Page 1 WF-10T Case Former WEXXAR WF-10T CASE FORMER Operation and Service Manual 10101 Nordel Court, Delta, B.C. V4G 1J8 Canada Telephone (604) 930-9300, Fax (604) 930-9368 WF-10T; Rev. 1.13...
Page 2 WF-10T Case Former...
Page 3: Table Of Contents
WF-10T Case Former Table of Contents Table of Contents LIST OF TABLES..........................V TABLE OF FIGURES........................VI PREFACE............................. VIII About this manual ........................ix How to use this manual ......................x SAFETY..........................1-1 ....................1-2 AFETY ONSIDERATIONS ....................... 1-2 AFETY TANDARDS ....................1-2...
Page 4 WF-10T Case Former Table of Contents CONTROLS........................5-23 ....................5-23 ONTROLS VERVIEW ....................5-23 ONTROLS ESCRIPTION AUTOMATIC CYCLE M ..................5-26 JOG M ........................5-28 DRY CYCLE M ..................... 5-29 BOX CALL M ......................5-31 ..................5-32 RIENTATION HANGES 5.7.1 Case Orientation Change-over Procedure ............
Page 5 WF-10T Case Former Table of Contents ..............8-75 REVENTATIVE AINTENANCE CHEDULE ..................8-77 AINTENANCE DJUSTMENTS 8.5.1 Mechanism Speeds .................... 8-77 8.5.2 Shock Absorbers ....................8-77 8.5.3 Conveyor Belt Tension & Tracking ..............8-77 8.5.4 Tape Head Adjustments ..................8-78 8.5.5 Pneumatic Supply Adjustments................
Page 6 WF-10T Case Former Table of Contents ENGINEERING SPECIFICATIONS ................10-96 10.1 ................... 10-96 PERATING ARAMETERS TRAINING GUIDE ......................11-97 11.1 ..................11-97 ERFORMANCE HECKLISTS 11.2 ............11-98 NSTRUCTIONS FOR SSESSING ERFORMANCE SERVICE & WARRANTY .................... 12-99 OPTIONS........................13-100 13.1 ..................13-100...
Page 7: List Of Tables
WF-10T Case Former List of Tables List of Tables Table 1: Inductive Sensors ......................4-21 Table 2: Photosensors....................... 4-21 Table 3: Interlock Switches......................4-22 Table 4: Sensor Cables ......................4-22 Table 5: Preliminary Start-up Checklist ..................6-42 Table 6: Mechanism HOME Positions and Valve Numbers............6-42 Table 7: Machine Start-up Procedures..................
Page 8 WF-10T Case Former Table of Figures Table of Figures Figure 1-1: Locked Out Electrical Disconnect and Filter-Regulator Assembly ......1-3 Figure 1-2: Example of Safety Interlock ..................1-4 Figure 1-3: Sample Cautionary Label..................1-4 Figure 2-1: Filter-Regulator Assembly..................2-8 Figure 3-1: Case Former Operator’s Side View ................ 3-10 Figure 3-2: Carriage Return Shocks Absorbers and Sensor.............
Page 9 WF-10T Case Former Table of Figures Figure 5-40: 'Alarm History' Screen................... 5-36 Figure 5-41: 'CLEAR' Button ..................... 5-36 Figure 5-42: ‘Password’ Window ....................5-36 Figure 5-43: 'Alphanumeric Keypad’ Window................5-36 Figure 5-44: ‘PREVIOUS’ Button....................5-36 Figure 5-45: 'Service' Button ..................... 5-37 Figure 5-46: 'TROUBLESHOOTING’...
Page 10: Preface
Due to technical advances and improvements, some of the information contained in this manual may be changed or modified without prior notice from WEXXAR/BEL. The WF-10T Case Former Operation and Service Manual was written to assist you in installing, operating, troubleshooting, maintaining, repairing, and training others to operate the machines properly.
Page 11: About This Manual
It includes references to instructor data sheets throughout the manual, and provides performance checklists. Chapter 12 explains WEXXAR/BEL product support policies and practices, as well as important warranty information. Chapter 13 provides a comprehensive index of terms commonly used in this manual.
Page 12: How To Use This Manual
WF20H Case Former Preface How to use this manual Please note that some of the images in this manual may differ slightly from your machine. This symbol alerts you to a risk of personal injury due to mechanical or pneumatic operation. This symbol indicates that an electrical hazard may be present.
Page 13: Safety
WEXXAR/BEL. The WF-10T has safety features to prevent you from injury while the machine is operating. Guard doors equipped with interlock switches prevent you from entering the work cell while the case formation is in progress;...
Page 14: Safety Considerations
NEMA 12 UL listed standard electrical control General Precautions Your WEXXAR packaging machine is a rugged piece of industrial machinery. It is equipped with various guards and other safety features, but it must be treated with respect at all times to avoid the possibility of personal injury.
Page 15: Lock-Out Provision
Electrical Power The main supply voltage for the WF-10T is 120V 60Hz single-phase. Switch off the main power disconnect switch located on the control panel, and lock it out before attempting service work outside of the electrical enclosure.
Page 16: Safety Interlocks
Lubricants, etc. 1.11 Read the attached Material Safety Data Sheets (Appendices A and B), which fully describe the specifications of all of the chemicals used with the WEXXAR Model WF-10T. Safety Oriented Design 1.12 All machine motions in the case erecting area are engineered to be performed low to the ground in order to make the machine safer.
