Personal Protective Equipment (PPE)
1. 2 Always wear your company's approved PPE while operating the machine 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. Ensure that the material’s processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met. Failure to comply with the MSDS requirements can cause personal injury, including death.
Molten Material! Wear eye and face protection, clothing that protects exposed skin, and heat-protective gloves when servicing equipment that contains molten hot melt. Even when solidified, hot melt can still cause burns Failure to wear appropriate personal protective equipment can result in personal injury
Hot surfaces! Avoid contact with the hot metal surfaces of guns, hoses, and certain components of the melter. If contact cannot be avoided, wear heat-protective gloves and clothing when working around heated equipment. Failure to avoid contact with hot metal surfaces can result in personal injury. The machine will not start unless all guard doors are closed.
Energy Shutoff Points
Pneumatic Energy Isolating Valve
This machine is equipped with a Pneumatic Energy Isolating Valve. The isolating valve isolates the equipment from the main air source and exhausts any air remaining in the machine.
Note: Two styles of Pneumatic Energy Isolating Valves are used on Pearson equipment
Identify the style on your machine and follow the instructions provided.
To dump air from the system, rotate the red head of the valve to the exhaust position.
a. The yellow window will read EXH.
Follow your company's lock out/tag out procedures.
To return air to the system, rotate the red head of the valve to the open position.
a The yellow window will read SUP
Manual air override button is provided for inspection and troubleshooting the pneumatic system. It must be deactivated in normal run mode (gauge pressure will read zero).
SMC Pneumatic Energy Isolating Valve
Fig: 1 - SMC Air Shutoff Valve
Fig: 2 - SMC Manual Override Button
To dump air from the system, push the yellow slide plate to the closed position
a The slide plate will read Closed
Follow your company's lock out/tag out procedures
To return air to the system, push the yellow slide plate to the open position.
a. The slide plate will read Open.
Manual air override button is provided for inspection and troubleshooting the pneumatic system. It must be deactivated in normal run mode (gauge pressure will read zero).
Fig: 4 - Norgren Manual Override
Fig: 3 - Norgren Air shutoff Valve
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 Disconnect to the OFF position.
Follow your company's lock out/tag out procedures
To reconnect power, turn the Electrical Disconnect to the ON position
Fig: 5 - Rotary Style Electrical Disconnect
Fig: 6 - Knife Blade Style Electrical Disconnect
Emergency Shutdown Procedures
1. In the event of an emergency, press the E-stop button, and follow your company's Emergency Shutdown Procedures.
Fig: 7 - E-Stop Button
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Operations Manual Machine Overview
In This Chapter
BF30-2AS Bliss Former
This chapter provides a machine overview and machine specifications Machine Overview
The Pearson BF30-2AS (A) is a 2-Piece Bliss Former with body wrap and insert autoloader and end panel insert blank slitter.
Pallets of body wrap blanks are loaded onto the material infeed conveyor (B) and the operator removes the dunnage. They are then are transported to a lift station (C) where a sheet feeder transfers the blanks into the body wrap hopper.
Pallets of end panel blanks are loaded onto a material infeed conveyor (D) for each BF30-2AS and the operator removes the dunnage. They are transported to a lift station (E) and elevated to a servo driven slitter (F) which cuts the corrugated sheets to the programmed width and loads the end panel insert hopper. The case is formed from the body wrap and end panel insert with external flanges, resulting in a smooth inside and a solid one piece bottom.
Machine Specifications
24 Volt D.C. Controls
Maximum reliability with all production proven machine components
Quick changeover features
Vacuum assist feed systems
Positive glue compression
Welded tubular steel frame
Belt Drive Feed System
UL approved electrical control panel
Allen Bradley Panelview 1000 Plus
Case Size Ranges
Please consult Pearson Packaging Systems regarding case size ranges.
Standard Electrical Specifications
Please see machine-specific electrical schematic
Machine Footprint
Please see machine-specific floor plan.
Programmable Logic Controller
Allen Bradley CompactLogix
BF30-2AS Bliss Former
In This Chapter
This chapter gives the steps, procedures and equipment necessary to operate the BF30-2AS H-Bliss Former
Note: The Infeed end of the machine (A) is the “rear,” the discharge end (B) is the “front.” Facing the machine in the direction of flow (C), the “operator’s right” is to the right, the “operator’s left” (E) is to the left.
