Get Packed 4-PP76ST Service Manual

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SERVICE MANUAL

Model 4-PP76ST

Get Packed Pty Ltd

P.O. Box 898

Artarmom NSW 1570

(02) 9452 3566

www.getpacked.com.au

_____________________________________________________________

INSTRUCTIONS FOR OPERATION AND REPAIR OF THE

PREFERRED PACK 4-PP76ST SEALER

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Page 1 SERVICE MANUAL Model 4-PP76ST Get Packed Pty Ltd P.O. Box 898 Artarmom NSW 1570 (02) 9452 3566 www.getpacked.com.au _____________________________________________________________ INSTRUCTIONS FOR OPERATION AND REPAIR OF THE PREFERRED PACK 4-PP76ST SEALER...
Page 2 Page 2 4-PP76ST Sealer Service Manual IMPORTANT - PLEASE READ THIS CAREFULLY The development of a good safety program, that is rigidly enforced, is absolutely imperative when involved in the operation of industrial equipment. Our machinery is well designed and includes extremely important safety features.
Page 3 Page 3 4-PP76ST Sealer Service Manual SAFETY PRECAUTIONS To avoid damage to the machine and injury to the operator, DO NOT use liquids of any kind: flammable materials, explosive materials, materials under extreme pressure, pressurized gases, volatile powders, or bulk...
Page 4: Table Of Contents
Page 4 4-PP76ST Sealer Service Manual TABLE OF CONTENTS ___________________________________________________________ Preface Unpacking 5 - 8 Warranty Notice Warranty 10-11 Warranty Exceptions Warnings 13-15 Chamber Machine Section Description and Specifications Installation and Basic Set-Up 17-23 Film Threading Diagram Front Panel Diagram...
Page 5: Unpacking
Page 5 4-PP76ST Sealer Service Manual UNPACKING THOROUGHLY INSPECT EQUIPMENT UPON ARRIVAL. If goods are received short or in a damaged condition, it is important that you notify the carrier’s driver before he leaves your company and insist on a notation of the loss or damage across the face of the freight bill.
Page 6 Page 6 4-PP76ST Sealer Service Manual Your new Preferred Pack Model PP76ST comes bolted to a pallet and has a tri-walled corrugated box strapped to the pallet to protect it. Cut steel straps and remove corrugated box. If your machine does not arrive in this condition, write on shipping paperwork that outside of box is damaged.
Page 7 Page 7 4-PP76ST Sealer Service Manual Check contents. You should have (1) Film Rack (1) Film Shaft (2) Film Roll Core Chucks (1) Hooded Chamber (1) Spare Band Ribbon Remove Bolts holding machine to pallet using 13mm wrench. UNPACKING...
Page 8 Page 8 4-PP76ST Sealer Service Manual Install plexiglass hood on top of upper seal frame. Insert steel locking clip into hole in upper seal frame. Push straight down on clip into hole, clip will automatically lock into position. UNPACKING...
Page 9: Warranty Notice
Page 9 4-PP76ST Sealer Service Manual IMPORTANT WARRANTY NOTICES OPERATING AND MAINTENANCE MANUAL The operating and maintenance manual has been carefully prepared to provide the user with all the information needed to properly install, operate, and maintain your Preferred Packaging equipment.
Page 10: Warranty
Page 10 4-PP76ST Sealer Service Manual PREFERRED PACKAGING SYSTEMS WARRANTY Preferred packaging systems, Inc. warrants each new product manufactured to be free from defects in material and workmanship for a period of (1) year from date of shipment by Preferred Packaging.
Page 11 Page 11 4-PP76ST Sealer Service Manual Preferred Packaging shall have no liability to any person for direct, indirect, incidental or consequential damages or delay resulting from any defect negligence, or tort and customer hereby waives for itself any and all claims for punitive damages and all claims of negligence of strict liability or both.
Page 12: Warranty Exceptions
Page 12 4-PP76ST Sealer Service Manual WARRANTY EXCEPTIONS The following sealer parts are considered to be consumable and not under warranty: Silicone Sponge Band Ribbon Teflon Tapes Transit Channel WARRANTY EXCEPTIONS...
Page 13: Warnings
Page 13 4-PP76ST Sealer Service Manual WARNINGS Every effort has been taken to ensure your safety while operating this machine; however, there still remain certain risks. Do not allow this machine to be operated before informing all personnel of the following warnings.
