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Pearson CE25-T Operation Manual

Case erector options
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CE25-T Case
Erector Options
Machine Operations Manual
8120 W Sunset Highway
Spokane, Washington 99224
509-838-6226/800-732-7766
FAX: 590-747-8532/www.pearsonpkg.com

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  • Page 1 CE25-T Case Erector Options Machine Operations Manual 8120 W Sunset Highway Spokane, Washington 99224 509-838-6226/800-732-7766 FAX: 590-747-8532/www.pearsonpkg.com...
  • Page 2 Therefore, this document is provided "as is" at the time of machine shipment. Please provide your machine serial number whenever ordering parts or referencing information to ensure Pearson Packaging Systems supplies you with the correct parts for your machine. Pearson Packaging Systems disclaims any liability or responsibility to any person for loss or damages, including but not limited to, the following: expenses, which may arise or result from the use of any information contained in this manual;...

  • Page 3: Table Of Contents

    Operations Manual CE25-T Case Erector Options About This Manual ................1-1 Operator Message Boxes ..........1-1 Category 3 Safety with PowerFlex 525 VFD........
  • Page 4 CE25-T Case Erector Options Operations Manual Machine Safety ........... . . 5-2 Machine Operation .

  • Page 5: About This Manual

    Operations Manual About This Manual This manual provides instruction on installation, machine safety, operation, preventive maintenance, troubleshooting and service procedures. IMPORTANT The features shown in this manual are standard. Customer option information is refer- enced in the Option section at the end of this manual. Please review the Option sec- tion, if applicable, before starting up, loading, running or shutting down the machine.
  • Page 6 Operations Manual Warning! Moving Parts can crush and cut. Do NOT operate with guard removed. Follow lock out procedure before servic- ing. Warning! Avoid injury. Do NOT operate machine without all guards in place. A potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

  • Page 7: Category 3 Safety With Powerflex 525 Vfd

    Operations Manual Equipment Option Category 3 Safety with PowerFlex 525 VFD In This Chapter This chapter provides an overview, operation instructions, troubleshooting and preven- tive maintenance for this purchased option. Option Overview Interlock E-Stop Option (Category 3 Safety) • This option has E-stops and Guard Doors wired back to (2) Self Monitoring Safety Relays (one for each circuit).

  • Page 8: Installation Procedures

    Equipment Option Operations Manual Installation Procedures This option is installed on the machine at the factory. Machine Safety Refer to the Machine Safety chapter of the Equipment Option manual. Machine Operation When an E-stop has been pressed or a guard door has been opened the reset button must be pressed to reset the safety relays before the machine can be restarted.

  • Page 9: Human-Machine Interface (Hmi)

    Fig: 1 - Allen-Bradley PanelView 400 Compact This section is intended to describe the screens and functions specific to the Pearson Pack- aging Systems. For technical information about the Allen-Bradley PanelView 400 Compact, refer to the manual shipped with this machine or visit Allen-Bradley’s web site at http://www.ab.com.

  • Page 10: Hmi Display Screens

    CE25-T Case Erector Options Operations Manual Fig: 2 - AB PanelView 400 Compact Layout HMI Display Screens Main Operator Station Screen: The main operator station screen is the display shown on the HMI during normal machine operation. The message display at the top is variable, and gives current necessary information.
  • Page 11 Operations Manual CE25-T Case Erector Options Press F1 to go to the product size select screen. Press F4 to go to the screen select screen. Screen Select Screen: The screen select screen allows access to many useful sections of the program.
  • Page 12 CE25-T Case Erector Options Operations Manual Mode Control Screen: This screen allows the operator to perform several machine functions manually. The top portion of the screen will show a list of machine manual func- tions which can be selected. See Table below.
  • Page 13 Operations Manual CE25-T Case Erector Options Case Size Select Screen The Case Size Select screen allows the operator to scroll through case sizes to select the size to run. The display at the bottom-left indi- cates the case size currently running through the machine.
  • Page 14 CE25-T Case Erector Options Operations Manual Setup Values Screen The Setup Values screen is an observa- tions screen only. The top portion lists the setup points and their values. The lower left portion of the screen shows the case size currently running.
  • Page 15 Operations Manual CE25-T Case Erector Options Register Values The register values are variables for each case. These include timer and counter set- tings specific to each case size and dimensions. Note: Only Maintenance level personnel can log in and change the register values.

