Page 1 VPK Operations Manual...
Page 2 About this Manual This manual is a reference tool for the Rovema VPK series bagmakers: models VPK-260 and VPK-360. It should be used in conjunction with instructor lead training. The following information is include in this manual: n Introduction n Safety Instructions...
Page 3: Table Of Contents
Rovema VPK Operator’s Manual Table of Contents Table of Contents Introduction ..................... 1-1 Safety Instructions ..................2-1 Safety Devices ....................... 2-2 Guard Doors ....................... 2-2 EMERGENCY STOP Push-Button ................2-3 Safety Labels......................2-4 Component Safety ....................2-5 Operator Safety ...................... 2-6 Operator Safety Guidelines ..................
Page 4 Rovema VPK Operator’s Manual Table of Contents Table of Contents (continued) Vertical Sealing Device ..................3-16 Seal Band Unit ......................3-17 Heating Bar ........................3-18 Sealing Band, Band Sensor, and Band Release Lever ............3-19 Drive System ........................3-20 Engage/Retract Device .................... 3-21 Touchscreen Controls ......................
Page 5 Rovema VPK Operator’s Manual Table of Contents Table of Contents (continued) Bag Shaping Devices ....................3-47 Gusset Device ........................3-48 Touchscreen Controls ....................3-49 STABILO SEAL® Sealing System ..................3-50 Touchscreen Controls ....................3-51 Theory of Operations ..................4-1 Forming Cycle ......................4-2 Timing Chart ......................
Page 6 Rovema VPK Operator’s Manual Table of Contents Table of Contents (continued) Settings Screen......................5-10 Cam Settings ........................5-11 Horiz. Cooling Settings ....................5-12 Vertical Cooling Settings (if equipped) ................. 5-12 Knife Settings ....................... 5-13 Film Tracking Settings ....................5-13 Vibrator ........................5-14 Bag Folder ........................
Page 7 Rovema VPK Operator’s Manual Table of Contents Table of Contents (continued) Machine Setup Procedures ................6-1 Powering the Bagmaker ..................6-2 Loading a Product Recipe..................6-3 Setting the Machine Speed and Bag Length ............6-4 Installing the Forming Set..................6-5 Loading a Film Roll ....................
Page 8 Rovema VPK Operator’s Manual Table of Contents Table of Contents (continued) Working with Components ................8-1 Replacing Heater Cartridges and Temp. Probes............ 8-2 Horizontal sealing Jaws .....................8-2 Vertical Sealing Device ....................8-5 Replacing the Film Feed Belts ................8-7 Replacing the Cutting Knife ..................8-8 Aligning the Forming Set ..................
Page 9: Introduction
Rovema VPK Operator’s Manual Introduction Introduction The Rovema VPK is a continuous motion form-fill-seal vertical bagmaker that packs a variety of products into bags. It forms, fills, and seals bags by forming flat packaging material into a tube, sealing the edges and bottom of the tube, filling the tube with product, cutting the tube to length, and sealing the top of the tube.
Page 10: Safety Instructions
Rovema VPK Operator’s Manual Safety Instructions Safety Instructions This section contains information on machine safety issues. These issues include: Bagmaker Safety Devices Component Safety Operator Safety Machine Lockout Procedure 3/2000 VPK REV(B) PANELVIEW 600...
Page 11: Safety Devices
Rovema VPK Operator’s Manual Safety Instructions Safety Devices The VPK safety devices include guard doors, an EMERGENCY STOP push-button, and safety labels. Guard Doors The guard doors isolate the operator from the forming and sealing area. The doors are also equipped with a switch that causes the machine to stop when they are opened.
Page 12: Emergency Stop Push-Button
Rovema VPK Operator’s Manual Safety Instructions Safety Devices EMERGENCY STOP Push-Button The EMERGENCY STOP push-button causes the bagmaker to immediately stop operating if pushed. This push-button should be used when there is perceived or actual damage occurring to the bagmaker or to an operator.
Page 13: Safety Labels
Rovema VPK Operator’s Manual Safety Instructions Safety Devices 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. CAUTION HOT SURFACE...
Page 14: Component Safety
Rovema VPK Operator’s Manual Safety Instructions Component Safety Rovema does not allow any electrical or mechanical modifications to the VPK bagmaker without explicit authorization. Only original Rovema spare parts and accessories should be used on the bagmaker; This ensures that the machine will perform safely and as designed.
Page 15: Operator Safety
Rovema VPK Operator’s Manual Safety Instructions Operator Safety Only properly trained personnel can operate the bagmaker. The operator is responsible for following the operator safety guidelines presented in this section as well as any employer safety guidelines. Operator Safety Guidelines Use the following safety guidelines for safe operation of the bagmaker.
Page 16: Lockout Procedures
Rovema VPK Operator’s Manual Safety Instructions Lockout Procedures The bagmaker must be properly locked out before any repair or maintenance tasks can be performed on it. This section describes procedures that should be used to lockout the air and power supplies.
Page 17: Power Lockout Procedure
Rovema VPK Operator’s Manual Safety Instructions Lockout Procedures Power Lockout Procedure Use the following procedure to lockout the electrical power supply: 1. Press the STOP push-button to halt the machine. 2. Turn the MAIN DISCONNECT switch to the OFF position to disable electrical power to the machine 3.
Page 18: Parts And Functions
Rovema VPK Operator’s Manual Parts and Functions Parts and Functions This section describes the major parts and functions of the VPK vertical bagmaker. These parts include the: Film Carriage Film Feeding Device Forming Set Vertical Sealing Device Horizontal Sealing Device...
Page 19: Film Carriage
Rovema VPK Operator’s Manual Parts and Functions Film Carriage The film carriage controls the supply of packaging material that the bagmaker uses to form bags. It includes a: Film Spindle Dancer Assembly Film Unwind Brake Film Tracking Assembly Out of Film Sensor Assembly...
Page 20: Film Spindle
Rovema VPK Operator’s Manual Parts and Functions Film Carriage Film Spindle The film spindle supports the packaging material on the film carriage. It consists of an air bladder that is partially enclosed within a metal housing. The housing has slots that allow sections of the air bladder to protrude through it.
