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HeatSeal HDX 2000 Operating Manual

Automatic l-sealer
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OPERATING MANUAL
HDX 2000 AUTOMATIC L-SEALER
SERIES B
READ ALL INSTRUCTIONS CAREFULLY BEFORE OPERATING EQUIPMENT
P/N: MPT-FM111278A
REV.0

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Summary of Contents for HeatSeal HDX 2000

  • Page 1 OPERATING MANUAL HDX 2000 AUTOMATIC L-SEALER SERIES B READ ALL INSTRUCTIONS CAREFULLY BEFORE OPERATING EQUIPMENT P/N: MPT-FM111278A REV.0...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Preface ........................... 3 Safety standards......................4 Machine Installation ...................... 8 Machine Setup & Adjustments ................... 14 Film Setup and Adjustments ..................34 Alarms & Troubleshooting ..................45 Maintenance & Cleaning ..................... 49 Notes ........................... 51...

  • Page 3: Preface

    PREFACE This manual gives instruction for the proper use of the machine. Keep it near the machine in a place that is known to all users. The manual is essential for safety. The HDX-2000 is an automatic packaging machine designed to package loose pieces or groups of products using a center- folded heat-shrink film.

  • Page 4: Safety Standards

    SAFETY STANDARDS WARNINGS It is extremely important to read this entire chapter as it contains important information regarding risks that personnel are subject to in the event of incorrect use of the machine. These basic standards must be observed as well as any other standards applicable in the location of installation.
  • Page 5 SAFETY STANDARDS SAFETY STICKERS The following safety stickers features on the machine On machine front panel. Danger of electrocution! Risk due to presence of electrical power in electrical system inside panel. While the machine is running, the panel must be mounted properly. On the sealing bar frame.
  • Page 6 SAFETY STANDARDS GUARDS The machine is fitted with a front guard (C1) and two rear guards (C2) and (C3). If one of these guards is opened, the machine stops. The buzzer (P2) and the “Alarm” key on the display indicate that there is an alarm. To reset machine operation, close the guards and press the RESET button Front View Rear View...
  • Page 7 SAFETY STANDARDS RESIDUAL RISKS The following prohibitions and warnings Dragging hazard! Hazard generated by moving elements (conveyor belts, motor driven rollers) in the event of contact during oper- ation. Burn hazard! Risk due to high temperature of the sealing bar. Do not touch the bar! Before performing operations in these zones, set the machine to “maintenance mode”, and wait for surfaces to cool.

  • Page 8: Machine Installation

    MACHINE INSTALLATION INSTALLATION AND OPERATION OF THIS SYSTEM MUST BE IN COMPLIANCE WITH ALL APPLICABLE ELECTRICAL AND SAFETY STANDARDS. A QUALIFIED ELECTRICIAN MUST CHECK THE ELECTRICAL SUPPLY CIRCUIT TO ENSURE CORRECT VOLTAGE AND CAPACITY. THE SYSTEM IS DESIGNED FOR INDUSTRIAL USE BY QUALIFIED PERSONNEL ONLY. ...
  • Page 9 MACHINE INSTALLATION MACHINE LAYOUT C: Electrical control panel Q1: Main switch S3: “SAFETY OVERRIDE” switch X1: RJ45 socket for PLC and HMI Ethernet connection X2: USB connector X3: External infeed conveyor connector X4: External outfeed conveyor connector X7: Upstream control connector X8: Downstream control connector...
  • Page 10 MACHINE INSTALLATION Technical Data Metric English Package Size 2980x1530x2000 (mm) 117x60.2x78.7 Package Weight 797 (kg) 1757 lb Machine Weight 645 (kg) 1422 lb Transport and Positioning Accessories Check the following is included with the machine: 2 Keys for the SAFETY OVERRIDE switch, (S3) ...
  • Page 11 MACHINE INSTALLATION Installing the levelers Lift the machine from the pallet by using a fork lift.  Install 4 levelers by threading into holes in frame until hand tight.  Lower machine to floor and adjust leveler to place machine at desired height. ...
  • Page 12 MACHINE INSTALLATION Installing the film opening rods...
  • Page 13 MACHINE INSTALLATION Electrical connections Voltage: 208-240 VAC, single phase Frequency: 50/60 HZ Max Power: 2.5 kW Full Load Amps: 11...