Page 17: Installation
WF-10T Case Former Installation 2 INSTALLATION Prerequisites To install the WEXXAR WF-10T Case Former you will require: • A forklift truck to remove the machine from the skid. • A spirit level to level the machine. • Compressed air and electrical power supplies.
Page 18: Removal From Crate
WEXXAR/BEL agent for corrective action. The crate should be dismantled and all packing materials and shipping ties should be removed.
Page 19: Location, Leveling And Conveyors
WF-10T Case Former Installation Location, Leveling and Conveyors CAUTION! The machine should NOT be operated on casters. 2.5.1 Location When selecting the machine location, carefully consider the following points: • Adequate access around the machine for correct operation and service.
Page 20: Service Connections
2.6.1 Compressed Air The WF-10T requires an air supply that must be clean and dry, and must not drop below 75 PSI to a maximum of 90 PSI. The air supply should be clean and dry, and the air-line should have a minimum inside diameter of 1/2”.
Page 21: Electrical Power
Before attempting any electrical connections, check the machine’s set-up voltage. This is listed on a label on the inside of the access panel of the electrical enclosure. The standard WEXXAR WF-10T voltage is 120V 60Hz 1-Phase, but alternate voltages are accommodated to meet specific customer requests.
Page 22: Component Identification
WF-10T Case Former Component Identification 3 COMPONENT IDENTIFICATION Stack Light (position may differ depending on machine configuration) Walk-In Frame Magazine Arch Guard Door Interlock Safety Carriage Touchscreen Switches Guide Track Case Blank Side-belt Height ‘B’ Conveyors Adjustment Bottom Flap Center Ski ‘D2’...
Page 23: Figure 3-2: Carriage Return Shocks Absorbers And Sensor
WF-10T Case Former Component Identification PRS-05 Carriage Return Sensor Carriage Return Shock Absorbers PRS-09 Jaws Close & Carriage Up Sensor Figure 3-2: Carriage Return Shocks Absorbers and Sensor Major Flap Shock Side-belt Folder Absorbers Conveyor Center Ski (Front Major Flap...
Page 24: Figure 3-4: Injector, Caliper, And Sensors
WF-10T Case Former Component Identification PRS-02 Injector Up Sensor PRS-03 Injector Down Sensor Injector PHS-04 Case Separator Up Sensor Caliper Caliper Slot Figure 3-4: Injector, Caliper, and Sensors Hopper Magazine Guide Pushers Rails Magazine Pusher Locks Infeed Supports PRS-01 Empty Magazine...
Page 25: Figure 3-6: Carriage And Jawplate Assemblies
WF-10T Case Former Component Identification Pin & Dome Assemblies Jawplates ‘D1’ Quick- Adjusts Sliding Bar PRS-08 Cylinder PRS-10 Extended Sensor Case Down Sensor PRS-07 Cylinder Retracted Sensor PRS-06 Jaws Open Start Figure 3-6: Carriage and Jawplate Assemblies Sensor 3-13...
Page 26: Major Components
WF-10T Case Former Component Identification Major Components 1) Calipers The Caliper is located at the infeed end of the magazine between the magazine assembly and the injector. The gap between the case injector and the calipers forms the caliper slot, which permits the separation of one case at a once.
Page 27 14) Hopper The magazine on the WF-10T, located at the input end of the machine, also serves as a gravity- fed Hopper, a storage area that holds stacked, flat case blanks, and advances them to be processed.
Page 28 WF-10T Case Former Component Identification 26) Pinblock The Pinblock is a small, flat plastic block that is used to mount pairs of pins on the jawplate in such a way that they can be extended, withdrawn, or moved laterally as needed to grip the material of various case sizes and to hold the corrugated case until the forming process.
Page 29: Pin And Dome Technology
Component Identification Pin and Dome Technology WEXXAR’s ultra-reliable Pin and Dome case forming technology has been proven to surpass all other forms of case opening technologies in its ability to provide continuous and repeatable output regardless of corrugated case quality. Unlike case formers that use vacuum for gripping and opening case blanks, Pin and Dome is a simple maintenance-free mechanical case gripping system that ensures maximum uptime.
Page 30: Theory Of Operation
WF-10T Case Former Theory of Operation THEORY OF OPERATION All motions of the WF-10T Case Former are controlled by the PLC (Programmable Logic Controller), which is located in the main electrical control enclosure. Inductive and optical proximity sensors are used to detect the position of the machine’s components and the cases being formed.
Page 31: Figure 4-1: Injector Down; Pins Penetrating Corrugate Flutes
WF-10T Case Former Theory of Operation 3) Case Injection The next step in the sequence is to move the case DOWN into the case forming jawplates. The case injector pushes downwards on the top edge of the separated case to impale the bottom...
Page 32 WF-10T Case Former Theory of Operation 6) Case Sealing and Discharge The conveyor belts move the case horizontally out of the flap folding stage into the sealing section, clearing the forming section for the next case. The side-belt conveyors grip the sides of the case to transport it over a tape applicator head (tape head) that applies pressure-sensitive tape under the bottom flaps and trims it to the correct length.