Page 21: Dancer Assembly
Rovema VPK Operator’s Manual Parts and Functions Film Carriage Dancer Assembly The dancer assembly maintains tension on the film web. It includes one fixed roller and a dancer arm assembly. When film is threaded through the bagmaker, a film loop forms between the fixed roller and the arm rollers.
Page 22: Film Unwind Brake
Rovema VPK Operator’s Manual Parts and Functions Film Carriage Film Unwind Brake The film unwind brake controls the unwinding of the film roll. It consists of a brake drum that is attached to the film spindle and a brake pad assembly that is actuated by the dancer assembly.
Page 23: Film Tracking Assembly
Rovema VPK Operator’s Manual Parts and Functions Film Carriage Film Tracking Assembly The film tracking assembly controls the position of the film carriage relative to the forming collar; thus controlling the alignment of the vertical seal. The assembly includes a DC drive motor and two limit switches.
Page 24: Touchscreen Controls
Rovema VPK Operator’s Manual Parts and Functions Film Carriage > Film Tracking Assembly Touchscreen Controls The film carriage movements are controlled by two switches on the touchscreen display. Whenever the bagmaker is turned on, pressing either of these switches will cause the film carriage to move (except when the E-STOP button is depressed).
Page 25: Out Of Film Sensor Assembly
Rovema VPK Operator’s Manual Parts and Functions Film Carriage Out of Film Sensor Assembly The out of film sensor assembly causes the bagmaker to stop forming bags when the film roll is exhausted or when the film tension is too high.
Page 26: Guide Rollers
Rovema VPK Operator’s Manual Parts and Functions Film Carriage Guide Rollers The guide rollers provide an almost frictionless path for the film to travel along up to the forming collar. The last set of rollers before the collar (setup rollers) are adjustable. These rollers change the angle of the film web to match the angle of the forming collar.
Page 27: Film Feeding Device
Rovema VPK Operator’s Manual Parts and Functions Film Feeding Device The film feeding device pulls film from the film carriage and pushes it down the forming tube for sealing. The device consists of two belts assemblies, a drive system, and an engage/retract device.
Page 28: Belts Assemblies
Rovema VPK Operator’s Manual Parts and Functions Film Feeding Device Belts Assemblies The belt assemblies suction the film tube and push it down the forming tube. Within each assembly is a vacuum chamber that directs vacuum through holes in the feeding belts. The suction produced by the vacuum increases the friction between the belts and the film tube while reducing the friction between the film tube and the forming tube.
Page 29: Drive System
Rovema VPK Operator’s Manual Parts and Functions Film Feeding Device Drive System The drive system turns the film feed belts to push the film down the forming tube. The system includes two motors (one for each belt assembly) and two servo amplifiers. The servo amplifiers power the drive motors and operate them in synchronization.
Page 30: Engage/Retract Device
Rovema VPK Operator’s Manual Parts and Functions Film Feeding Device Engage/Retract Device The engage/retract device moves the film feeding belts to and from the forming tube. It also maintains belt pressure against the tube. The device consists of two pneumatic cylinders, a pressure regulator, and a pressure gauge.
Page 31: Touchscreen Controls
Rovema VPK Operator’s Manual Parts and Functions Film Feeding Device Touchscreen Controls The film feeding device has one control on the touchscreen display. The BELTS switch controls the engage/retract device. When this switch is set to OPENED, the belts move away from the forming tube. When the switch is set to CLOSED, the belts move against the forming tube.
Page 32: Forming Set
Rovema VPK Operator’s Manual Parts and Functions Forming Set The forming set shapes the flat film into a tube and guides product into the bags. It consists of a forming collar, a forming tube, and securing knobs. The forming collar folds the film into a tube. While doing so, it folds one edge of the tube inside out and lays the opposite edge over it.
Page 33: Vertical Sealing Device
Rovema VPK Operator’s Manual Parts and Functions Vertical Sealing Device The vertical sealing device joins the edges of the film tube together. The device includes: a seal band unit, a drive system, an engage/ retract device, and a seal band support.
Page 34: Seal Band Unit
Rovema VPK Operator’s Manual Parts and Functions Vertical Sealing Device Seal Band Unit The seal band unit joins the edges of the film tube together by melting the inner film layer to itself. When the forming set folds the film into a tube, it turns a small portion of one edge inside out and lays the opposite edge over it.
Page 35: Heating Bar
Rovema VPK Operator’s Manual Parts and Functions Vertical Sealing Device > Seal Band Unit Heating Bar The heating bar creates the heat needed to melt the inner film layer. Within the bar are replaceable heating cartridges and a replaceable temperature probe. A temperature controller on the bagmaker’s control panel controls the heating of the bar.
Page 36: Sealing Band, Band Sensor, And Band Release Lever
Rovema VPK Operator’s Manual Parts and Functions Vertical Sealing Device > Sealing Band Unit Sealing Band, Band Sensor, and Band Release Lever The sealing band transfers heat from the heating bar to the film tube. The band sensor causes the bagmaker to stop forming bags if the band breaks.
Page 37: Drive System
Rovema VPK Operator’s Manual Parts and Functions Vertical Sealing Device Drive System The drive system turns the sealing band in synch with the film feeding belts. This keeps the band stationary with respect to the film and prevents the band from wrinkling the film. The system includes an AC drive motor, a speed controller, and a gear box.
Page 38: Engage/Retract Device
Rovema VPK Operator’s Manual Parts and Functions Vertical Sealing Device Engage/Retract Device The engage/retract device moves the seal band unit against and away from the forming tube. The device uses a pneumatic cylinder to perform the engage and retract movements. Settings on the touchscreen control the timing of the movements.
Page 39: Touchscreen Controls
Rovema VPK Operator’s Manual Parts and Functions Vertical Sealing Device Touchscreen Controls The timing of the engage/retract movements are controlled by a switch on the touchscreen display. The device is timed to engage the film ###ms before the film feeding device begins advancing the film and to retract from the film ###ms after the film stops moving.