(D)
Fig: 1 - BF30-2AS Bliss Former Machine Flow
Operator Control Station
The Operator Control Station has the controls that start or stop machine operation in the event of an emergency.
A controlled Emergency Stop button (E-stop) (A) is located on the right of the Operator Control Station. When the E-Stop button is pushed, power to the machine is disrupted and the machine immediately stops. The E-stop button must be pulled back out before the machine can be restarted.
The blue Machine Reset button (B) must be pressed when it is illuminated to reset the safety relays before the machine can be restarted A reset is required whenever an E-stop has been pressed or a guard door has been opened After it is pushed, the air dump comes on, and the Cycle Start begins to flash when the machine is ready to start.
The green Cycle Start button (C) starts the machine. It flashes when the machine is in standby mode and ready to start, and is on solid when the machine is running
The red Cycle Stop button (D) causes the machine to come to a controlled stop. The machine cycles twice with the vacuum off before coming to a complete stop to completes any cases in process.
Fig: 2 - BF30-AS Operator Control Station
The end panel sheet and body wrap elevators are open and guarded by light curtains (A). A beacon light (B) indicates when the light curtain is muted to allow stacks of material to pass through.
The Light Curtain Override selector switch allows the operator to reset the light curtain if it is blocked when an E-Stop is pressed or the machine faults and shuts down
1. 2 3 4
To reset the light curtain turn and hold the Light Curtain Override switch.
Press the Light Curtain Reset when it starts flashing.
Press the Machine Reset button.
Go to the Manual functions in the HMI and jog the material out of the light curtain See the HMI Chapter for more information
Fig: 4 - Light Curtain Controls
Fig: 3 - Light Curtain
Beacon Light Stack
A four light beacon with a warning horn is located above the operator station.
Flashing: Alarm
Solid: E-Stop or door open
Flashing: Hoppers low or material conveyor issue
Solid: Machine running
Flashing: Discharge high level
Warning Horn Operation
1. 2. 3.
Note: Red Amber Green Blue
When the Machine Reset button is pushed, the horn will cycle on an off for three seconds before the Cycle Start button begins flashing.
When there is an alarm, or low air pressure, the horn will cycle on an off for three seconds. See the HMI for more information.
If air is detected when the machine starts the horn will sound continuously. It will not turn off after three seconds.
Under no circumstances should you enter the machine if the system is pressurized
Fig: 5 - Beacon Light Stack
Material Handling Infeed Controls
The material handling infeed system has a system Emergency Stop button and System Reset button located on the electrical panel (A). Each of the three material infeed conveyors has a pedestal (B) with controls for that specific conveyor.
System Controls
A controlled Emergency Stop button (E-stop) (C) is located on the electrical panel and on each of the control pedestals When the E-Stop button is pushed, power to the material handling infeed conveyors is disrupted and the machine immediately stops. The E-stop button must be pulled back out before the machine can be restarted.
The blue System Reset button (D) must be pressed when it is illuminated to reset the safety relays before the material handling infeed conveyor system can be restarted. A reset is required whenever a system Estop has been pressed. After it is pushed, conveyor reset buttons on the pedestals come on begins to flash when the machine is ready to start. C
Fig: 6 - Material Handling Infeed Controls
Fig: 7 - Infeed System Controls
Conveyor Pedestal
A controlled Emergency Stop button (E-stop) (A) is located on the electrical panel and on each of the control pedestals. When the EStop button is pushed, power to the material handling infeed conveyors is disrupted and the
machine immediately stops. The E-stop button must be pulled back out before the machine can be restarted.
The blue System Reset indicator (B) lights when the System Reset button is required. The system must be reset before the individual conveyor can be reset.
The rest of the buttons on the conveyor pedestal only control the specific infeed conveyor they are located near.
The blue Reset button (C) must be pressed when it is illuminated to reset the safety relays before the conveyor can be restarted.
The green Stack Ready button (D) is pressed after dunnage has been removed and the stack of material is ready to feed into the system.
The Inside Up/Down switch (E) raises and lowers the inside rails on the infeed conveyor
The Outside Up/Down switch (F) raises and lowers the outside rails on the infeed conveyor
F
Fig: 8 - Conveyor Pedestal Controls
Pre-Run Steps
Loading the Adhesive
1 Allow the hot melt adhesive system time to come up to temperature.
a b
Check the level of hot melt adhesive and the temperature
Ensure the hot melt adhesive is flowing freely
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. Ensure that the material's processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met. Failure to comply with the MSDS requirements can cause personal injury, including death.