Page 33: Sensors & Cables
WF-10T Case Former Theory of Operation Sensors & Cables 4.2.1 Inductive Sensors Inductive proximity switches utilize non-contact sensing and solid-state circuitry to ensure durability in the most hostile environments. They turn ON when a metallic object moves into their magnetic field. They monitor the position of the machine components, and are used to verify if a motion has been completed before proceeding.
Page 34: Interlock Switches
WF-10T Case Former Theory of Operation WARNING! As the solenoid assembly de-energizes, either as part of the machine control sequence or in the case of an electrical failure, the possibility of unwanted actuator movement must be considered, so use caution when performing maintenance.
Page 35: Controls
‘pushbuttons’ displayed on the screen. It also provides instructions on machine operation. This section lists the standard controls on a WF-10T. Actual control functions may vary depending on options installed on your machine. Pay special attention to the location of the three ‘EMERGENCY STOP’...
Page 36: Figure 5-4: 'Service' Screen
WF-10T Case Former Controls Figure 5-4: 'Service' Screen 4) Touchscreen Display The following control descriptions refer to the software ‘buttons’ or ‘switches’ which appear on the display screen, and which act as though they were hardware equivalents. Touching the ‘Service’...
Page 37: Figure 5-6: 'Main Control' Button
WF-10T Case Former Controls 5) ‘MAIN CONTROL’ Button This button is located to the bottom left of the touchscreen when the machine is in JOG mode. Pressing the ‘MAIN CONTROL’ button will take the machine into CYCLE mode for regular operation.
Page 38: Automatic Cycle Mode
WF-10T Case Former Controls 8) ‘TOTAL NUMBER OF CASES’ Button and Display The ‘TOTAL NUMBER OF CASES’ display indicates the total number of cases formed. This counter can be reset to 0. The reset button is the blue word ‘RESET’. When this button is touched, a confirmation message will appear.
Page 39: Figure 5-13: Changing The Box Size
WF-10T Case Former Controls Figure 5-13: Changing the Box Size Figure 5-14: SMALL BOX Selected When the selection of box size is changed, the title on the ‘LARGE BOX/SMALL BOX’ button on the ‘Main Control’ screen will change to match the new box size.
Page 40: Jog Mode
WF-10T Case Former Controls JOG Mode This feature is useful for training purposes or for troubleshooting. See Section 9.3: ‘Machine Sequence Troubleshooting’. Touch the ‘JOG CONTROL’ button on the ‘Main Control’ screen to enter into JOG mode. Touching the ‘JOG CONTROL’ button displays the ‘Jog Control’ screen.
Page 41: Dry Cycle Mode
WF-10T Case Former Controls 17) ‘Setup’ Screen screen ‘Setup’ provides access to the many features related to machine diagnostics and tuning. Figure 5-23: 'Setup' Screen DRY CYCLE Mode For the purposes of troubleshooting, machine operators may choose to operate the machine without any cases loaded. This function is called ‘DRY CYCLE’, and is available in either JOG or AUTOMATIC...
Page 42: Figure 5-27: 'Remote Demand Off/On' Toggle Switch
WF-10T Case Former Controls 18) REMOTE DEMAND Operation Located in the center of the ‘Setup’ screen, this toggle switch turns the REMOTE DEMAND operation ON or OFF. REMOTE DEMAND is used to halt machine operation if cases are not moving away from the machine on the downstream conveyor, thus avoiding jams.
Page 43: Box Call Mode
WF-10T Case Former Controls BOX CALL Mode The BOX CALL mode provides the highest level of control over the production of boxes. It limits the machine to the production of a box only when it is called for by the operator. To activate the BOX CALL mode, touch the ‘BOX CALL OFF/ON’...
Page 44: Case Orientation Changes
The WF-10T case former is not only unique in its use of mechanical case gripping through Pin & Dome technology to form the case from the bottom, it uses this technology to erect either right- hand or left-hand cases through a relatively straightforward machine change-over procedure.
Page 45: Figure 5-35: Right-Handed Case Orientation
Since the case proceeds on the machine centerline from the magazine through to the formed case discharge, the balance of machine adjustments are unaffected by the direction of case erecting. The WF-10T erecting a right-handed case...
Page 46: Case Orientation Change-Over Procedure
WF-10T Case Former Controls 5.7.1 Case Orientation Change-over Procedure The default case orientation, or ‘handing’, for WF-10T case formers is configured with right-handed cases. Machine operators requiring left- handed case orientation can change the machine’s case orientation by following the instructions below. For someone familiar with the...
Page 47: Figure 5-37: Case Orientation Toggle Switch
WF-10T Case Former Controls Figure 5-37: Case Orientation Toggle Switch Figure 5-38: Case Orientation 'Handing' Change-over 5-35...
Page 48: Figure 5-39: 'Alarm History' Button
WF-10T Case Former Controls 19) ‘ALARM HISTORY’ Button The ‘Alarm History’ screen displays the time and date of each alarm condition that the machine has experienced. The ‘Alarm History’ screen can be accessed by pressing the ‘ALARM HISTORY’ button in the upper left-hand corner of the ‘Setup’...
Page 49: Figure 5-45: 'Service' Button
WF-10T Case Former Controls 20) ‘SERVICE’ Button The ‘SERVICE’ button is located in the upper right-hand corner of the screen. Touch the ‘SERVICE’ button to bring up the ‘Service’ screen. On the ‘Service’ screen are the phone and fax numbers for...
