Page 1 Continuous Motion Cartoner Operator’s Manual Customer: Machine: 200246 Order No.: 39077 ROVEMA Packaging Machines L.P. 650 Hurricane Shoals Road, NW Lawrenceville, GA 30045 Phone: 770-513-9604 Fax: 770-513-0814 http://www.rovema.com...
Page 2: Table Of Contents
Lockout Procedures ................2-10 Air Supply Lockout..................2-10 Electrical Power Supply Lockout...............2-11 Section 3: Functional Descriptions ........3-1 Functional Descriptions ................3-2 Variable and Fixed Side................3-2 Carton Production..................3-3 Case Production ..................3-3 Carton Material ...................3-3 Carton Designations ...................3-4 Gluing ......................3-4 200246 CMK Operators Manual (02/06/2006)
Page 3 Front and Rear Pushers ................4-7 Hold Down Device ...................4-8 Carton Erector ..................4-9 Flap Raiser ....................4-10 Side Guides and Air Nozzle ..............4-11 Carton Conveyor ...................4-12 Carton Chain.....................4-13 Front Flap Closers ..................4-14 Rear Flap Closers..................4-15 Bucket Conveyor ...................4-16 200246 CMK Operators Manual (02/06/2006)
Page 4 Downstream Setup Menu .................5-33 Cartoner Setup Screen ................5-34 Cartoner Setup Screen - Continued............5-35 Bag Transfer Setup Menus ...............5-36 Configuration Screen ................5-37 Panelview Config Mode ................5-37 Copy Current Parameters to All Recipies ..........5-37 Main Drive Servo ..................5-37 200246 CMK Operators Manual (02/06/2006)
Page 5 Emergency Stop ..................6-8 Product Rejection ...................6-9 Section 7: Working with Components ......7-1 Adjusting Dimensions on Dials and Scales..........7-3 Carton Dimensions .................7-4 Set Up and Adjustments ..............7-10 Carton Supply ..................7-12 Adjusting the Carton Guide...............7-12 Supply Conveyor Tension.................7-13 200246 CMK Operators Manual (02/06/2006)
Page 6 Adjust Bucket Conveyor - Continued ............7-38 Product Supply Conveyor Base Setting............7-39 Bucket Conveyor Base Setting ..............7-40 Conveyor Adjustments:................7-41 Filling Height Monitoring ................7-42 Adjusting Fill Height Monitoring: ...............7-42 Tensioning the Bucket Conveyor Chains..........7-43 Tensioning the Main Drive Belt ..............7-44 200246 CMK Operators Manual (02/06/2006)
Page 7 Preparatory Actions ..................8-6 Checks ......................8-6 Monthly Maintenance...................8-8 Checks ......................8-8 Other Maintenance Procedures ..............8-10 Lubrication....................8-14 Section 9: Troubleshooting..........9-1 Alarm Banner....................9-1 Alarm Screen ....................9-2 Alarm History Screen..................9-3 Alarms and Warnings ................9-4 Alarm Messages ..................9-4 Warning Messages ...................9-13 200246 CMK Operators Manual (02/06/2006)
Page 8: Section 1: Introduction
This manual has been prepared for the machine number indicated on the front cover. This manual is a reference tool for the Rovema CMK – Continuous Motion Cartoner. It should be used in conjunction with instructor lead training. ROVEMA machines have been designed in accordance with the customer's requirements.
Page 9: About This Manual
Information This symbol indicates a description of functions. Important Note Denotes a particular function to be observed during operation. Manual Operations Symbol indicates work to be performed manually, e.g. changing the format parts, etc. 200246 CMK Operators Manual (02/06/2006)
Page 10: Introduction To The Cmk
Section 1: Introduction Introduction to the CMK The CMK continuous motion cartoner is designed to meet a wide variety of bag-in- box applications as well as other side load applications. The CMK is a horizontal carton loading machine used to erect, fill and close cartons.
Page 11 Introduction to the CMK Main Areas Emergency Stop Button Emergency Touchscreen Stop Button Infeed Tunnel Guard Infeed Bucket Conveyor Electrical Lubrication Cabinet Reservoir Supply Product Tamper Figure 1.2 Shows the back view of the CMK machine. 200246 CMK Operators Manual (02/06/2006)
Page 12 The CMK takes carton blanks and erects them (Areas 1-5). Bags, filled with product, are transported to the CMK and the CMK inserts the bags into the cartons (Area 6). The CMK closes and seals the cartons (Areas 7-11) and transfers them to downstream equipment for further processing (Area 12).
Page 13 Rovema CMK Operator’s Manual Section 1: Introduction Introduction to the CMK Side View Top View Figure 1.4 Overview of CMK- Continuous Motion Cartoner. (Side and Top views.) See next page for corresponding number descriptions. 200246 CMK Operators Manual (02/06/2006)
Page 14 10- Second Flap Inserter 11- Gluing Station 12- Carton Discharge 13- Central Lubrication 14- Connection Monitoring 15- Bucket Conveyor 16- Height Adjustment 17- Length Adjustment 18- Angle Encoder 19- Carton/Bag Reject Conveyor 20- Electrical Cabinet 200246 CMK Operators Manual (02/06/2006)
Page 15: Section 2: Safety Instructions
Rovema ULF Operator’s Manual Section 2: Safety Instructions Section 2: Safety Instructions This section contains information on machine safety issues. These issues include: ! Operator Safety ! Component Safety ! Safety Devices ! Machine Lockout Procedures 200246 CMK Operators Manual (02/06/2006)
Page 16: Operator Safety
Section 2: Safety Instructions Operator Safety Only properly trained personnel must operate the machine. ROVEMA is prepared to train your operators. The operator is responsible for following the operator safety guidelines presented in this section as well as any employer safety guidelines.
Page 17: Sound Level
Before starting the production, the operator must be sure that no other person is in the danger area of the machine. In Case of Danger I mmediately press an EMERGENCY STOP button! Daily before starting the production, make sure the EMERGENCY STOP buttons are functioning properly! 200246 CMK Operators Manual (02/06/2006)
Page 18: Component Safety
Spare Parts Only original ROVEMA spare parts and accessories should be used. ROVEMA is not liable for any damage caused due to the use of foreign products. Maintenance Before starting any cleaning, maintenance and repair procedures, be sure that the main switch is turned OFF, and make sure that it cannot be turned ON again.
Page 19: Safety Devices
The user must ensure that all safety devices are examined by a qualified specialist (e.g. by the safety inspector) at regular intervals. Under no circumstances shall such intervals exceed one year! 200246 CMK Operators Manual (02/06/2006)
Page 20: Machine View
Rovema ULF Operator’s Manual Section 2: Safety Instructions Safety Devices Machine View Door Switch Locations Emergency Stop Button Protective Doors Figure 2.1 Shows the Safety Devices 200246 CMK Operators Manual (02/06/2006)
Page 21: Dangerous Areas
All modifications on safety devices must be documented and confirmed by a responsible specialist. ROVEMA can make available safety devices in conformity with the customer's specifications. 200246 CMK Operators Manual (02/06/2006)
Page 22: Emergency Stop Push-Button
As soon as an EMERGENCY STOP switch is pressed, the machine stops, high- power to all drives will be interrupted, and the air pressure is dropped. Figure 2.3 Shows the EMERGENCY STOP push-button on a typical operator control panel. 200246 CMK Operators Manual (02/06/2006)
Page 23: Safety Labels
Safety Labels Safety labels alert an operator to a particular hazard. These labels appear at various places on the machine. Look for these labels, read them, and follow their instructions. Figure 2.4 Danger High Voltage label. 200246 CMK Operators Manual (02/06/2006)
Page 24: Lockout Procedures
2. Place a lockout clamp through the lockout hole in the Air Disconnect Handle. 3. Place a pad lock through one of the holes in the lockout clamp. Air Disconnect Handle Lockout Clamp Pad Lock Lockout Tag Figure 2.5 Shows the air supply locked out. 2-10 200246 CMK Operators Manual (02/06/2006)
Page 25: Electrical Power Supply Lockout
If the switch will turn to the ON position then the lockout procedure was not successful and must be performed again. Main Disconnect Switch Lockout Clamp Lockout Handle Pad Lock Lockout Tag Figure 2.6 Shows the electrical supply locked out. 2-11 200246 CMK Operators Manual (02/06/2006)
Page 26: Section 3: Functional Descriptions
The CMK carton machine is used to manufacture filled cartons. The prepackaged product and carton blanks are delivered to the CMK machine. The carton blanks are then erected and filled with product. The cartons are then closed and sealed.