Molten Material! Wear eye and face protection, clothing that protects exposed skin, and heat-protective gloves when servicing equipment that contains molten hot melt. Even when solidified, hot melt can still cause burns Failure to wear appropriate personal protective equipment can result in personal injury
Hot surfaces! Avoid contact with the hot metal surfaces of guns, hoses, and certain components of the melter. If contact can not be avoided, wear heat-protective gloves and clothing when working around heated equipment. Failure to avoid contact with hot metal surfaces can result in personal injury. The machine will not start unless all guard doors are closed
Loading Corrugated Material
Load corrugated material onto the end panel and body wrap material infeed conveyors as follows:
1. Make sure the blue Reset button is not illuminated. Place a stack of material on the conveyor.
Use Inside Up/Down switch to raise the inside dunnage rails to support the stack.
Remove the fork truck or lift.
Note:
Tear off the end dunnage (A) at the scoreline on both sides and remove it. Be careful not to break the plane of the light curtain (B) when removing the end dunnage closest to the entry point on the end panel infeed conveyors.
Lower the inside rails and raise the outside rails (C). This can be done at the same time.
Remove the center dunnage sheet (D).
When all dunnage has been removed, lower the stack onto the conveyor Press the Stack Ready button.
Fig: 10 - Removing End Dunnage
Fig: 11 - Removing Center Dunnage
Fig: 9 - Stack Raised on Inside Rails
Machine Start Up
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.
Verify all employees other than the operator are clear.
At the machine main electrical enclosure switch the main power disconnect to the ON position.
At the machine main air inlet open the safety ball valve to the FULL OPEN position.
Check the main air regulator pressure for 85 PSI. Adjust if necessary.
On the touch screen enclosure and at the remote mounted switch enclosure pull out the Emergency Stop button(s).
On the front panel of the hot melt tank move the circuit breaker switch to the ON position.
Temperature settings will vary from 250° F to 350° F dependent upon type of hot melt being used. Check manufacturers recommended operating temperature.
Note:
Once the hot melt system has reached operating temperature the machine is ready to run.
With the machine E-stopped, go to the Operation Mode screen on the HMI and press the Auto Mode button
Before proceeding with actual machine operation announce in a loud and clear voice CLEAR, listen for response and visually check that all personnel are out of harm’s way.
On the touch screen enclosure and at the remote mounted switch enclosure pull out the Emergency Stop button(s). The Machine Reset button will illuminate.
Press the Machine Reset button. The signal horns sounds, and the Cycle Start button begins to flash when it is enabled.
Press the Cycle Start button.
Observe the operation and output of the product.
Air Pressure Switch
The machine drives are on and the air supply pressure to the machine is 75 PSI or less for more than 10 seconds.
a. b. A horn will sound for a period of 5 seconds. The machine will fault out and cease operating.
Note:
Unless a pressure of 75 PSI or more is maintained to the machine, auto cycling is not possible.
If, allowing for normal pressure bleed off five seconds after stopping the machine, by use of either Emergency Stop button or opening one of the safety guard panels, air pressure of at least 10 PSI is detected by the air sensing switch, the horn will cycle on and off and the machine touch screen will flash a warning signal until:
a. The residual pressure has been released from the machine by turning to the off position the main air supply safety ball valve which is installed in-line, before the machines air supply dump valve.
b.
Power has been restored to the machine.
Making A Box in Manual Mode
With the machine E-stopped, go to the Setup Menu on the HMI and select the Operational Mode (A).
At the Operation Mode screen, press the Manual Mode button (B)
Before proceeding with actual machine operation announce in a loud and clear voice CLEAR, listen for response and visually check that all personnel are out of harm’s way.
On the touch screen enclosure and at the remote mounted switch enclosure, pull out the Emergency Stop button(s). The Machine Reset button illuminates.
Press the Machine Reset button. The Cycle Start button begins to flash.
Press the Cycle Start button.
Go back to the Setup Menu and select Manual Control (C).
Touch the side arrow (D) to go to the next screen.
Fig: 12 - Setup Menu
Fig: 13 - Operation Mode Screen
8. On the Manual Controls screen, use the Drives button (E) to turn the drives on. The material drive and exit conveyor motors start running. .