  • Page 14: Machine Setup & Adjustments

    MACHINE SETUP & ADJUSTMENTS MAIN MACHINE COMPONENTS Film Unwinder Film Inverter Infeed Belt Outfeed Belt L-Sealer Film Puller Scrap Film Winder Door Guards Operator HMI Electric Control Box/Panel...
  • Page 15 MACHINE SETUP & ADJUSTMENTS MACHINE FEATURES The HDX-2000 is an automatic packaging machine designed to package loose pieces or groups of products using a center- folded heat-shrink film. A wide range of products with different shapes and sizes can be packaged with the HDX-2000. The HDX-2000 can be fed manually or by means of an infeed conveyor or other machinery.
  • Page 16 MACHINE SETUP & ADJUSTMENTS CONTROL PANEL This machine is equipped with an touch screen control panel adjustable by 180°, where it is possible to set all operation and programming features Only use one finger to select an object on the panel for correct touch panel use. If the panel is pressed in two or more points at the same time it is possible to select an object unintentionally.
  • Page 17 MACHINE SETUP & ADJUSTMENTS MAIN BUTTONS AND ICONS Button Description Button Description Select recipe Alarm siren switch off Recipe quick load Save recipe Start / Stop cycle Load recipe Automatic / Manual New recipe Alarm Delete recipe Set up Load recipe from USB Conveyor belt movement and execution of Save recipe on USB film pulling/winder/unwinder...
  • Page 18 MACHINE SETUP & ADJUSTMENTS START UP Turn the main switch (Q1) to ON The display comes on and the Logo screen appears Press the “RESET” (S2) Button, then the Logo Triangle homing is required at every start-up (this is recommended when packing batches of products with different heights).
  • Page 19 MACHINE SETUP & ADJUSTMENTS HOW TO USE THE MACHINE This machine can operate in 2 modes: MANUAL and AUTOMATIC MANUAL MODE Upon power up, the machine is in Manual Mode by default Press to enable Manual mode. To enable Manual program controls, press the start cycle button.
  • Page 20 MACHINE SETUP & ADJUSTMENTS PASSWORD Some functions are password protected to guarantee correct operation of the machine and to prevent the operator from accidentally modifying the PLC program which controls all operations. There are 3 password levels, each of which is protected by a different User Name and Password. ...
  • Page 21 MACHINE SETUP & ADJUSTMENTS RECIPE The machine is supplied with 2 recipes saved with standard parameters (It can however store up to 100 recipes). LOADING A RECIPE To load a recipe, Follow the procedure below: Select the recipe. The selected recipe is Press Press loaded automatically.
  • Page 22 MACHINE SETUP & ADJUSTMENTS NEW RECIPE CREATION DELETING A RECIPE SAVING DATA RECIPE IMAGE...
  • Page 23 MACHINE SETUP & ADJUSTMENTS RECIPE MANAGEMENT The recipes can be managed (Edit parameters/Create new programs) with a “Standard” or a “Fast” procedure. STANDARD MANAGEMENT “Standard” recipe management involves changing the parameters from the initial page by pressing the relevant area (e.g. sealing bars, film) SEALING BAR PARAMETERS To edit the values, press anywhere on the...