Page 40: Seal Band Support
Rovema VPK Operator’s Manual Parts and Functions Vertical Sealing Device Seal Band Support The seal band support holds the seal band unit and positions the unit relative to the forming tube. It includes position locking levers, pivot locking levers, and lateral adjustment bolts.
Page 41: Horizontal Sealing Device
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device The horizontal sealing device creates the top and bottom seals in a bag and cuts the bag from the film tube. Top and bottom seals (horizontal seals) are created in the same manner as the vertical seal;...
Page 42: Jaw Assemblies
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device Jaw Assemblies The jaw assemblies create horizontal seals in the film tube. Seal are created when the front and back sides of the film tube are pressed together and heated for a period of time. The heat causes the inner film layer to melt and the pressure causes the two sides of the inner film layer to mix and form a bond (seal).
Page 43: Jaw Body
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device > Sealing Jaws Jaw Body The jaw bodies create the heat needed to melt the inner film layer. They consist of two halves. The upper half creates bottoms seals while the lower half creates top seals. Within each body are two replaceable heating cartridge and a replaceable temperature probe.
Page 44: C-Frames, Jaw Carriers And Jaw Springs
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device > Sealing Jaws C-Frames, Jaw Carriers and Jaw Springs The c-frames, the jaw carriers, and the jaw springs work in conjunction to create the pressure needed to mix the two sides of the inner film layer.
Page 45: Seal Pressure
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device > Sealing Jaws Seal Pressure The sealing pressure is determined by the amount of jaw spring compression. The amount of compression is determined by the distance between the jaw springs and the c-frames. As this distance increases, the sealing pressure decreases.
Page 46: Drive System
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device Drive System The drive system shapes the motion of the sealing jaws (“D-Motion”). It is this motion that causes the sealing jaws to open and close around a bag. The system includes a servo motor, a servo amplifier, gearing, and crank arms.
Page 47: Touchscreen Controls
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device > Drive System Touchscreen Controls Sealing time is determined by the speed of the horizontal sealing device. Settings on the touchscreen display control the speed of the device. These settings affect the jaw profile. The jaw profile describes the speed of the sealing jaws at various points in the “D-Motion”.
Page 48: Knife Assembly
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device Knife Assembly The knife assembly cuts the bags from the film tube. It is housed between the upper and lower sections of the front jaw assembly. When the sealing jaws close, the knife extends to cut through the film.
Page 49: Touchscreen Controls
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device > Knife Assembly Touchscreen Controls A switch on the touchscreen controls the movements of the cutting knife. This switch determines when the knife can extend and cut a bag from the film tube and whether the knife will be used during bag production.
Page 50: Temperature Controllers
Rovema VPK Operator’s Manual Parts and Functions Horizontal Sealing Device Temperature Controllers The temperature controllers monitor and adjust the horizontal sealing temperatures. There is one controller for each jaw assembly. The controller applies full voltage to the heating cartridges until the set sealing temperature is reached.
Page 51: Registration Sensor
Rovema VPK Operator’s Manual Parts and Functions Registration Sensor The registration sensor allows the bagmaker to use registered film. Because registered film has artwork printed at evenly spaced intervals, the bagmaker must seal the film between the printed sections. In order for it to accomplish this, it must detect the location of the printed sections and position them relative to the horizontal sealing device.
Page 52: Touchscreen Controls
Rovema VPK Operator’s Manual Parts and Functions Registration Sensor Touchscreen Controls The registration sensor has three switches that control its operation; the WINDOW IN switch, the OFFSET IN switch, and the ENABLE/DISABLE switch. The WINDOW INswitch determines when the bagmaker will examine the signal from the sensor;...
Page 53: Pneumatics System
Rovema VPK Operator’s Manual Parts and Functions Pneumatics System The pneumatics system controls the compressed air supply to the bagmaker. The system distributes compressed air to the bagmaker’s pneumatic cylinders, the vacuum generator, and the cooling devices. The system includes a primary manifold and an air filter/regulator.
Page 54: Primary Manifold
Rovema VPK Operator’s Manual Parts and Functions Pneumatics System Primary Manifold The primary manifold distributes compressed air to the horizontal and vertical cooling devices, the vacuum system and the solenoid bank. A pressure switch is also connected to the primary manifold.
Page 55: Pressure Switch
Rovema VPK Operator’s Manual Parts and Functions Pneumatic System Pressure Switch The pressure switch monitors the available air pressure in the primary manifold. If the pressure falls below the preset limit, the switch signals the bagmaker to stop forming bags and to display the “LOW AIR PRESSURE”...
Page 56: Horizontal And Vertical Cooling Devices
Rovema VPK Operator’s Manual Parts and Functions Pneumatics System Horizontal and Vertical Cooling Devices The horizontal and vertical cooling devices release compressed air onto the horizontal and vertical seals. These devices direct compressed air from the primary manifold, through valves, through air lines, to cooling wands.
Page 57: Vacuum System
Rovema VPK Operator’s Manual Parts and Functions Pneumatics System Vacuum System The vacuum system creates the suction for the film feeding belt assemblies. The system includes a vacuum generator, an air filter, and a vacuum gauge. The vacuum generator uses compressed air to generate a vacuum.
Page 58: Solenoid Bank
Rovema VPK Operator’s Manual Parts and Functions Pneumatics System Solenoid Bank The solenoid bank supplies compressed air to all of the bagmaker’s pneumatic cylinders. The PLC activates each solenoid valve in the bank at a specific time to perform a forming operation.
Page 59: Optional Equipment
Rovema VPK Operator’s Manual Parts and Functions Optional Equipment Optional equipment enhances the capabilities of the bagmaker. This equipment includes: Bevel Plates Bag Grippers Foam Deflators Splice Table Automatic Film Tracking Sensor Gusseting Device STABILO Sealing System 3-42 3/2000 VPK REV(B) PANELVIEW 600...
