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brenton PROMACH 4113 System Manual

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BEC Machine #4113
Revision Date - 17 July 2019
Prepared Especially For
JM Smuckers
CUSTOM
CARTONER
SYSTEM MANUAL

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Summary of Contents for brenton PROMACH 4113

  • Page 1 BEC Machine #4113 Revision Date - 17 July 2019 Prepared Especially For JM Smuckers CUSTOM CARTONER SYSTEM MANUAL...
  • Page 2 © 2019 Brenton Engineering. All Rights Reserved. Section 106 of the 1976 Copyright Act forbids any party other than the author (Brenton Engineering Com- pany) to: Reproduce owned work in copies or phonorecords, to prepare derivative works based upon the work;...

  • Page 3: Table Of Contents

    Outside Manufacturer's Components ......1-1 Brenton Engineering Components ....... . 1-1 About this Manual .
  • Page 4 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Table of Contents 17 July 2019 Chapter 3: System Operation Operating Procedures ........... 3-1 Starting the Machine .
  • Page 5 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Table of Contents Adjustment Scales ..........3-55 The Information &...
  • Page 6 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Table of Contents 17 July 2019 Drive Chains ........... . . 5-20 Replacing Vertical Linear Bearings on Gantry’s .
  • Page 7 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 List of Figures List of Figures Chapter 1: Introduction and Safety E-Stop Buttons........... . . 1-6 Security Interlock Switch .
  • Page 8 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 List of Figures 17 July 2019 The Shutdown Screen ..........3-52 The Security Interlock .
  • Page 9 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 List of Figures Loader 2 Side 1 Horizontal Lubrication Locations ......5-35 Loader 2 Side 2 Horizontal Lubrication Locations .
  • Page 10 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 List of Figures 17 July 2019 Page IV...
  • Page 11 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Introduction and Safety Contents Introduction and Safety Contents Introduction............1-1 Warranty Information .

  • Page 12: Introduction And Safety Contents

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Introduction and Safety Contents 17 July 2019 Page II...

  • Page 13: Chapter 1: Introduction And Safety

    320-852-7705 Warranty Information Outside Manufacturer's Components Items are considered outside manufacturer's components if they are not built at Brenton Engineering; for example, Allen Bradley PLC's. Your Brenton Engineering packaging system contains outside manufacturer's components. In general, most companies offer a 90 day warranty. For specific information on outside manufacturer's warranties, reference the VENDOR DATA MANUALS.

  • Page 14: About This Manual

    Copyright Notice © 2019 Brenton Engineering Section 106 of the 1976 Copyright Act forbids any party other than the author (Brenton Engi- neering) to: Reproduce owned work in copies or phonorecords, to prepare derivative works based upon the work; to distribute copies or phonorecords of the work to the public by sale or other transfer of ownership, by rental or lease.

  • Page 15: General Terms And Conditions Of Sale

    Introduction and Safety General Terms and Conditions of Sale FORMATION OF CONTRACT: The terms and conditions set forth in this document constitute the offer of Brenton Engineering Com- pany ("Seller") to sell the item(s) of sale (IOS) specified herein. NO ACCEPTANCE SHALL BE EFFECTIVE WHICH VARIES THE TERMS AND CONDITIONS STATED IN THIS OFFER OR PROPOSES ADDITIONAL TERMS.

  • Page 16: Safety

    Introduction and Safety 17 July 2019 Safety At Brenton Engineering Company (BEC), we are committed to building quality packaging and material handling equipment. To achieve this, our machines must be efficient, easy to maintain, and safe to operate. Before attempting to operate the equipment, become familiar with the safety recommen- dations and operational components of your Cartoner.

  • Page 17: Hazard Messages

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Introduction and Safety Hazard Messages Notations appear on pages of this manual to alert the reader to important messages regard- ing a significant hazard for personnel or equipment. These messages convey three levels of risk as defined below.

  • Page 18: Operation Safety

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Introduction and Safety 17 July 2019 Operation Safety The following safety precautions are recommended for all personnel who operate this equipment. • Operators should immediately report unsafe working conditions to a supervisor.

  • Page 19: Maintenance Safety

    • Use only specified replacement parts. Never use non-specific fuses that have not been specified Brenton Engineering. Potential fire and/or damage may result. • Before restarting the system, ensure personnel are not in the system and that the sys- tem and external devices are operating properly.

  • Page 20: Security Interlock Switch

    17 July 2019 Security Interlock Switch Brenton Engineering used an Interlock Switch, attached to each access door, to guard against unsafe entry into this system. It interlocks the guard to the machine control system and ensures machine power is isolated and remains isolated while the guard door is open.

  • Page 21: Electrical Lockout And Tagout Recommendations

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Introduction and Safety Electrical Lockout and Tagout Recommendations (See OSHA 1910.147 & OSHA 1910.333 (b)(2) for exception to procedures) To avoid hazards of electrical shock or other personal injuries, the main power disconnect for the system and any other separate sources of power for the system shall be locked out &...

  • Page 22: Pneumatic Lockout And Tagout Recommendations

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Introduction and Safety 17 July 2019 Pneumatic Lockout and Tagout Recommendations To avoid hazards of moving mechanisms, pinch points and other personal injuries, the main compressed air supply valve for the system shall be locked out & tagged as a safety precaution during entry and maintenance to the system.

