Page 13 Section 5 LABELING UNIT version: Module 40/60/90/120 The coupling between the backing film and the label must be such that: – the label does not come away as the film slides around a roller 35 mm in diameter; – the label easily comes away from the...

  • Page 14: Instructions For Handling And Installation

    Section 5 LABELING UNIT version: Module 40/60/90/120 INSTRUCTIONS FOR HANDLING AND INSTALLATION PACKAGING AND UNPACKING The machine is packed with protection cardboard. to avoid any damage to these components and to All the information needed by the subjects who will reduce overall dimensions during transport.
  • Page 15 Section 5 LABELING UNIT version: Module 40/60/90/120 Reel carrier disk assembly 1 -Assemble the dandy rollers, if they are disassembled. dandy roller IDM-01_007_0.tif 2 -Assemble the reel carrier disks on the winding and unwinding rollers. reel carrier disk IDM-01_008_0.tif START photocell assembly...

  • Page 16: Electrical Connections

    Section 5 LABELING UNIT version: Module 40/60/90/120 labelling gear Important screw To attach labels to rotating bottles, reduce the primary diameter of the spacer gear to suit the ratio of the bottle’s actual peripheral speed to the gear (SK-0130-A) peripheral speed of the plate center.

  • Page 17: Adjustment Instructions

    Section 5 LABELING UNIT version: Module 40/60/90/120 ADJUSTMENT INSTRUCTIONS Foreword – label ejection speed (see page 15). The machine can be adjusted in several different configurations, including the following changes and/or Important adjustments: Refer to the sizing parameter tables for the –...

  • Page 18: Deviation Rollers Adjustment

    Section 5 LABELING UNIT version: Module 40/60/90/120 3 -Loosen the fixing screw on the bottom flange. 4 -Manually shift the winder disk upwards or downwards, turning it to facilitate this adjustment. 5 -Tighten the fixing screw on the bottom flange.

  • Page 19: Stop Photocell Adjustment

    Section 5 LABELING UNIT version: Module 40/60/90/120 STOP PHOTOCELL ADJUSTMENT Take action on the knobs to adjust the horizontal and vertical position of the stop photocell. To ensure accurate operation, it is a good idea to choose an edge of label as vertical as possible for the reading position.

  • Page 20: Driving Roller - Counter-Roller Adjustment

    Section 5 LABELING UNIT version: Module 40/60/90/120 DRIVING ROLLER - COUNTER-ROLLER ADJUSTMENT It is a good idea to check the preloading of the springs serving the (rubber-coated) counter-roller’s flexible bearings because: – if the springs are too slack, the paper will not be drawn correctly and this will result in label positioning errors;...

  • Page 21: Adjusting The Paper-Braking Pad

    IDM-41200600900.tif ADJUSTING THE CLUTCH ON THE WINDER SPOOL In the MODULE 40 version, the revolving motion of the winder spool is driven by the main motor by means of a belt transmission with an adjustable clutch control.

  • Page 22: Driving Motor Belt Adjustment

    Section 5 LABELING UNIT version: Module 40/60/90/120 DRIVING MOTOR BELT ADJUSTMENT In some versions (e.g. MODULE 120), there is a belt and pulley drive between the motor and the driving roller. Refer to the “Assembly drawings” document for further details.

  • Page 23: Speed Adjustment

    AUTOMATIC ADJUSTMENT OF THE LABEL-READING PHOTOCELL’S SENSITIVITY In some versions of the MODULE 40, a program is – switch off the machine from the main circuit-breaker; installed that enables the sensitivity of the photocell – place a piece of backing paper in the groove where reading the labels to be adjusted automatically.

  • Page 24: Manual Adjustment Of The Label-Reading Photocell's Sensitivity

    Section 5 LABELING UNIT version: Module 40/60/90/120 MANUAL ADJUSTMENT OF THE LABEL-READING PHOTOCELL’S SENSITIVITY On machines that do not have the automatic regulating option, the photocell’s sensitivity can be adjusted by means of a screw trimmer situated on the PL006 card inside the switchboard.