  • Page 16: Alarm Status

    CE25-T Case Erector Options Operations Manual Alarm Status The Alarm Status screen is a data collection screen which accumulates the frequency and cumulative time the current alarm was active. The top portion of the screen lists the current alarm condition. The first column shows the number of times this alarm has occurred in the time between alarm resets.

  • Page 17: Alarm History

    Operations Manual CE25-T Case Erector Options Alarm History The Alarm History screen displays the causes of up to 99 machine alarms, from most recent to oldest in the top portion of the screen. Use the up/down keys to scroll through the list.
  • Page 18 Fig: 12 - Log In Screen b. The Maintenance level has the next level of accessibility with access to the timer and float value screens. The OEM level of access is the highest for the Pearson Service Technicians. Log In Procedure: Note: You can log in using the Log In screen or on the individual HMI screens that require a log in there will be a login button.

  • Page 19: Password Screen

    Fig: 13 - Password HMI Screen A time and date display is included for information purposes. Note: If the password is lost or forgotten, call the Pearson Packaging Service Department at 800-732-7766 for assistance. Machine Info The Machine Information screen displays contact information for Pearson Packaging Systems and the number of machine cycles run.
  • Page 20 CE25-T Case Erector Options Operations Manual This Page Intentionally Left Blank 3-12 10/02/2012 C-Options...

  • Page 21: Tape Sensing

    Installation Procedures This options is factory installed Machine Safety Refer to the Machine Safety chapter of the CE25-T Case Erector Options manual. Machine Operation The following sensors make up the tape sensing option package. No tape feed detect - for broken or uncut tape (sensor to detect rotation of tape...
  • Page 22 CE25-T Case Erector Options Operations Manual Also known at tape fail to apply. b. The no tape feed detect occurs when the case at sealing sensor (A) is blocked, but the tape roll motion sensor (B) is not made. Fig: 1 - Case at Sealing Sensor...

  • Page 23: Troubleshooting

    E-Stop/Guard Door Open (Solid) Machine Jam (Flashing) Amber Discharge High Level (Solid) d. Green Machine Running (Solid) Cycle Stop (Flashing) Blue Magazine Low Level (Solid) Tape Low Level (Flashing) Troubleshooting Review the Troubleshooting chapter of the CE25-T Case Erector Options manual. C-Options 4/10/2012...

  • Page 24: Preventive Maintenance

    CE25-T Case Erector Options Operations Manual Preventive Maintenance Refer to the Preventive Maintenance chapter of the CE25-T Case Erector Options manual. Service To contact our Service Department, please call 800-732-7766. When prompted, enter 2 for the Service Department. Select the appropriate number for the service branch you would like to contact when prompted.

  • Page 25: Beacon Indicator Bank

    Operations Manual Equipment Option Beacon Indicator Bank In This Chapter This chapter provides an overview, operation instructions, troubleshooting and preven- tive maintenance for this purchased option. Standard Option Overview Allen-Bradley Beacon Indicator Light. Beacon indicator banks may come with the fol- lowing features: •...

  • Page 26: Installation Procedures

    Equipment Option Operations Manual Installation Procedures Remount the beacon indicator light. The beacon light will be located inside the main electrical panel wrapped in bubble wrap. b. Unwrap the beacon light. Push the modules together at the alignment points and twist into the locked position.
  • Page 27 Operations Manual Equipment Option The blue light illuminates when adhesive is low. An individual light may be programmed to remain solid for one function, and flash for a second function. The warning horn may be programmed to sound for a set amount of time or remain on until the operator addresses the warning.
  • Page 28 Equipment Option Operations Manual This Page Intentionally Left Blank 05/16/2011 Options...
  • Page 29 CE25-T Case Erector Machine Operations Manual 8120 W Sunset Highway Spokane, Washington 99224 509-838-6226/800-732-7766 FAX: 590-747-8532/www.pearsonpkg.com...
  • Page 30 Therefore, this document is provided "as is" at the time of machine shipment. Please provide your machine serial number whenever ordering parts or referencing information to ensure Pearson Packaging Systems supplies you with the correct parts for your machine. Pearson Packaging Systems disclaims any liability or responsibility to any person for loss or damages, including but not limited to, the following: expenses, which may arise or result from the use of any information contained in this manual;...
  • Page 31 Operations Manual CE25-T Case Erector About This Manual ................1-1 Operator Message Boxes ..........1-1 Machine Safety ..................
  • Page 32 CE25-T Case Erector Operations Manual Running the Machine ..........5-3 Machine Startup .