9. Touch the button labeled Touch To Pick Wrap (F). The body-wrap vacuum pick cylinders extends and pull one bodywrap blank from the bottom of the stack. The button changes to Touch to Kick Wrap.
10.Press Touch to Kick Wrap (G). The body-wrap travels through the material belt drive until it is centered under the mandrel blocker.
Press Touch to Kick End Panel (H). The end panel blank is driven against and formed around the mandrel blocker by the internal flange fold shoes. 11.
12.When both pieces are in place the mandrel blocker drives the end panel blank into the body-wrap blank and down into the die frame assembly where it is formed into a completed container.
13.This completes one container cycle. When the box exits the machine, use the Drives button to turn the drives off. The material drive and exit conveyor motors will stop running.
14.Examine the container construction before proceeding to AUTOMATIC MODE.
Fig: 14 - Manual Controls - Pick Wrap
Fig: 15 - Manual Controls - Kick Wrap F
H
CAUTION
Normal changeover and adjustments are listed in Case Adjustment Points and can be done by the machine operator. Machine performance adjustments should be done ONLY by knowledgeable personnel.
Performance Checks
Ensure that blanks are properly loaded in the magazine. Remove badly deformed blanks or those out of tolerance with specifications.
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.
Case Inspection
Every hour one case should be removed from the line and inspected by observation and disassembly. This will ensure that any problem with the machine or the material is less likely to cause case failure. Cases should be inspected in the following areas:
a End panel seated against the body-wrap This is important to the stacking strength of the case. The end panels should be fully seated on the body-wrap. Top of case tapered outward. It is normal for the top of the case to be slightly wider than the bottom, however, the amount of this taper should be no more than 1/8”.
Glue joints. When any case is torn apart, the corrugated liner on one side of the joint should be torn This is called fiber tear You also want to check the length of the glue lines The end of each body wrap glue line should extend to within 3/8” to 1/2” of the end of the paper b c.
Checking Box Construction
1 . 2 .
3.
Check to see the end panel is seated evenly in the body wrap.
Check to see that completed box is all around square.
a Measure on the diagonals (see illustration) are dimensions equal within plus or minus 1/8”?
Are overlaps even, did the material bend at a right angle on the score lines. a.
Tear open a glued portion of the box. Is the glue joint approximately 1/4” wide, did the corrugated material separate from itself along the glue line?
a b If these conditions are satisfied continue on to Automatic Mode
If not, one or more machine components needs adjustment Go to the Troubleshooting section of this manual or access the troubleshooting section of the touch screen control for possible cause and effects
Machine Shutdown Normal Shutdown
To stop automatic operations press the Cycle Stop button. The machine will complete the last container The container remains on the mandrel blocker, the horizontal die plates in the up position
Shutdown
Press any of the emergency stop red push buttons.
If emergency red push buttons are not within reach, open any of the SAFETY INTERLOCKED DOORS and the machine will instantly stop.
Note:
Note:
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
This machine is equipped with a pressure sensing device which serves two functions. The first is to prevent the machine from operating with inadequate air pressure. The second function is to sense any air pressure left after a system “dump.” A signal horn will sound and a RED warning panel will be displayed on the touch screen control indicating air pressure in the system DO NOT ENTER MACHINE. until air can be bled off.
All emergency stops are maintained stops and must be pulled out and the Machine Reset button pressed before power to machine will resume. Clear the cases from the set up section
Pull out all emergency stop buttons, then restart machine operations
Ensure all personnel are clear before restarting.
Press the Machine Start button
Allow air pressure to build to machine.
Press the cycle start/stop button to begin machine sequence.
IMPORTANT
If the main electrical disconnect has been turned off, it many be necessary to clear any cases in process before restarting the machine.
Product Clean Out
To clean out product currently in the magazine in preparation for a product size change, follow the instructions below.
1 Remove the product from the magazines
In This Chapter
This chapter discusses the proper way to unpack and level the machine, pre-run preparation steps, how to connect the electrical and air supplies, and any final checks necessary before starting the machine
Receiving the Machine
Thoroughly inspect machine for shipping damages before and after removing from transport carrier's vehicle. Note any apparent damages and capture with video or digital photos. Indicate any areas of damage on shipping documents and with Pearson Technical at 800-732-7766.