Page 27: Functional Descriptions
Some maintenance and adjustment procedures require the base settings for the fixed side of the machine to be reset to be in alignment with the other areas of the machine. Fixed Side Variable Side 200246 CMK Operators Manual (02/06/2006)
Page 28: Carton Production
Cartons consist of various layers including the Cover, insert and rear side. The individual layers are different in terms of the materials they are made of and are a major factor in determining the quality designation. 200246 CMK Operators Manual (02/06/2006)
Page 29: Carton Designations
(the track) and the amount of glue can be adjusted on the HMI operating display and on the glue device. The glue nozzles that are used are also an important consideration for the specific glue application. (Consult the operating instructions for the glue device to obtain additional information.) 200246 CMK Operators Manual (02/06/2006)
Page 30: Transporting And Shipping
The outer carton must be vented and there is a free space of at least 1 cm between the top carton and the outside carton. An intermediate carton insert layer should also be placed between each layer of the cartons. 200246 CMK Operators Manual (02/06/2006)
Page 31: Storage
100 hours (roughly 4 days). After that, the folding resistance of grooved cartons increases during storage time. Sufficiently scoring the carton is the best way to ensure it can be stored for a relatively long time and it will work well in carton machines. 200246 CMK Operators Manual (02/06/2006)
Page 32: Carton Considerations
Out of alignment gluing usually only occurs when the wrong fiber direction was selected. The fibers must always run perpendicular to the longitudinal seal of a carton. Figure 3.6 200246 CMK Operators Manual (02/06/2006)
Page 33: Folds
Scoring of the four groves that run parallel to the longitudinal seam is a requirement for machine cartons. A scoring angle of at least 120° must be achieved. For safety reasons, however, the greatest possible angle up to 180° should not be attempted. 200246 CMK Operators Manual (02/06/2006)
Page 34: Bent Or Curved Cartons
7.5 % +/- 1% for the duration of processing. (A water content of 7.5% corresponds to a relative moisture ratio at equilibrium of about 55 % +/- 5 % at a standard temperature of 20 °C for typical cartons.). 200246 CMK Operators Manual (02/06/2006)
Page 35: Gluing Considerations
If the prescribed processing temperatures are exceeded for some time, then dangerous decomposition products may be produced. In this case, all necessary measures should be taken to eliminate these vapors (e.g. by a suitable exhaust). Follow the glue manufacturer's instructions! 3-10 200246 CMK Operators Manual (02/06/2006)
Page 36: Glue Vapors
When working with solvents, ensure good ventilation and prevent open fire! Follow the safety instructions indicated on the supplier's instruction information! 3-11 200246 CMK Operators Manual (02/06/2006)
Page 37: Properties
100% firmness. A temperature decrease of 10 - 20 % may provoke a viscosity increase of 20 - 50%! 3-12 200246 CMK Operators Manual (02/06/2006)
Page 38: Contact Pressure
The glue application devices are very hot! The gluing mechanism, the glue supply container, the glue hoses and the application nozzles are especially hot. Appropriate protective equipment is required for jobs performed on these machine parts! 3-13 200246 CMK Operators Manual (02/06/2006)
Page 39: Section 4: Parts And Functions
This section provides an overview of the equipment and typical process flow descriptions. The CMK continous motion cartoner is designed to meet a wide variety of bag-in- box applications as well as other side load applications. The CMK is a horizontal carton loading machine used to erect, fill and close cartons.
Page 40: Areas Of The Machine
The illustration below shows the areas of the machine and the sequence of operations for production from a carton blank to the finished carton. Figure 4.1 Shows the typical sequence of operations for the CMK. Sequence of Operations Cartons feed in on the carton supply.
Page 41: Carton Supply
HMI touchscreen display. The carton supply belt is activated, to fill the carton magazine, by a filling level monitoring device located in the carton magazine. Carton Supply Monitoring Device Figure 4.2 Shows the carton supply. 200246 CMK Operators Manual (02/06/2006)
Page 42: Carton Supply Setup
There must also be a right angle between the cartons and the supply conveyor. Retaining Roller Carton Guide Carton Guide Figure 4.3 Shows the carton supply guides. 200246 CMK Operators Manual (02/06/2006)
Page 43: Carton Magazine
If there is not enough weight, the cartons may not be grasped and separated into individual cartons. Side Carton Guide Front Carton Guides Side Carton Guide Filling Level Signal Device Adjustment Locations Figure 4.4 Shows the carton magazine. 200246 CMK Operators Manual (02/06/2006)
Page 44: Separation Of Cartons
The separating pushers are arranged in pairs, (#2) is the front pushers and (#4) is the rear pushers. The time of activation can be adjusted on the machine’s HMI touchscreen. Figure 4.6 Shows the pushers location. 200246 CMK Operators Manual (02/06/2006)
Page 45: Front And Rear Pushers
Demonstrates the pushers action. When the rear pushers (#4) are activated, the carton is pushed out of the magazine and falls onto the guide rails of the driver chain. Figure 4.8 Demonstrates the pushers action. 200246 CMK Operators Manual (02/06/2006)
Page 46: Hold Down Device
To adjust the location of the hold down device, loosen the bolts on the fastening device and move the hold-down device into position. When it is in the proper position, tighten the bolts. Adjustment Bolts Hold Down Device Figure 4.9 Shows the hold down device. 200246 CMK Operators Manual (02/06/2006)
Page 47: Carton Erector
At the same time, the two upper cover flaps are raised to the side guides by a pneumatically activated flap raiser. The lower cover flap runs into the lower side guide. Upper Flap Air Nozzle Pneumatic Flap Raiser Guides Lower Flap Guide Figure 4.10 Shows the carton erector. 200246 CMK Operators Manual (02/06/2006)
Page 48: Flap Raiser
A base setting adjusts the driver chain so that it runs synchronously with the carton chain. Air Nozzle Flap on Pneumatic Flap Raiser Figure 4.11 Shows the flap raiser and air nozzle. 4-10 200246 CMK Operators Manual (02/06/2006)
Page 49: Side Guides And Air Nozzle
The side guides (1) and air nozzles (2) are adjusted to match the length of the flap. Adjustment positions are used to correct the distances of the guides and air nozzles. Carton Figure 4.12 Demonstrates the carton erector. 4-11 200246 CMK Operators Manual (02/06/2006)
Page 50: Carton Conveyor
The flights hold the cartons in a rectangular shape until they are filled and closed. Flights Chain Flights Figure 4.13 Shows a carton in the drivers. 4-12 200246 CMK Operators Manual (02/06/2006)
Page 51: Carton Chain