  • Page 33: About This Manual

    Operations Manual About This Manual This manual provides instruction on installation, machine safety, operation, preventive maintenance, troubleshooting and service procedures. IMPORTANT The features shown in this manual are standard. Customer option information is refer- enced in the Option section at the end of this manual. Please review the Option sec- tion, if applicable, before starting up, loading, running or shutting down the machine.
  • Page 34 Operations Manual Warning! Moving Parts can crush and cut. Do NOT operate with guard removed. Follow lock out procedure before servic- ing. Warning! Avoid injury. Do NOT operate machine without all guards in place. A potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

  • Page 35: Machine Safety

    In This Chapter Safety is paramount during all phases of design, development, construction, and test- ing of Pearson Packaging Systems machines This chapter explains machine safety practices that can help minimize operating haz- ards and create a safe machine operation and environment.

  • Page 36: Machine Safety Features

    Never operate the machine when it is unprotected. Disconnect electrical power and air before removing any guards or shrouds or disabling any other protective device. Pearson Packaging Systems assumes no responsibility or liability for any personnel injury or equipment damage resulting from unsafe machine operation.
  • Page 37 16. Check safety devices routinely and replace them at the first indication of defec- tiveness or failure. 17. Troubleshoot and correct any malfunctions immediately. Call Pearson Packaging Systems Service at 800-732-7766 with any questions. 05/16/2011...

  • Page 38: Before You Operate Or Service The Machine For The First Time

    18. Never blow compressed air toward any person. It is recommended to use protec- tive eye wear when using compressed air. 19. Do not improvise repairs. Pearson Packaging Systems assumes no responsibility or liability for any machines altered in any way or by anyone other than an autho- rized Pearson representative.

  • Page 39: At The Beginning Of Each Shift

    It is the machine purchaser’s responsibility to establish and implement comprehen- sive lockout/tagout and safety policies for the protection of machine users. Pearson Packaging Systems has established the following guidelines for the lockout/ tagout policy to assist you in this effort.

  • Page 40: Electrical Safety

    This machine uses electricity of sufficient voltage to cause serious injury or death if mishandled. Note: Drive settings have been adjusted and set at Pearson Packaging Systems. Con- sult the machine documentation for drive settings. Permit only trained/qualified electrical technicians to work on electrical compo- nents, regardless of whether the components are live or dead.

  • Page 41: Pressurized System Safety

    Setting section of the Instruction manual provides base pressure settings for all pressurized systems that are not run at line pressure. These base settings could require minimal adjustment to best suit actual running conditions. Do not increase/decrease machine stopping times without consulting Pearson Packaging Systems. 05/16/2011...

  • Page 42: Robot Safety Procedures

    Operations Manual Robot Safety Procedures The ANSI robot standards (RIA R15.06-1999) list the following procedures for entering a robot cell. Personnel entering the robot cell when drive power is available shall have total con- trol of the robot. This shall be accomplished by the following: Control of the robot shall be removed from the automatic mode.

  • Page 43: Personal Protective Equipment (Ppe)

    Operations Manual Personal Protective Equipment (PPE) Always wear your company's approved PPE while operating the to minimize your injury risk. For machines using hot melt adhesive heed the following warnings. Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent-based material through a compatible Nordson melter, read and comply with the material’s MSDS.

  • Page 44: Energy Shutoff Points

    Note: Two styles of Pneumatic Energy Isolating Valves are used on Pearson equip- ment. Identify the style on your machine and follow the instructions provided. SMC Pneumatic Energy Isolating Valve...

  • Page 45: Norgren Pneumatic Energy Isolating Valve

    Operations Manual Norgren Pneumatic Energy Isolating Valve To dump air from the system, push the yellow slide plate to the closed position. The slide plate will read Closed. Follow your company's lock out/tag out procedures. To return air to the system, push the yel- low slide plate to the open position.

  • Page 46: Electrical Disconnect

    Operations Manual Electrical Disconnect Fig: 5 - Rotary Style Electrical Disconnect Fig: 6 - Knife Blade Style Electrical Disconnect Note: The Electrical Disconnect is located on the front of the Main Electrical Panel. To disconnect power from the Main Electrical Panel, turn the Electrical Discon- nect to the OFF position.