  • Page 23: Installation And First Time Power Up

    17 July 2019 Introduction and Safety Installation and First Time Power Up Brenton Engineering Company employs skilled service technicians to assist equipment purchasers with installation and startup of new equipment, as well as continuous technical support. For transportation purposes, equipment may be broken down into various sections. For example: •...
  • Page 24 Route electrical wire bundles, pneumatic lines, and mechanical assemblies. • Carefully pull exposed electrical wire ends through the conduit bodies to avoid dam- age. Personnel at Brenton Engineering number the electrical wires to assist in the re- installation process. •...

  • Page 25: Emergency Stop Location Drawing

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Introduction and Safety Emergency Stop Location Drawing Figure 1 - 5 E- Stop Location Drawing Page 1-13...
  • Page 26 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Introduction and Safety 17 July 2019 Page 1-14...

  • Page 27: Chapter 2: System Description

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Description Contents System Description Contents Machine Overview ............2-1 Major Components .
  • Page 28 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Description Contents 17 July 2019 Page II...

  • Page 29: Chapter 2: System Description

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Description System Description Machine Overview Major Components Machine design wash down and metric hardware and components Bag Alignment Conveyor • Air Blower alignment knifes. • Justify to one side before entering buckets. (Center on bucket).

  • Page 30: Bag Racetrack Conveyor

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Description 17 July 2019 Bag Racetrack Conveyor • Buckets to receive both sizes with doser on center. • Future size to be taken into consideration. If different buckets needed TBD •...

  • Page 31: I/O

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Description • Armor block for most components Guarding • Guard master safety relays (quote) • Schmersal power to lock switches (quote) • ¾ acrylic for doors Operational Review The system operates in two modes Water/White Plano, and Coffee/Printed Plano.

  • Page 32: Pack Patterns

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Description 17 July 2019 Pack Patterns The chart below depicts the product this machine was designed to run. Table 2-1. Machine Pack Pattern Chart DESCRIPTION PROD- "OUTSIDE PRODUCT PROD- DIREC VER-...

  • Page 33: Machine Floor Plan

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Description Machine Floor Plan The floor plan drawing below shows the machine layout, as sold. Figure 2 - 1 Machine Floor Plan Page 2-5...
  • Page 34 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Description 17 July 2019 Page 2-6...

  • Page 35: Chapter 3: System Operation

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Contents System Operation Contents Operating Procedures ........... 3-1 Starting the Machine .
  • Page 36 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation Contents 17 July 2019 Alarm Messages ..........3-56 Warning Messages .

  • Page 37: Chapter 3: System Operation

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation System Operation Operating Procedures Starting the Machine To Start Your Cartoner System: 1. Turn "ON" the Main Electrical Disconnect. 2. Turn "ON" the Main Pneumatic Disconnect. 3. Fill the Magazine with the correct corrugated blanks for the current production run.

  • Page 38: Loading Corrugated Blanks Into The Magazines

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Loading Corrugated Blanks into the Magazines 1. Place about a one inch group of blanks against the clips. 2. Lean the remaining blanks, until the Magazine is full all the way down the conveyor.

  • Page 39: Operator Control Panels

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Operator Control Panels The Main Electrical Enclosure (CP1) The Main High Power Electrical Panel contains the Programmable Logic Controller (PLC), Servo Drives, Variable Frequency Drives (VFD), power supplies, transformers, control relays, fuses, and other electrical components that provide control to the system.

  • Page 40: The Hmi Left Side (Cp2)

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The HMI Left Side (CP2) The Main Operator Control Station for this system is designed around a Allen Bradley touchscreen Human Machine Interface. The Human Machine Interface (HMI) is in direct link with the Programmable Logic Controller (PLC) that directs control of the packaging system.
  • Page 41 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-1. Control Panel 2 Button Descriptions (Continued) BUTTON DESCRIPTION This button is a complete system E-stop. It stops every piece of equipment on the system. The servo power to all motors turns off and brakes are immediately EMERGENCY STOP applied causing all motion to stop.

  • Page 42: Hmi Right Side (Cp3)

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 HMI Right Side (CP3) The Main Operator Control Station for this system is designed around a Allen Bradley touchscreen Human Machine Interface. The Human Machine Interface (HMI) is in direct link with the Programmable Logic Controller (PLC) that directs control of the packaging system.
  • Page 43 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-2. Control Panel 3 Button Descriptions (Continued) BUTTON DESCRIPTION Press this button to bring the system to a controlled stop at the end of the cur- CYCLE STOP rent cycle.

  • Page 44: Infeed Left Operator Station (Cp4)

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Infeed Left Operator Station (CP4) This operator station allows the operator to control basic machine functions. Figure 3 - 4 Control Panel 4 Table 3-3. Control Panel 4 Button Descriptions...

  • Page 45: Infeed Right Operator Station (Cp5)

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Infeed Right Operator Station (CP5) This operator station allows the operator to control basic machine functions. Figure 3 - 5 Control Panel 5 Table 3-4. Control Panel 5 Button Descriptions...

  • Page 46: Infeed Left Operator Station (Cp6)

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Infeed Left Operator Station (CP6) This operator station allows the operator to control basic machine functions. Figure 3 - 6 Control Panel 6 Table 3-5. Control Panel 6 Button Descriptions...

  • Page 47: Discharge Right Operator Station (Cp7)

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Discharge Right Operator Station (CP7) This operator station allows the operator to control basic machine functions. Figure 3 - 7 Control Panel 7 Table 3-6. Control Panel 7 Button Descriptions...

  • Page 48: Glue Control Panel

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Glue Control Panel This panel is located on the Glue Tank provided with the system. See Figure 3 - 8. For more information, see the Glue tank manual provided with the system vendor documenta- tion.