The two adjustable chains can be set to Dimension A of the carton by means of a setting position. An additional setting position adjusts the carton chain on the variable carton machine side to Dimension H. The entire variable side moves with this setting. Figure 4.14 Shows the carton chain. 4-13 200246 CMK Operators Manual (02/06/2006)
Page 52: Front Flap Closers
The cartons move along the conveyor and the front flaps are pushed against the rotating disk to close the flap. Front Front Flap Flap Figure 4.15 Shows the front flap closer. 4-14 200246 CMK Operators Manual (02/06/2006)
Page 53: Rear Flap Closers
The flaps are inserted and held in place by rod guides. The recess is synchronized to the carriers of the outer carton chain. This makes it possible for the disk to insert the rear flap. Rear Rear Flap Flap Figure 4.16 Shows the rear flap closer. 4-15 200246 CMK Operators Manual (02/06/2006)
Page 54: Bucket Conveyor
Depending on the nature and design of the carton machine system, individual pouches, packs consisting of a number of pouches or other multi-piece products are used on the supply conveyor. Adjustable Bucket Width Figure 4.17 Shows the bucket conveyor. 4-16 200246 CMK Operators Manual (02/06/2006)
Page 55: Product Insertion - Barrel Loader
Each slide belongs to one bucket. The insertion slides move in a guide through which they are push product into the bucket. Insertion Chains Plates Insertion Location Figure 4.18 Shows the barrel loader 4-17 200246 CMK Operators Manual (02/06/2006)
Page 56 The entire upper conveyor may be adjusted vertically for different product heights. Figure 4.19 Shows a carton having product inserted. 4-18 200246 CMK Operators Manual (02/06/2006)
Page 57: Gluing Station
The flaps are held in a drying zone until the hot melt has cured sufficiently to hold the flaps closed Upper Flap Guides Glue Nozzle Figure 4.20 Shows the gluing station. 4-19 200246 CMK Operators Manual (02/06/2006)
Page 58: Closing Flaps
Closing Plate moves down to close flap. Glue Applicator Pressing Plate moves in to hold seal. Figure 4.21 Shows the closing flap guides. 4-20 200246 CMK Operators Manual (02/06/2006)
Page 59: Flap Guides
The cover flaps remain in a straight position until they reach the gluing station. • The third group guides the cover flaps after the glue station and closes them. (These flap guides are shown in the figure below.) Flap Guides Figure 4.22 Shows the flap guides. 4-21 200246 CMK Operators Manual (02/06/2006)
Page 60: Carton Guides
(fixed) flights of the carton, the inner (adjustable) flights, the height adjustment and the carton holding surface form the frame for cartons. Adjustable Flight Fixed Flight Upper Guide Fixed Holding Surface Figure 4.23 Shows the carton guides. 4-22 200246 CMK Operators Manual (02/06/2006)
Page 61: Drying Zone
The length of the drying zone is designed to allow sufficient time for the glue to cool off so the flaps will remain sealed when the carton leaves the machine. Side Guides Figure 4.24 Shows the drying zone. 4-23 200246 CMK Operators Manual (02/06/2006)
Page 62 (6). Inside the drying zone, the cartons are moved along by the inner and outer drivers (3 + 4) of the chain. The height guide (1) extends to the end of the carton machine. Figure 4.25 Shows the drying zone. 4-24 200246 CMK Operators Manual (02/06/2006)
Page 63: Carton Removal Chain
The removal chains are equipped with small drivers located on the side. These drivers transfer cartons from the carton removal conveyor chain. Removal Chain Carton Drivers Removal Chain Figure 4.26 Shows the carton removal chain. 4-25 200246 CMK Operators Manual (02/06/2006)
Page 64: Product Reject Conveyor
If the product is not pushed into the cartons by the barrel loader, it will go to the end of the supply conveyor and falls onto the rejection conveyor. The rejection conveyor is located under the supply conveyor. Figure 4.27 Shows the product rejection conveyor. 4-26 200246 CMK Operators Manual (02/06/2006)
Page 65: Bag Transfer Stations
The number of bags placed in each bucket is the number of bags that will be placed in each carton. The bag transfer stations are controlled on the HMI of the CMK cartoner. The bag transfer stations are numbered as shown below.
Page 66 Adjustment Adjustment Bag Width Adjustment Stage 1 Roller Height Adjustment Bag Conditioning Rollers Flow of Bags Emergency Stop Button Roller Height Adjustment Figure 4.29 Shows the flow of bags entering the Bag Transfer Station. 4-28 200246 CMK Operators Manual (02/06/2006)
Page 67 The final drop, into the bucket conveyor, will have a stack of bags containing the number of bags to be placed into each carton. Stage 1 Stage 2 Stage 3 Stage 4 Bucket Conveyor Figure 4.30 Shows the end view of a Bag Transfer Station. 4-29 200246 CMK Operators Manual (02/06/2006)
Page 68 Tunnel Guard. If product is so high that it pushes the Tunnel Guard open, the machine will stop. Dial Indicator Number Bag Width Adjustment Knob Emergency Stop Button Tunnel Guard Machine Ready Button Bucket Conveyor Figure 4.31 Shows the side view of a Bag Transfer Station. 4-30 200246 CMK Operators Manual (02/06/2006)
Page 69: Section 5: Operator Controls
This section describes the controls used to operate the machine. These controls include a touchscreen display, also known as the HMI (Human-Machine-Interface), a Main Disconnect switch, an Air Disconnect handle, and several push-buttons. Figure 5.1 Shows a typical main control panel. 200246 CMK Operators Manual (02/06/2006)
Page 70: Hmi (Human-Machine-Interface)
Alarms Button (Access Alarms Screen) Screen Name Working Area Menu Tree Bar Only the working area and the screen name will change for each screen entered. The other buttons and indicators will appear on each screen. 200246 CMK Operators Manual (02/06/2006)
Page 71: Menu Tree
The sections of the HMI Menu Tree are as follows: Parameters Adjustments Recipes View Data View I/O Alarms The Config. Button allows access to the PanelView setup. Figure 5.3 Shows the items on the Menu Tree. 200246 CMK Operators Manual (02/06/2006)
Page 72: Parameters And Submenus
Others determine when an operation will occur during the loading cycle. The parameter descriptions of each submenu are described on the Parameters Charts following the screen pictures. Parameters Submenus Figure 5.4 Shows the settings on the Main Parameters screen. 200246 CMK Operators Manual (02/06/2006)
Page 73: Main Parameters Screens
Rovema CMK Operator’s Manual Section 5: Operator Controls HMI (Human-Machine-Interface) Main Parameters Screens Figure 5.5 Main Parameters Screen 2. Figure 5.6 Main Parameters Screen 3. 200246 CMK Operators Manual (02/06/2006)
Page 74: Main Parameters Descriptions
Flap Close Var.Sd Pos Offset This determines the position of the Flap Closer on the Variable Side of the machine when the CMK is at zero (cycle stop position). This will rotate the position of the Flap Closer, this number of degrees, from the home position.