  • Page 47: Emergency Shutdown Procedures

    Operations Manual Emergency Shutdown Procedures In the event of an emergency, press the E-stop button, and follow your company's Emergency Shutdown Procedures. Fig: 7 - E-Stop Button 2-13 05/16/2011...
  • Page 48 Operations Manual This Page Intentionally Left Blank 2-14 05/16/2011...

  • Page 49: Machine Overview

    Machine Overview In This Chapter This chapter provides a machine overview and machine specifications. Machine Overview Fig: 1 - CE25-T Case Erector - Right Side A Magazine Feed System and Infeed Area B Setup Area C Adhesive and Discharge Area...

  • Page 50: Machine Specifications

    CE25-T Case Erector Operations Manual Machine Specifications • 24 Volt D.C. Controls • Pneumatic flap folding • Easy to read scales at all changeover points • Small machine footprint 3048mm long by 1625mm wide • Ergonomically friendly powered horizontal case magazine •...
  • Page 51 Operations Manual CE25-T Case Erector Standard Electrical Specifications Voltage Phase kVA (@ std. voltage) 230/460V 8.00 Compressed Air Consumption SCF/Cycle @ 80 PSI per cycle @ 5.5 bar 0.691 0.0200 Machine Footprint Length Width Height Shipping Speed* Weight 10’ 5’ 4”...
  • Page 52 CE25-T Case Erector Operations Manual This Page Intentionally Left Blank 9/17/2010 MCE25T-2a...

  • Page 53: Installation

    Note: If the machine arrives with change parts, unpack the box carefully and identify all parts. Notify Pearson's Service Department at 800-732-7766 if parts are missing. Unpacking and Moving the Machine After inspecting the machine, use a fork lift or electric pallet jacks to slide the skidded machine to the work location.

  • Page 54: Leveling The Machine

    Perform a test run of the machine. Make any necessary adjustments to the placement and/or leveling of the machine. After the Pearson Packaging technician has reviewed the placement of the machine, bolt the machine to the floor to prevent movement. 12/1/2010...

  • Page 55: Power Connections

    Operations Manual Power Connections Electrical Power Note: A dedicated electrical circuit is recommended for this machine. Refer to machine nameplate for voltage specifications. Connect plant power to machine at the main electrical control panel. If in doubt, consult your electrical contractor. Be sure all personnel are clear of the machine and guards are in place when starting.

  • Page 56: Air Supply

    Operations Manual Air Supply The machine requires a clean, dry air supply with a constant pressure of 80 PSI. Note: This machine is equipped with an electrical air supply and dump valve. Pressing the E-stop button exhausts compressed air in the machine circuit. Pulling out the E-stop button and pushing the Start button re-energizes the system.

  • Page 57: Machine Operation

    CE25-T Case Erector Machine Operation In This Chapter The CE25-T Case Erector erects KD cases into cases at a rate of up to 25 cases per minute. This chapter gives the steps, procedures and equipment necessary to operate the CE25-T Case Erector.

  • Page 58: Machine Controls

    CE25-T Case Erector Operations Manual Machine Controls Operator Control Station Safety Always wear appropriate PPE when operating this machine. The Operator Control Station has the controls that start or stop machine operation and stop the Case erector in the event of an emergency.

  • Page 59: Running The Machine

    Operations Manual CE25-T Case Erector Running the Machine Pre-Run Steps/Loading the Magazine Orient and load the knocked-down cases in the horizontal case magazine so the minor flap, when viewed in position for vacuum cup to index pick off, is point- ing toward the direction of flow.
  • Page 60 CE25-T Case Erector Operations Manual The chain in the magazine bed will advance the KD cases as the sensors detect blanks are needed. Load a second stack of blanks at the load station. This stack will advance to the staged station.

  • Page 61: Machine Startup

    Ensure all guards, shrouds, and other protective devices are in place before turning on the power. NEVER OPERATE THE MACHINE UNPROTECTED. Be certain all oper- ators are wearing the appropriate protective gear. Pearson Packaging Systems assumes no responsibility for any injury to personnel or damage to equipment.

  • Page 62: Machine Shutdown

    CE25-T Case Erector Operations Manual Ensure reliable stripping of blanks from magazine. Make certain the adhesive system is loaded and operating properly. Ensure all sensors are clean, correctly adjusted and functioning properly. Machine Shutdown Emergency Shutdown Press any of the emergency stop red pushbuttons.