  • Page 49: The Human Machine Interface

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Human Machine Interface The Numeric Keypad When the operator presses a digital display button, a numeric keypad opens in the center of the terminal screen. The top of the numeric keypad shows the current value after the operator enters it and the range of values the operator can enter.

  • Page 50: The System Information Screen

    17 July 2019 The System Information Screen On the System Info Screen, you may do the following: View the System Info View Brenton Contact Information View the Job Number Go to the Menu Screen Figure 3 - 10 The System Info Screen Table 3-7.

  • Page 51: The Main Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Main Screen On the Main screen you may control the primary functions of the machine. Figure 3 - 11 The Main Screen Table 3-8. The Main Screen Button Descriptions...
  • Page 52 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-8. The Main Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 The machine can only be started from one location at a time. Press this button to cancel the remote start. The...

  • Page 53: The Menu Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Menu Screen On the Menu screen you may do the following. Enter User Password View the Active User Log Out a User Go to any of the Displayed Screens (Thick...
  • Page 54 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-9. The Menu Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Drive (VFD) Press this button to go to the Drive (VFD) Screen. Fault Codes Glue Press this button to go to the Glue Settings Screen.

  • Page 55: The Glue Control Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Glue Control Screen On the Glue Control Screen you may do the following. Set the On and Off Positions for the Turn the Glue or Setup Vacuum on or...
  • Page 56 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-10. The Glue Setup Screen Default Settings (Continued) PARAMETER SMALL SMALL SMALL SMALL LARGE LARGE LARGE LARGE Carton 1 Initial Carton Glue 40.0 40.0 40.0 40.0 40.0...
  • Page 57 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-10. The Glue Setup Screen Default Settings (Continued) PARAMETER SMALL SMALL SMALL SMALL LARGE LARGE LARGE LARGE Carton 1 Final Carton Glue 78.0 78.0 78.0 78.0 78.0...
  • Page 58 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-10. The Glue Setup Screen Default Settings (Continued) PARAMETER SMALL SMALL SMALL SMALL LARGE LARGE LARGE LARGE Carton 2 Final Carton Glue 178.0 178.0 178.0 178.0 178.0...
  • Page 59 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-11. The Glue Setup Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 1. Press this button to enter the Left 2nd Glue Stop Position. •...
  • Page 60 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-11. The Glue Setup Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to synchronize the servo Sync Servos Sync Servos motion group. Syncing the servos aligns the mechanical and electrical zero positions.

  • Page 61: The Glue Control Purge Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Glue Control Purge Screen On the Glue Control Purge screen you may purge each of the glue nozzles. Hot melt glue can cause burns or serious injury. Stay clear of glue nozzles WARNING when activated.
  • Page 62 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-12. The Glue Control Purge Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Prior to purging glue, ensure that there is a Purge Final Glue catch container in place.

  • Page 63: The Active Alarms Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Active Alarms Screen On the Active Alarms Screen, you may view the active alarm messages. Figure 3 - 15 The Active Alarms Screen Table 3-13. The Active Alarms Screen Button Descriptions...

  • Page 64: The Alarm History Screen

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The Alarm History Screen On the Alarm History Screen, you may do the following: View the Alarm Messages Scroll Through the Alarms Clear the Alarm History Go to the Menu Screen...
  • Page 65 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-14. The Alarm History Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to scroll down one page of alarms. Menu Press this button to go to the Menu Screen.

  • Page 66: The Vfd Fault Codes Screen

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The VFD Fault Codes Screen On the VFD Fault Codes Screen, you may view the current fault codes for each VFD. This screen is helpful for troubleshooting VFD’s.

  • Page 67: The Pack Select Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Pack Select Screen On the Pack Select screen, you may do the following: Accept the Pack Pattern Select a Pack Pattern Confirm that the Manual Changeover...

  • Page 68: The Auto Adjust Teach Screen

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The Auto Adjust Teach Screen On the Auto Adjust Teach Screen, you may teach the Auto Adjust Positions. Figure 3 - 19 The Auto Adjust Teach Screen Table 3-17.
  • Page 69 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-17. Auto Adjust Teach Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to display the numeric keypad AA (Axis2) Front End to enter the Auto Adjust Front End position, in AA (Axis2) Front End degrees.

  • Page 70: Setting Auto Adjust Positions

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Setting Auto Adjust Positions Follow this procedure for adjusting the Auto Adjust Positions. 1. On the Main Screen, press Menus to go to the Menus Screen. 2. Press User Password. Enter the user password and press enter on the keypad.

  • Page 71: The Jog Sol Control Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Jog SOL Control Screen On the Jog SOL Screen, you may jog the indicated conveyors or go to the Manual Func- tion or Menus Screens. Jog functions are only available when all E-stops are pulled, all...

  • Page 72: The Manual Control Screen

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The Manual Control Screen On the Manual Control Screen, you may do the following: Inch Jog or Cycle Jog Any of the Test the Light Beacons Servo Components Listed...
  • Page 73 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-19. Manual Control Screen Button Descriptions STATE 1 DESCRIPTION STATE 2 Inch Press this button to enable or disable inch jog Inch Jog Off mode. Jog On With Control Power present, press this button to jog the indicated component.

  • Page 74: The Reference Main Servo Screen

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The Reference Main Servo Screen On the Reference Main Servo Screen, you may do the following: Reference any of the Indicated Go to the Auto Adjust Servos or Main...
  • Page 75 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-20. The Reference Main Servo Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press and hold this button for two seconds to Depositor Belt Reference the Depositor Belt to the home prox- Hold 2 Sec imity sensor.
  • Page 76 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-20. The Reference Main Servo Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Menu Press this button to go to the Menu Screen. Page 3-40...

