Summary of Contents for DURAVANT Hamer 540
- Page 1 MODEL 540 OPERATION MANUAL 14650 28 Avenue North Plymouth, MN 55447-4821 USA TELEPHONE # (763) 231-0100 (800) 927-4674 FAX # (763) 231-0101 WEBSITE: www.hamerinc.com MADE IN THE *** Rev.4...
- Page 3 IMPORTANT Some Machine Assembly drawings are labeled with a range of reference Serial Numbers. Refer to the Serial Number Plate on your machine to relate to the correct Machine Assembly drawing. Those Machine Assembly drawings without reference Serial Numbers should be current to your machine.
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Page 5: Table Of Contents
TABLE OF CONTENTS SECTION ONE Model 540 Form, Fill & Seal Machine • Machine Specifications....................1 • Film & Bag Specifications..................1 • Film Roll Belt Path (Standard & High Speed Wind)..........2 • Machine Layout......................3 • Operator Controls (Electrical Control Panel.............. 4 Touchscreen Display –... - Page 6 Setting Up & Adjusting the Model 540 FFS...............21 • Installing Roll of Polyethylene Film................21 • Loading Film into the Film Feed Belts...............22 • Positioning the Vertical Heat Seal................22 • Positioning the Photo Eye Assembly................23 • Positioning the Single Hole Punch................23 •...
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Page 7: Section One
SECTION ONE MODEL 540 FORM, FILL AND SEAL MACHINE Rev.4... -
Page 9: Machine Specifications
MACHINE SPECIFICATIONS Also see machine layout for Power, Air and Water locations. Power (Standard) Requires one electrical drop of 230V, 60Hz, single phase Requirements (SEE ELECTRICAL SCHEMATICS FOR FLA) (Optional) Requires one electrical drop of 220V, 50Hz, single phase (SEE ELECTRICAL SCHEMATICS FOR FLA) Requires one air drop: One 1/2”... -
Page 10: Film Roll Belt Path (Standard & High Speed Wind)
FILM ROLL BELT PATH (STANDARD & HIGH SPEED) HIGH SPEED FILM ROLL BELT PATH STANDARD FILM ROLL BELT PATH Rev.4... -
Page 11: Machine Layout
MACHINE LAYOUT 2'-7" 3'-2" CONTROL PANEL 230VAC, 1-PHASE 60HZ, 46FLA (OPTIONAL: 50HZ, 46FLA) SEE NOTE 5 3'-7" AIR IN 30 CFM @ 80 PSI " LINE MINIMUM EXAUST VENT PRODUCT IN-FEED 2'-11" 1'-2" 1'-2" 7'-9" 9'-8" 12'-10" 14'-5" 7'-6" 0" MIN. 2"... - Page 12 OPERATOR CONTROLS (Electrical Control Panel) (Refer to the “Electrical Parts List for Schematic” when odering replacement parts for your control panel) FIGURE ONE Rev.4...
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Page 13: Operator Controls
OPERATOR CONTROLS (CONTINUED) 1. Low Level Indicator Light - when the light is “on” indicates that the level of product in the Volumetric Hopper is below that of the Detector. 2. Side Seal Temperature Controller - controls the amount of heat required for the Vertical Heat Sealer to seal the sides of a bag (See Figure Two). -
Page 15: Touchscreen Display - Operator Control Station
TOUCHSCREEN DISPLAY – OPERATOR CONTROL STATION: The following guide will help you understand the Touchscreen Display and assist you in setting up and troubleshooting your machine. When the main power is turned on to the machine, Touchscreen Display activates. OPERATOR INTERFACE This screen appears when the machine is powered up. -
Page 16: Setup Menu
SETUP MENU This screen accesses the Machine Set-up Functions and Timers. Press the RECTANGULAR Buttons to access the desired menu. DUMP SELECTOR MENU This menu allows the Machine Operator to select the number of times the Volumetric will dump before the bag will advance. -
Page 17: Volumetric Filler Speed Control Menu
VOLUMETRIC FILLER SPEED CONTROL MENU The Rotation Speed of the Volumetric Filler is controlled by this screen. The speed can be changed by Pressing the RECTANGULAR BOX above the graph and entering the motor speed (Hz) on the numeric key pad or by Pressing the SLOWER and FASTER Buttons to adjust the speed. The average bags per minute is displayed in the Bottom Rectangular Box. -