Page 14 Page 14 4-PP76ST Sealer Service Manual pinch, and in running nip points, many of which are capable of causing severe injury and/or permanent disfigurement. WARNING..To minimize the potential for personnel injury, always be sure that machine operators and others working on the machinery are properly trained in the correct usage of the equipment and properly instructed regarding the safety procedures for operation.
Page 15 Page 15 4-PP76ST Sealer Service Manual the potential release of hazardous fumes. ADEQUATE VENTILATION MUST BE PROVIDED AT ALL TIMES. WARNING..It is important that the machine operator unplug the machine when he/she has finished operating the unit. WARNINGS...
Page 16: Description And Specifications
Page 16 4-PP76ST Sealer Service Manual DESCRIPTION AND SPECIFICATIONS OF PREFERRED PACK MODEL PP76ST DESCRIPTION This compact “all-in-one” unit allows the operator to seal and shrink all in one step. The operator simply places the product in the sealing area and lowers the hood to apply the seal pressure necessary to cut the film.
Page 17: Installation And Basic Set-Up
Page 17 4-PP76ST Sealer Service Manual INSTALLATION AND BASIC SET-UP OF L’SEALER PORTION OF MACHINE IMPORTANT Read this manual carefully, and make it available to everyone connected with the supervision, maintenance, or production of this machine. Additional copies are available at your request.
Page 18 Page 18 4-PP76ST Sealer Service Manual any doubt, get qualified assistance to do the initial installation. Do not take any chances! Do not attempt to install, adjust, or operate this machine without first reading the contents of this manual.
Page 19 Page 19 4-PP76ST Sealer Service Manual Start from the right side (back) of machine to slide film rack onto tracks. Continue to slide film rack from right to left toward front of machine. NOTE: At this point, film rack will be difficult to move as the film rack is now in contact with slider bearings.
Page 20 Page 20 4-PP76ST Sealer Service Manual Now move film rack back to the right. Rack will now only move forward toward operator or front of machine. It will not be able to slide off from the back side. INSTALLATION...
Page 21 Page 21 4-PP76ST Sealer Service Manual MOUNTING FILM Select the proper width of center-fold film for the item being packaged, allowing for width and height of package. With the package properly positioned within the film in the sealing area, allow sufficient film to overlap the sealing bars so that a seal may readily be made without any possibility of open areas due to insufficient film.
Page 22 Page 22 4-PP76ST Sealer Service Manual the rollers, across the product tray, and into the sealing area to ensure sufficient film to begin operation. Place product toward rear of film separator tray. Then move product into seal area. Be sure to leave the bag loose around the product when making the seal.
Page 23 Page 23 4-PP76ST Sealer Service Manual on a concentric cam. To adjust pin wheels depth, use Allen key provided and adjust wheel without pins using the concentric cam to turn wheel on shaft to position wheel deeper into pins. Then re-lock Allen screws.
Page 24: Film Threading Diagram
Page 24 4-PP76ST Sealer Service Manual FILM THREADING DIAGRAM Product Tray Film FILM THREADING...
Page 25: Front Panel Diagram
Page 25 4-PP76ST Sealer Service Manual PREFERRED PACK -- Front Panel Diagram • Main switch is in OFF position. Machine will not operate. Seal Only • Main switch in SEAL only position (ON1). Machine will only seal product NOT shrink.
Page 26 Page 26 4-PP76ST Sealer Service Manual Seal and Shrink • Main switch in SEAL and SHRINK position (ON2), both functions are available. Machine will take approximately 10-15 minutes to warm up. You will know it is ready when chamber temperature thermostat light goes off.
Page 27 Page 27 4-PP76ST Sealer Service Manual Seal Time: Amount of time band ribbon heats up. Recommended setting for PVC: 0.8 Sec. Recommended setting for Polyolefin: 0.8 ~ 1.2 Sec. Note: The proper seal time is the shortest time possible to cleanly seal and cut your film.
Page 28 Page 28 4-PP76ST Sealer Service Manual used. Remember that thinner gauge films require less heat and less shrink time. CONTROL PANEL...
Page 29: Sequence Of Operation
Page 29 4-PP76ST Sealer Service Manual SEQUENCE OF OPERATION Product is placed on the film separator tray. The product tray functions as a means to separate the film, allowing placement of product between upper and lower portions of the film.