Page 75 Central Lubrication Interval This determines how often the Central Lubrication system will automatically apply lubricant to the various locations on the machine. Figure 5.8 Main parameters descriptions - Continued 200246 CMK Operators Manual (02/06/2006)
Page 76: Carton Magazine Parameters Screens
Rovema CMK Operator’s Manual Section 5: Operator Controls HMI (Human-Machine-Interface) Carton Magazine Parameters Screens This screen contains the parameters required to feed the carton magazine with carton blanks. Figure 5.9 Carton Magazine Screen 200246 CMK Operators Manual (02/06/2006)
Page 77: Carton Magazine Parameters Descriptions
Carton Magazine Empty Count The number of cycles that the machine is allowed to run after detecting that the magazine is low. Figure 5.10 Carton Magazine Parameter Descriptions 200246 CMK Operators Manual (02/06/2006)
Page 78: Pls Timing Channels Screens
These screens contain the PLS (Programmable Limit Switch) parameters. These include the Product Detect, Carton Release, Flap Lifter, Load Enable, Jam Detect, Open Flap Detect. Leaflet Enable and Laser Printer Enable values. Figure 5.11 Cartoner PLS Screen 1 of 5 5-10 200246 CMK Operators Manual (02/06/2006)
Page 79 Rovema CMK Operator’s Manual Section 5: Operator Controls HMI (Human-Machine-Interface) Figure 5.12 Cartoner PLS Screen 2 of 5 Figure 5.13 Cartoner PLS Screen 3 of 5 5-11 200246 CMK Operators Manual (02/06/2006)
Page 80 Rovema CMK Operator’s Manual Section 5: Operator Controls HMI (Human-Machine-Interface) Figure 5.14 Cartoner PLS Screen 4 of 5 Figure 5.15 Cartoner PLS Screen 5 of 5 5-12 200246 CMK Operators Manual (02/06/2006)
Page 81: Cartoner Pls Parameters Descriptions
This determines if the Open Flap Detector will be used during production. When enabled, a carton is rejected from the cartoner discharge conveyor if an open flap is detected. Figure 5.16 Cartoner PLS Parameter Descriptions 5-13 200246 CMK Operators Manual (02/06/2006)
Page 82 Laser Printer On Pos This determines when a signal will be sent to the Laser Printer Leaflet Printer Off Pos to print on the carton. Figure 5.17 Cartoner PLS Parameter Descriptions - Continued 5-14 200246 CMK Operators Manual (02/06/2006)
Page 83: Bag Transfers Screens
Stage 3, Stage 3 drops bags to Stage 4, Stage 4 is the final Stage and drops the stacked bags into the bucket on the bucket conveyor. This is the number of bags that will be placed into each carton. Figure 5.18 Bag Transfer Screen 1 of 5 5-15 200246 CMK Operators Manual (02/06/2006)
Page 84 Rovema CMK Operator’s Manual Section 5: Operator Controls HMI (Human-Machine-Interface) Figure 5.19 Bag Transfer Screen 2 of 5 Figure 5.20 Bag Transfer Screen 3 of 5 5-16 200246 CMK Operators Manual (02/06/2006)
Page 85 Rovema CMK Operator’s Manual Section 5: Operator Controls HMI (Human-Machine-Interface) Figure 5.21 Bag Transfer Screen 4 of 5 Figure 5.22 Bag Transfer Screen 5 of 5 5-17 200246 CMK Operators Manual (02/06/2006)
Page 86: Bag Transfer Parameters Descriptions
This determines the speed of the conveyors within the Transfer Stations. Prod Lngth/Gap Chk(%/cycle) This parameter allows the CMK to check for proper product spacing on the acceleration belt as the bags enter the Bag Transfer stations. At full speed one bag cycle is made up by the length of the bag itself plus the gap to the next bag.
Page 87 Therefore each Bag Transfer station will not necessarily have unique Drop Bucket parameters even when each station is properly dropping stacks into unique buckets. Figure 5.24 Bag Transfer Parameter Descriptions - Continued 5-19 200246 CMK Operators Manual (02/06/2006)
Page 88 BT Stage 4 Open Time This is the amount of time that the Bag Transfer Station slides remain open while releasing product to the next location. Figure 5.25 Bag Transfer Parameter Descriptions - Continued 5-20 200246 CMK Operators Manual (02/06/2006)
Page 89: Bagger Sync Screens
Section 5: Operator Controls HMI (Human-Machine-Interface) Bagger Sync Screens These screens contain information about the cartoner (CMK) synchronization with the baggers. The cartoner will send a signal to the bagger at the appropriate time to so that the bagger will begin producing product.
Page 90 Rovema CMK Operator’s Manual Section 5: Operator Controls HMI (Human-Machine-Interface) Figure 5.27 Bagger Sync Screen 2 of 3 Figure 5.28 Bagger Sync Screen 3 of 3 5-22 200246 CMK Operators Manual (02/06/2006)
Page 91: Bagger Sync Parameters Descriptions
Timing error would build up leading to delays that, in turn, would cause the Transfer Station to fill up before Stage 4 could make its drop. This would cause miscounts in the drop stack. Figure 5.29 Bagger Sync Parameter Descriptions 5-23 200246 CMK Operators Manual (02/06/2006)
Page 92 Transfer Station to fill up before Stage 4 could make its drop. This would cause miscounts in the drop stack. Figure 5.30 Bagger Sync Parameter Descriptions - Continued 5-24 200246 CMK Operators Manual (02/06/2006)
Page 93 Transfer Station to fill up before Stage 4 could make its drop. This would cause miscounts in the drop stack. Figure 5.31 Bagger Sync Parameter Descriptions - Continued 5-25 200246 CMK Operators Manual (02/06/2006)
Page 94: Cartoner Glue Setup Screen
Cartoner Glue Setup Screen The Glue Setup screens provide a simple means of enabling and configuring the glue zones on the CMK. The CMK has two glue zones, “Major Flap Glue” and “Minor Flap Glue”. Each glue zone has a “master” enable switch. This “master” enable switch is located at the top of each screen’s working area.
Page 95: Checkweigher Feedback Screen
HMI (Human-Machine-Interface) Checkweigher Feedback Screen This screen contains the settings used to determine the information about the carton weights received from the checkweigher and sent back to the baggers. Figure 5.33 Checkweigher Feedback Screen 5-27 200246 CMK Operators Manual (02/06/2006)
Page 96: Checkweigher Feedback Parameters Descriptions
Feedback Calculation This is the number of samples that will be used to calculate Samples the actual weights by averaging the feedback carton weights from each bagger. Figure 5.34 Checkweigher Feedback Parameter Descriptions 5-28 200246 CMK Operators Manual (02/06/2006)
Page 97: Additional Screens
When operating the complete system, verify that the Downstream Interlocks are ON for all of the baggers and the cartoner. The system will not shut down properly if a problem occurs when the Downstream Interlock is in the “Off Position. Figure 5.35 Adjustments Screen 5-29 200246 CMK Operators Manual (02/06/2006)
Page 98: Servo Menu Screens
Green to Red. The machine must then be put in an E-Stop condition (by opening a guard door or pressing an E-Stop button) in order for the home sequence to be properly initiated the next time the machine is started. Figure 5.36 Servo Axis Screen 5-30 200246 CMK Operators Manual (02/06/2006)
Page 99: Batch Control Menu
“Product To Produce” count reaches zero (0). CAUTION: The machines only go into a “Standby” mode under these circumstances. They will restart automatically if the “Batch Case Target” count is updated on the CMK HMI screen. Figure 5.37 Batch Control Screen 5-31...
