Page 1: Table Of Contents
HS Former MANUAL CONTENTS 1.0 ABOUT THIS MANUAL 1.1 Aftersales Support 2.0 INTRODUCTION 3.0 SAFETY FIRST 3.1 Put Safety First!!! 3.2 Local Safety aspects 3.3 Essential Do’s & Don’ts 3.4 Safety Rules 4.0 SPECIFICATIONS/DIMENSIONS 4.1 System Overview 4.2 Typical Machinery Layout 5.0 DESCRIPTION OF ASSEMBLIES...
Page 2: Setup Screen
HS Former 6.7 PLC Inputs Slot 1-2 6.8 PLC outputs Slot 3-4 6.9 Production Statistics 6.10 Current Alarm Screens 6.11 Alarm Statistics Screen 6.12 Machine Settings Screen 6.13 Changeover Screen 6.14 Setup Screen 1 6.15 Setup Screen 2 6.16 Main drive Speed 6.17 Clock Set Screen...
Page 3 HS Former 11.5 To Fit To The Frame Gate 11.6 To Fit The Hopper Back Plate 11.7 To Fit The Agitator Rods 11.8 To Fit The Guide Rods 11.9 To Change The Vacuum Cup Assembly & Feed Bar 11.10 To Renew The Vacuum Cups 11.11 To Change The Plunger &...
Page 4: About This Manual
HS Former 1.0 - ABOUT THIS MANUAL CONTINUOUS IMPROVEMENT POLICY Bradman-Lake, Inc has a policy of continual research and improvement and we reserve the right to make such modifications and design changes as are considered necessary in the light of experience. For this reason illustrations and particulars given in this Manual may differ in detail from machines in current production.
Page 5: Aftersales Support
Please call our dedicated Aftersales Team on: +1 704 588 3301 Or by e-mail: bradmanlakespares@bradmanlake.com Our dedicated Aftersales Team exists to ensure that you get the best from your Bradman Lake machine throughout its life. We aim is to ensure that your machine keeps running efficiently in your production environment.
Page 6: Introduction
HS Former 2.0 - INTRODUCTION The Erector is an electrically operated, automatic, carton-erecting machine. It is powered from an external 240 VAC supply and has a self-contained venturi vacuum system, which forms part of the carton feed system. Location of the machine relative to other equipment, such as conveyor systems, is assisted by four wheels on the base of the cabinet.
Page 7: Safety First
HS Former 3.0 - SAFETY FIRST 3.1 - PUT SAFETY FIRST: The machinery described in this manual has been designed for the sole purpose of packaging the specified product. Any other products must be approved beforehand by Bradman-Lake Inc. Packaging of unsuitable products could result in damage to the machinery and injury to the operator.
Page 8: Essential Do's & Don'ts
HS Former  Instructing operators how to deal with any foreseeable mishandling of the machine. Although Bradman-Lake tries to guard against every possible misuse of the machine, there are some circumstances where additional warning labels may be needed. Pinch Point warning labels are positioned on the machine to warn operators/engineers of areas of concern where fingers may get caught if misused.
Page 9: Safety Rules
HS Former 3.4 SAFETY RULES:  No one should operate this equipment unless they have read the service manual and have been instructed on safety and operation of the machine.  All guards must be in their proper place before starting machine.
Page 10: Specifications/Dimensions
4.0 SPECIFICATIONS/DIMENSIONS 4.1 SYSTEM OVERVIEW The HS Former is an electrically operated, automatic, carton erecting machine. It is powered from an external power supply and has a self-contained vacuum system which forms part of the carton feed system. The machine is designed to form cartons or trays from a supply of specially profiled, flat, carton blanks.
Page 11: Description Of Assemblies
HS Former 5.0 - DESCRIPTION OF ASSEMBLIES 5.1 - PLUNGER SLIDE ASSEMBLY: The plunger slide assembly comprises of two interconnected plunger slide castings, each having an upper and lower bearing block bolted to it. The bearing blocks slide vertically on two fixed pillars, one either side of the cabinet.