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
To protect the machine feet from damage, leave the machine skidded when moving
To prevent damage to the machine ensure the fork lift forks or pallet jack forks bear against the skid only when moving the machine Do not use forklift on the underside of the frame.
Check for any loose bolts, nuts or fastenings. Tighten as necessary.
It is not uncommon for bolts, nuts and fastenings to become loose during shipment due to vibration.
It is not uncommon for bolts, nuts and fastenings to become loose during shipment due to vibration.
Check that drive chains are tight. If not, tension using a chain sag equivalent of 2% of the center distance.
Shipping bolts are identified by a yellow tag; (See Fig: 1 - Shipping Bolt Tag).
Leveling the Machine Tools
4 ft. Minimum Bubble-type Level
¾” Wrench or Socket
Note:
A bubble-type level (4 ft. minimum) is useful when leveling the machine.
IMPORTANT
Prior to leveling the machine, place anti-seize on the leg leveler threads. Install the leg levelers.
Note:
Optional leg extensions may be required if the machine deck exceeds standard elevation.
Refer to machine floor plan drawing for machine height
Extend all leg levelers to desired machine height
Adjust the leg levelers until the machine is level
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.
Fig: 1 - Shipping Bolt Tag
Electrical Power
Note: 1.
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. When the machine is connected to an air supply, the cylinders retract to the home position.
Using a volt meter, measure the applied voltages on the power feed to the machine main connections Power should be ± 10% of nameplate voltage
Turn power on. Perform a motor rotation check of the motor. If the motor initially runs in the wrong direction, reverse the polarity. Recheck the motor.
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.
Note: 1
Size the air line to match the inlet line on the air prep unit.
Once air is connected, manually lock air (open) onto machine.
a. Check or perform a pneumatic integrity test of all hoses, fittings, and cylinders.
Correct any discrepancies found to leak or discharge air from pneumatic system. b.
2. The pressure is maintained at a constant level to the machine by use of a built in regulator.
a. The regulator may be set by pulling the regulator adjustment knob outward and turning the knob until the desired pressure reads on the gauge. It will be necessary that the machine’s control power and main air output be on to set the air pressure. This is because the machine’s slow start feature will need to be open. b.
Air Line Sizing Chart
The values given in this chart should be used to select the minimum air line size (npt), and air compressor horsepower to supply a single Pearson Systems machine. The chart is based on a 100 PSI air supply with less than 2 PSI pressure loss. The distances are the pipe line length from the machine, back to the air compressor, or to a large header. The cubic feet per minute (CFM) value is the volume of free air which the machine uses. If more than one machine is supplied by the air line, all the CFM requirements of the machines must be totaled and the sum CFM used to determine the air line size. The air compressor horsepower rating is based on the volume of free air, at 100 PSI, that a 100% duty cycle compressor should be able to supply.
To determine the minimum air line size required, refer to the floor plan drawing to find the maximum CFM requirement If more than one machine will be supplied, add the CFM requirement for each machine and find the total Although the CFM required will vary with the production speed at which the machine will be used, we recommend installing a pipe size which will be sufficient at the maximum rated speed of the machine This will avoid expensive rework in the future Next, estimate the length of
pipe in feet, needed to reach the air compressor. Each elbow or tee fitting should be considered equal to 5' additional length. Fittings should therefore be kept to a minimum. Now find the row which is the CFM you need, and the column which is the pipe length, and this will show the minimum pipe size required.
The pipe size given should be used for the entire run. Stepping down is not recommended.
Length Of Pipe Run In Feet
Final Checks
Before making any adjustments to the machine: turn off main power; turn off air supply; follow lock out/tag out procedures.
1. 2. Verify machine and case/tray set up before attempting to run case/tray.
Jog a product through the machine to ensure the machine is operating properly.
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In This Chapter
This chapter provides detailed instructions for changing from one product size to another.
Note: It is recommended that the following procedures be performed by a minimum of two personnel.
Always use caution when lifting and follow safety procedures.