Page 60: Bevel Plates
Rovema VPK Operator’s Manual Parts and Functions Optional Equipment Bevel Plates The bevel plates isolate the horizontal seals from the impact of the product drop. Because they hold the product drop above the horizontal seals, they also allow the seals additional cooling time.
Page 61: Splice Table
Rovema VPK Operator’s Manual Parts and Functions Optional Equipment Splice Table The splice table is used to attach the beginning of a full film roll to the end of an exhausted film roll. When the bagmaker runs out of film, the...
Page 62: Automatic Film Tracking Sensors
Rovema VPK Operator’s Manual Parts and Functions Optional Equipment Automatic Film Tracking Sensors The automatic film tracking sensors keep the edges of the vertical seal aligned. There are two optical sensors; one positioned just inside of the film web (inner sensor) and one positioned just outside of the film web (outer sensor).
Page 63: Touchscreen Controls
Rovema VPK Operator’s Manual Parts and Functions Optional Equipment > Auto. F. Tracking Sensors Touchscreen Controls Switches on the touchscreen display determine when the bagmaker can perform automatic film tracking adjustments. When the jaw drive encoder count is between the cam values, the motion controller signals the PLC to perform any necessary film tracking adjustments.
Page 64: Bag Shaping Devices
Rovema VPK Operator’s Manual Parts and Functions Optional Equipment Bag Shaping Devices The VPK bagmaker can be equipped with two devices that alter the shape of a bag; a gusseting device and a STABILO sealing device. STABILO Seal Gusset Figure 3.45 Shows a flat bottom bag with gussets and STABILO seals.
Page 65: Gusset Device
Rovema VPK Operator’s Manual Parts and Functions Optional Equipment > Bag Shaping Devices Gusset Device The gusset device adds extra folds in the film tube to create a bag that will stand on its bottom. There are two types of gusseting devices;...
Page 66: Touchscreen Controls
Rovema VPK Operator’s Manual Parts and Functions Bag Shaping Devices > Gusset Device Touchscreen Controls The touchscreen controls for the gusset device determine when the gusset plows and fingers will be extended to fold the film. The device is timed so that the gusset folds are formed by the time the jaws touch.
Page 67 Rovema VPK Operator’s Manual Parts and Functions Optional Equipment > Bag Shaping Devices STABILO SEAL Sealing System ® The STABILO SEAL sealing system creases the corners of the film ® tube. The system includes four corner sealing units. Each unit has a stationary sealing rail and a heated sealing jaw.
Page 68: Touchscreen Controls
Rovema VPK Operator’s Manual Parts and Functions Bag Shaping Devices > STABILO Sealing Device Touchscreen Controls The sealing system has two switches on the touchscreen display. The HEAT switch toggles the power to the STABILO temperature controllers on and off. The SEAL switch enables and disables the system.
Page 69: Theory Of Operations
Rovema VPK Operator’s Manual Theory of Operations Theory of Operations This section describes the theory behind the forming cycle, heat sealing, the vertical sealing cycle, the horizontal sealing cycle, and film registration. 3/2000 VPK REV(B) PANELVIEW 600...
Page 70: Forming Cycle
Rovema VPK Operator’s Manual Theory of Operations Forming Cycle The forming cycle is based on a 360 degree virtual encoder count (resolver count). During one revolution of the horizontal sealing jaws, all of the forming operations occur once. Most of the operations start and stop at a specific degrees of rotation.
Page 71 Rovema VPK Operator’s Manual Theory of Operations 3/2000 VPK REV(B) PANELVIEW 600...
Page 72: Heat Sealing
Note: It is recommended that you set the SEAL MODE switch on the jaw profile screen to AUTO. If you are unable to achieve quality seals by changing the sealing temperature, contact the Rovema Service Department for assistance. 3/2000 VPK REV(B) PANELVIEW 600...
Page 73: Vertical Sealing Cycle
Rovema VPK Operator’s Manual Theory of Operations Vertical Sealing Cycle The vertical sealing cycle starts just before the film starts moving. The vertical sealing device is timed to engage the film tube a few milliseconds before the film feeding device begins advancing film. This allows sufficient sealing time for the film position in front of the sealing band.
Page 74: Horizontal Sealing Cycle
Rovema VPK Operator’s Manual Theory of Operations Horizontal Sealing Cycle The horizontal sealing cycle begins when the film starts moving. The horizontal sealing device operates at a speed that will allow it to create a specific number of bags each minute. As the sealing jaws close on the film, they push the front and back sides of the film tube together.
Page 75: Film Registration
Rovema VPK Operator’s Manual Theory of Operations Film Registration The registration sensor allows the bagmaker to use registered film. Registered film is designed to be sealed at specific locations. To accomplish this, the bagmaker must identify these locations and time the sealing jaws to land on them.
Page 76: Operator Controls
Rovema VPK Operator’s Manual Operator Controls Operator Controls This section describes the controls used to operate the bagmaker. These controls include a touchscreen display, temperature controllers, a MAIN DISCONNECT switch, an AIR DISCONNECT lever, several push-buttons, and a selector switch.
Page 77: Operator Interface
Rovema VPK Operator’s Manual Operator Controls Operator Interface The operator interface is used to load, run, or modify a product recipe; and to monitor bag production. The interface consists of a touchscreen display, a numeric keypad, a function keypad, and arrow keys.
Page 78: Touchscreen Display And Function Keys
Rovema VPK Operator’s Manual Operator Controls Operator Interface Touchscreen Display and Function Keys The touchscreen collects and displays information. The display is composed of screens. Each screen is a collection of touch sensitive cells that initiate machine functions, change product recipes, activate additional screens, or display information.
Page 79 Rovema VPK Operator’s Manual Operator Controls Operator Interface Numeric Keypad The numeric keypad is used to change a function’s value. When a function has an editable value, an input dialog box will appear on the touchscreen. Once the new value is entered into the dialog box and the ENTER key is pressed, the new value will replace the old value.
Page 80 Rovema VPK Operator’s Manual Operator Controls Operator Interface Arrow Keys The arrow keys are used with the recipe management screens. They allow you to scroll through a list of product recipes to load or save. They are also used to change the name of a product recipe.