Page 12: Forming Head Assembly
HS Former 5.3 - FORMING HEAD ASSEMBLY: This assembly forms the ' die ' which shapes the carton. It is mounted across the front of the former, directly below the plunger head. Four curved plates form a rectangular aperture conforming to the outside of the erected carton. The upper horizontal surfaces act as a platform for the carton blank.
Page 13: Carton Feed Assembly
HS Former 5.4 - CARTON FEED ASSEMBLY: Two feed arms are mounted on the oscillating feed shaft. The feed shaft is driven by the adjustable link connected to the pivot shaft. At the end of each feed arm is a pivoting block.
Page 14: Gate & Hopper Assembly
HS Former 5.7 - GATE AND HOPPER ASSEMBLY: This assembly comprises of a gate frame secured to a transverse mounting bar at the rear of the machine, adjacent to the feed shaft. From the gate frame, rods extend rearwards to the hopper back plate, which is mounted on a hopper support bar.
Page 15: Drive Assembly
HS Former 5.8- DRIVE ASSEMBLY The drive unit consists of an AC motor mounted on a slide base. The motor drives the torque limiter shaft by means of a timing belt on the motor shaft and a driven pulley on the torque limiter shaft.
Page 16: Gearbox
HS Former 5.10- GEARBOX The gearbox is of the shaft-mounted type. An anchor is fixed to the main base frame to restrain the gearbox. The anchor length is adjusted to give the correct tension to the timing belt to the gearbox.
Page 17: Logo Screen
HS Former 6.2 - LOGO SCREEN This is the first screen that appears after the machine is powered up. Figure 6.2.1- Logo Screen Pushing Shut Down shuts down the machine. (This prompt is only visible if the engineering password is used.)
Page 18: Run Screen
HS Former 6.3 - RUN SCREEN This screen provides an overview of the machine using a status bar and graphical representation of certain faults i.e. an open guard door will alarm in the status bar and the corresponding door will flash red and yellow on the machine graphic.
Page 19: Recipe Screen
HS Former 6.4 - RECIPE SCREEN Figure 6.4.1 - Recipe Screen The Recipe screen allows the operator or engineer to create, load and rename recipes specific to individual products. If you have a new product similar to an existing one, then you can modify the existing program and save as thus reducing the amount of input to create a new product.
Page 20: Main Menu
HS Former 6.5 - MAIN MENU The main menu screen is accessed from the Run screen. There are both operator and engineer specific selections, engineering is usually password protected and may be configured to have multiple levels of access. 6.5.1- Main Menu Screen Figure 6.5.1- Main Menu Screen...
Page 21: Engineering Menu
6.6 - ENGINEERING MENU SCREEN Figure 6.6.1- Engineering Menu Screen The engineering menu contains all of the separate set up menus required for Bradman Lake or customer engineers to fine tune the performance of the machine. 1. Setup- Displays the Setup Screen 1.
Page 22: Plc Inputs Slot
HS Former 6.7 - PLC INPUTS SLOT 1-2 This screen displays the status of PLC on- board inputs/outputs. Each line shows the state of that particular parameter. The Back returns to the previous I/O Screen Home- Displays the Main Run Screen.
Page 23: Production Statistics
HS Former 6.9 - PRODUCTION STATISTICS Figure 6.9.1- Data Screen This screen displays performance related statistics including a breakdown of “Jam Type” to allow analysis of downtime, this in turn can help engineers pro-actively maintain certain areas of the machine if for example, the plunger has an increased amount of jams compared to the previous month.
Page 24: Current Alarm Screens
HS Former 6.10 - CURRENT ALARMS SCREENS Figure 6.10.1- Current Alarms Screen This screen displays current faults and alarms and will show more detail regarding the fault compared to the status bar on the run screen.  Back- Returns to the Operator Screen.
Page 25: Alarm Statistics Screen
HS Former 6.11 - ALARMS STATISTICS SCREEN Figure 6.11.1- Alarms History Screen This screen will monitor the cumulative total of each different fault, displayed will be the total number of occurrences followed by the total amount of downtime associated to the fault and the fault description.