Page 18: Side Sealer Setup Menu
SIDE SEALER SETUP MENU This screen accesses the Side Sealer Setup Timers. Press the RECTANGULAR BUTTONS to access the desired Timer. SIDE SEALER “ON” DELAY TIMER MENU The Side Sealer “ON” Delay Timer is controlled by this screen. This timer controls the Time Delay before the Side Sealer Solenoid turns on. -
Page 19: Side Sealer "Off Delay Timer Menu
SIDE SEALER “OFF DELAY TIMER MENU The Side Sealer “OFF” Delay Timer is controlled by this screen. This timer controls the length of time that the Side Sealer Solenoid stays on. The time can be adjusted by Pressing the TOP RECTANGULAR BOX and entering the time on the numeric key pad or by Pressing the UP / DOWN ARROWS. -
Page 20: Lubricator Timer Menu (Optional)
LUBRICATOR TIMER MENU (OPTIONAL) The (Optional) Water Lubricator time is controlled by this screen. The time can be adjusted by Pressing the RECTANGULAR BOX and entering the time on the numeric key pad or by Pressing the UP / DOWN ARROWS. •... -
Page 21: Bag Counter Menu
BAG COUNTER MENU The Bag Counts of the machine can be monitored and reset from this screen. Press the MIDDLE RECTANGULAR Button to reset the two (resetable) bag counters. Press the BOTTOM RECTANGULAR Button to return to the Main Menu. BAG PER MINUTE RATE COUNTER MENU The Bags Per Minute Rate the machine is running can be monitored from this screen. -
Page 22: Input / Output Monitor Menu
INPUT / OUTPUT MONITOR MENU Press the MIDDLE RECTANGULAR Buttons to access the desired Input / Output Monitor Screen. Press the BOTTOM RECTANGULAR Button to return to the Main Menu. INPUT MONITOR MENU The status of the Inputs can be monitored from this screen. If the Input is on, there will be an X in the box next to the description. -
Page 23: Output Monitor Menu
OUTPUT MONITOR MENU The status of the Outputs can be monitored from this screen. If the Output is on, there will be an X in the box next to the description. Press the RETURN Button to go back to the Input / Output Monitor Menu. COMBINED INPUT / OUTPUT MONITOR MENU The status of the Inputs and Outputs can be monitored at the same time from this screen. -
Page 24: Machine Status Monitor Menu
MACHINE STATUS MONITOR MENU The run status of the machine can be monitored from this screen. Press the BOTTOM RECTANGULAR Button to return to the Main Menu. ALARM STATUS MONITOR MENU The status of any current alarms and the history of previous alarms can be viewed from this screen. Press the SQUARE BOXES to view or clear the Alarm Summary or the Alarm History. -
Page 25: Low Roll Alarm Menu
LOW ROLL ALARM MENU This screen will pop up if the (Optional) Low Roll sensor turns on. If this screen appears, the machine will drop out of Automatic Mode and will not run until the roll of film is replaced and the Roll Sensor turns off. Pressing the SQUARE Button will override the low sensor and allow the machine to continue running until the roll is empty. -
Page 26: Programmable Logic Controllers
HORNER PLC INPUT FUNCTIONAL DESCRIPTION: INPUT FUNCTION DESCRIPTION ADDITIONAL INFORMATION Start Pushbutton Lights when the Start Button is If the input indicator is “ON” at depressed. any other time, the start button is faulty. Cycle Stop Push Light s when all Stop Buttons are pulled Always use one of the Stop button out indicating that the machine is ready... - Page 27 HORNER PLC INPUT FUNCTIONAL DESCRIPTION (CONTINUED) INPUT FUNCTION DESCRIPTION ADDITIONAL INFORMATION Top Seal and Shows the status of the Variable If the input indicator light is “ON” Volumetric Drive Speed Drives. the Drives are functioning properly, No Faults. Low Roll Sensor Light is “ON”...