Page 30 Page 30 4-PP76ST Sealer Service Manual SEQUENCE OF OPERATION After completion of basic setup as described on pages 18-27 plug the sealer’s cord into the power source. With film threaded (see instructions for mounting film), place right hand on package and slide product into the upper left hand corner of the film (i.e., corner formed by...
Page 31 Page 31 4-PP76ST Sealer Service Manual the film with left hand moving package and film into lower right corner of seal area. Allow from ” to 1” of extra film around package. This will allow some slack film between the package and the sealing bars, reducing film tension.
Page 32 Page 31 4-PP76ST Sealer Service Manual Once shrink cycle time is complete, operator may remove completed product from chamber. To increase cycle time and speed of operation, follow this procedure: Turn Selector switch to SEAL ONLY position (ON1). SEQUENCE OF OPERATION...
Page 33 Page 32 4-PP76ST Sealer Service Manual Place product into seal area and seal only. Turn selection switch to seal and shrink (ON2). SEQUENCE OF OPERATION...
Page 34 Page 33 4-PP76ST Sealer Service Manual Place additional product into seal area and now seal and shrink both products at the same time, increasing output of machine. Adjusting Product Grill: If product is too tall, film tension is created, producing weak seals.
Page 35 Page 34 4-PP76ST Sealer Service Manual Adjust grill, holding screws downward into lower threaded hole. Product now sits half way below seal area, reducing film tension when sealing and place seal in center of package. SEQUENCE OF OPERATION...
Page 36 Page 35 4-PP76ST Sealer Service Manual TROUBLESHOOTING The following guidelines are provided to aid in determining the source of any operation difficulties which may develop. performing the tests and checks which follow, carefully inspect for any loose components, broken or loose wires, poor electrical connections, etc., while testing the various switches, controls, relays,...
Page 37 Page 36 4-PP76ST Sealer Service Manual Seal Time Make sure seal timer is not set on zero (0) on time dial. Check pulse switch adjustment. Make sure switch is being activated when the seal bar is within ” of contact with seal pad.
Page 38 Page 37 4-PP76ST Sealer Service Manual F6 – 15AMP FUSE (F6): F5 – 15 AMP Pulse Transformer F4 – 1 AMP Protection F3 – 5 AMP F2 – 2 AMP F1 – 20 AMP Check all fuses. TROUBLESHOOTING: NO HEAT TO BAND RIBBON...
Page 39 Page 38 4-PP76ST Sealer Service Manual CR2: Magnetic Contactor Check to see CR2 contactor is ok and the points are not burned or no wire has come loose. Check for voltage present at both primary T2 and secondary of transformer T2 as per values shown in the voltage specifications (220 volt primary, 66 volt secondary).
Page 40 Page 39 4-PP76ST Sealer Service Manual Check for broken band ribbon inside or outside the corner bead. Check for bad connections on each end of band ribbon. Make sure wires are connected to each end of compensator. TROUBLESHOOTING: NO HEAT TO BAND RIBBON...
Page 41 Page 40 4-PP76ST Sealer Service Manual TR2: Timer Board Check TR2 Timer Board to make sure no wire has come loose, the contactor of the Relay on the board is ok. TROUBLESHOOTING: NO HEAT TO BAND RIBBON...
Page 42 Page 41 4-PP76ST Sealer Service Manual Seal Time Improper setting of seal time compensator. Refer to page 27 for proper adjustment. Improper operating technique. Too much film tension, make sure film is relaxed prior to sealing. Check band ribbon to see if cleaning or replacement is necessary.
Page 43 Page 42 4-PP76ST Sealer Service Manual Wavy silicone rubber sealing pad. Replace. (See instructions on page 53.) Seal pad pressure incorrect. TROUBLESHOOTING: WEAK SEALS AND/OR POOR FILM CUT-OFF...
Page 44 Page 43 4-PP76ST Sealer Service Manual MAGNETIC HOLD DOWN ON SHRINK CHAMBER Magnet NOTE: There are two magnets on the machine, one to hold the hood chamber down for duration of shrink time, the other is for seal time.
Page 45 Page 44 4-PP76ST Sealer Service Manual Sealing Time Not at Zero Check seal timer (TR2) setting. Make sure it is not set at zero. Also, check to see if burned or damaged. Check for 220 volts (nominal) to primary transformer (T1).
Page 46 Page 45 4-PP76ST Sealer Service Manual Check for 24 (nominal) volts DC output from + (positive) and – (negative) wires number 20 ( + ) and 21 (-)on terminals of rectifier. If no DC 24 voltage, replace rectifier. TROUBLESHOOTING:...
Page 47 Page 46 4-PP76ST Sealer Service Manual NO AIR FLOW F6 – 15 AMP F5 – 15 AMP F4 – 1 AMP F3 – 5 AMP F2 – 2 AMP FUSE (F1): Blower Motor F1 – 20 AMP Protection Check all fuses.