Page 100: Batch Control Menu - Continued
Figure 5.38 Batch Control Screen 5-32 200246 CMK Operators Manual (02/06/2006)
Page 101: Downstream Setup Menu
This allows test products to be sent across the metal detector and checkweigher conveyors for calibration purposes. Normal production will resume when Calibration mode is turned off. Figure 5.39 Downstream Setup Screen 5-33 200246 CMK Operators Manual (02/06/2006)
Page 102: Cartoner Setup Screen
“Continuous” to make a continuous run of empty cartons. The “Empty Carton Mode” button may be toggled to “One Shot” to run one carton through the machine for testing purposes. Figure 5.40 Cartoner Setup Screen 5-34 200246 CMK Operators Manual (02/06/2006)
Page 103: Cartoner Setup Screen - Continued
“Barrel Height Adjust” buttons. Pressing the “+” button moves the barrel loader in the upper direction, the “-” button moves it down. Figure 5.41 Cartoner Setup Screen 5-35 200246 CMK Operators Manual (02/06/2006)
Page 104: Bag Transfer Setup Menus
Disabling the transfer station turns off the upstream permissive signal from the cartoner to the corresponding bagger. Figure 5.42 Bag Transfer Menu 5-36 200246 CMK Operators Manual (02/06/2006)
Page 105: Configuration Screen
The View Shift Register Setup Screen and the View PLS Config Screens will be described separately in this section. Figure 5.43 Shows the Config screen 5-37 200246 CMK Operators Manual (02/06/2006)
Page 106: Pls (Programmable Limit Switch) Config
These values should only be adjusted by properly trained personnel. These screens are accessed from the Configuration Screen of the HMI. Figure 5.44 Shows the Config screen Screen 1 of 2 5-38 200246 CMK Operators Manual (02/06/2006)
Page 107: Pls (Programmable Limit Switch) Compensation Parameters
Glue Timing Compensation This is time amount of time required to adjust this position to adjust for the delay in the solenoid valves reaction time. Figure 5.45 Shows the PLS Config descriptions 5-39 200246 CMK Operators Manual (02/06/2006)
Page 108: Shift Register Setup
Functions can correctly be disabled when cartons are not present and the cartons can be tracked from individual baggers. These values should only be adjusted by properly trained personnel. Figure 5.46 Shows the Shift Register Setup screen 5-40 200246 CMK Operators Manual (02/06/2006)
Page 109: Recipe Management Screen
It also allows you to load or rename any of the recipes. Figure 5.47 Shows the Recipes Management Screen. 5-41 200246 CMK Operators Manual (02/06/2006)
Page 110: Indication Of Edited Recipe
The screen shows the number and name of the currently loaded recipe, and provides a Save button, which allows the recipe to be saved. The Operator may also return to the Recipe Management screen without saving the current recipe by pressing the Exit button. 5-42 200246 CMK Operators Manual (02/06/2006)
Page 111: Save To Selected Recipe Screen
Exit button. While the save function is in progress, the text on the Save button changes to display “Saving”. When the save is complete, the Save button will return to its normal state. 5-43 200246 CMK Operators Manual (02/06/2006)
Page 112: Load Recipe Screen
Recipe Management screen without loading a recipe by pressing the Exit button. While the load function is in progress, the text on the Load button changes to display “Loading”. When the load is complete, the Load button will return to its normal state. 5-44 200246 CMK Operators Manual (02/06/2006)
Page 113: Rename Recipe Screen
Use the scroll arrows to select the desired recipe. The Operator may also return to the Recipe Management screen without renaming a recipe by pressing the Exit button. The recipe name can be up to 40 characters in length. 5-45 200246 CMK Operators Manual (02/06/2006)
Page 114: View Recipe List Screen
The screen shows a scroll list of all 100 recipes in the controller’s memory. Use the scroll arrows to select the desired recipe. The Operator may return to the Recipe Management screen by pressing the button with the “X” graphic. 5-46 200246 CMK Operators Manual (02/06/2006)
Page 115: View Data Screen
This depends on when the count is reset. Figure 5.54 Production Data Screen 5-47 200246 CMK Operators Manual (02/06/2006)
Page 116: View I/O Screens
Inputs and outputs that are ON will be displayed in green while those that are OFF will be gray. The I/O screens provide an excellent means of troubleshooting issues with the machine. Figure 5.55 Typical I/O Screen 5-48 200246 CMK Operators Manual (02/06/2006)
Page 117: Panelview Configuration Screen
Once in the screen, a button will be present that provides access to the PanelView configuration menu. Please consult the PanelView user’s manual provided by the manufacturer regarding the content of the PanelView configuration menu. Figure 5.56 Configuration Screen 5-49 200246 CMK Operators Manual (02/06/2006)
Page 118: Buttons And Switches
Section 5: Operator Controls Buttons and Switches The push buttons and switches on the machine are the: ! MAIN DISCONNECT Switch ! MACHINE READY Push-Button ! JOG/RUN Push-Button ! STOP Push-Button ! EMERGENCY STOP Push Button 5-50 200246 CMK Operators Manual (02/06/2006)
Page 119 When the button is not lit, it indicates that there is an active alarm present. Note: If a fault is present, the Main HMI display will indicate the fault. Figure 5.58 Shows the MACHINE READY push-button. 5-51 200246 CMK Operators Manual (02/06/2006)
Page 120 STOP Push-Button The STOP push-button ends the automatic packing operation once the current cycle is complete. Press and release this push-button to end packing operations under normal circumstances. Figure 5.60 Shows the STOP push-button. 5-52 200246 CMK Operators Manual (02/06/2006)
Page 121 This button should be used whenever there is perceived or actual damage occurring to personnel or to the machine. Figure 5.61 Shows the EMERGENCY STOP push-button. 5-53 200246 CMK Operators Manual (02/06/2006)
Page 122: Air Disconnect Handle
¼ turn clockwise to turn the air supply On. Figure 5.62 Shows the Air Disconnect Handle in the Off position. Figure 5.63 Shows the Air Disconnect Handle in the On position 5-54 200246 CMK Operators Manual (02/06/2006)
Page 123: Section 6: Operating Procedures
! Shutdown Conditions Conditions for putting the equipment into operation are: ! Knowledge and understanding of this manual. ! Completed training. ! Finished installation and connection of the equipment. ! Rigorous observance of safety instructions. 200246 CMK Operators Manual (02/06/2006)
Page 124: Startup
Ensure a proper compressed air supply. Improper connection may provoke damages and malfunctions of the devices. Therefore, make sure that the machine is connected "Positive phase sequence" to the electrical network. Only authorized specialists are allowed to perform this connection! 200246 CMK Operators Manual (02/06/2006)
Page 125: Activate The Machine
If any alarms exist, resolve the alarms before proceeding. If no alarms exist to this point, press the Stop pushbutton to halt the operation. The user should ensure that a safety inspector regularly inspects all protection devices! 200246 CMK Operators Manual (02/06/2006)
Page 126: Jogging The Machine
The jogging screens may be accessed from the Adjustments Screen then picking the Cartoner Setup button on the HMI. Refer to the Operator Controls section for detailed information on operating the Jogging menus. 200246 CMK Operators Manual (02/06/2006)
Page 127: Routine Operations
10. If all required conditions are met, the machine will then begin production. 11. If all required conditions are not met (such as the machine is waiting on product, material or downstream equipment), the machine will go into Standby mode. 12. Monitor operations. 200246 CMK Operators Manual (02/06/2006)
Page 128: Routine Operations - Continued
18. The cycle Stop button should be used to initiate stopping production under normal circumstances 200246 CMK Operators Manual (02/06/2006)
Page 129: Shut Down The Machine
4. Clean the machine by following the maintenance procedures outlined in the Maintenance Procedures section of this manual. Safety devices must not be bypassed or disabled! Repairs may only be performed with the master switch OFF! 200246 CMK Operators Manual (02/06/2006)
Page 130: Emergency Stop
Opening guard doors on the individual machines will cause local E-Stop conditions affecting only that machine. E-Stop Recovery – CMK Cartoner Whenever the cartoner is E-Stopped the entire machine should be inspected for possible problems and cleared if necessary. Especially the following areas: •...