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Page 28: Outputs
HORNER PLC OUTPUT FUNCTIONAL DESCRIPTION OUTPUT FUNCTION DESCRIPTION ADDITIONAL INFORMATION Film Feed & Fill Output energizes the Film Feed and The Film Feed Motor and Conveyor Motors Fill Conveyor Motor Starters. Conveyor Motor are started in Auto Mode when the Start Button is pressed. -
Page 29: Outputs
HORNER PLC OUTPUT FUNCTIONAL DESCRIPTION (CONTINUED) OUTPUT FUNCTION DESCRIPTION ADDITIONAL INFORMATION Patch Feed Advance Output is “ON” when Patch Parameters adjustable through (Optional) Feed Timer is timing down. Touchscreen Display. Seal Wash (Optional) Optional Machine Feature Optional Machine Feature Fill Opening Output turns “ON”... -
Page 30: Setting Up & Adjusting The Model 540 Ffs
SETTING UP & ADJUSTING THE MODEL 540 FFS: INSTALLING A ROLL OF POLYETHYLENE FILM 1. Release Lock Knob and raise the Pivot Bar, leaving it rest in the vertical position (See Figure Three, below). 2. Install the roll of Polyethylene Film on the Hub of the Roll Holder. 3. -
Page 31: Loading Film Into The Film Feed Belts
LOADING FILM INTO THE FILM FEED BELTS (Refer to “Operator Controls” section for control settings) 1. On the Control Panel, turn the Main Disconnect to the “on” position. 2. Check to be sure there is air to the machine. 3. Adjust the Side Seal Temperature Controller setting to your type of film and film thickness. Testing the bags at various temperature settings will yield the best results. -
Page 32: Positioning The Photo Eye Assembly
POSITIONING THE PHOTO EYE ASSEMBLY The centering of the Label with the Bag is determined by the position of the Photo Eye. 1. Pull back on the Cam Lock to release the Photo Eye Assembly. 2. Compare the center of the Label with the center of the Bag. Measure the distance from the center of the Label to the center of the bag. -
Page 33: Air Pressure Regulator / Filter
AIR PRESSURE REGULATOR / FILTER The Air Pressure Regulator should be set to read 80 PSI. With air connected, pull up on the knob of the regulator. This unlocks the knob so air pressure can be adjusted. Once the pressure is set to 80 PSI, push the knob back down to lock the knob. -
Page 34: Teflon Cloth
TEFLON CLOTH After a period of machine operation, Film residue may build up on the Teflon Cloth of the Vertical Heat Seal Pad. This will cause the Vertical Heat Seal Knife to form the bags improperly. To eliminate the Film residue, lift and turn the Heat Seal Pad Knobs ¼... -
Page 35: Film Feed Belts; Removal & Replacement
FILM FEED BELTS REMOVAL AND REPLACEMENT: CAUTION: TURN THE MAIN DISCONNECT ON THE CONTROL PANEL TO THE "OFF" POSITION AND REMOVE THE AIR SUPPLY FROM THE MACHINE BEFORE MAKING ADJUSTMENTS. 1. Turn the Main Disconnect to the "off" position and remove the Air Supply to the machine. 2. -
Page 36: Film Roll Brake Cam
FILM ROLL BRAKE CAM The Dancer Arm and Film Feed Rollers aid in the film unwind process. When the film feed drive system stops, the Unwind Assist Cylinder powers the Dancer Arm back to the home position. In this position, the Dancer Arm needs to activate the Brake Air Valve. This is achieved by the positioning of the Brake Cam. -
Page 37: Film Clamp
FILM CLAMP When the Film Feed Drive System stops, the Film Clamp Bar closes on the film, holding it in place. At this point, all the force on the film is being confined to the Film Unwind area and not the Film Feed Drive System. -
Page 38: Jaw Air Cylinder Adjustment & Replacement
JAW AIR CYLINDER ADJUSTMENT & REPLACEMENT CAUTION: TURN THE MAIN DISCONNECT ON THE CONTROL PANEL TO THE "OFF" POSITION AND REMOVE THE AIR SUPPLY FROM THE MACHINE BEFORE MAKING ADJUSTMENTS. After a period of machine operation, the Jaw Cylinder will need to be replaced. When replacing the Air Cylinder, the Cylinder Stroke determines how far the jaws open and close. -
Page 39: Jaw Liner Installation Instructions
JAW LINER INSTALLATION INSTRUCTIONS CAUTION: TURN THE MAIN DISCONNECT ON THE CONTROL PANEL TO THE "OFF" POSITION AND REMOVE THE AIR SUPPLY FROM THE MACHINE BEFORE MAKING ADJUSTMENTS. To install Jaw Liners: 1. Place first screw through UHMW Jaw Liner and thread one turn into Jaw. 2. - Page 40 FIGURE EIGHT FIGURE NINE Rev.4...