Page 48 Page 47 4-PP76ST Sealer Service Manual Remove bottom cover from underside on machine. Capacitor Check Blower motor to make sure no wires are loose. Replace capacitor and replace if bad. TROUBLESHOOTING: NO AIR FLOW...
Page 49: Maintenance
Page 48 4-PP76ST Sealer Service Manual BAND RIBBON REPLACEMENT The band ribbon is subject to constant wear and will eventually require replacement. To replace band ribbon, proceed as described below. Before working on machine, switch machine off and disconnect power cord from wall outlet.
Page 50 Page 49 4-PP76ST Sealer Service Manual Replacing Band Ribbon Loosen screw holding Band Ribbon in corner. Loosen screw holding Band Ribbon inside rear compensator assembly. MAINTENANCE: REPLACING BAND RIBBON...
Page 51 Page 50 4-PP76ST Sealer Service Manual Loosen screw holding Band Ribbon in front compensator assembly. Use pre-cut Band Ribbon and place piece of teflon tape around corner of band ribbon ”L x ”W x 3 mill. Install Band Ribbon on corner first then insert into each end of front and side compensator.
Page 52 Page 51 4-PP76ST Sealer Service Manual Compensator Screw Place other end of band ribbon in slot along front seal area. With band ribbon in slot, use screwdriver to move front compensator forward until band ribbon is inside compensator and compensator is resting against the front seal bar.
Page 53 Page 52 4-PP76ST Sealer Service Manual Tape Replacement The item most subject to wear on the sealer is the teflon tape used to cover the silicone sponge rubber on the sealing bar. This ”x 10 mill tape should never be permitted to burn through.
Page 54 Page 53 4-PP76ST Sealer Service Manual SILICONE RUBBER SEALING PAD REPLACEMENT Occasionally it will be necessary to replace the silicone rubber sealing pads. This should be done if the following is noted: • Gaps in the seal • Weak seals •...
Page 55 Page 54 4-PP76ST Sealer Service Manual Sealing Pad Pressure Adjustment for Head Return Cylinder Uniform pressure between the Band Ribbon and the sealing pads must always be maintained for proper sealing uniformity, and to prevent Band Ribbon hot-spots and premature burnout.
Page 56 Page 55 4-PP76ST Sealer Service Manual Pulse Switch Adjustment The sealing cycle should not begin until the chamber hood is within 1/4” or less of the film to be sealed. If the Band Ribbon energizes before the hood is within 1/4” of the film, loosen the lock- nut and turn the screw (located at the rear end of the side seal bar) up slightly (counterclockwise when viewed from above).
Page 57 Page 56 4-PP76ST Sealer Service Manual Adjustment of Magnets for Correct Chamber Pressure All magnets have been factory adjusted for equal sealing pressure throughout the length of both the front and side seal bars. However, if an adjustment is required, proceed as follows: Disconnect the sealer’s power source.
Page 58 Page 57 4-PP76ST Sealer Service Manual Replacing Front and Side Transite Bars Turn power switch to OFF position. Film Support Bracket See instructions on replacing Band Ribbon on page 47. Transite Bar Holding Screw Remove film support bracket which is mounted next to transite holding channel.
Page 59 Page 58 4-PP76ST Sealer Service Manual S1: Power Switch PL1: Power Indicator POWER SWITCH FUSE RATE F1: 20A /250V ON1: Seal 2A /250V ON2: Seal + Sh rink 5A /250V 1A /250V F5: 15A /250V F6: 15A /250V M1: Fan Motor...
Page 60: Parts List
Page 59 4-PP76ST Sealer Service Manual PREFERRED PACK MODEL PP76ST Item Part # Parts List Nomenclature 10100A Main Switch TC003 Temperature Control Shrink Timer Seal Timer Fuse – 20 AMP Fuse – 2 AMP Fuse – 5 AMP Fuse – 1 AMP Fuse –...
Page 61 Page 60 4-PP76ST Sealer Service Manual PP76ST REPLACEMENT PARTS Part # Description YFE385602 Band Ribbon 76-M1006 Brackets – Chamber Shaft Mounting Bracket 76-E2006 Capacitor – Blower Motor 76-M1011 Chamber Height Adj. Assembly 76-M1016 Channel – Transite – Front Mounting 76-M1021 Channel –...
Page 62 Page 61 4-PP76ST Sealer Service Manual Part # Description YFM215015 Hub – Fan Mounting 76-M1086 Legs 76-M1091 Loading Tray YFM22020 Locking Casters 76-E2041 Magnet 76-M1101 Magnet – Upper Mounting Bracket YFE240001 Motor – Blower YFM225025 Mounting Bracket – Pulse Switch YSOK00604 Pin Perforator –...
Page 63 Page 62 4-PP76ST Sealer Service Manual Spare Parts List – PP76ST Item Part # Description Qty. Price YFE260060 Fuse – F3, F5 4AMP YFE260055 Fuse – F4, 1AMP YFE265065 Fuse FU6, .5 AMP 76-E2026 Fuse – FU, FU2, 16 AMP 43-1125 ”...