Page 50: Figure 5-49: 'Plc Inputs' Screen
WF-10T Case Former Controls Figure 5-49: 'PLC Inputs’ Screen 24) ‘PLC Inputs’ Screen The ‘PLC Inputs’ screen displays 24 function indicators, for 24 machine functions. If one of the 24 machine components is not functioning, the corresponding indicator will be flashing on and off.
Page 51: Figure 5-53: 'Plc Outputs' Screen
WF-10T Case Former Controls Figure 5-53: 'PLC Outputs' Screen 26) ‘PLC Outputs’ Screen The ‘PLC Outputs’ screen displays sixteen buttons. Each of these output buttons controls a PLC output directly. To test these functions, stop the machine and remove any unformed cases from the magazine.
Page 52: Operating Procedures
Safety Equipment Safety The WF-10T has safety features to prevent you from injury while the machine is operational. Guard doors, equipped with interlock switches, are in place to prevent you from entering the work cell while the case forming is in progress; the machine will not run if these doors are open. The access door of the electrical enclosure also has to be closed for the machine to operate.
Page 53: Start-Up
Turn clockwise or pull out to release. • Is the tape applicator on the WF-10T properly installed, loaded with a tape roll, and ready to go? The end of the tape should be on the front roller, with the sticky side facing the incoming case.
Page 54: Start-Up Procedures
WF-10T Case Former Operating Procedures Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 5: Preliminary Start-up Checklist Machine Start-up Preliminary checks Check if the machine is set up for the right case size. Check if the machine is properly loaded.
Page 55: Table 7: Machine Start-Up Procedures
WF-10T Case Former Operating Procedures Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 7: Machine Start-up Procedures Machine Start-up Start-up Procedures Select the procedure for the desired mode of operation below: AUTOMATIC CYCLE Operation: Press the ‘RESET’...
Page 56: Monitoring
Operating Procedures Monitoring 6.3.1 Monitoring Machine Operation The WEXXAR WF-10T is completely automated. It requires very little monitoring once it is running. Monitoring the machine involves: • Ensuring that the machine has enough flat cases stacked up in its hopper.
Page 57: Magazine Pushers
WF-10T Case Former Operating Procedures 6.3.3 Magazine Pushers Two magazine pushers hold the stacked cases vertically and provide a moderate gravitational directional force to help move the cases towards the separator end of the magazine. 1) Place some case blanks in the magazine.
Page 58 WF-10T Case Former Operating Procedures Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 8: Machine Loading Checklist Loading the Machine Position fresh cases in the magazine behind the magazine pushers. One at a time, lift each of the two magazine pushers up to clear the stacked cases, pull them back, and reposition them to push on the last case.
Page 59: Clearing A Case Jam
Operating Procedures Clearing a Case Jam The WEXXAR Model WF-10T Case Formers will provide reliable, trouble-free performance on a wide variety of case sizes. Occasional jams are not uncommon, but frequent jamming can usually be traced to a particular reason, such as incorrectly set machine adjustment, and corrected.
Page 60: Shutdown
WF-10T Case Former Operating Procedures Shutdown NOTE: Normal stopping of the machine should be accomplished by using the ‘STOP’ button. There are several options to stop the machine: 1. ‘STOP’ Button: Pushing the ‘STOP’ button is the proper way to stop the machine in a non-emergency situation.
Page 61: Case Size Adjustments
Safety Equipment Safety The WF-10T has safety features to prevent you from injury while case size adjustments are being performed. Guard doors, equipped with interlock switches, are in place to prevent you from entering the work cell while the case forming is in progress; the machine will not run if these doors are open.
Page 62: Machine Adjustments
Case Size Adjustments Machine Adjustments The WF-10T has seven machine adjustments that are required when switching between case sizes. The case size adjustment sequence described in the following pages and as shown on the machine itself is ordered so that the adjustments occur in a logical order.
Page 63: Case Size Adjustment Instruction Labels
WF-10T Case Former Case Size Adjustments Case Size Adjustment Instruction Labels For detailed machine adjustment instructions, refer to the case size adjustment instruction labels on the interior of the side guard doors and the jawplate adjustment instruction label on the jawplate assembly.
Page 64: Case Dimension Measurements
WF-10T Case Former Case Size Adjustments Case Dimension Measurements Before setting any of the machine adjustments, measure all case dimensions on the scale provided on the conveyor assembly on the operator’s side of the machine. Refer to the images below.
Page 65: Case Size Range
Case Size Range The following table and diagram show the maximum and minimum case sizes that can be run using the standard WF-10T configuration. Please call your factory representative for more details. Note that the following dimensions are outside dimensions.
Page 66: Case Blank Length Dimension 'A' Adjustment
WF-10T Case Former Case Size Adjustments Case Blank Length Dimension ‘A’ Adjustment Before making any machine adjustments, refer to the shutdown procedure outlined in Section 6.5: ‘Shutdown’. Using the detachable Dimension ‘A’ hand crank located on the operator’s side of the machine, adjust the pointer to the measured case blank length, Dimension ‘A’.
Page 67: Bottom Flap Height Dimension 'M' Adjustment
WF-10T Case Former Case Size Adjustments Bottom Flap Height Dimension ‘M’ Adjustment Before making any machine adjustments, refer to the shutdown procedure outlined in Section 6.5: Bottom flat height Dimension ‘M’ ‘Shutdown’. provides baseline datum adjusting Dimension ‘B’, so it is important to adjust Dimension ‘M’...