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Page 41: Product Slapper & Wiggler
FIGURE TEN PRODUCT SLAPPER AND WIGGLER The purpose of the Product Slapper is to insure that all product in the product chamber falls into the bag during the fill cycle. During this cycle, the Slapper administers a sharp blow to the product in the chamber, causing it to fall into the bag below. -
Page 42: Setting Up & Adjusting The Hot Air Sealer
SETTING UP & ADJUSTING THE HOT AIR SEALER: SETTING UP THE HOT AIR SEALER 1. After completing bag set up for the Model 540 FFS. 2. Check to be sure there is air to the Hot Air Sealer. 3. Turn the Top Seal Motor Switch to the “On” position. This will drive the Film Feed Belts. Also the Heat Elements will turn on and the Temperature Controller heat level should start rising until it reaches the set temperature. -
Page 43: Film Feed System
FILM FEED SYSTEM The Hot Air Sealer's Film Feed System is suspended from the Film Feed Carriage (See Figure Eleven), which rolls horizontally in either direction to adjust to various bag widths. To adjust the Film Feed Carriage, loosen the Carriage Lock Knob (See Figure Eleven). Position the Hot Air Sealer's Film Feed Carriage so that the pinch point of the Film Feed Belts are approximately 1/2"... -
Page 44: Film Feed Belt Tension
FILM FEED BELT TENSION: If the Film Feed Belts are drooping or sagging, you will need to check the belt tension by inspecting all of the Belt Tensioners (6) and slack pulleys (2) as shown in (Figure Eleven). 1. Slightly loosen the Hex Bolt that secures the main body of the Belt Tensioner. 2. -
Page 45: Machine Speed
MACHINE SPEED The operating speed of the Hot Air Sealer may need to be adjusted to match that operating speed of the Conveyor. To adjust the speed of the Hot Air Sealer: • (Refer to “Touch Screen Display – Operator Control Station” to Adjust the Hot Air Sealer speed as follows: 1. -
Page 46: Maintenance Instructions And Schedules
MAINTENANCE INSTRUCTIONS AND SCHEDULES: GENERAL MAINTENANCE 1. Drain the Filter Water Separator Bowl if any water is present. WARNING: DO NOT ALLOW BOWL TO BECOME FULL, CHECK HOURLY. DAILY: (These tasks should be performed at the beginning of each shift and checked between roll changes) VERTICAL HEAT SEALER 1. -
Page 48: Troubleshooting Guide
TROUBLESHOOTING GUIDE: • Refer to the "Programmable Controller" section for additional Troubleshooting information. SYMPTOM CAUSE CORRECTION In the hand mode, wether the No power to the Check #OL111 overload to reset the M503 starter Conveyor Drive Motor or Film Drive Motors. for the Conveyor Drive Motor. - Page 49 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSE CORRECTION The machine stops and the film is The Film Unwind Assist The Film Clamp may need adjustment for broken. (the film breaks when the has developed a problem. clearance or the Cylinder may not be engaging. Dancer Roller is pulled against the Check the Unwind Assist Cylinder for proper machine frame.)
- Page 50 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSE CORRECTION Side Seal is not being formed Film is sticking to the Side Scrape off the Heat Seal Bar. A rapid build up of properly. Seal Bar or Teflon Cloth. film on the Heat Seal Bar indicates that the bar should be hotter.
- Page 51 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSE CORRECTION Bag is tearing under the top Seal stress before the seal Reduce the distance the bags drop when seal. cools. leaving the hot air sealer. If possible, allow additional time for the seal to cool before handling.
- Page 52 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSE CORRECTION Bags have poor or no top seal. The two sheets of film are not welding together – (Continued). Sealing pulley assembly is Decrease the product volume or increase your worn or out of adjustment. bag size.
- Page 53 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSE CORRECTION The side seals are weak. The Slight film movement while Adjust the film clamp to hold securely. side seals are open or tear the side seal is being made. Rebuild or replace the fill opening cylinders if apart easily –...
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Page 54: Parts Ordering
PARTS ORDERING When ordering replacement parts, give the part name, part number, model number of the machine and the serial number of the machine. This will help greatly in supplying the correct parts in the least amount of time. Rev.4... -
Page 55: Section Two
SECTION TWO MODEL 540 ASSEMBLY DRAWINGS Rev.4... - Page 125 LIMITED WARRANTY Hamer, LLC warrants that each machine manufactured by us shall be free from defects in material and workmanship for a period of one year from the date of shipment to the original purchaser. Hamer, LLC’s sole obligation under this warranty shall be limited to the repair or exchange of any part(s), which under normal and proper use and maintenance, proves to our satisfaction, to be defective, provided notice of such defect and a written description of the alleged defect is promptly given by the purchaser.
- Page 126 WARNING PERSONAL INJURY MAY RESULT FROM DISREGARDING THE FOLLOWING SAFETY PRECAUTIONS -MACHINE IS TO BE PROPERLY CONNECTED TO YOUR BUILDING SAFETY GROUND. -READ INSTRUCTION MANUAL THOROUGHLY BEFORE OPERATING THIS MACHINE. -DISCONNECT ELECTRICAL AND AIR POWER BEFORE PERFORMING MAINTENANCE OR REPAIR WORK. -DO NOT OPERATE MACHINE WITH SAFETY GUARDS REMOVED.
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