Page 131: Product Rejection
• Metal Detector: Located after the discharge conveyor is a metal detector with its own reject system. • Checkweigher: Located after the metal detector is a checkweigher, also with its own reject system. 200246 CMK Operators Manual (02/06/2006)
Page 132: Section 7: Working With Components
If the carton is new, measure the areas identified on the carton illustration. Use those measurements to make the initial settings on the CMK carton machine. Mechanical adjustments are numbered on the machine. The numbers are located on dials and scales.
Page 133 Rovema CMK Operator’s Manual Section 7: Working with Components Figure 7.1 Shows the locations of the numbered dials and scales indicators. 200246 CMK Operators Manual (02/06/2006)
Page 134: Adjusting Dimensions On Dials And Scales
Turn the hand wheel until the dimension (in millimeters) appears in the display of the corresponding setting position. Adjustment Number Scale Dial Setting Adjustment Handle Adjustment Handle Adjustment Number Figure 7.2 Example of dials and scales. 200246 CMK Operators Manual (02/06/2006)
Page 135: Carton Dimensions
Dial: #13 Scale: #2 & Dial #5 Dial: #17 Dial: #10, #11, & #12 Flow of Production Dial: #14 Figure 7.3 Carton Illustration with locations to measure for dial and scale settings. 200246 CMK Operators Manual (02/06/2006)
Page 136 Transfer Station 2: Right Guide Transfer Station 3: Left Guide Transfer Station 3: Right Guide Transfer Station 4: Left Guide Transfer Station 4: Right Guide Transfer Station 5: Left Guide Transfer Station 5: Right Guide 200246 CMK Operators Manual (02/06/2006)
Page 137 Transfer Station 2: Right Guide Transfer Station 3: Left Guide Transfer Station 3: Right Guide Transfer Station 4: Left Guide Transfer Station 4: Right Guide Transfer Station 5: Left Guide Transfer Station 5: Right Guide 200246 CMK Operators Manual (02/06/2006)
Page 138 Transfer Station 2: Right Guide Transfer Station 3: Left Guide Transfer Station 3: Right Guide Transfer Station 4: Left Guide Transfer Station 4: Right Guide Transfer Station 5: Left Guide Transfer Station 5: Right Guide 200246 CMK Operators Manual (02/06/2006)
Page 139 Transfer Station 2: Right Guide Transfer Station 3: Left Guide Transfer Station 3: Right Guide Transfer Station 4: Left Guide Transfer Station 4: Right Guide Transfer Station 5: Left Guide Transfer Station 5: Right Guide 200246 CMK Operators Manual (02/06/2006)
Page 140 Transfer Station 2: Right Guide Transfer Station 3: Left Guide Transfer Station 3: Right Guide Transfer Station 4: Left Guide Transfer Station 4: Right Guide Transfer Station 5: Left Guide Transfer Station 5: Right Guide 200246 CMK Operators Manual (02/06/2006)
Page 141: Set Up And Adjustments
Carton (these are not numbered), #10 & #11, #13 & #14, #13.1 & #14.1, #12, #17, #20, #21, and finally #19 (#19 has at two locations). Note: Verify all adjustments are correct prior to running the machine as incorrect adjustments will cause damage to the machine. 7-10 200246 CMK Operators Manual (02/06/2006)
Page 142 19. Document and record all the final dial and scale settings for future reference. Note: Verify all adjustments are correct prior to running the machine as incorrect adjustments will cause damage to the machine. 7-11 200246 CMK Operators Manual (02/06/2006)
Page 143: Carton Supply
Turning the adjustment knob moves the carton guide forward or backward. Carton Guide Carton Guide Carton Guide Adjustment Knob and Dial Indicator Figure 7.4 Adjusting the carton guide. 7-12 200246 CMK Operators Manual (02/06/2006)
Page 144: Supply Conveyor Tension
Supply Conveyor Tension The tension of the carton supply conveyor can be adjusted with the threaded bolts. Turning the bolts moves the conveyor deflection roller forward or backward. Conveyor Tension Bolts Figure 7.5 Conveyor tension bolts. 7-13 200246 CMK Operators Manual (02/06/2006)
Page 145: Adjusting The Retaining Roller
The centerline of the retaining roller should run vertically over the discharge edge. The roller should be aligned so it is centered on the carton. Retaining Roller Adjustments Discharge Edge Filling Level Photoeye Figure 7.6 Carton Magazine 7-14 200246 CMK Operators Manual (02/06/2006)
Page 146: Front And Rear Pusher Adjustment Instructions
It should not be any thicker than one carton or two cartons will be pushed off. To replace the pusher, loosen the fastening screw and replace the pusher with a new one. Figure 7.7 Pusher Adjustments. 7-15 200246 CMK Operators Manual (02/06/2006)
Page 147: Main Drive Chain
If they are not, you can turn the chain’s sprocket by loosening the screws (4) and adjusting the chain so that the two chains are in the same position. Figure 7.8 Driver Chain 7-16 200246 CMK Operators Manual (02/06/2006)
Page 148: Chain Tension Drive Chain
(4) until the required tension is reached. Tension the driver chain (1) so that it is taut and is inside the closed guide. The tension of the chains must be the same on both sides. Figure 7.9 Chain Tension 7-17 200246 CMK Operators Manual (02/06/2006)
Page 149: Tension Drive Chain Drive Belt
After the clamping disk has been adjusted, tighten the fastening bolts again. Bolt Disk Clamping Disk Belt Figure 7.10 Chain Drive Belt 7-18 200246 CMK Operators Manual (02/06/2006)
Page 150 After any drive belts have been adjusted, the tensions should be rechecked after they have run for a while. Sensor Figure 7.11 Shows the overload clutch. 7-19 200246 CMK Operators Manual (02/06/2006)
Page 151: Carton Chain
Run some test cartons in JOG mode and make any required corrections. Flights Adjust to Carton Size Figure 7.12 Shows how to adjust the bucket width. 7-20 200246 CMK Operators Manual (02/06/2006)
Page 152 The marks are red and shown in the illustration below with the arrow. They are sometimes referred to as the mechanical zero point of the machine. For the carton chain, the drivers of the fixed chains must be on this mark. Figure 7.13 Setting the chain base setting. 7-21 200246 CMK Operators Manual (02/06/2006)
Page 153: Carton Chain Base Setting Adjustment
After you have made the adjustment on one side of the carton machine, check the position of the fixed drivers on the other side and readjust as necessary. Figure 7.14 Carton Chain base setting. 7-22 200246 CMK Operators Manual (02/06/2006)
Page 154: Tensioning The Carton Chain
• Tighten the clamping sleeve. • Tension the spring with the tension nut. • Secure it with the lock nut. Clamping Sleeve Tension Lever Adjustment Nuts Threaded Rod Spring Figure 7.15 Tensioning the Carton Chain. 7-23 200246 CMK Operators Manual (02/06/2006)
Page 155: Position Drivers Vertically
This makes up for signs of wear on the rails. To adjust the chain guide: • Loosen the lock nut (3) • Screw in the adjustment screw (4) until the chain has the right amount of play in it. Figure 7.16 Positioning Drivers. 7-24 200246 CMK Operators Manual (02/06/2006)
Page 156: Replacing Chain Segments
The chains are each equipped with a number of chain locks. Only segments between two locks can be removed for replacement. There is one driver for each segment. Figure 7.17 Replacing chain segments. 7-25 200246 CMK Operators Manual (02/06/2006)
Page 157: Tensioning Carton Chain Drive Belts
• The tension on the belt must be adjusted so that the belt cannot be raised up from the toothed disks. Tension Roller Belt Fastening Bolts Figure 7.18 Tensioning the Carton Chain drive belt. 7-26 200246 CMK Operators Manual (02/06/2006)