Page 68: Case Blank Height Dimension 'B' Adjustment
Vertical Adjustment Chain Lock arch. For more information, contact your Wexxar/BEL representative. Ensure that you re- lock the vertical adjustment chain lock before continuing. Figure 7-12: Dimension Figure 7-11: Dimension ‘B’...
Page 69: Jawplate Case Width Dimension 'D1' Adjustment
WF-10T Case Former Case Size Adjustments 7.9 Jawplate Case Width Dimension ‘D1’ Adjustment There are 3 machine adjustments affected by the width of the formed or erected case. The first is ‘D1’, the width between the carriage jawplates, which feature the pin and dome technology that is used to grip the bottom flaps and open the unformed case blanks.
Page 70: Figure 7-16: Jawplate Formed Case Width 'D1' Adjusts
WF-10T Case Former Case Size Adjustments When you are satisfied with the width between the jawplates, first tighten the handles that clamp the pivot block width adjustment with jaws parallel. Extend the synchronizer bar and jaw cylinder for LH cases. Retract the synchronizer bar and jaw cylinder with the jaws parallel for RH cases.
Page 71: Table 15: Dimension 'D1' Adjustments
WF-10T Case Former Case Size Adjustments Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 15: Dimension ‘D1’ Adjustments Size Adjustments Jawplate Formed Case Width Adjustment (Dimension ‘D1’) Measure the outside dimension of the formed case width on the scale provided.
Page 72: Horizontal Pinblock Adjustments
WF-10T Case Former Case Size Adjustments 7.9.1 Horizontal Pinblock Adjustments Before making machine adjustments, refer to the shutdown procedure outlined in Section 6.5: ‘Shutdown’. If, after calibrating Dimension ‘D1’, were unable make jawplates parallel, open the jawplates look instances where...
Page 73: Table 16: Horizontal Pinblock Adjustments
WF-10T Case Former Case Size Adjustments Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 16: Horizontal Pinblock Adjustments Size Adjustments Horizontal Pinblock Adjustment Ensure that the pinblocks on the major and minor jawplates do not interfere with each other.
Page 74: Pinblock Mounting Orientation
WF-10T Case Former Case Size Adjustments 7.9.2 Pinblock Mounting Orientation Before making any machine adjustments, refer to the shutdown procedure outlined in Section 6.5: ‘Shutdown’. Adjust the number of pins penetrating the case flaps to best suit the case. Raise the pins in the pinblocks mounted on the jawplates where they should penetrate into the case flaps;...
Page 75: Bottom Carriage Jawplate Pin & Dome Position Adjustments
WF-10T Case Former Case Size Adjustments 7.9.3 Bottom Carriage Jawplate Pin & Dome Position Adjustments The position and extension of the pins that are inserted into the edges of the bottom flaps when the case is injected down onto them and that ‘grip’ the case for opening may need to be adjusted depending on the case size and proportions.
Page 76: Center Ski Case Width Dimension 'D2' Adjustment
WF-10T Case Former Case Size Adjustments 7.10 Center Ski Case Width Dimension ‘D2’ Adjustment Before making machine adjustments, refer to the shutdown Direction of Case Travel procedure outlined in Section 6.5: Rear Flap Folder ‘Shutdown’. Kicker Arm The center ski that serves to...
Page 77: Conveyor Case Width Dimension 'D3' Adjustment
WF-10T Case Former Case Size Adjustments 7.11 Conveyor Case Width Dimension ‘D3’ Adjustment Before making any machine adjustments, refer to the shutdown procedure outlined in Section 6.5: ‘Shutdown’. The most practical way to adjust the conveyor width to the case size is to use a formed case.
Page 78: Carriage Case Length Dimensionc Adjustment
WF-10T Case Former Case Size Adjustments 7.12 Carriage Case Length Dimension C Adjustment The formed case length adjustment determines how far the carriage needs to push the erected case into the conveyor so that the rear of the case is in the right position for rear minor flap folding.
Page 79: Testing The Size Adjustments
WF-10T Case Former Case Size Adjustments Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 20: Dimension ‘C’ Adjustments Size Adjustments Carriage Formed Case Length Adjustment (Dimension ‘C’) Follow the shutdown procedure outlined in Section 6.5.
Page 80: Table 21: Full Cycle Sequence
WF-10T Case Former Case Size Adjustments Table 21: Full Cycle Sequence Full Machine Cycle Sequence STEP 1 Case Separator UP / DOWN STEP 2 Injector DOWN / UP Carriage FORWARD STEP 3 Jawplates OPEN STEP 4 Kicker Arm STEP 5...
Page 81: Quick Size Change Guide
WF-10T Case Former Case Size Adjustments Quick Size Change Guide 7.14 The case size change table (Table 22) in this section is used to make case size changeover simpler and faster. For each case, the optimum set-up parameters can be determined and entered into Table 22.
Page 82: Machine Maintenance
Safety Equipment Safety The WF-10T has safety features to prevent you from injury while maintenance is in progress. Guard doors, equipped with interlock switches, are in place to prevent you from entering the work cell while the case forming is in progress; the machine will not run if these doors are open. The access door of the electrical enclosure also has to be closed for the machine to operate.
Page 83: Safety
The WF-10T Spare Parts Maintenance Kit contains all of the parts necessary for maintaining the Uni- Drive system. Contact the factory or your local WEXXAR/BEL distributor for price and availability.