  • Page 63: Product Clean Out

    Operations Manual CE25-T Case Erector Press emergency stop button for complete shutdown. Note: All operating power is immediately cut and the air is “dumped” (all operating lamps go out). Suddenly stopping the machine in this manner will not damage the equipment.
  • Page 64 CE25-T Case Erector Operations Manual 9/17/2010 MCE25T-2a...

  • Page 65: Changeover Procedures

    Operations Manual CE25-T Case Erector Changeover Procedures In This Chapter This chapter provides detailed instructions for changing from one product size to another. IMPORTANT Scales and pointers reference case dimensions on most adjustments but not all. Blank tolerances cannot be held to an exact dimension from one run to the next; there is a ±...
  • Page 66 CE25-T Case Erector Operations Manual Note: KD position in setup area is set by KD stop position. This constant is critical to ensure KD is opened fully and in position for flight lag indexing to tape head or sealing section.

  • Page 67: Magazine Adjustments

    Operations Manual CE25-T Case Erector Magazine Adjustments IMPORTANT Adjust all points to the knocked down blank measurements. Magazine Side Guide (Setup Point #1) Loosen the quick-release handles (A). Fig: 3 - Magazine Overhead Adjustment Slide the assembly to the appropriate knocked down length on the scale.
  • Page 68 CE25-T Case Erector Operations Manual Magazine Hold Down (Setup Point #2) Loosen the adjustment knob (A). Slide the magazine hold down assembly (B) to the appropriate measurement for the knocked down blank height. Note: Ensure the magazine hold down has a minimum clearance of 1/8" or 3mm to edge of blank.
  • Page 69 Operations Manual CE25-T Case Erector Case Selection Vacuum Cups (Minor Panel) (Setup Point #3) Fig: 6 - Case Selection Vacuum Cup Adjustment (Minor Panel) Loosen the adjustment knob (A). Vertically adjust the case selection vacuum cups to two-thirds of the top minor flap's height.
  • Page 70 CE25-T Case Erector Operations Manual Case Selection Vacuum Cup (Major Panel) (Setup Point #4) Fig: 7 - Case Selection Vacuum Cup Adjustment (Major Panel) Loosen the adjustment knob. Vertically adjust the case selection vacuum cup to be placed in the middle of the major panel.
  • Page 71 Operations Manual CE25-T Case Erector Case Index Transfer (Setup Point #5) Loosen the adjustment knob (A). Fig: 8 - Case Index Transfer Adjustment Slide the blank index transfer assembly to the appropriate knocked down length on the scale. Tighten the adjustment knob.
  • Page 72 CE25-T Case Erector Operations Manual Case Transfer Rail (Setup Point #6) Remove the adjustment crank handle (A) from the storage location. Loosen the quick release handle (B). Fig: 9 - Case Transfer Rail Adjustment Place the adjustment crank handle on the adjustment shaft.

  • Page 73: Set-Up Area Adjustments

    Operations Manual CE25-T Case Erector Set-Up Area Adjustments Overhead (Setup Point #7) Remove the adjustment crank handle (not shown) from the storage location. Fig: 11 - Overhead Adjustment Loosen the quick-release handle (A). Place the adjustment crank handle on the adjustment shaft (B).
  • Page 74 CE25-T Case Erector Operations Manual Case Stop (Setup Point #8) Loosen the adjustment knob (A). Fig: 12 - Case Stop Adjustment Slide the case stop assembly to the appropriate measurement for knocked down case length. Tighten the adjustment knob. 6-10...
  • Page 75 Operations Manual CE25-T Case Erector Lower Vacuum Cup (Setup Point #9) Lift the adjustment handle (A). Fig: 13 - Lower Vacuum Cup Adjustment Slide the vacuum cup assembly to the appropriate case length measurement on the scale. Drop the adjustment handle into the closest slot, or to a position 1-2", or 25.4- 50.8 mm, shorter than case length.
  • Page 76 CE25-T Case Erector Operations Manual Leading Flap Folder (Setup Point #10) Remove the adjustment crank handle from the storage location and place on the adjustment shaft. Note: The leading flap folder adjustment shaft is located toward the middle of the machine.
  • Page 77 Operations Manual CE25-T Case Erector Guide Rail and Tape Head (Setup Point #11) After removing from its storage location, place the adjustment crank handle on the adjustment shaft. Note: The guide rail and tape head adjustment shaft is located toward the discharge end of the machine.
  • Page 78 CE25-T Case Erector Operations Manual Erecting Assembly Note: This is not a scaled adjustment. Adjust the case opening assembly away from the magazine to allow easier access to the quick-release handles (A). Loosen the quick-release handles. Fig: 18 - Erecting Assembly Insert a KD case through the hopper and into the erecting assembly.