Page 158: Tension Drive Chain: Main Shaft-Carton Chain
Once the cause is determined and eliminated, the clutch may be locked back in place by moving the carton machine forward in JOG mode. Figure 7.19 Tensioning the Drive Chain. 7-27 200246 CMK Operators Manual (02/06/2006)
Page 159: Barrel Loader
Check the height adjustment before installing the pusher plates. Scale Attach handle to loosen nut. Figure 7.20 Adjusting the Barrel Loader height limit switch. 7-28 200246 CMK Operators Manual (02/06/2006)
Page 160: Insertion Slides Cover Guide
To remove the insertion slides cover, pull down and turn the locking knob to hold it open, pull the guide off the bracket. Pull Down and Turn Knob Pull Cover from Bracket Figure 7.21 Replacing Insertion Slide covers. 7-29 200246 CMK Operators Manual (02/06/2006)
Page 161 • If the slide should not be inserted into the carton, remove adjustment screw (2). • To remove the entire slide, loosen the fastening screw (5). This may be necessary to replace the rollers (4). Figure 7.22 Replacing Insertion Slides. 7-30 200246 CMK Operators Manual (02/06/2006)
Page 162: Tensioning Upper Conveyor (Barrel Loader) Chains
• Adjust tension screw (2). • Tighten lock nut (3). NOTE: The tension must be the same on both chains. Otherwise the insertion slides will not be in a straight line. Figure 7.23 Tensioning the Barrel Loader 7-31 200246 CMK Operators Manual (02/06/2006)
Page 163: Flap Closers
This setting should be checked in JOG mode. If the disk is not aligned properly, loosen the clamping screw (1) and rotate the disk to the proper position. Re-check it in JOG mode. Figure 7.24 Adjusting the Flap Closers. 7-32 200246 CMK Operators Manual (02/06/2006)
Page 164: Flap Closer Drive Belts Tension
You can also use this feature to perform a base setting. If this state occurs under uncontrolled conditions, for example while you are replacing a toothed belt, a base setting must be performed! Figure 7.25 Tensioning the Flap Closer drive belts. 7-33 200246 CMK Operators Manual (02/06/2006)
Page 165: Glue Device
Depending on the design and specifications of the gluing unit, switching signals for the glue heads may also be adjusted on the gluing unit. If this option is used, please observe the operating instructions for the gluing unit! Figure 7.26 Adjusting Glue Heads location. 7-34 200246 CMK Operators Manual (02/06/2006)
Page 166: Drying Zone
The rounded rods can be adjusted in the slots (2) after loosening the clamping screws (3). After a change, a carton should be moved through the machine in JOG mode to check all settings Figure 7.27 Drying Zone Adjustments. 7-35 200246 CMK Operators Manual (02/06/2006)
Page 167: Guides
NOTE: The guides must always be checked after an adjustment is made. Move a carton through the machine in JOG mode to check for any problems. Flap Guides Flap Guides Adjustments Figure 7.28 Flap Guide adjustments. 7-36 200246 CMK Operators Manual (02/06/2006)
Page 168: Bucket Conveyor
Open Access Cover Loosen Bolt Location #19 (See Below) Loosen Bolt Figure 7.29 Adjusting the bucket size. 7-37 200246 CMK Operators Manual (02/06/2006)
Page 169: Adjust Bucket Conveyor - Continued
Check the width setting of the buckets after the machine has been running for a short time! Adjustment Location #19 Wrench on Cylinder Adjustment Cylinder Buckets Adjust in Size Figure 7.30 Adjusting the bucket size. 7-38 200246 CMK Operators Manual (02/06/2006)
Page 170: Product Supply Conveyor Base Setting
The adjustable side of the bucket wall (3) may be adjusted depending on the size of product. The position of the adjustable side is independent of the base setting. Figure 7.31 Bucket Conveyor base setting. 7-39 200246 CMK Operators Manual (02/06/2006)
Page 171: Bucket Conveyor Base Setting
(2) becomes free. • Remove the three screws again, put them back in their places and screw them in finger-tight Figure 7.32 Bucket Conveyor base setting. 7-40 200246 CMK Operators Manual (02/06/2006)
Page 172: Conveyor Adjustments
After you are finished with the adjustment, check all positions of the base setting. The position can be seen on the display as a display of actual position. It corresponds to angle position 0° (zero degrees). Figure 7.33 Conveyor adjustments. 7-41 200246 CMK Operators Manual (02/06/2006)
Page 173: Filling Height Monitoring
Filling height monitoring is used to monitor the height of product in the bucket. Adjusting Fill Height Monitoring: Loosen the clamping lever (5). Move to desired location on the scale (3) as indicated by the arrow below. Figure 7.34 Adjusting the bucket conveyors Fill Height Monitoring height. 7-42 200246 CMK Operators Manual (02/06/2006)
Page 174: Tensioning The Bucket Conveyor Chains
Minor expansion in the chain can be compensated for by this spring. Note: The tension must be the same on both sides. Proximity Sensor Tension Spring Tension Spring Figure 7.35 Adjusting the Bucket Conveyor tension. 7-43 200246 CMK Operators Manual (02/06/2006)
Page 175: Tensioning The Main Drive Belt
• Turn the tension screw (5) to move the entire unit. • Turn in the tension screw (5) until the desired tension of the drive belt (1) has been reached. • Tighten the fastening screws (4). Figure 7.36 Tensioning the main drive belt. 7-44 200246 CMK Operators Manual (02/06/2006)
Page 176: Carton Removal Chain Base Setting
After you are finished with the adjustment, check all positions of the base setting. The position can be seen on the display as a display of actual position. It corresponds to angle position 0° (zero degrees). Figure 7.37 Carton removal chain base setting. 7-45 200246 CMK Operators Manual (02/06/2006)
Page 177: Tensioning The Chain Removal Drive Belts
The drive belt (3) runs over a tension roller (2). This roller can be moved by loosening the clamping screw (1). Loosening the clamping screw and pressing down the tension roller tensions the belt. After the tensioning is complete, tighten the clamping screw. Figure 7.38 Tensioning the drive belts. 7-46 200246 CMK Operators Manual (02/06/2006)
Page 178: Tensioning The Removal Conveyors
The tension must be the same on the two chains. After tensioning is complete, check the position of the drivers (3). The two drivers must line up with each other on the mark for the zero setting. Figure 7.39 Tensioning the Removal Conveyors. 7-47 200246 CMK Operators Manual (02/06/2006)
Page 179: Section 8: Maintenance
In order to avoid misunderstandings, it is necessary to charge clearly in writing different persons or person groups with their individual tasks. Before performing any cleaning or maintenance procedures on the machine, ensure that the electrical power and pneumatic supplies are properly locked-out and tagged-out. 200246 CMK Operators Manual (02/06/2006)
Page 180: Cleaning Intervals
Also commercially available mild household cleansers may be applied using a moist cloth. Use only cleansers that are harmless to mechanical and electrical parts of the machine. Display When cleaning the display, use only a moist cloth, please. Never use cleansers! 200246 CMK Operators Manual (02/06/2006)
Page 181: Daily Maintenance
A1: Remove glue residue. • A2: Perform maintenance on the gluing unit per the manufacturer’s instructions. • A3: Drain off water from condensation in the pneumatic condensation bowl. • A4: Verify that the central lubrication system is activated. 200246 CMK Operators Manual (02/06/2006)