  • Page 77: The Axis Reference Auto Adjust Servo Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Axis Reference Auto Adjust Servo Screen On the Reference Infeed Servo Screen, you may do the following: Reference any of the Indicated Go to the Servos or Menus Screens...
  • Page 78 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-21. The Reference Auto Adjust Servo Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press and hold this button for two seconds to AA Servo (Axis4)

  • Page 79: The Maintenance Global Settings Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Maintenance Global Settings Screen On the Maintenance Global Settings Screen, you may do the following: Set the New Month Set the New Minute Set the New Date...
  • Page 80 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-22. Maintenance Global Settings Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to increase the backlight setting by 1. Press this button to decrease the backlight setting by 1.

  • Page 81: The Disable Bypass Options Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Disable Bypass Options Screen On the Disable/ Bypass Options Screen, you may bypass the downstream run signal, open flap detection, transfer 1 product camera, transfer 2 product camera, or go to the Mainte- nance or Menus screen.

  • Page 82: The Barcode Scanner Screen

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The Barcode Scanner Screen On the Barcode Screen, you may view the current product assignment, check the data from the barcode scanner and scale or go to any of the displayed screens.

  • Page 83: The Open Flap Detect Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Open Flap Detect Screen On the Open Flap Detection Screen, you may view the open flap detection bits. You may also enable or disable the indicated flap detections or set the Reject Beam Count adjust- ment.
  • Page 84 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-25. The Open Flap Detect Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to or Disable the Manufacturer’s Flap Detection. Press this button to display the numeric keypad to enter the reject beam count. This...

  • Page 85: The Bag Reject Clear Fault Prompt

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation The Bag Reject Clear Fault Prompt On the Bag Reject Clear Fault Prompt, you may confirm that the Bin was manually cleared. Figure 3 - 29 The Bag Reject Clear Fault Prompt Table 3-26.

  • Page 86: The Pressure Regulators Screen

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The Pressure Regulators Screen On the Pressure Regulator, you may view and set the pressure percentage for each pres- sure regulator. Figure 3 - 30 The Pressure Regulator Screen Table 3-27.

  • Page 87: The Pressure Regulator Screen

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-28. The Pressure Regulator Screen Button Descriptions STATE 1 DESCRIPTION STATE 2 Main Press this button to go to the Main Screen. Press this button to display the numeric keypad to...

  • Page 88: The Shutdown Screen

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The Shutdown Screen On the Shutdown Screen, you may either confirm or cancel the HMI software shutdown: Figure 3 - 31 The Shutdown Screen Table 3-29. The Shutdown Screen Button Descriptions...

  • Page 89: Instrumentation & Controls

    Instrumentation & Controls Security Interlock Switch Brenton Engineering used an Interlock Switch, attached to each access door, to guard against unsafe entry into this system. It interlocks the guard to the machine control system and ensures machine power is isolated and remains isolated while the guard door is open.

  • Page 90: Pneumatic Controls

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Pneumatic Controls The Pneumatic Discharge Valve Assembly This Assembly is located on the right side of the machine, near the HMI. It controls and conditions the air coming into the Cartoner.

  • Page 91: Instrumentation

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Instrumentation Adjustment Scales Adjustment scales are used as a gauge for many of the changeover procedures. The changeover section of the operators manual will describe the correct procedures for each of these scales.

  • Page 92: The Information & Alarm History Displays

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 The Information & Alarm History Displays Alarm Messages An Information Window appears on the Alarm History Screen. When a fault, error or con- dition occurs, a message is displayed until the fault, jam or condition clears. Correct the condition and press the Fault Reset button to clear the message and continue machine operation.
  • Page 93 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # The Variable Frequency Drive Remedy the cause of the fault. INFEED CONV VFD has faulted.
  • Page 94 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # MAGAZINE ROTATE, DEPOSITOR There is an ethernet fault for Check ethernet connections to...
  • Page 95 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE AUTO Screen” on page 3 - 38. See ERR_MSG[34] The servo is not referenced.
  • Page 96 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE FLIGHTS Screen” on page 3 - 38. See...
  • Page 97 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE TRANSFER Screen” on page 3 - 38. See...
  • Page 98 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE TRANSFER Screen” on page 3 - 38. See...
  • Page 99 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE FLIGHTS Screen” on page 3 - 38. See...
  • Page 100 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE FLIGHT Screen” on page 3 - 38. See ERR_MSG[54] The servo is not referenced.
  • Page 101 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE TRANSFER Screen” on page 3 - 38. See...
  • Page 102 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE FLIGHTS Screen” on page 3 - 38. See...
  • Page 103 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE TRANSFER Screen” on page 3 - 38. See...
  • Page 104 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE Screen” on page 3 - 38. See ERR_MSG[70] The servo is not referenced.
  • Page 105 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE Screen” on page 3 - 38. See...
  • Page 106 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Reference the servo. See “The Reference Main Servo REFERENCE AUTO Screen” on page 3 - 38. See...
  • Page 107 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # • Check overload indica- tor. If it is tripped, Reset overload. •...
  • Page 108 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # INSIGHT TRAILING BAG There is an ethernet fault for Check ethernet connections to...
  • Page 109 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # Check for the cause of the ERR_MSG[116 CARTON MISSING AT A carton is missing at the load missing carton.
  • Page 110 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # STATION 2 BAG 2 Check for a mechanical bind ERR_MSG[127 The indicated cylinder is...
  • Page 111 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # STATION 3 CARTON Check for a mechanical bind ERR_MSG[140 COMPRESS LH The indicated cylinder is...
  • Page 112 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # STATION 4 COMPRESS Check for a mechanical bind ERR_MSG[154 The indicated cylinder is...
  • Page 113 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-30. Alarm Message Condition and Corrections (Continued) ERROR ALARM MESSAGE CONDITION CORRECTION MESSAGE # ERR_MSG[167 CARTON JAM AT FINAL There is a jam at the indicated Clear the jam.