  • Page 79: Discharge Area Adjustments

    Operations Manual CE25-T Case Erector Discharge Area Adjustments Case Discharge Hold Down (Setup Point #12) Loosen the quick-release handle (A). Slide the case discharge hold down assembly to the appropriate case open depth measurement on the scale. Note: Case discharge hold down scale set-...
  • Page 80 CE25-T Case Erector Operations Manual This Page Intentionally Left Blank 6-16 9/17/2010 MCE25T-2a...

  • Page 81: How To

    Operations Manual CE25-T Case Erector How To In This Chapter This chapter provides how to procedures for adjustment and minor repairs. Thread the Tape Head Fig: 1 - Threading the Dekka Tape Head Avoid the cutter knife blade that is mounted between the two rubber contact rollers.
  • Page 82 CE25-T Case Erector Operations Manual Firmly push the new roll on so it seats against the rear flange of the tape mandrel. Note: This positioning will ensure the tape is applied evenly on the center line of the box. IMPORTANT Position the tape so the sticky side meets the incoming box.

  • Page 83: Troubleshooting

    Operations Manual Troubleshooting In This Chapter This chapter provides troubleshooting scenarios and possible solutions. Note: If the information provided in this chapter does not resolve or provide a resolution for the machine issue being experienced, please contact our Service Department at 800-732-7766.
  • Page 84 Check both ends of HMI cable to verify it is not loose or unplugged. Check HMI set up for communication baud rate. Rate should equal 9600. Consult Pearson Service department for instructions on access- ing HMI Set up. If the Drive System fails to run...
  • Page 85 Operations Manual Troubleshooting If Flight Chain fails to run ... Remove any debris jammed in the machine. Turn on the main disconnnect and use the start-up procedure. Ensure the flight lugs are not catching or rub- bing on the sprockets. Check the spur gears inside the overhead to be sure they are engaged.
  • Page 86 Operations Manual This Page Intentionally Left Blank 05/16/2011...

  • Page 87: Preventive Maintenance

    Operations Manual CE25-T Case Erector Preventive Maintenance In This Chapter This chapter provides information on daily and weekly machine preventive mainte- nance. Safety Before performing any machine adjustment or maintenance, close the Pneumatic Energy Isolating Valve and the Electrical Disconnect.

  • Page 88: Prevention Of Early Oxidation

    CE25-T Case Erector Operations Manual Ensure personnel are clear of machine and wear proper eye protection! Never turn blower hose directly upon skin. Regularly wipe off dirt, dust, and excess grease and oil Never hose-down or steam-clean this machine, as water and/or steam will harm elec- trical parts.

  • Page 89: Equipment Maintenance Schedule

    Operations Manual CE25-T Case Erector Equipment Maintenance Schedule Hourly Maintenance Inspect the air cylinders for plugs and leaks. Rebuild or replace as necessary. Daily Maintenance Check the Air Prep Unit. Check that air pressure is regulated to 80 psi. If not, contact your mainte- nance department.

  • Page 90: Lubrication Schedule

    CE25-T Case Erector Operations Manual Weekly Maintenance Note: Contact your maintenance department if maintenance is required on any of the fol- lowing Weekly Maintenance Items. Inspect the air and vacuum piping for plugs and leaks. Clean and/or replace defective hoses.
  • Page 91 Operations Manual CE25-T Case Erector IMPORTANT The monthly lubrication is variable depending the on the machine operation time and environment. Machines operating on a 24-hour schedule or in an environment con- taining higher concentrations of dust, dirt, or debris may need to be wiped down and lubricated more frequently.
  • Page 92 CE25-T Case Erector Operations Manual This Page Intentionally Left Blank 10-6 9/17/2010 MCE25T-2a...

  • Page 93: Service

    Operations Manual Service In This Chapter This chapter provides information on machine service including part replacement instructions, parts lists, part ordering procedures and how to use the Bill of Materi- als. Note: If the information provided in this chapter does not resolve or provide a resolu- tion for the machine issue being experienced, please contact our Service Department at 800-732-7766.

  • Page 94: Parts Lists

    Operations Manual Parts Lists Standard Purchased Parts When available, Pearson Packaging Systems provides vendor data sheets to aid in identifying, servicing, and replacing standard purchased parts. Recommended Spare Parts List The Recommended Spare Parts (RSP) list for each machine is included in this man- ual.