  • Page 24 MACHINE SETUP & ADJUSTMENTS...
  • Page 25 MACHINE SETUP & ADJUSTMENTS FILM PARAMETERS (WITH MACHINE IN MANUAL MODE Opening the inverter triangle To set the opening of the inverter trian- gle, press the height (e.g. 70) and enter the desired value. Another option for opening them is to move the upper inverter by pressing buttons The upper inverter will move according...
  • Page 26 MACHINE SETUP & ADJUSTMENTS PACKAGING OF PRODUCTS WITH AN IRREGULAR SHAPE If packaging products with an irregular shape, We recommend the manual setting (Do not mark the box with a flag next to “Product Length”). In this case, the film is sealed when the photocell reads the start of the product and the set height (e.g. 180). The available settings are: Product Length, Feeding Start Delay, Product Height, Front Film, Rear film (only with horizontal product sensor).
  • Page 27 MACHINE SETUP & ADJUSTMENTS On the second page, it is possible to set:  Film Loosening,  Closing Conveyor  Belt Reversal,  Conveyor Belt,  Printer Film Loosening Press the number indicating the film loosening time and set the value (default: 0.00 sec).
  • Page 28 MACHINE SETUP & ADJUSTMENTS On the third page, it is possible to set:  Load Belt,  Unload Belt, Load belt The function is only available if is included in the OPTIONAL FEATURES. Loading belt on. Adjust the load belt speed with regard to the speed of the infeed belt (IN).
  • Page 29 MACHINE SETUP & ADJUSTMENTS FILM UNWINDER PARAMETERS Press the button to enter the data related to the manual settings of the film unwinder, so that every time you load a program, you can apply the saved settings. Enter the film reel position with reference to the millimetre scale (X1) , Figure 4, Page Enter the number of micro punches (MF) used.
  • Page 30 MACHINE SETUP & ADJUSTMENTS STANDARD MANAGEMENT (FROM “IMAGE”) Another way of managing the parameters of a recipe is using button Press Press This displays the image of the machine and, if selected, of the tunnel as well. Press the “red Dot” to display the screen with the parameters that can be set in the area involved.
  • Page 31 MACHINE SETUP & ADJUSTMENTS BATCH COUNTER This function sets the number of products to be packaged. Once the set number of products have been packaged, A025: BATCHED NUMBER REACHED, alarm will activate.
  • Page 32 MACHINE SETUP & ADJUSTMENTS CONFIGURATION PAGE This configurations page can be accessed from the home page by pressing “Factory parameters” button “Optional” button “Manual controls” button “Service” button “Configuration” button “Power meter” button. Only available with power meter option installed. “Language settings”...
  • Page 33 MACHINE SETUP & ADJUSTMENTS PAUSE TIME This function is used to program the machine’s “Pause” Time. During this phase, the sealing bar resistor switch off (A condition that ensures considerable energy savings), while all of the other machine function stay on. Once the pause time elapses, the resistors are heated up again.