Page 81: Operations Screen
Rovema VPK Operator’s Manual Operator Controls Operator Interface Operations Screen The operations screen displays the most commonly used touchcells and provides access to all other screens. The cells (switches) on this screen include the: MOVE FILM Switch JOG SELECT Switch...
Page 82: Jogging Select Switch
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Operations Screen MOVE FILM Switch Use this switch to control the film tracking position. Press the LEFT switch to move the film carriage (and the film web) towards the left- hand side of the forming collar. Press the RIGHT switch to move the film carriage (and the film web) towards the right-hand side of the forming collar.
Page 83: Belts Switch
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Operations Screen BELTS Switch Use this switch to open or close the film feed belts. When this switch is set to OPEN, the film feeding belts move away from the forming tube.
Page 84: Length Switch
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Operations Screen LENGTH Switch This switch sets the machine bag length. Pressing this switch displays a input dialog box. Use the numeric keypad to input the desired bag length in millimeters.
Page 85: Settings Screen
Rovema VPK Operator’s Manual Operator Controls Operator Interface Settings Screen The settings screen contains switches that control forming operations, recipe management, and data monitoring. H.COOL/ PHOTOEYE PRINTER STABILO MENU MENU SETUP MENU V. SEAL/ FEEDER/KNIFE CAM 9/ MENU F. TRACK MENU...
Page 86: Cam Settings
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Settings Screen Cam Settings Many of the screens under the settings screen control cam settings. Cam settings determine when forming operations will occur based on the position of the horizontal sealing jaws. The position of the sealing jaws are tracked by a 360 Degree “virtual encoder”.
Page 87: Horiz. Cooling Settings
Rovema VPK Operator’s Manual Operator Controls Op. Interface > Settings Screen > Cam Settings Horiz. Cooling Settings These settings determine when the horizontal cooling device can be activated to cool horizontal seals. When the encoder count is between these settings, the motion controller will signal the PLC to energize the horizontal cooling solenoid valve.
Page 88: Knife Settings
Rovema VPK Operator’s Manual Operator Controls Op. Interface > Settings Screen > Cam Settings Knife Settings These settings determine when the knife can be extended to cut a bag from the film tube. When the encoder count is between these settings, the motion controller will signal the PLC to energize the knife solenoid valve.
Page 89: Vibrator
Rovema VPK Operator’s Manual Operator Controls Op. Interface>Settings Screen>Cam Settings Vibrator These settings determine when the bag vibrator can be activated to settle the product in the bag. When the encoder count is between these settings, the motion controller will signal the PLC to energize the vibrator solenoid valve and the vibrator will shake the bag.
Page 90: Jaw Seal Settings Screen
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Settings Screen Jaw Seal Settings Screen This screen contains switches that control the speed of the sealing jaws as the move through the sealing portion of the “D-Motion” path (sealing cycle) and a switch that affects the speed of the film relative to the speed of the sealing jaws.
Page 91: Film Bulge Factor Setting
Rovema VPK Operator’s Manual Operator Controls Op. Interface > Set Scrn > Jaw Seal Settings Film Bulge Factor Setting This setting causes the film feeding device to run some percentage slower or faster than the horizontal sealing device. Bulge factors between 80% and 100% cause the film to move slower than the sealing jaws which stretches the bags downward during filling.
Page 92: Auto/Man Switch
Rovema VPK Operator’s Manual Operator Controls Op. Interface > Settings Scrn > J. Profile Setings AUTO/MAN Switch This switch toggles the jaw profile mode between automatic and manual. When set to AUTO, the bagmaker calculates the postseal time, the postseal angle, and the preseal time. When set to MAN, the operator must determines these parameters.
Page 93: Feeder Screen
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Settings Screen Feeder Screen The feeder screen synchronizes the bagmaker and the product feeder. It also determines the method of synchronization between the two machines. The drop time setting synchronizes the release of product from the product feeder with the closing of the sealing jaws.
Page 94 Rovema VPK Operator’s Manual Operator Controls Operator Interface > Settings Screen The SYNC MODE SELECT switch activates a screen where you can choose the method of synchronization; Stroke on Demand or Master/Slave. Note: Before the screen is displayed a password is required.
Page 95: Printer Screen
PLC to activate the printer. The CAM ON/CAM OFF switch is only used when the zipper applicator has been physically removed from the bagmaker. Note: Please consult the Rovema Service Department before removing the zipper applicator. PRINTER FILM TRAVEL mm: USE WITH...
Page 96: Vertical Seal Screen
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Settings Menu Vertical Seal Screen This screen controls the movements of the vertical seal engage/retract device. The v. seal in delay setting determines when the vertical sealing device will engage the film tube. The v. seal out delay setting determines when the vertical sealing device will retract from the film tube.
Page 97: Photoeye Screen
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Settings Screen Photoeye Screen This screen controls the operation of the registration sensor. The “window in” setting determines when the motion controller will examine the signal from the registration sensor. This prevents the sensor from detecting artwork that is printed in the same path as the registration marks.
Page 98: Stabilo Seal Screen
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Settings Screen Stabilo Seal Screen This screen controls the operation of the STABILO SEAL sealing ® system. The HEAT switch toggles the power to the stabilo temperature controls on and off. The SEAL switch enables and disables the sealing system.
Page 99: Recipe Management Screen
Rovema VPK Operator’s Manual Operator Controls Operator Interface > Settings Screen Recipe Management Screen The recipe management screen includes switches that allow you to load or save a product recipe. Product recipes contain all of the settings required to form a particular bag style.
Page 100: Recipe Load Selection Screen
Rovema VPK Operator’s Manual Operator Controls Op. Interface > Settings Screen > Recipe Mang. Recipe Load Selection Screen This screen is used to load a product recipe. Loading a recipe removes all of the current settings and replaces them with the new settings. To load a recipe, use the UP and DOWN arrow keys to scroll through and select a product recipe from the list.