  • Page 95: Bill Of Material

    To order parts under warranty, follow the steps above and provide the following information: Serial number of the machine or original part P.O. #. Pearson part number. Quantity required. Description of failure or justification for warranty replacement. New Purchase Order Number (required).

  • Page 96: Part Description

    Assemblies, Level 3 and 4 – Parts. Sub Part/Rev The part number for each machine component and the part revision number is included on the list. Use this part number when ordering spares from Pearson Pack- aging Systems, 800-732-7766. Part Description A brief description of the part, its size, color, material, etc.

  • Page 97: Abbreviations

    Operations Manual Abbreviations Approx.: Approximately CSL: Constant Scoreline FBA: Fibre Box Association Fig. : Figure FOLF: Full Over Lap Flap Hi-Cap Mag. : High Capacity Magazine HP: Horsepower hr: Hour HSC: Half Slotted Case HZ: Hertz KD: Knocked Down max.: Maximum min.: Minimum opt.: Optimum Para.

  • Page 98: Glossary

    Operations Manual Glossary Air Prep Unit: The air prep unit consists of a Lock out Valve, integral Filter Regula- tor, Soft Start Valve and an Exhaust Valve. The unit is used to filter and regulate the incoming compressed air to the rest of the system. The Soft Start Valve will slowly build the air pressure during startup.
  • Page 99 Operations Manual Main Air Filter/ Regulator (Combo): Protects machine components by filtering and regulating the air going into the machine. Acts as a water trap and needs to be drained and/or cleaned periodically. Main Air Regulator: The main air regulator is an adjustable device attached to the air source of the machine.
  • Page 100 Operations Manual Slow Build Valve: Prevents a surge of high pressure air during machine start-up. Dur- ing start-up, air is allowed to enter the system slowly. When the system air builds enough pressure, the valve shifts and allows full volume through. If there is a large loss of air in the system (due, for example, to a leaking hose or a damaged air cylinder) during machine start, pressure in the system will not build and the valve will not open.
  • Page 101 CE25-T Case Erector Options Machine Operations Manual 8120 W Sunset Highway Spokane, Washington 99224 509-838-6226/800-732-7766 FAX: 590-747-8532/www.pearsonpkg.com...
  • Page 102 Therefore, this document is provided "as is" at the time of machine shipment. Please provide your machine serial number whenever ordering parts or referencing information to ensure Pearson Packaging Systems supplies you with the correct parts for your machine. Pearson Packaging Systems disclaims any liability or responsibility to any person for loss or damages, including but not limited to, the following: expenses, which may arise or result from the use of any information contained in this manual;...
  • Page 103 Operations Manual CE25-T Case Erector Options About This Manual ................1-1 Operator Message Boxes ..........1-1 Category 3 Safety with PowerFlex 525 VFD........
  • Page 104 CE25-T Case Erector Options Operations Manual This Page Intentionally Left Blank i-ii 4/10/2012 C-Options...

  • Page 105: About This Manual

    Operations Manual About This Manual This manual provides instruction on installation, machine safety, operation, preventive maintenance, troubleshooting and service procedures. IMPORTANT The features shown in this manual are standard. Customer option information is refer- enced in the Option section at the end of this manual. Please review the Option sec- tion, if applicable, before starting up, loading, running or shutting down the machine.
  • Page 106 Operations Manual Warning! Moving Parts can crush and cut. Do NOT operate with guard removed. Follow lock out procedure before servic- ing. Warning! Avoid injury. Do NOT operate machine without all guards in place. A potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

  • Page 107: Category 3 Safety With Powerflex 525 Vfd

    Operations Manual Equipment Option Category 3 Safety with PowerFlex 525 VFD In This Chapter This chapter provides an overview, operation instructions, troubleshooting and preven- tive maintenance for this purchased option. Option Overview Interlock E-Stop Option (Category 3 Safety) • This option has E-stops and Guard Doors wired back to (2) Self Monitoring Safety Relays (one for each circuit).

  • Page 108: Installation Procedures

    Equipment Option Operations Manual Installation Procedures This option is installed on the machine at the factory. Machine Safety Refer to the Machine Safety chapter of the Equipment Option manual. Machine Operation When an E-stop has been pressed or a guard door has been opened the reset button must be pressed to reset the safety relays before the machine can be restarted.