Page 26: Machine Settings Screen
HS Former 6.12 - MACHINE SETTINGS SCREEN ENGINEERING ENABLES SCREEN Figure 6.12.1- Engineering Enables Screen This screen displays the settings for the back log adjustments.  Air Pressure- This toggles the air pressure alarm on or off.  Low Hopper Detection- This will toggle the low carton hopper alarm enabled or disabled.
Page 27: Changeover Screen
HS Former 6.13 - CHANGEOVER SCREEN Figure 6.13.1 - Changeover Screen This screen displays a step by step guide for the tooling changeover procedure.  Back- Returns to the Main Menu. - 27 -...
Page 28: Setup Screen
HS Former 6.14 - SETUP SCREEN 1 Figure 6.14.1 - Setup Screen 1 Use this screen to adjust and synchronize the various timings.  Air Eject On- Specifies the location to engage the plunger air eject.  Air Eject Off- Specifies the location to disengage the plunger air eject.
Page 29 HS Former 6.15 - SETUP SCREEN 2 Figure 6.15.1- Setup Screen 2 Use this screen to adjust and synchronize the open flap rejection (if installed).  Low Warning Duration- Duration of the low hopper warning alarm.  Low Feed Stop - Number of picked cartons between sensing a low hopper condition and stopping carton erection.
Page 30: Main Drive Speed
HS Former 6.16 - MAIN DRIVE SPEED SCREEN Figure 6.16.1- Main Drive Speed Screen This screen will be used on initial setting of the equipment and after replacing the main motor drive. Once the CAL button is selected the machine will run at full speed at which point the engineer should count the number of plunger strokes per minute.
Page 31: Clock Set Screen
HS Former 6.17 - CLOCK SET SCREEN Figure 6.17.1- Clock Set Screen This screen displays the totals of faults and alarms over a given period. The time and date should be changed at least twice a year when daylight savings time starts and ends. The Panel View clock automatically adjusts for daylight savings time, however, the PLC clock does not.
Page 32: Operating Instructions
 All moving parts are free from obstruction 7.3 POWERING UP THE MACHINE To apply power to the HS, switch the main disconnect to the ON position. The lights on the Control Panel and photocells should come on. The operator interface will boot-up and the Logo Screen will appear.
Page 33: Jogging The Machine
HS Former 7.6 JOGGING THE MACHINE The JOG button allows the operator to move the various machine elements in small increments throughout its working cycle. The machine will only run when this button is held down. Jogging is invaluable to the operator/technician when setting the machine up for different carton sizes, or for troubleshooting.
Page 34: Fault Diagnosis/Troubleshooting
HS Former 8.0 - FAULT DIAGNOSIS / TROUBLESHOOTING 8.1 TROUBLESHOOTING Machine stoppages generally occur for the following reasons:  E-Stops or Guard Doors are opened  Carton Jams occur during the feed or forming cycle  Insufficient Air Supply to the Vacuum Feed System ...
Page 35: Vacuum System Diagnostic Chart
HS Former 8.2- VACUUM SYSTEM DIAGNOSTIC CHART VACUUM CUPS FAIL TO PICK CARTON FROM HOPPER ARE THERE REFILL THE CARTONS IN THE HOPPER HOPPER? ARE THE IS THERE CHECK THE VACUUM CUPS VACUUM AT AIR SUPPLY AND REACHING THE SOURCE?
Page 36: Machine Adjustment
HS Former 9.0- MACHINE ADJUSTMENT Bradman-Lake designers have made carton size adjustment on the HS Former as easy and as simple as possible for the machine operator or engineer. This is done by the introduction of a series of “Change parts”. These change parts simply swap over for the previous parts to allow the machine to run different sized cartons, without any real adjustment.
Page 37: Hopper Gate Frame Adjustment
2mm. the hopper side guide rods should be set to have a 0.5mm gap from the carton. The Top Retaining Bar is optional and decided by Bradman Lake at the point of order depending on carton size and shape.
Page 38: Plunger Adjustment
HS Former 9.4 PLUNGER ADJUSTMENT Switch the machine into the brake hand mode, then by means of the handwheel rotate until the Plunger is in its highest position. To remove the Plunger from the Plunger Mounting Bracket, unscrew the two upper screws on the bracket, labeled in the diagram as securing screws “A”.