Page 101: Recipe Save Selection Screen
Rovema VPK Operator’s Manual Operator Controls Op. Interface > Settings Screen > Recipe Mang. Recipe Save Selection Screen This screen is used to save the current machine settings under a previously save recipe name. Use the UP and DOWN arrow keys to scroll through and select a previously save product recipe.
Page 102: Alarms Screen
Rovema VPK Operator’s Manual Operator Controls Operator Interface Alarms Screen The alarms screen appears whenever an alarm or warning condition exists in the machine. Once the alarm or warning condition has been corrected and the CLEAR ALARMS switch has been pressed, the alarm or warning message will be cleared.
Page 103: Temperature Controllers
Rovema VPK Operator’s Manual Operator Controls Operator Interface Temperature Controllers The temperature controllers monitor and adjust the sealing temperatures. There is one controller for each jaw assembly and one for the seal band unit. The controller applies full voltage to the heating cartridges until the set sealing temperature is reached.
Page 104: Main Disconnect Switch
Rovema VPK Operator’s Manual Operator Controls MAIN DISCONNECT Switch The MAIN DISCONNECT switch turns on or off all electrical power to the bagmaker. Turn this switch to the ON position to connect power to the bagmaker. Turn this switch to the OFF position to disconnect power to the bagmaker.
Page 105: Air Disconnect Lever
Rovema VPK Operator’s Manual Operator Controls AIR DISCONNECT Lever The AIR DISCONNECT lever controls the flow of air to the bagmaker. Move the lever to its vertical position to supply air to the machine. Move the lever to its horizontal position to stop the supply of air to the machine.
Page 106: Push-Buttons And Selector Switch
Rovema VPK Operator’s Manual Operator Controls Push-Buttons and Selector Switch The push-buttons and selector switch control the operating mode of the bagmaker. They include the SYSTEM READY lighted push-button, the JOG/AUTO selector switch, the JOG/RUN push-button, the STOP push- button, and the EMERGENCY STOP push-button.
Page 107: Jog/Run Push-Button
Rovema VPK Operator’s Manual Operator Controls Push-Buttons and Selector Switch JOG/RUN Push-Button The JOG/RUN push-button runs the bagmaker in the selected operating mode. When the JOG/AUTO selector switch is set to JOG, press and hold the JOG/RUN push-button to jog the film drive or the jaw drive.
Page 108: Emergency Stop Push-Button
Rovema VPK Operator’s Manual Operator Controls Push-Buttons and Selector Switch EMERGENCY STOP Push-Button The EMERGENCY STOP push-button immediately halts bag production without regard to the forming cycle. Press the EMERGENCY STOP button once to immediately halt the machine. This button should be pressed whenever there is perceived or actual damage occurring to personnel or to the machine.
Page 109: Machine Setup Procedures
Rovema VPK Operator’s Manual Machine Setup Procedures Machine Setup Procedures This section describes procedures that can be used to prepare the bagmaker to form bags. These procedures include: Powering the Bagmaker Loading a Product Recipe Setting the Machine Speed and Bag Length...
Page 110: Powering The Bagmaker
Rovema VPK Operator’s Manual Machine Setup Procedures Powering the Bagmaker To power the bagmaker, you must activate the electrical and pneumatic supplies. To activate the electrical supply, turn the MAIN DISCONNECT switch to the ON position. To activate the pneumatic supply, rotate the AIR DISCONNECT lever to the vertical position.
Page 111: Loading A Product Recipe
Rovema VPK Operator’s Manual Machine Setup Procedures Loading a Product Recipe The product recipe contains all of the forming parameters that the bagmaker needs to form bags. When the machine is first turned on, the last product recipe that was used on the machine is automatically loaded.
Page 112: Setting The Machine Speed And Bag Length
Rovema VPK Operator’s Manual Machine Setup Procedures Setting the Machine Speed and Bag Length The bagmaker needs to know the machine operating speed and the bag length before it can form bags. When the bagmaker is first turned on, it loads the machine speed and bag length settings from the last production run.
Page 113: Installing The Forming Set
Rovema VPK Operator’s Manual Machine Setup Procedures Installing the Forming Set Each bag style requires a different forming set. The forming set for the desired bag style should be install before the film is threaded through the machine. This procedure describes how to install a forming set.
Page 114: Loading A Film Roll
Rovema VPK Operator’s Manual Machine Setup Procedures Loading a Film Roll Once the forming set has been installed, the film roll can be loaded onto the film carriage. To load a film roll: 1. Remove the film spindle form the film carriage.
Page 115: Threading A Film Roll
Rovema VPK Operator’s Manual Machine Setup Procedures Threading a Film Roll After the film roll is loaded on the film carriage, it can be threaded through the bagmaker. To thread the film: 1. Use the film routing label (located on the side of the bagmaker) to pull the film through the film carriage and up to the forming collar.
Page 116: Vertical Seal Setup
Rovema VPK Operator’s Manual Machine Setup Procedures Vertical Seal Setup The vertical sealing device must be positioned relative to the forming tube before it can create vertical seals. Setting up the vertical sealing device consists of moving it within striking distance of the forming tube and centering the vertical sealing band on the desired sealing location.
Page 117 Rovema VPK Operator’s Manual Machine Setup Procedures Vertical Seal Setup To position the device: 1. Loosen the position locking levers. 2. Slide the vertical sealing device towards the forming tube until the sealing band is 18 millimeters away from the forming tube in the retracted position.
Page 118: Pneumatic Pressure Settings
Rovema VPK Operator’s Manual Machine Setup Procedures Pneumatic Pressure Settings The pressure settings for the engage/retract devices and the cooling devices will depend on the production environment. Ambient temperature, component wear, and other factors effect the pressure settings for these devices. However, as a starting point, set the...
Page 119: Setting The Film Tension
Rovema VPK Operator’s Manual Machine Setup Procedures Setting the Film Tension Proper film tension prevents slack from forming in the film web. When the film web losses tension, the film moves away form the registration sensor or shifts around the forming collar. Before setting the film tension, you must setup the dancer assembly to produce nominal film tension.