Page 84: Conveyor Side-Belt Replacement
WF-10T Case Former Machine Maintenance 8.2.3 Conveyor Side-Belt Replacement The side-belts can be easily and quickly replaced with a minimum of downtime. Wexxar/BEL recommends replacing both belts at the same time. The procedure is as follows: 1. Remove the safety covers.
Page 85: Maintenance
WF-10T Case Former Machine Maintenance 8.2.5 Maintenance 8.3.1 Non-Lube Pneumatic System Maintenance A coalescing-type mist separator that effectively removes 99.9% of oil mist from incoming air. Combined with pre-lubricated air cylinders and valves, this provides reliable pneumatic operation. Maintenance •...
Page 86: Routine Operator Maintenance
WF-10T Case Former Machine Maintenance 8.3.3 Routine Operator Maintenance WARNING! The tape knife blade is sharp, and can cause serious injury. Instructions • Clean the tape knife with solvent • Lubricate the blade guard with silicone Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance.
Page 87 WF-10T Case Former Machine Maintenance Check the ‘S’ box for Satisfactory Performance and ‘US’ box for Unsatisfactory Performance. Table 25: Cleaning the Machine Maintenance and Cleaning Cleaning Remove any corrugated fragment deposits that have accumulated. Check the pneumatic filter bowl filter for debris.
Page 88 WF-10T Case Former Machine Maintenance Every 3 Months Thoroughly clean all adjustment screws, sprockets, chain and sliding components, and then lightly grease. See Section 8.6: ‘Lubrication’ for correct grease. • Lubricate width and height adjustment leadscrews with Food Grade Fuchs Geralyn FMG 387 lubricant.
Page 89: Figure 8-2: Conveyor Belt Tensioning
These controls are not meant to be adjusted except under the instruction of the Wexxar/BEL Service Department. Before making adjustments to the flow controls, refer to the ‘Pneumatic Control Circuit’ diagram in the Supplementary Manual. Note that a cylinder’s exhaust air is restricted in order to reduce the speed of the cylinder’s motion.
Page 90: Figure 8-3: Inductive Sensor Adjustment Range
2. Place two marks on the belt 25" apart. 3. Tension until the marks are 25¼" apart. 8.5.4 Tape Head Adjustments For adjustments and set-up of the adhesive system on the WF-10T, refer to the separate Dekka Tape Head Manual supplied with this machine. 8.5.5 Pneumatic Supply Adjustments Little adjustment is necessary.
Page 91 Use Food Safe Fuchs Geralyn FMG 387 lubricant or equivalent. 8.6.2 Ball Bearings All ball bearings used on Wexxar/BEL packaging machines are sealed-for-life, and regular lubrication is not required. 8.6.3 Tape Head The DEKKA WEX-22 Series Tape Heads are designed as a low maintenance item, and should not require lubrication in normal use.
Page 92 To safely work on the machine, disconnect the compressed air supply and power supply. The guard doors around the WF-10T will ensure that you do not accidentally enter the machine’s working cell while its components are energized. Never attempt to disable any of the safety features or enter in through the discharge end while the machine is still powered.
Page 93 WF-10T Case Former Machine Maintenance General Troubleshooting The most common error in troubleshooting packaging machinery problems is an incorrect diagnosis of the problem. Errors cause much lost time and needless expense and are avoided by a careful analytical approach before attempting corrective action. Always start by ensuring that all case size adjustments have been made correctly.
Page 94: Table 26: General Troubleshooting Reference
WF-10T Case Former Machine Maintenance Table 26: General Troubleshooting Reference Problem Possible Cause Remedial Action Bottom Flap Height Case buckles or tears Dimension ‘M’ datum Set Dimension ‘M’ lower. during separation set too high If case separator is not too high, then Case Adjust Dimension ‘B’...
Page 95: Table 27: Machine Sequence Troubleshooting
WF-10T Case Former Machine Maintenance Machine Sequence Troubleshooting The machine sequence is controlled by a PLC located inside the electrical enclosure. The controller responds to inputs from the panel buttons and various sensors on the machine mechanisms, and it provides outputs that control the solenoid valves in the pneumatic system.
Page 96 WF-10T Case Former Machine Maintenance Step Problem Description Remedial Action Sequence Ensure that Jawplates are not Case jams when pinblocks are parallel when the injected into the mounted on jawplate carriage is in its jawplate pins. without obstructing RETRACTED position.
Page 97 4. The PLC terminals (‘IN+’ and ‘IN-‘, ‘DC24+’, and ‘DC COM’) are all operating at 24 V DC. In the unlikely event that LEDs are illuminated improperly, and you do not have the appropriate PLC interface, or training, contact WEXXAR's service department. Without the appropriate equipment and training to correct this status, there is nothing else that you can do.
Page 98: Table 28: General Pneumatic Troubleshooting Reference
Machine Maintenance Pneumatic Troubleshooting The pneumatic system of your WEXXAR Case Former is designed to give long, trouble-free service. Most pneumatic problems can be avoided by ensuring that the machine receives a supply of clean, dry air, and that the lubricator is properly adjusted, and always filled with the correct oil.