  • Page 114: Warning Messages

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Warning Messages Warning messages display the current status of the machine. The conditions may require remedy to resume operation, but other are simply a current status and do not require any action by the operator.
  • Page 115 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-31. Warning Message Condition and Corrections (Continued) ERROR WARNING MESSAGE CONDITION CORRECTION MESSAGE # The indicated guard door is Close the guard door. Ensure ERR_MS- GUARD DOOR #1 OPEN currently open.
  • Page 116 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Table 3-31. Warning Message Condition and Corrections (Continued) ERROR WARNING MESSAGE CONDITION CORRECTION MESSAGE # The hot side air is dumped. Check the limit switch ERR_MS- LS30902_LS30902A HOT...
  • Page 117 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 System Operation Table 3-31. Warning Message Condition and Corrections (Continued) ERROR WARNING MESSAGE CONDITION CORRECTION MESSAGE # The downstream photoeye is Check for the cause of the currently blocked.
  • Page 118 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 System Operation 17 July 2019 Page 3-82...
  • Page 119 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Contents Troubleshooting Contents Sequence Of Operation ..........4-1 Initial Conditions Before Startup .
  • Page 120 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting Contents 17 July 2019 Page II...

  • Page 121: Chapter 4: Troubleshooting

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Troubleshooting Sequence Of Operation Initial Conditions Before Startup 1. Turn the red hand valve in on the "Manual Discharge Valve" to turn on the main air supply. Air flow is supplied to the following components: •...

  • Page 122: Carton Magazine And Carton Setup

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Carton Magazine and Carton Setup Cartons are hand loaded into the Carton Magazine. The cartons are picked out of the Mag- azine by the presentation unit and held in a horizontal position. Next, Loader 1 picks and places onto an indexing racetrack conveyor known as Axis 2.

  • Page 123: Bag Conveyors

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Bag Conveyors Bags are fed from the Buyer's Check Weigher and are transferred onto the "Bag Align- ment conveyor. A blower blows air across the bags as they are conveyed ahead. Bags are transferred onto the Bag Feed conveyor;...

  • Page 124: Loader 2 Bag Gantry

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Loader 2 Bag Gantry The Overhead Gantry Pick & Place (loader 2) uses forked tools to pick two bags and places them onto the carton blanks. Figure 4 - 3...

  • Page 125: The Carton Forming And Inspection Station

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting The Carton Forming and Inspection Station The carton blank and bag is indexed to the carton forming station, where a vision system inspects the placement of the bag. If the bag placement is incorrect, the flights advance, and the bag and carton is driven off of the end of the conveyor.

  • Page 126: Loader 4, Glue, And Compression

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Loader 4, Glue, and Compression As the race track (Axis 3) moves the cartons to the next carton forming station, glue is applied. Then the overhead tool (Loader 4) picks the two cartons, the upper trailing minor flaps are tucked closed and held in compression to seal the flaps.

  • Page 127: Sensor Functions

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Sensor Functions Your BEC Packaging system contains proximity switches, solenoid valves, and photo electric eyes: • PROXIMITY SWITCHES generate a high frequency electro-magnetic field. When an object enters this field, the prox's circuit recognizes a change and turns its solid state output ON or OFF.

  • Page 128: Retro-Reflective Sensors

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Retro-Reflective Sensors The illustration below depicts a retro-reflective, infrared photoelectric sensor. An infrared light beam is emitted from the emitter side of the sensor. The light beam bounces back to collector side of the sensor from a remote mounted reflector.

  • Page 129: Diffuse Sensors

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Diffuse Sensors The illustrations below, depicts a diffuse, infrared photoelectric sensor. An infrared light beam is emitted from the emitter side of the sensor. The light beam expands as it is emitted from the device, but is not reflected back to the collector portion of the sensor by a reflec- tor.

  • Page 130: Inductive Proximity Sensor

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Inductive Proximity Sensor Inductive sensors work by generating a current that sets up an electromagnetic field around the sensing device. When this field is disturbed, a change in the electrical current that drives the field is sensed.

  • Page 131: Sensor Descriptions

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Sensor Descriptions Each sensor on the machine is labeled. The tables below describe the type of sensor and its function. Table 4-1. Pressure Switch LABEL FUNCTION PS 30701...
  • Page 132 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Table 4-3. Hall Effect Sensors (Continued) LABEL FUNCTION LABEL FUNCTION HES 40204A Loader Forks Bag 2 HES 40708 Carton 1 Final Comp Retracted Right Hand Retracted HES 40303...
  • Page 133 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Table 4-3. Hall Effect Sensors (Continued) LABEL FUNCTION LABEL FUNCTION HES 40515A Side Comp Rotary Cyl HES 40611A RH Carton 1 Side Comp Extended Transfer Open Station 3...
  • Page 134 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Table 4-4. Photo Eyes LABEL FUNCTION LABEL FUNCTION PE 40104 Station 1 Low Magazine PE 40312 Carton 2 At Transfer From 1st Glue Station 4 PE 40107 Infeed Bag Reject Full...
  • Page 135 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Table 4-5. Solenoid Valves LABEL FUNCTION LABEL FUNCTION SOL 40903 Station 1 Top Lid Vac SOL 41103A Station 3 Side Comp Cylinder Extend Rotary Cylinder Extend 1st Carton Forming Tool...
  • Page 136 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Table 4-5. Solenoid Valves (Continued) LABEL FUNCTION LABEL FUNCTION SOL 40907A Station 2 1st Comp B4 SOL 41307 Carton 1 Final Comp Transfer To 1st Glue Extend RH...
  • Page 137 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Table 4-5. Solenoid Valves (Continued) LABEL FUNCTION LABEL FUNCTION SOL 41116 Station 3 Carton Comp SOL 41416A 1st Glue Gun RH Cyl Retract RH 1st Carton Forming Tool...