Page 120: Setting The Film Tracking Position
Rovema VPK Operator’s Manual Machine Setup Procedures Setting the Film Tracking Position Film tracking controls the alignment of the vertical seal. You will want to set the film tracking position so that the edges of the film tube are even with one another or so that the outer edge slightly overlaps the inner edge.
Page 121: Positioning The Automatic Film Tracking Sensors
Rovema VPK Operator’s Manual Machine Setup Procedures Positioning the Automatic Film Tracking Sensors Automatic film tracking automatically keeps the edges of the film tube even. In order for automatic film tracking to work effectively, the automatic film tracking sensors must be positioned relative to the film web after the film tracking path has been established.
Page 122: Registration Sensor Setup
Rovema VPK Operator’s Manual Machine Setup Procedures Registration Sensor Setup The registration sensor must be setup according to the film type. If the bagmaker is using nonregistered film, the sensor must be disable or it will cause registration errors. If the bagmaker is using registered...
Page 123: Sensor Setup For Non-Registered Film
Rovema VPK Operator’s Manual Machine Setup Procedures Registration Sensor Setup Sensor Setup for Non-Registered Film If the bagmaker is using nonregistered film, the only setup task that needs to be performed is to disable the sensor. To disable the registration sensor: 1.
Page 124: Sensor Setup For Registered Film
Rovema VPK Operator’s Manual Machine Setup Procedures Registration Sensor Setup Sensor Setup for Registered Film When the bagmaker is using registered film, the registration sensor must be positioned relative to the registration marks, enabled, and the photoeye window and photoeye correction values must be set.
Page 125 Rovema VPK Operator’s Manual Machine Setup Procedures Sensor Setup for Registered Film Photoeye Window and Photoeye Correction Settings The values for the photoeye window and photoeye correction settings will depend on the film layout. The photoeye window setting tells the bagmaker when to look for the registration marks.
Page 126 Rovema VPK Operator’s Manual Machine Setup Procedures Sensor Setup for Registered Film Determining the Photoeye Window Value If there is no artwork printed in the registration field, set the photoeye window setting to zero (0). This allows the bagmaker to continually look for the registration marks.
Page 127 Rovema VPK Operator’s Manual Machine Setup Procedures Sensor Setup for Registered Film Determining the Photoeye Correction Value To determine the photoeye correction value, you must create a few empty bags so that you can see where the bagmaker is creating the horizontal seals.
Page 128: Operating Procedures
Rovema VPK Operator’s Manual Operating Procedures Operating Procedures This section describes procedures that may be used on a daily basis when operating the bagmaker. It describes how to: Start a Production Run Shut Down the Bagmaker Restart the Bagmaker after and E-Stop...
Page 129: Start-Up
Rovema VPK Operator’s Manual Operating Procedures Start-Up Use the following procedures to start-up the bagmaker. At this point, the forming collar should be installed in the machine and the film should be loaded and thread down past the film transport belts.
Page 130: Preparing The Bagmaker
Rovema VPK Operator’s Manual Operating Procedures Preparing the Bagmaker Use the following procedure to prepare the bagmaker to form empty bags. To prepare the bagmaker to form empty bags: 1. Check that the machine is powered up. If it is not, refer to section 6-0, Machine Setup Procedures.
Page 131: Making Empty Bags
Rovema VPK Operator’s Manual Operating Procedures Making Empty Bags Empty bag production will indicate whether adjustments need to be made to the sealing devices, to the film tracking, to film feeding, or to film registration (if using registered film). Use the following procedure to make empty bags: 1.
Page 132 Rovema VPK Operator’s Manual Operating Procedures Checking Empty Bags Use the following procedure to check the empty bags: 1. Squeeze the bags to check the integrity of the seals. If the seals leak air, check the sealing temperature. 2. Check that the edges of the vertical seal are even.
Page 133: Making Filled Bags
Rovema VPK Operator’s Manual Operating Procedures Making Filled Bags Once the bagmaker is producing empty bags, it is ready to produce filled bags. Filled bag production will indicate whether adjustments need to be made to the product drop timing or product drop quantity.
Page 134: Checking Filled Bags
Rovema VPK Operator’s Manual Operating Procedures Checking Filled Bags Use the following procedure to check the quality of the filled bags: 1. Check the amount of product in the bags. If the bags do not have the correct amount of product in them, check the product feeder.
Page 135: Starting A Production Run
Rovema VPK Operator’s Manual Operating Procedures Starting a Production Run Once the bagmaker is producing quality filled bags, start the normal production run. To start the normal production run: 1. Set the JOG/AUTO selector switch to the AUTO position. 2. Press the SYSTEM READY push-button.
Page 136: Shut Down The Bagmaker
Rovema VPK Operator’s Manual Operating Procedures Shut Down the Bagmaker Use the following procedures to stop or shut down the bagmaker in normal and emergency situations. Emergency Stop Press the EMERGENCY STOP push-button to stop the bagmaker in an emergency situation.
Page 137: Restart The Bagmaker After An E-Stop
Rovema VPK Operator’s Manual Operating Procedures Restart the Bagmaker After an E-Stop Use the following procedure to restart the bagmaker after an EMERGENCY STOP. 1. Use the alarms screen to help resolve the problems that caused the emergency stop. 2. Pull out the EMERGENCY STOP push-button.
Page 138: Jog The Bagmaker
Rovema VPK Operator’s Manual Operating Procedures Jog the Bagmaker Jogging the bagmaker means to operate it at a slow steady pace. Both the film feeding device and the horizontal sealing device can be jogged independent of one another. Use film feed jogging to advance film down the forming tube.
Page 139: Working With Components
Rovema VPK Operator’s Manual Working with Components Working with Components This section describes procedures that can be used to replace or realign components. These procedures include: Replacing Heater Cartridges and Temperature Probes Replacing the Feeding Belts Replacing the Cutting Knife...
Page 140: Replacing Heater Cartridges And Temp. Probes
Rovema VPK Operator’s Manual Working with Components Replacing Heater Cartridges and Temp. Probes This section describes how to replace the heating cartridges and the temperature probes in the horizontal sealing jaws and in the vertical sealing band unit. Horizontal sealing Jaws At some point, the heating cartridges and the temperature probes inside of the horizontal sealing jaws must be replaced.