Overview
Operations Manual Legend Text
HMI Mandrel Blocker Replacement Body Wrap
Magazine Width Body Wrap Guide Rails Body Wrap
Material Stop Trailing Body Wrap Vacuum Cups
Body Wrap Kicker Body Wrap Kicker Backstop
Body Wrap Guide Rails End Panel Magazine Width
End Panel Magazine Depth End Panel Material Stop
End Panel Guide Rails Die Compression Side Fold
Shoes Body Wrap Conveying Bundle Material
Backstop Body Wrap Bundle Feed Material Width
Body Wrap Bundle Feed Material Backstop End Panel Sheet Width Slitter Carriage Position Body
Mandrel Blocker Replacement - Changeover Point #1 Note: Note:
When the air pressure to the machine has been shut off a mandrel locking cylinder engages and holds the mandrel in the full up position. DO NOT attempt this or the following procedures unless the mandrel is in the full up and locked position.
With the crank handle provided, turn the end panel depth adjustment #9 lead screws counter-clockwise. This will increase the distance between the end panel magazines and provide more clearance for removing the mandrel blocker halves.
Loosen and remove the two bolts (A) to the mandrel blocker (B).
Tilt and lift the blocker from the mandrel and remove it from the machine.
Install the new mandrel blocker.
Replace and tighten the bolts
Repeat the procedure for the other side.
Fig: 1 - Mandrel Blocker Replacement
Bliss Former
Body Wrap Material Magazine Width and Guide Rails - Changeover Point #2 & 3
Note:
Changeover points #2 and #3 are adjusted at the same time.
Loosen the two quick-release handles (A) for the body wrap guide rails (changeover point #3)
Use the crank handle to rotate the rod end (B) to adjust the body wrap magazine width to the appropriate setting on the digital counter (C).
Adjust the body wrap rails to the appropriate scale setting (D).
Tighten the quick-release handles.
Fig: 2 - Body Wrap Guide Rail Adjustment
Fig: 3 - Body Wrap Material Magazine Adjustments
Body Wrap Magazine Depth - Changeover Point #4
The body wrap blank needs to be centered under the mandrel blocker.
1 . 2 . Loosen the quick-release handle (A).
Use the crank handle to rotate the rod end (B) to adjust the body wrap magazine depth to the appropriate scale setting (C). Tighten the quick-release handle 3.
Fig: 4 - Body Wrap Magazine Depth
1 . 2 . 3.
Body Wrap Material Stop - Changeover Point #5 B
Loosen the bolt (A)
Turn the adjustment moving the body wrap magazine forward or backward until the edge of the plate is at the appropriate scale setting (B) Tighten the bolt.
A
Fig: 5 - Body Wrap Material Stop
Trailing Body Wrap Vacuum Cups - Changeover Point #6
Loosen the quick-release handles (A) to each of the six vacuum cup assemblies (B).
Slide the vacuum cups assemblies to the appropriate box size This adjustment is not scaled.
Tighten the quick-release handles.
Fig: 6 - Trailing Body Wrap Vacuum Cups
Operations Manual BF30-2AS Bliss Former
Body Wrap Kicker - Changeover Point #7
1 . 2 . 3 .
Loosen the quick-release handle (A).
Slide the body wrap kicker to the appropriate scale setting
Tighten the quick-release handle. (B)
Fig: 7 - Body Wrap Kicker
Body Wrap Kicker Backstop- Changeover Point #8
1 . 2 . 3 .
Loosen the quick-release handle (A).
Slide the body wrap kicker backstop to the appropriate scale setting
Tighten the quick-release handle. (B)
Fig: 8 - Body Wrap Kicker Backstop
End Panel Magazine Width - Changeover Point #9
1. Use the crank handle to rotate the rod end (A) to adjust the body wrap magazine width to the appropriate setting on the digital counter (B).
Fig: 9 - End Panel Magazine Width
End Panel Magazine Depth - Changeover Point #10
1 . 2 . 3.
Loosen the quick-release handle (A).
Use the crank handle to rotate the rod end width to the appropriate scale setting (C) Tighten the quick-release handle.
Note: (B)
to adjust the body wrap magazine
The distance between the end panel lower support plate and the mandrel blocker should measure 5/16”.
Fig: 10 - End Panel Magazine Depth
Operations Manual BF30-2AS Bliss Former
End Panel Material Stop- Changeover Point #11
1 . 2 . 3 .
Loosen the two bolts (A).
Slide each assembly to the appropriate scale setting
Tighten the bolts. (B)
B
Fig: 11 - End Panel Material Stop
End Panel Guide Rails - Changeover Point #12
1. Use the crank handle to rotate the rod end (A) to adjust the end panel guide rails to the appropriate setting on the digital counter (B).