  • Page 34: Film Setup And Adjustments

    FILM SETUP & ADJUSTMENTS FILM FEATURES This machine can work with polyolefin heat-shrink film between 9 and 38 micron, 40-150 gauge, think, both technical and suitable for food. The special features of our films assure their outstanding reliability, with regard both to compliance with laws in force and an excellent machine performance.
  • Page 35 FILM SETUP & ADJUSTMENTS LOADING AND ROUTING FILM To insert the film, Set the Machine to “MANUAL” Mode. Turn the “SAFETY DEVICE EXCLUSION” Switch (S3) to ON and Open the guards (C1), (C2), (C3). STEP 1 To make it easier to position the film reel, take out the carriage (C) supporting the reel (which means lowering handle M1 and pulling the carriage).
  • Page 36 FILM SETUP & ADJUSTMENTS STEP 2 Rear View Bottom Side of the Film Take the lower end of the film near the rear of the reversal triangle and pass it under the lower triangle (Ti) from the outside inwards and over the infeed belt (N1). STEP 3 Then pass the upper side of the film over the upper triangle (Ts).
  • Page 37 FILM SETUP & ADJUSTMENTS STEP 4 Move the end of the film (#) that will go inside the triangles to the left, parallel with the infeed belt (N1) and pass the film un- der and above the infeed belt, aligning the ends of the film right after the belt itself. STEP 5 Pass the film between the two rollers (R3) and between the two wheels (R4) of the pulling device.
  • Page 38 FILM SETUP & ADJUSTMENTS ADJUSTMENTS Before packaging, it is necessary to make a few “Manual” Adjustments. FILM REEL POSITIONING The film reel must be positioned according to open- ing “H” of the triangle. Figure 1 Reel positioning is correct when the right side of the reel is at distance “A”...
  • Page 39 FILM SETUP & ADJUSTMENTS Figure 4 Figure 3 Then place the reel with reference to the millimetre ruler (HDX 2000) on the support. Adjust the 2 Containment guides (B) by using the knobs (M3) in order to block the reel, leaving 0.2 in (5 mm) of space between the guides and the reel POSITIONING THE MICROPUNCHES Place the number of micropunches (MF)
  • Page 40 FILM SETUP & ADJUSTMENTS ADJUSTMENT OF “FILM SEPARATING” ROD AND RETURN ROLLER  The rod (A1) allows the 2 edges of the film real to be separated. Position the rod inside the two edges so the end is 0.39 in (10 mm) behind the crease of the film. ...
  • Page 41 FILM SETUP & ADJUSTMENTS ADJUSTMENT OF “FILM LIFTING” RODS  Rods (A1) and (A3) are used to keep the film lifted correctly during product insertion. Adjust their position according to the dimension and shape of the product being packaged until the best packaging result in obtained.
  • Page 42 FILM SETUP & ADJUSTMENTS BELT TENSION ADJUSTMENT With the first package, and at least once a month. Check the Infeed and Outfeed Belts are aligned in the middle when moving. Should disbandment be noted, or noises heard, it could mean the roller where the belt slides are not at perfect right angles with the drive direction.
  • Page 43 FILM SETUP & ADJUSTMENTS OUTFEED BELT Turn screw (A) counter-clockwise in order to shift the outfeed belt in the direction shown in figure ↑. Turn screw (B) counter-clockwise in order to shift the outfeed belt in the direction shown in figure ↓. Correct belt tension is obtained when there is approximately 1.6 in (40mm) between the loading surface and the...
  • Page 44 FILM SETUP & ADJUSTMENTS PACKAGING Having made all the necessary adjustments, the machine is ready to proceed with packaging. With the machine in “AUTOMATIC” mode, press the start cycle button The belts will start operating and it is possible to place the product on the infeed belt (N1).

  • Page 45: Alarms & Troubleshooting

    ALARMS & TROUBLESHOOTING ALARMS This machine provides a series of ALARMS needed to monitor any dangerous situations and malfunctioning Each time an ALARM occurs, the Machine Stops. The buzzer (P2) turns red and emits an acoustic signal. The symbol appears on the display. The alarm reset procedure is as follows Note: press to stop the acoustic...
  • Page 46 ALARMS & TROUBLESHOOTING LIST OF ALARMS ALARM CAUSE SOLUTION Remove the cause of the alarm. 1 of the 3 “EMERGENCY” buttons (S1.1), Release the “EMERGENCY” button by turning it to the right. (S1.2), (S1.3) has been pressed. Press the RESET button (S2). Only with “loading/unloading belt”...
  • Page 47 ALARMS & TROUBLESHOOTING ALARM CAUSE SOLUTION TEMPERATURE CIRCUIT The thermocouples (BT1) and (BT2) are A015 Check the electrical connections and replace if faulty ERROR not working The film unwinder has turned for too long Clear blockage preventing lever from moving freely due to mechanical block of the lever (L) A017 UNWINDER: TIME OUT...
  • Page 48 ALARMS & TROUBLESHOOTING ALARM CAUSE SOLUTION SEALING BAR: An error has been detected on the servo Observe the error code on the servo drive and Contact A050 DRIVE ERROR drive the technical service. SEALING BAR: A problem occurred during the sealing A054 Contact the technical assistance service.

  • Page 49: Maintenance & Cleaning

    MAINTENANCE & CLEANING PRECAUTIONS AND SETTING TO MAINTENANCE MODE CAUTION!  Maintenance must be performed exclusively by skilled personnel familiar with the machine.  Never carry out maintenance, lubrication, or repairs when the machine is in operation and/or connected to the power supply. ...
  • Page 50 MAINTENANCE & CLEANING MAINTENANCE PLAN OF SAFETY DEVICES The periodical control of the “SAFETY DEVICES” listed in the table is required. Frequency Component Operation  Opening of front guards (C1) and rear guards (C2) and (C3) guards, both in manual and automatic mode Every Month Front and Rear Guards ...

  • Page 51: Notes

    NOTES ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________...