Page 99: Table 30: Cylinders Not Moving
WF-10T Case Former Machine Maintenance Table 30: Cylinders not moving Problem Cause Solution Compressed air Connect air supply. not connected Mechanical Jam Clear mechanical jam. Socket loose Tighten socket. Open Circuit Cable broken Replace cable. Overheating / Usual cause is high...
Page 100 WF-10T Case Former Machine Maintenance Case Drivebelt System Troubleshooting The Uni-Drive side-belt system is designed to keep the case square during sealing, which results in a technically stronger seal and a better finished appearance. This is achieved by linking the drives on the side-belts to a single motor and reduction gear, which inherently synchronize belt speeds.
Page 101: Figure 9-1: Lowering The Tape Head Bracket
WF-10T Case Former Machine Maintenance 9.7.5 Cases Jam Frequently Between Belts Turn OFF the machine as soon as a jam occurs and before clearing the jam. Check for the following jam causes: • Tape head may be adjusted too high.
Page 102 Machine Maintenance Bottom Flap Folding Troubleshooting The WF-10T is unique among fully automatic bottom flap folding machines in that it employs a unique system of flap folding technologies working in unison. The function of the flap folders is to integrate the folding of the minor flaps and major flaps within the shortest possible time and travel distance.
Page 103: Figure 9-2: Elevating The Tape Head Bracket
WF-10T Case Former Machine Maintenance 9.8.7 Major Flaps Have a Tapered Gap or Gap / Overlap Combination • Verify that case dimensions are square. • Verify that the tape unwind tension is not excessive. This can cause the major flaps to be pulled back, causing a rear gap.
Page 104 Main Air Pressure and Electrical Supplies are locked OFF. Comprehensive information on the set-up, operation, and maintenance of the adhesive system on the WF-10T is contained in the separate Dekka Tape Head Manual supplied with this machine. 9.9.1 Tape Does Not Stick To Case Surface The tape is not bonding to the corrugated board of the flaps or ends of the case to provide a secure seal.
Page 105 WF-10T Case Former Machine Maintenance 9.9.2 Tape is not Cut Uniformly The tape is not cut properly every time. In the worst situations, several cases may be taped together. Check the following conditions: • Tape head position. If the tape head is set too high, the cut-off knife will not be fully activated, resulting in poor cut-off.
Page 106 Repair Procedures 9.10 The operating time before significant wear will occur with WEXXAR packaging machines depends upon the service duty to which the machine is subjected, and can vary widely between different customers. Many wear points are quite simple (bushings, rod ends, etc.), and the corrective action is self-evident.
Page 107 WF-10T Case Former Machine Maintenance 9.10.2 Conveyor Drivebelt Repairs To change the drivebelts, 1) Slacken the belt-tensioning nuts to the fully BACK position. This will permit belt removal by starting at the idle pulley end, and lifting the belt off upwards and back.
Page 108: Table 31: Operating Parameters
WF20T Case Former Engineering Specifications 10 ENGINEERING SPECIFICATIONS Operating Parameters 10.1 Table 31: Operating Parameters Safety Guarding Integrated safety guarding with keyed interlock switches. UL/cUL listed standard electrical control panel, NEMA 12. Meets NFPA-79 standard. Controls Built-in 24V DC power supply for safe, low voltage sensors and operating controls.
Page 109: Table 8: Machine Loading Checklist
WF20T Case Former Training Guide 11 TRAINING GUIDE Performance Checklists 11.1 To instruct trainees in the performance and operation of the machine, use the Performance Checklists found throughout this manual, notably in Section 6: ‘Operating Procedures’, Section 7: ‘Case Size Adjustments’, and Section 8: ‘Machine Maintenance’. Refer to the following Performance Checklist Tables: Table 32: Performance Checklists Table #...
Page 110 WF20T Case Former Training Guide Instructions for Assessing Performance 11.2 Before the Performance Assessment 1. Verify that the work area conforms to all safety standards. 2. Verify that tools, equipment, and material needed to perform the task are on hand. During the Performance Assessment 1.
Page 111 To order parts or arrange for service, please call or fax us. Warranty Machinery and parts manufactured by WEXXAR are warranted for a period of one year from date of shipment against failure or defective workmanship. Components purchased from other manufacturers by WEXXAR are warranted for the duration of the manufacturer’s warranty.
Page 112 WF-10T Case Former Options 13 OPTIONS Tape Monitoring System 13.1 The tape monitoring system alerts the machine attendant when a taping fault occurs, and when it is time to replace the tape roll. A tape-roll-follower arm is fitted to the machine. A small wheel mounted on the end of the follower arm makes contact with the tape roll.
Page 113 WF-10T Case Former Index 14 INDEX Case Quality ..........9-87 Case Sealing..........4-20 Case Separation ........... 4-18 Case Separator ..........3-14 Case Size Range .......... 7-53 Adhesive Adjustments ........8-78 Case Supply..........4-18 Adjustments Center Ski ............. 7-64 Adhesive........... 8-78 Center Ski Case Width........
Page 114 WF-10T Case Former Index Rear............3-16 Maintenance ....... 8-70, 8-73, 8-74 Flap Folders ..........3-14 Cleaning ........... 8-75 Flap Folding ..........9-90 Mechanical..........8-79 Front Flap Folder .......... 7-64 Pneumatic System........8-73 Preventative..........8-75 Routine Operator ........8-74 Maintenance Adjustments......8-77 Manual Shut-off Valve........