Fig: 12 - End Panel Guide Rails
Die Compression - Changeover Point #13
1. Use the crank handle to rotate the rod end to the appropriate digital counter setting to adjust the end panel guide rails (A) (B)
Fig: 13 - Die Compression Adjustment
Side Fold Shoes - Changeover Point #14
1 . 2 . 3.
For each side, loosen the quick-release handle .
to move end panel kicker (A) (B) (C)
Use the crank handle to rotate the threaded rod end backstop to the appropriate setting on the scale . Tighten the quick-release handles.
Fig: 14 - Side Fold Shoes Adjustment
Operations Manual BF30-2AS Bliss Former
Body Wrap Conveying Bundle Material Backstop - Changeover Point #15 1 . 2 3
Loosen the quick-release handles (A).
Move the backstop (B) to the appropriate setting on the scale
Tighten the quick-release handles. (C).
Fig: 15 - Body Wrap Conveying Bundle Material Backstop
Body Wrap Bundle Feed Material Width - Changeover Point #16
1. Use the crank handle to rotate the threaded rod end appropriate setting on the digital counter (B). to adjust the width to the (A)
Fig: 16 - Body Wrap Bundle Feed Material Width
Operations Manual BF30-2AS Bliss Former
Body Wrap Conveying Bundle Material Backstop - Changeover Point #17 1 . 2 3
Loosen the quick-release handles (A).
Move the backstop to the appropriate setting on the scale
Tighten the quick-release handles. (B).
Fig: 17 - Body Wrap Conveying Bundle Material Backstop
End Panel Sheet Width - Changeover Point #18
1. Use the crank handle to rotate the threaded rod end appropriate setting on the digital counter (B). to adjust the width to the (A)
Fig: 18 - End Panel Sheet Width
Slitter Carriage Position - Changeover Point #19
1 . 2 . 3.
Loosen the quick-release handles (A).
Use the crank handle to rotate the rod end (B) to adjust the slitter carriage position to the appropriate setting on the digital counter (C) Tighten the quick-release handles.
Fig: 19 - Slitter Carriage Position
Body Wrap Pre-Fold - Changeover Point #20
1 . 2 . 3 .
Loosen the quick-release handles (A).
Move the body wrap pre-folds to the appropriate settings on the scales
Tighten the quick-release handles. (B)
Fig: 20 - Body Wrap Pre-Fold Adjustment
Operations Manual BF30-2AS Bliss Former
Trailing Body Wrap Stack Funnel - Changeover Point #21
1 . 2 . 3.
Loosen the two quick-release handles (A).
Move the trailing body wrap stack funnel to the appropriate settings on the scales (B)
Tighten the quick-release handles.
Fig: 21 - Trailing Body Wrap Stack Funnel
Leading Body Wrap Stack Funnel - Changeover Point #22
1 . 2 . 3.
Loosen the two quick-release handles (A).
Move the leading body wrap stack funnel to the appropriate settings on the scales (B)
Tighten the quick-release handles.
Fig: 22 - Leading Body Wrap Stack Funnel
BF30-2AS Bliss Former
In This Chapter
This chapter provides information on the display screens located in the Allen-Brad-
ley PanelView Plus 1000 Operator Interface; including the layout and function of each screen.
Electronic Operator Interface
The Allen-Bradley PanelView Plus 1000 is an electronic operator interface the operator gathers information from the LED display and presses the touch screen to perform a particular function. Some items in the PanelView can be changed directly by any operator (such as choosing case size) while other items require a password (such as servo motor parameters)
This section is intended to describe the screens and functions specific to the Pearson Packaging Systems BF30-2AS Bliss Former. For technical information about the Allen-Bradley PanelView Plus 1000, refer to the manual shipped with this machine or visit Allen-Bradley’s web site at http://www.ab.com.
Fig: 1 - Allen-Bradley PanelView Plus 1000
HMI Display Screens
Home is the first screen that appears on startup and displays during normal machine operation. It provides access to all the other screens in the HMI.
Legend Table
Maintenance Icon
Active Recipe
Alarm/Message Display
Magnifier
Menu Button
Machine Status Displays
Pearson Icon
Appears when maintenance tasks are due. Press to go to the Maintenance screen.
Active recipe display - Shows the currently active recipe.