  • Page 138: Light Tree Status Indicator

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Light Tree Status Indicator The system is equipped with a LIGHT TREE STATUS INDICATOR mounted on top of the machine. The INDICATOR is composed of three colored lenses (red, amber and green).

  • Page 139: Troubleshooting

    If the problem(s) cannot be solved after consulting this section and/or appropriate sections of this manual, feel free to call Brenton Engineering Company's Service Department at (800) 535-2730. Table 4-7. Troubleshooting Chart...
  • Page 140 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Table 4-7. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Servo Fault Possible conditions that cause this problem include an e-stop condi- tion, a position error, a mechanical bind, or product blocking the servo assembly.
  • Page 141 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Table 4-7. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION The overload contact on the motor Check overload indicator. If it is starter is open. tripped, Reset overload. The rated amperage draw on the motor...

  • Page 142: Vfd Settings

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 VFD Settings The settings in the chart below represent the setting as of the time of shipment. Adjust- ments could be made after installation, so it is wise to record VFD setting for future recov- ery when changes are made.

  • Page 143: Discharge Conv Drive 601

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Troubleshooting Discharge Conv Drive 601 Table 4-9. Discharge Drive 601 VFD Parameter Settings PARAM # DESCRIPTION VALUE UNITS INTER- DEFAU VALUE Accel Time 1 2.00 10.00 0.00 Decel Time 1 2.00...

  • Page 144: Vacuum Blower Drive 701

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Troubleshooting 17 July 2019 Vacuum Blower Drive 701 Table 4-10. Vacuum Blower 701 VFD Parameter Settings PARAM # DESCRIPTION VALUE UNITS INTER- DEFAU VALUE Accel Time 1 5.00 10.00 0.00 Decel Time 1 5.00...

  • Page 145: Chapter 5: Changeover And Maintenance

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Contents Changeover and Maintenance Contents Lockout and Tagout Recommendations ........5-1 Electrical System .
  • Page 146 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance Contents 17 July 2019 Page II...

  • Page 147: Chapter 5: Changeover And Maintenance

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Changeover and Maintenance Lockout and Tagout Recommendations Electrical System (See OSHA 1910.147 & OSHA 1910.333 (b)(2) for exception to procedures) To avoid hazards of electrical shock or other personal injuries, the main power disconnect for the system and any other separate sources of power for the system shall be locked out &...

  • Page 148: Pneumatic And Vacuum Systems

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Pneumatic and Vacuum Systems To avoid hazards of moving mechanisms, pinch points and other personal injuries, the main compressed air supply valve for the system shall be locked out & tagged as a safety precaution during entry and maintenance to the system.

  • Page 149: Changeover Location Drawing

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Changeover Location Drawing This drawing shows the location of each of the changeover steps on this system. Use this drawing along with the changeover quick ref- erence chart and/ or the pictorial changeover to successfully complete the changeover procedure.

  • Page 150: Changeover Quick Reference Charts

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Changeover Quick Reference Charts This chart is a quick reference to changeover settings. These settings are subject to change. Table 5-1. Changeover Quick Reference Chart DESCRIPTION...

  • Page 151: Pictorial Changeover

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Pictorial Changeover • Empty the infeed of all product and let the machine come to a cycle stop. • Press Cycle Stop. • Press any E-Stop button.

  • Page 152: The Tool 4 Change Out (X2) Adjustment

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Changeover Location #1 Tool 4 Change Out (x2) • Loosen and remove the thumb knob. • Change to the correct change part, according to the changeover chart.
  • Page 153 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Changeover Location #2 Tool 4 - Compression (x4) • Loosen and remove the bolt using a 13mm wrench. • Slide the plate to align with the correct hole.
  • Page 154 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Changeover Location #3 Tool 3 - Upstream • Loosen the kip handle. • Adjust the Tool 3 - Upstream to the correct number on the scale, according to the changeover chart.
  • Page 155 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Changeover Location #4 Tool 3 - Downstream • Loosen the kip handle. • Adjust the Tool 3 - Downstream to the correct number on the scale, according to the changeover chart.

  • Page 156: The Infeed Conveyor Downstream Adjustment

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Changeover Location #5 Infeed Conveyor Downstream • Loosen the kip handles. • Adjust the Infeed Conveyor Downstream to the correct numbers on the scale, according to the changeover chart.
  • Page 157 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Changeover Location #6 Infeed Conveyor Upstream • Loosen the bolts. • Adjust the Infeed Conveyor Upstream to the correct numbers on the scale, accord- ing to the changeover chart.

  • Page 158: The Mag Height Hand Crank Adjustment

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Changeover Location #7 Mag Height Hand Crank • Use the hand crank to adjust the Mag Height Hand Crank up to stop or down to stop, according to the changeover chart.