Page 115 WF-10T Case Former Index Ringpins ............7-60 Synchronization Bar ........7-58 Safety......1-1, 6-40, 7-49, 8-70, 9-80 Tape Compressed Air.......... 1-3 Tape Head ......3-16, 8-79, 9-92 Electrical ............. 1-3 Tape Applicator ..........9-92 Guard Doors ..........1-3 Troubleshooting ........9-92 Interlock Switches........
Page 116 WF30T Case Former Appendix A: MSDS Geralyn FMG 387 APPENDIX A Material Safety Data Sheets: Fuchs Lubricants – Geralyn FMG...
Page 117 WF30T Case Former Appendix A: MSDS Geralyn FMG 387 FUCHS LUBRICANTS CANADA LTD. PACIFIC DIVISION Material Safety Data Sheet WHMIS Not controlled...
Page 118 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
Page 119 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
Page 120 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
Page 121 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
Page 122 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
Page 123 WF30T Case Former Appendix A: MSDS Geralyn FMG 387...
Page 124 WF-10T Case Former Appendix B: Keystone Nevastane HT-2 APPENDIX B Material Safety Data Sheets: Keystone Lubricants – Nevastane HT-...
Page 125 WF-10T Case Former Appendix B: Keystone Nevastane HT-2...
Page 126 WF-10T Case Former Appendix B: Keystone Nevastane HT-2...
Page 127 WF-10T Case Former Appendix B: Keystone Nevastane HT-2...
Page 128 WF-10T Case Former Appendix B: Keystone Nevastane HT-2...
Page 129 WF-10T Case Former Appendix B: Keystone Nevastane HT-2...
Page 130 Operation & Service Manual Effective May 17, 2007 65-06-11 Replaces 65-06-10, March 2, 2007 BEL 252 V.02 Fully Automatic Top and Bottom Uniform Case Tape Sealer Wexxar Packaging Inc Phone (604) 270-0811 • Fax (604) 270-7897 E-mail: sales@wexxar.com 66-05-11 5/16/2007...
Page 131 B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r SAFETY CAUTION WHEN THE MACHINE IS FIRST SWITCHED ON, THE CASE TOP FLAP FOLDING SNAP FOLDERS WILL CYCLE ONCE AUTOMATICALLY.
Page 132 B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r TABLE OF CONTENTS Installing The BEL 252 ________________________________________________________5 _____________________________________________________5...
Page 133 B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Trouble Shooting Guide ______________________________________________________19 Section 1 - Corrugated Case Quality &...
Page 134: Leveling The Machine
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Installing the BEL 252 Remove the through bolts that secure the machine to the base.
Page 135: Machine Adjustments
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Machine Adjustments Safety: Disconnect machine electrics and compressed air before making any machine...
Page 136: Case Height Adjustment
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r In practice it is best to first open up all three adjustments to fully clear the height and width of box.
Page 137: Snap Folder Width Adjustment
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r 2.
Page 138 B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r 4.
Page 139: Snap Folder Manual / Automatic Modes
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r 5.
Page 140: Operating The Machine
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r PERATING THE ACHINE SAFETY: Note that when the machine is first switched on, the Snap Folders will cycle once...
Page 141: Service And Maintenance Procedures
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Service and Maintenance Procedures Uni-Drive Side Belt Drive System Figure 2...
Page 142: Chain Drive
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r The Uni-Drive side belt system is designed to keep the case square during sealing which results in a technically stronger seal and a better-finished appearance.
Page 143: Snap Folder Adjustments And Servicing
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r 4.
Page 144: Arch Cross Member Vertical Slide Adjustment
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r When the switch is set to the “Manual”...
Page 145 B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Fig.
Page 146: Procedure To Adjust Vertical Slider Bearing Clearance
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Procedure to Adjust Vertical Slider Bearing Clearance SAFETY - Disconnect the machine from both electrical and air supply lines before making any adjustments or changes.
Page 147: Preventative Maintenance Guide Bel 250/ 252
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Preventative Maintenance Guide BEL 250/ 252 •...
Page 148: Trouble Shooting Guide
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Trouble Shooting Guide Section 1 - Corrugated Case Quality &...
Page 149: Section 2 - Case Drive Belt System
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Section 2 - Case Drive Belt System The Uni-Drive side belt system is designed to keep the case square during sealing which results in a technically stronger seal and a better looking appearance.
Page 150: Section 3 - Top Flap Folding
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Problem: Frequent Belt Breakage.
Page 151 B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r •...
Page 152 B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Problem: Top Major Flaps Have a Gap in Center.
Page 153: Section 4 - General Taping Conditions
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Section 4 - General Taping Conditions Problem: Tape Does Not Stick To Case Surface.
Page 154 B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Problem: Tape tail does not stick down properly.
Page 155: Section 5 - Case Infeed And Indexing
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Section 5 - Case Infeed and Indexing Feeding in of cases is an important issue in the efficient operation of automatic case closing.
Page 156: Optional Equipment
B E L 2 5 2 F u l l y A u t o m a t i c U n i f o r m C a s e T a p e S e a l e r Optional Equipment BEL 252 - Stainless Steel Adjustable Leg Extenders with U.H.M.W.

Wexxar WF-10T Operation And Service Manual

Table of Contents

List of Tables

Table of Contents

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Wexxar WF-10T

Summary of Contents for Wexxar WF-10T

Table of Contents