Page 182: After Stopping
Drain condensed water from the bowl on the air regulator. See the below figure for reference to the condensation bowl. Condensation Bowl Figure 8.1 Condensation Bowl • Remove all product residues or packaging waste from the machine at least one time each day. 200246 CMK Operators Manual (02/06/2006)
Page 183 Remove glue residue from the nozzles of all glue heads. When working on hot machine parts, including glues nozzles, Always wear appropriate safety gloves. Glue Nozzles become very hot! Figure 8.2 Shows a gluing device. 200246 CMK Operators Manual (02/06/2006)
Page 184: Weekly Maintenance
Check all drive belts and re-adjust belt tension if necessary. Replace damaged drive belts. Guiding Rollers: Check to see if all guiding rollers move smoothly. Feeding belts, grouping belts and discharging belts: Check for excessive wear or damage. Replace if necessary. 200246 CMK Operators Manual (02/06/2006)
Page 185 B4: Check the central lubrication oil level. • B5: Check the oil level on the main gear unit. • B6: Perform maintenance on the gluing unit per the manufacturer’s instructions. • B7: Clean all guides. 200246 CMK Operators Manual (02/06/2006)
Page 186: Monthly Maintenance
Other procedures are to be realized in conformity with WEEKLY MAINTENANCE. Regular maintenance and servicing of the machine help to prevent losses of production! Regular checking, maintenance and servicing of the safety devices help ensure operator safety! 200246 CMK Operators Manual (02/06/2006)
Page 187 C7: Check the air filter for the blower and replace, if necessary. • C8: Lubricate the main shaft, if needed. • C9: Check ventilation in the electrical cabinet. • C10: Check the warning signs on the machine to make sure they are visible. 200246 CMK Operators Manual (02/06/2006)
Page 188: Other Maintenance Procedures
Replacing sections of the driver chain: To replace a driver in the folding carton chain: • Open the chain lock (1). • Remove the old driver (2). • Insert the new driver (2). • Close the chain lock (1). 8-10 200246 CMK Operators Manual (02/06/2006)
Page 189 Rovema CMK Operator’s Manual Section 8: Maintenance Other Maintenance Procedures Adjusting the play of the folding carton conveyor chain: • Loosen the locking nut (1). • Use the bolt (2) to adjust the guide rail. 8-11 200246 CMK Operators Manual (02/06/2006)
Page 190 • Remove the screws (1). • Remove the Bar (2). • Replace the side wall (3) of segment. • Insert the bar (2) again and hold it in place. • Screw in the screws (1). 8-12 200246 CMK Operators Manual (02/06/2006)
Page 191 • Replace the rollers that are positioned crossways (4) by loosening the threaded pin (5) and removing the bolt (6). • Installation is in the opposite order. After the rollers are replaced, adjust the guide with nuts (1) so there is only a little play. 8-13 200246 CMK Operators Manual (02/06/2006)
Page 192: Lubrication
The drawings below illustrate the layout of the central lubrication system. (1) Pneumatic connection (2) Pump (3) Line (4) Cup chain lubrication (5) Cup chain lubrication (6) Cup chain lubrication (7) Intermediate chain (optional) (8) Folding carton chain (9) Folding carton chain 8-14 200246 CMK Operators Manual (02/06/2006)
Page 193 The lubrication intervals must be set according to the working conditions of the machine (cycle number, product residue, temperature, etc.). • Do not lubricate immediately before turning the unit off or the lubricant will not be evenly distributed. 8-15 200246 CMK Operators Manual (02/06/2006)
Page 194: Section 9: Troubleshooting
The intention of the Alarm Banner is to alert the operator to the fact that alarms exist, not necessarily to give an accounting of all alarms. Figure 9.1 Shows a sample Alarm banner. 200246 CMK Operators Manual (02/06/2006)
Page 195: Alarm Screen
Some alarm conditions can be resolved simply by pressing the Ready button, while other alarms require the operator to resolve conditions on the machine prior to pressing the Ready button. Figure 9.2 Shows a sample Active Alarm screen. 200246 CMK Operators Manual (02/06/2006)
Page 196: Alarm History Screen
Date and Time stamp on the Alarm History screen. The operator may clear the Alarm History by pressing the Clear Alarm History button on this screen. Figure 9.3 Shows a sample Alarm History screen. 200246 CMK Operators Manual (02/06/2006)
Page 197: Alarms And Warnings
*Any* Home Failed The prox signal was not seen by Refer to the drawing and check Fault the drive during the homing the home prox wiring, including sequence. the 24v source voltage to the drive. 200246 CMK Operators Manual (02/06/2006)
Page 198 The pressure switch has dumped. If the condition still malfunctioned. exists, check air supply pressure at regulator, check for proper operation of air pressure sensor. 200246 CMK Operators Manual (02/06/2006)
Page 199 Carton Discharge A carton is jammed in the After the machine stops, open the Jam Fault discharge area of the CMK guard doors and clear the mis-fed cartoner. carton. Determine the reason for the jammed carton and make adjustments, if necessary. Close...
Page 200 Coupon Feeder Fault The coupon feeder has Refer to the operator’s manual for experienced a fault condition. the coupon feeder. Clear the fault, then press the MACHINE READY push-button to reset the machine. 200246 CMK Operators Manual (02/06/2006)
Page 201 The feedback signal from the If the feedback signal is received Too Late checkweigher was received later too late in the target window then than required by the CMK proper bagger tracking cannot be cartoner. guaranteed. Speed up the Metal Detector...
Page 202 Check each in order to verify that the lights have not burned out. If none of the E-Stop pushbuttons are pressed then check the wiring and replace the contactor or pushbutton if necessary. 200246 CMK Operators Manual (02/06/2006)
Page 203 Close the guard doors and press the Machine Ready pushbutton to prepare for operation. NOTE: All bags must be cleared from the Barrel Loader area (including buckets and carton flights) or jams will occur on startup. 9-10 200246 CMK Operators Manual (02/06/2006)
Page 204 Once the machine cycle stops, Product Jam Fault reject conveyor. clear the mis-fed bags. Determine the reason for the jam and make adjustments, if necessary. Press the Machine Ready pushbutton to prepare for operation. 9-11 200246 CMK Operators Manual (02/06/2006)
Page 205 9-12 200246 CMK Operators Manual (02/06/2006)
Page 206: Warning Messages
The prox signal was not seen by Refer to the drawing and check Transfer 1 Axis the drive during the homing the home prox wiring, including Home Failed sequence. the 24v source voltage to the drive. 9-13 200246 CMK Operators Manual (02/06/2006)
Page 207 Determine if the infeed station. conveyor is running too slow or too fast. Verify that the infeed conveyor is in the correct position. 9-14 200246 CMK Operators Manual (02/06/2006)
Page 208 9-15 200246 CMK Operators Manual (02/06/2006)
Page 209 Jog Mode the jog mode. mode, access the Cartoner Setup Screen, from the Adjustments screen. The machine may be toggled out of jog mode by pressing the Cartoner Jog Mode button on that screen. 9-16 200246 CMK Operators Manual (02/06/2006)

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