  • Page 159: The Magazine Clips Adjustment

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Changeover Location #8 Magazine Clips • Loosen the bolts using a 13 mm wrench. • Adjust the Magazine Clips to the correct number on the scale, according to the changeover chart.

  • Page 160: The Hmi Pack Pattern Change

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Changeover Location #9 • Press the new pack pattern selection. • Press the Manual Changeover Complete button. • Press and hold the Accept button for two seconds.

  • Page 161: Barcode Scanner Reading Barcode On Magazine

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Changeover Location #10 Barcode Scanner • Load the magazine with the correct blanks for the new production run. Figure 5 - 11 Barcode Scanner Reading Barcode on Magazine •...

  • Page 162: Completing The Changeover

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Completing the Changeover • Ensure all personnel and tools are clear of the working path of the machine. • Press Control Power button to reset the system.

  • Page 163: Maintenance

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Maintenance Electrical P.M. • Electrical PM on this system is minimal. Periodic inspection is all that is required to ensure that the electrical connections and components are secure and maintained.

  • Page 164: Daily Inspections

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Daily Inspections • Remove remnants of glass, cardboard, glue, film, labels, etc. off the guides walk planes belts or channel to avoid obstructions, clean with compressed air or soft cloth.

  • Page 165: Three-Month Preventative Maintenance

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Three-Month Preventative Maintenance • Remove chain guards. Check the drive chains for each section to ensure they are aligned with sprockets and running freely without excessive noise.

  • Page 166: Pulleys & Sprockets

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Pulleys & Sprockets • All pulleys should be checked for surface build-up. Clean if necessary. Check to be sure set screws and/or set collars are tight and properly aligned on their shafts.

  • Page 167: Replacing Vertical Linear Bearings On Gantry's

    If you are unfamiliar with the procedure, do not attempt. Injury could WARNING occur if precautions are not taken to brace up the gantry loaders. Brenton recommends this procedure is completed by an OEM technician. WARNING Follow plant and OSHA maintenance lock-out/tag out prior to starting this WARNING procedure.

  • Page 168: Face Plate Removal

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 3. Remove the base plate using an Allen Wrench. Do one side at a time. 4. Have another person hold the face plate while removing the bolts.

  • Page 169: Bearing Rails

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance 8. Remove the 4 flat head bolts holding on the bearing you are replacing. 9. Slide the bearing block off of the top of the bearing rail.

  • Page 170: Referencing Positions

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Referencing Positions Use the reference position measurements in this section to determine when the component is properly referenced. During day-to-day operations the recipe selection should send each axis to correct position.

  • Page 171: Axis 2 Upstream

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Axis 2 Upstream • Measure from inside to inside of the conveyor rail. Figure 5 - 18 Axis 2 Upstream Reference Measurement Table 5-3. Axis 2 Upstream Reference Measurements...

  • Page 172: Axis 3 Downstream

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Axis 3 Downstream • Measure from inside to inside of the conveyor rail. Figure 5 - 19 Axis 3 Downstream Reference Measurement Table 5-4. Axis 3 Downstream Reference Measurements...

  • Page 173: Axis 3 Upstream

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Axis 3 Upstream • Measure from outside to outside of the conveyor rail. Figure 5 - 20 Axis 3 Upstream Reference Measurement Table 5-5. Axis 3 Upstream Reference Measurements...

  • Page 174: Axis 4 Upstream

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Axis 4 Upstream • Measure from outside to outside of the conveyor rail. Figure 5 - 21 Axis 4 Upstream Reference Measurement Table 5-6. Axis 4 Upstream Reference Measurements...

  • Page 175: Non-Wash Down Sections Cleaning & Sanitation

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Non-Wash Down Sections Cleaning & Sanitation • Use a paint scraper or putty knife to remove hardened grease, glue or grime. • Using an air hose at medium air pressure, blow down the whole machine.

  • Page 176: Wash Down Procedure

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Wash Down Procedure The frequency in which the machine is cleaned depends on many variables. The following are general guidelines: Inspect daily the buildup of product on the mattop conveyor and other mechanical compo- nents of the loader.

  • Page 177: Lubrication

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Lubrication • The high-speed gearboxes as seen on the servomotors are sealed for life and mainte- nance free. The oil used is a high quality synthetic gear oil.

  • Page 178: Lubrication Location Drawing

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Lubrication Location Drawing The locations of the required lubrications for the system are in the drawing below. Figure 5 - 22 The Lubrication Location Drawing Page 5-32...

  • Page 179: 200 Hour Linear Bearing Grease Zerk Lubrications

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance 200 Hour Linear Bearing Grease Zerk Lubrications The following linear bearing zerks should be lubricated with food grade grease every 200 hours of operation. See “Lubrication” on page 5 - 31. The location and quantity of linear...
  • Page 180 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 • Loader 1 Side 1 Vertical Bank Linear Bearing (2 Zerks) Figure 5 - 25 Loader 1 Side 1 Vertical Lubrication Locations • Loader 1 Side 2 Vertical Bank Linear Bearing (2 Zerks)

  • Page 181: Loader 2 Lubrication

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Loader 2 Lubrication • Loader 2 Side 1 Horizontal Linear Bearing (2 Zerks) Figure 5 - 27 Loader 2 Side 1 Horizontal Lubrication Locations • Loader 2 Side 2 Horizontal Linear Bearing (2 Zerks)
  • Page 182 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 • Loader 2 Side 1 Vertical Bank Linear Bearing (2 Zerks) Figure 5 - 29 Loader 2 Side 1 Vertical Bank Lubrication Locations • Loader 2 Side 2 Vertical Bank Linear Bearing (2 Zerks)