Page 39: Routine Maintenance/Cleaning
HS Former 10.0- ROUTINE MAINTENANCE / CLEANING IMPORTANT: BEFORE PERFORMING MAINTENANCE TASKS, ENSURE THAT YOU READ AND UNDERSTAND THE SAFETY INSTRUCTIONS GIVEN IN SECTION 3.0, page 3.1. Before attempting to perform cleaning or maintenance work, isolate the machine from the electrical and pneumatic supplies, check that the machine has come to rest and that all compressed air has been released.
Page 40 HS Former  Check the state of wear of the motor brake. Renew the linings if necessary.  Remove the motor terminal box cover and check that the connections are tight and that the leads are in good condition (i.e., no signs of overheating or arcing, no cracks in the insulation covering).
Page 41: Recommended Lubricants
HS Former 10.3- RECOMMENDED LUBRICANTS NOTE: Care should be taken when choosing the correct lubricant for the servicing of the erector, as the machine may be being used in a food factory therefore requiring approved food quality grease. This is something that needs to be checked.
Page 42: Installation Of Change Parts
HS Former 11.0 - INSTALLATION OF CHANGE PARTS 11.1 - TO INSTALL A FORMING TOOL  Release the motor brake.  Turn the hand wheel counter-clockwise until the plunger is at the top of its stroke.  Place the forming tool on the two retaining angles and secure it with the retaining nuts.
Page 43: To Set Corner Folders
HS Former PLUNGER MOUNTING BRACKET SCREW SCREW ALIGNING PLATE PLUNGER HEAD Figure 11.2.1 - Plunger Head adjustment Note: If changing heads subsequently, there is no need to disturb the cap screws B. 11.3 - TO SET BRASS CORNER FOLDERS If applicable) ...
Page 44: To Fit To The Frame Gate
HS Former 11.5 - TO FIT THE FRAME GATE  With the brake released, turn the hand wheel counter-clockwise until the feed bar is well clear of the frame gate position.  Loosen the frame gate securing screws, place the gate in position and tighten the screws.
Page 45: To Renew The Vacuum Cups
HS Former 11.10 - TO RENEW THE VACUUM CUPS  Replace a few carton blanks in the hopper between the guide rods, with the stack pusher resting up against the blanks. Release the motor brake.  Place a carton blank on the forming die between the register pins.
Page 46: To Change The Hopper Gate
HS Former 11.12 - TO CHANGE THE HOPPER GATE  Remove the hopper back plate.  Remove the guide rods.  Remove the agitator rods and their linkage.  Remove the hopper gate and fit the replacement hopper gate in its place.
Page 47: Guidelines For Cartons
HS Former 12.0 - GUIDELINES FOR THE PRE-PRODUCTION & STORAGE OF TOP LOAD CARTONS. 12.1 INTRODUCTION The efficiency of any packaging, or carton forming machine depends on the condition and quality of the cartons being used. Incorrectly manufactured cartons or badly stored cases of cartons will affect the efficiency and performance of a packing line.
Page 48: Handling & Storage Of Cartons
HS Former PRINT FACE UPPERMOST Figure 12.2.2 Lock Style Carton 12.3 HANDLING & STORAGE OF CARTONS A carton storage area must be situated in a waterproof, well ventilated building away from direct sunlight and with an optimum storage temperature of approximately sixteen (16) degrees centigrade (sixty (60) degrees Fahrenheit and a relative humidity in the region of 40% to 50%.
Page 49 HS Former Figure 12.3.1 Avoid the Use of String to Secure Cartons BOARD DIVIDER Figure 12.3.2 Keep Cartons in Original Sbipper - 49 -...
Page 50: Packing Carton Blanks For Transit
HS Former Avoid leaving cartons in the machines magazine during long breaks in production, especially overnight when air conditioning or temperature changes occur. Dampness in the atmosphere during wash down can also have a detrimental effect on the exposed cartons. Cartons presented to the cartoning machine must be flat and no twist or bowing of the carton is permissible.

This manual is also suitable for:

Hs2/60