  • Page 25: Operating Instructions

    Section 5 LABELING UNIT version: Module 40/60/90/120 OPERATING INSTRUCTIONS DESCRIPTION OF THE CONTROLS (VERS.60/90/120/40 KEYBOARD) The labeling units for attaching self- adhesive labels in the MODULE 60 and MODULE 90 range are complete with a terminal for controlling the machine functions and setting the operating parameters.

  • Page 26: Basic Terminal Functions

    Section 5 LABELING UNIT version: Module 40/60/90/120 Basic terminal functions The operator can test the machine’s functions using encoder, you need to press the RESET button. If there the RESET, STOP, TEST keys alone; the keys on the are no alarm signals, the display shows the word top line are only used for setting the operating “READY”, followed by an indication of the reference...

  • Page 27: Setting The Size-Related Operating Parameters

    Section 5 LABELING UNIT version: Module 40/60/90/120 2 -Press the UP and DOWN keys (or the A+UP, The parameters accessible to the user are: A+DOWN combinations) to specify the value of the C00 – Size code password. This is the number associated with the parameters for 3 -Confirm the password with the Enter key.
  • Page 28 Section 5 LABELING UNIT version: Module 40/60/90/120 In the synchronized mode with encoder, this parameter P02 – STOP delay influences the relationship between the speed measured The parameter P02 establishes by how many motor by the encoder and the label delivery speed. High values steps to delay the stoppage of the label.

  • Page 29: Diagnostic Functions

    Section 5 LABELING UNIT version: Module 40/60/90/120 Diagnostic functions To use the diagnostic functions, simply press the The numbers (0 or 1) under the fields A, B, C and D combination of keys “A + TEST”. The display shows enable you to control the status of the inputs for the...

  • Page 30: Description Of The Controls (Version 40 E)

    DESCRIPTION OF THE CONTROLS (VERSION 40 E) The “MODULE 40 E” labeling unit for self-adhesive labels is complete with a power switchboard and a push button control panel.
  • Page 31 Caution - Precaution – 5 flashes followed by a pause: overheating or Generally speaking, several MODULE 40 units are anomaly in the electronic card controlling the driving installed on the same labeling machine; in this motor.

  • Page 32: Inserting A Reel

    Section 5 LABELING UNIT version: Module 40/60/90/120 The labeling machine containing the unit does not – automatic adjustment of the label-reading need to be in operation to be able to perform a test, nor photocell’s sensitivity does the START sensor need to generate a command –...
  • Page 33 Section 5 LABELING UNIT version: Module 40/60/90/120 4 -Unwind about 1½ meters of paper rollers and remove the labels from this stretch of paper. 5 -Thread the paper through the rollers and adjust the position of the rings so that they just come into contact with the edge of the paper.
  • Page 34 (attached to the driving roller guard). IDM-41200601800.tif 10 -Pull the paper about 20 centimeters beyond the winder spool (for Module 40 only). winder spool IDM-41200601900.tif English - 26 -...
  • Page 35 Section 5 LABELING UNIT version: Module 40/60/90/120 11 -Close the driving roller guard and bring the locking handle perpendicular to the paper braking pad. handle IDM-41200602000.tif 12 -Thread up to about 10-15 mm of the paper into the unwinding device. If necessary, fold the paper over to double its thickness.

  • Page 36: Removing The Rewound Paper

    Section 5 LABELING UNIT version: Module 40/60/90/120 14 -Check the vertical position of the stop sensor. stop sensor Important For proper operation of the stop sensor, position the reading point on an edge of the label that is as vertical as possible.

  • Page 37: Maintenance Instructions

    Section 5 LABELING UNIT version: Module 40/60/90/120 MAINTENANCE INSTRUCTIONS Danger - Warning Important Maintenance operations shall be carried out by Oxidation may damage the metallic parts and the specifically qualified personnel, who have been electrical equipment. trained for the purpose and possess the necessary...