Page 141 Rovema VPK Operator’s Manual Working with Components Replacing Heater Cartridges and Temp Probes Horizontal sealing Jaws 5. Remove the two hex head bolts that secure the knife assembly to the c-frame. 6. Remove the two socket head cap screws that hold the jaw carrier in the c-frame.
Page 142 Rovema VPK Operator’s Manual Working with Components Replacing Heater Cartridges and Temp Probes Horizontal sealing Jaws 9. Remove the terminal housing from the jaw body. 10. Remove the terminal housing cover to expose the ceramic connectors. 11. Disconnect the heating cartridges and the temperature probe from the ceramic connectors.
Page 143: Vertical Sealing Device
Rovema VPK Operator’s Manual Working with Components Replacing Heater Cartridges and Temp Probes Vertical Sealing Device At some point, the heating cartridges and the temperature probe inside of the seal band unit must be replaced. Use the following procedure to replace these items. Before starting this procedure, make sure that the bagmaker is locked-out and that the seal band unit has cooled.
Page 144 Rovema VPK Operator’s Manual Working with Components Replacing Heater Cartridges and Temp Probes Vertical Sealing Device 3. Disconnect the heating cartridges and the temperature probe from the ceramic connectors. 4. Remove the heating cartridges and the temperature probe form the heating bar assembly.
Page 145: Replacing The Film Feed Belts
Rovema VPK Operator’s Manual Working with Components Replacing the Film Feed Belts Over time, the film feed belts will begin to loose traction against the film because of wear. At that point, it is time to replace the belts. Use the following procedure to replace them.
Page 146: Replacing The Cutting Knife
Rovema VPK Operator’s Manual Working with Components Replacing the Cutting Knife When the cutting knife consistently fails to produce a crisp cut it is time to replace it. Use the following procedure to replace the knife. Before starting this procedure, make sure that the bagmaker is locked-out.
Page 147: Aligning The Forming Set
Rovema VPK Operator’s Manual Working with Components Aligning the Forming Set Forming set alignment is critical to bag forming. If the forming set is not properly aligned, the vertical seal may not form or the bags may appear twisted. The forming set alignment positions the forming tube so that it is square with the machine frame and so that there is equal clearance between the forming tube and the forming collar on all sides.
Page 148: Aligning The Belt Assemblies
Rovema VPK Operator’s Manual Working with Components Aligning the Belt Assemblies Whenever the belt assemblies are removed from their drive shafts, they must be aligned to the flat surfaces on the forming tube when they are reinstalled. The following procedure describes how to align the belt assemblies to the forming tube.
Page 149: Changeover Procedure
Rovema VPK Operator’s Manual Changeover Procedure Changeover Procedure This procedure describes how to changeover the bagmaker to form a different bag style. To changeover the bagmaker: 1. Remove the existing forming set. 2. Install the appropriate forming set. 3. If the bag style you want to form requires a different vertical sealing device, remove the existing vertical sealing device and install the appropriate vertical sealing device.
Page 150: Maintenance Procedures
Rovema VPK Operator’s Manual Maintenance Procedures Maintenance Procedures The following procedures describe how to clean and maintain the bagmaker. The scheduling of the procedures is based on the bagmaker running one shift per day (hours per shift). If the bagmaker is operating for more or fewer shifts, adjust the cleaning and maintenance schedules accordingly.
Page 151: Daily Cleaning
Daily Cleaning Each day, use the following procedure to clean the bagmaker. 1. Use an appropriate cleaning agent to clean any food contact surfaces. If necessary, contact the Rovema Service Department to identify an appropriate cleaning agent for your specific application.
Page 152: Daily Maintenance
Rovema VPK Operator’s Manual Maintenance Procedures Daily Maintenance Each day, use the following procedure to maintain the bagmaker. 1. Check that the guard door switches and the EMERGENCY STOP switch is working properly. 2. Remove any condensed water from the air filter/regulator bowl.
Page 153: Weekly Maintenance
Rovema VPK Operator’s Manual Maintenance Procedures Weekly Maintenance Each week, use the following procedure to maintain the bagmaker. 1. Remove the jaw drive covers and inspect the timing belts for wear and proper tensioning. 2. Check that all of the film guide rollers are moving freely.
Page 154: Troubleshooting Guide
Rovema VPK Operator’s Manual Troubleshooting Guide Troubleshooting Guide This chapter contains a list of fault messages, their possible cause(s), and corrective actions that may resolve them. EMERGENCY STOP PUSH-BUTTON POSSIBLE CAUSE CORRECTIVE ACTION 1) The E-STOP push-button is 1) Reset the E-STOP push-button.
Page 155 Rovema VPK Operator’s Manual Troubleshooting Guide JOGGING MODE POSSIBLE CAUSE CORRECTIVE ACTION 1) The JOG/AUTO selector switch is set 1) Set the selector switch to AUTO. to JOG. TEMPERATURE OUT OF RANGE POSSIBLE CAUSE CORRECTIVE ACTION 1) The temperature controller is not 1) Set the JAW HEAT ENABLE cell to ENABLE.
Page 156 Rovema VPK Operator’s Manual Troubleshooting Guide SCALE NOT READY/FEEDER NOT READY POSSIBLE CAUSE CORRECTIVE ACTION 1) The SCALE or FEEDER ENABLE 1) Set the switch to "DISABLE". switch is set to ENABLE but the scale 2) Wait for the scale or feeder to send a or feeder has not sent its ready signal.
Page 157 Rovema VPK Operator’s Manual Troubleshooting Guide MOTION CONTROLLER AND SERVO AXIS MODULE ERROR MESSAGES ERROR MESSAGE CORRECTIVE ACTION Jaw Resolver Loss Refer to the 1394 Controller User Manual Film Resolver Loss to resolve motion controller and axis Jaw Axis Module HDWR Fault module errors.

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