  • Page 109: Human-Machine Interface (Hmi)

    Fig: 1 - Allen-Bradley PanelView 400 Compact This section is intended to describe the screens and functions specific to the Pearson Pack- aging Systems. For technical information about the Allen-Bradley PanelView 400 Compact, refer to the manual shipped with this machine or visit Allen-Bradley’s web site at http://www.ab.com.

  • Page 110: Hmi Display Screens

    CE25-T Case Erector Options Operations Manual Fig: 2 - AB PanelView 400 Compact Layout HMI Display Screens Main Operator Station Screen: The main operator station screen is the display shown on the HMI during normal machine operation. The message display at the top is variable, and gives current necessary information.
  • Page 111 Operations Manual CE25-T Case Erector Options Press F1 to go to the product size select screen. Press F4 to go to the screen select screen. Screen Select Screen: The screen select screen allows access to many useful sections of the program.
  • Page 112 CE25-T Case Erector Options Operations Manual Mode Control Screen: This screen allows the operator to perform several machine functions manually. The top portion of the screen will show a list of machine manual func- tions which can be selected. See Table below.
  • Page 113 Operations Manual CE25-T Case Erector Options Case Size Select Screen The Case Size Select screen allows the operator to scroll through case sizes to select the size to run. The display at the bottom-left indi- cates the case size currently running through the machine.
  • Page 114 CE25-T Case Erector Options Operations Manual Setup Values Screen The Setup Values screen is an observa- tions screen only. The top portion lists the setup points and their values. The lower left portion of the screen shows the case size currently running.
  • Page 115 Operations Manual CE25-T Case Erector Options Register Values The register values are variables for each case. These include timer and counter set- tings specific to each case size and dimensions. Note: Only Maintenance level personnel can log in and change the register values.
  • Page 116 CE25-T Case Erector Options Operations Manual Alarm Status The Alarm Status screen is a data collection screen which accumulates the frequency and cumulative time the current alarm was active. The top portion of the screen lists the current alarm condition. The first column shows the number of times this alarm has occurred in the time between alarm resets.
  • Page 117 Operations Manual CE25-T Case Erector Options Alarm History The Alarm History screen displays the causes of up to 99 machine alarms, from most recent to oldest in the top portion of the screen. Use the up/down keys to scroll through the list.
  • Page 118 Fig: 12 - Log In Screen b. The Maintenance level has the next level of accessibility with access to the timer and float value screens. The OEM level of access is the highest for the Pearson Service Technicians. Log In Procedure: Note: You can log in using the Log In screen or on the individual HMI screens that require a log in there will be a login button.
  • Page 119 Fig: 13 - Password HMI Screen A time and date display is included for information purposes. Note: If the password is lost or forgotten, call the Pearson Packaging Service Department at 800-732-7766 for assistance. Machine Info The Machine Information screen displays contact information for Pearson Packaging Systems and the number of machine cycles run.
  • Page 120 CE25-T Case Erector Options Operations Manual This Page Intentionally Left Blank 3-12 10/02/2012 C-Options...

  • Page 121: Tape Sensing

    Installation Procedures This options is factory installed Machine Safety Refer to the Machine Safety chapter of the CE25-T Case Erector Options manual. Machine Operation The following sensors make up the tape sensing option package. No tape feed detect - for broken or uncut tape (sensor to detect rotation of tape...
  • Page 122 CE25-T Case Erector Options Operations Manual Also known at tape fail to apply. b. The no tape feed detect occurs when the case at sealing sensor (A) is blocked, but the tape roll motion sensor (B) is not made. Fig: 1 - Case at Sealing Sensor...

  • Page 123: Troubleshooting

    E-Stop/Guard Door Open (Solid) Machine Jam (Flashing) Amber Discharge High Level (Solid) d. Green Machine Running (Solid) Cycle Stop (Flashing) Blue Magazine Low Level (Solid) Tape Low Level (Flashing) Troubleshooting Review the Troubleshooting chapter of the CE25-T Case Erector Options manual. C-Options 4/10/2012...

  • Page 124: Preventive Maintenance

    CE25-T Case Erector Options Operations Manual Preventive Maintenance Refer to the Preventive Maintenance chapter of the CE25-T Case Erector Options manual. Service To contact our Service Department, please call 800-732-7766. When prompted, enter 2 for the Service Department. Select the appropriate number for the service branch you would like to contact when prompted.

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