  • Page 183: Loader 3 Lubrication

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Loader 3 Lubrication • Loader 3 Side 1 Horizontal Linear Bearing (2 Zerks) Figure 5 - 31 Loader 3 Side 1 Horizontal Lubrication Locations • Loader 3 Side 2 Horizontal Linear Bearing (2 Zerks)
  • Page 184 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 • Loader 3 Side 1 Vertical Bank Linear Bearing (2 Zerks) Figure 5 - 33 Loader 3 Side 1 Vertical Lubrication Locations • Loader 3 Side 2 Vertical Linear Bearing (2 Zerks)

  • Page 185: Loader 4 Lubrication

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Loader 4 Lubrication • Loader Side 1 Horizontal Linear Bearing (2 Zerks) Figure 5 - 35 Loader 4 Side 1 Horizontal Lubrication Locations • Loader 4 Side 2 Horizontal Linear Bearing (2 Zerks)
  • Page 186 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 • Loader Side 1 Vertical Linear Bearing (2 Zerks) Figure 5 - 37 Loader 4 Side 1 Vertical Lubrication Locations • Loader 4 Side 2 Vertical Linear Bearing (2 Zerks)

  • Page 187: 400 Hour Linear Bearing Grease Zerk Lubrications

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance 400 Hour Linear Bearing Grease Zerk Lubrications The following linear bearing zerks should be lubricated with food grade grease every 400 hours of operation. See “Lubrication” on page 5 - 31. The location and quantity of linear...

  • Page 188: Glue Conveyor Auto Adjust Lubrications

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Glue Conveyor Auto Adjust Lubrications • Glue Conveyor Auto Adjust Linear Bearing (2 Zerks) Figure 5 - 40 Glue Conveyor Auto Adjust Linear Bearing • Glue Conveyor Auto Adjust Linear Bearing (2 Zerks)

  • Page 189: Carton Forming Conveyor

    Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance Carton Forming Conveyor • Carton Forming Auto Adjust Gluing Conveyor Linear Bearing (2 Zerks) Figure 5 - 42 Carton Forming Auto Adjust Linear Bearing • Carton Forming Auto Adjust Bag Conveyor Linear Bearing (2 Zerks)

  • Page 190: Carton Flights

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Carton Flights • Carton Flights Auto Adjust Bag Conveyor Linear Bearing (2 Zerks) Figure 5 - 44 Carton Flights Auto Adjust Linear Bearing • Carton Flights Auto Adjust Bag Conveyor Linear Bearing (2 Zerks)
  • Page 191 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Changeover and Maintenance • Discharge Auto Adjust Gluing Conveyor Linear Bearing (2 Zerks) Figure 5 - 46 Discharge Auto Adjust Linear Bearing • Discharge Auto Adjust Gluing Conveyor Linear Bearing (2 Zerks)

  • Page 192: Maintenance Log

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Changeover and Maintenance 17 July 2019 Maintenance Log Table 5-8. Maintenance Log DATE INITIALS COMMENT Page 5-46...

  • Page 193: Spare Parts List & Bill Of Materials

    Spare Parts List & Bill of Materials Spare Parts Legend Code & Description ABPB Pushbutton Push Button Actuators Fitting/Tubing Adapter/Hubs PHASE Phase Adjusters Bronze/Brass Bushing PLC Hardware BELT Belt Pulley Bearing PNEU Air Prep BUSH Bushing PNLS Panel Mounted Misc. Paint Chain &...
  • Page 194 - Normal Wear Part / likely to replace in 12-24 months Level C - General Spare Part / likely to replace in 24-36 months 4113 J M Smuckers Machine Series: Cartoner 1-800-535-2730 Brenton.amsales@promachbuilt.com 3/4/2019 updated 5/8/19 AVG. LEAD TOTAL PRICE...
  • Page 195 *These are suggested quantities. Actual quantities, if any, should be determined by the end user. All parts and equipment purchased by Brenton Engineering that are covered by outside manufacturers’ warranties are, in turn, warranted to the purchaser for the period of time specified by the original equipment manufacturer.
  • Page 197 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Electrical Programs & Prints Electrical Programs & Prints Table of Contents Servo Program(s) Ladder Logic Human Machine Interface Electrical Prints Page 6-1...
  • Page 198 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Electrical Programs & Prints 17 July 2019 Place copies of all software here after completing startup. Page 6-2...
  • Page 199 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Electrical Programs & Prints Servo Program Page 6-3...
  • Page 200 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Electrical Programs & Prints 17 July 2019 Ladder Logic Page 6-4...
  • Page 201 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Electrical Programs & Prints Human Machine Interface Page 6-5...
  • Page 202 JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Electrical Programs & Prints 17 July 2019 Page 6-6...
  • Page 203 Brenton Engineering Company JM Smuckers Machine 4113 Cartoner 17 July 2019 Appendix A: Index Appendix A: Index , 3-27 , 3-2 Active Alarms Jog Mode , 3-55 , 3-35 Adjustment Scales Jog SOL Control , 3-28 Alarm History , 3-32...

  • Page 204: Chapter 4: Troubleshooting

    JM Smuckers Brenton Engineering Company Cartoner Machine 4113 Appendix A: Index 17 July 2019 , 1-4 Safety , 4-7 Sensors , 4-1 Sequence Of Operation , 4-20 Servo Fault , 3-1 Startup , 4-19 Troubleshooting , 3-30 VFD Fault Codes...

Table of Contents