  • Page 38: Cleaning The Stop Photocell

    Section 5 LABELING UNIT version: Module 40/60/90/120 2 -Gently turn the brake pad and clean it with a soft cloth dipped in a suitable solvent. You can use spirit or citric acid based solvents in this case. 3 -Restore the brake to its original position and tighten the knob once again.

  • Page 39: Cleaning The Rubber Roller/Counter-Roller

    Section 5 LABELING UNIT version: Module 40/60/90/120 CLEANING THE RUBBER ROLLER/COUNTER-ROLLER Proceed as follows. 1 -Open the driving unit and clean with a cloth dipped in a liquid detergent. Do not use sharp tools that could damage the surface treatment.

  • Page 40: Cleaning The Reel Carrier Disks

    Section 5 LABELING UNIT version: Module 40/60/90/120 CLEANING THE REEL CARRIER DISKS Important Do not use oils or hydrocarbon- based solvents (e.g. petrol, spirit or the like) to clean the transparent disks, since they could be damaged. Clean with a soft cloth dipped in a neutral detergent (soap).
  • Page 41 The STEP LIMIT alarm appears on the parameter, referring to the following table: display. MODULE 40 one unit corresponds to 0.25 mm MODULE 60-90 one unit corresponds to 0.33 mm MODULE 120 one unit corresponds to 0.50 mm The STEP LIMIT alarm appears on the The stop sensor fails to read the labels on the backing tape correctly.
  • Page 42 To remove the paper wrapped around the roller, switch off the unit at the switchboard, tear the paper and pull it off. For the Module 40: gradually screw down the clutch adjustment knob on the winder spool until you obtain a smooth operation.

  • Page 43: Part Replacement Instructions

    Section 5 LABELING UNIT version: Module 40/60/90/120 PROBLEM CORRECTIVE ACTION The labeling unit runs on half speed. One of the three phases of the encoder is faulty. Change the encoder. Check the alignment/level of the unwinding device and winder plates, which The paper on the winder spool is must coincide.

  • Page 44: Unwinding Unit Brake Belt - Replacement

    Section 5 LABELING UNIT version: Module 40/60/90/120 3 -Unscrew the fastening screws of the winding/unwinding unit. 4 -Take the unit on the bench. winding/unwinding unit IDM-01_028_0.tif UNWINDING UNIT BRAKE BELT - REPLACEMENT 1 -Disassemble the unwinding unit by taking it onto the bench.

  • Page 45: Label Detaching Blade - Replacement

    Section 5 LABELING UNIT version: Module 40/60/90/120 LABEL DETACHING BLADE - REPLACEMENT Blade replacement might also become knob necessary when a new bottle format is used. Carry out the following operations: 1 -loosen the locking knob and remove the blade;...

  • Page 46: Driving Rollers - Replacement

    Section 5 LABELING UNIT version: Module 40/60/90/120 4 -Remove the motor from the roller housing with the roller. motor IDM-01_039_0.tif 5 -Unscrew the fastening screw of the roller and remove it. roller 6 -Replace the motor and repeat the same operations the other way round.
  • Page 47 Section 5 LABELING UNIT version: Module 40/60/90/120 2 -Unscrew the hinge screw until you can remove the bushing. bushing IDM-41200603200.tif 3 -Remove the hinged unit from its hinged unit housing. IDM-41200603300.tif 4 -Unscrew the fastening screws of plate the upper plate.

  • Page 48: Disposal Of The Machine

    Section 5 LABELING UNIT version: Module 40/60/90/120 DISPOSAL OF THE MACHINE In case of machine disposal, please address to the Manufacturer, who will arrange for and authorise it according to the applicable laws and regulations in force. English - 40 -...

This manual is also suitable for:

Module 60Module 90Module 120

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