Displays status of machine, alarms and messages.
Opens the Conveyor Home screen, which displays a map of the system.
Press to open the Menu Bar
Displays the current machine mode, machine state and case count
Return to Home screen
Fig: 2 - HMI Home Screen
Fig: 3 - Conveyor Home Screen
Menu Bar
Press the Menu button in the lower left corner of the screen to open the menu bar. The icons on the menu bar provide access to additional menu screens.
• • Icon Press Close Press Login to close the menu bar. to open the user login popup window.
Action Description
Returns to the Home screen
Opens Changeover Menu
Opens Setup Menu
Opens I/O Menu
Opens Alarm Menu
Opens Maintenance Menu
Opens Help Menu
Screen Access
Changeover Menu
Setup Menu
Sensor Menu
Recipe Select
Changeover Values
Configuration Values
Recipe New/Edit
Manual Control
Sensor Map
Output Test
Alarm History Alarm Status
Maintenance Setup
Required Maintenance
Maintenance History
User Manual Parts & Service
Training
Alarm Menu
Maintenance Menu
Help Menu
Map Guide
Operational Mode
Glue Pattern Values
Optional Functions
Sensor Descriptions
Alarm Descriptions
Message History
Clean Lubricate
Inspect
Wire Schematic
Pneumatic Schematic
Login
A login popup is provided for screens that require a maintenance login to make changes to machine values. The operator login is the default.
To log in:
1 Go to the Login window in one of the following ways.
a. Open the menu bar and press the Login button (A), then press Login (B) when the login popup appears.
b.
Press a button for a function that requires login (C). These buttons are displayed, but appear shaded.
2 A window appears for entering username and password.
a Press the User Name button (D) and enter the login name on the keypad. Press the Password button (E) and enter the password for the login name on the keypad.
Press Login (F).
Fig: 4 - Login Popup
Fig: 5 - I/O Menu with Shaded Button
Fig: 6 - User Name and Password Entry
To change a password:
1. Press the Password button (G) in the Login Popup to view user names or change the password for Operator or Maintenance
2.
Log in at the appropriate level.
b
a. To change the Operator password, log in as an Operator. To change the Maintenance password, log in as Maintenance
3. Press the Change Password button (H).
4.
Note:
Change the password and save
If the password is lost or forgotten, call the Pearson Packaging Service Department at 800-732-7766 for assistance
To log out:
1. When finished, press Logout (I) to go back to the default setting.
2.
3.
If the screens are not accessed within 12 minutes, the HMI automatically logs out.
To minimize the popup, press Close (J).
Fig: 9 - Login Popup
Fig: 8 - Password Screen
Fig: 7 - Login Popup
Alarms
When an alarm or message is displayed on the Home screen, an indicator (A) appears at the affected area on the machine map.
• Red indicators are displayed at alarm locations.
•
Yellow indicators are displayed at message locations.
Press the indicator to go to a screen that contains details about the alarm or message, and instructions on how to fix the condition and resume operation.
Fig: 11 - Example Message Screen
Fig: 10 - Example Home Screen with Alarms (CE25-G shown)
Changeover Menu
Press the Changeover icon (A) on the menu bar to open the Changeover Menu Screen Press the buttons (B) to access screens to assist with case size changeover.
Recipe Select
The Recipe Select screen lists the preprogrammed case size recipes. Press the Changeover icon (C) on any of the screens to return to the Changeover Menu.
To change the case size, press E-Stop, then touch the recipe (D) for the next order to be run. A Recipe Changed message appears (E). If there is more than one screen of recipes, press the side arrow (F) to scroll to the next page.
Changeover Values and Map can be accessed directly by pressing the buttons on the Recipe Select screen (G)
Fig: 12 - Changeover Menu Screen
Fig: 13 - Recipe Select Screen
Fig: 14 - Recipe Changed
Changeover Values
The Changeover Values screen lists the changeover setpoints for the selected recipe.
•
Recipe Setpoint (A) is current setting value for the changeover point. The default is the value that was set at the factory.
To edit recipe setpoints, log in as maintenance, then press the button for the setpoint to be edited. Follow the screen directions for changing the value.
Map
The Changeover Map screen shows a visual display of the machine showing the location of the changeover points. Each adjustment is labeled with the adjustment number (B). Press the number to go to the guide screen for the specific changeover point.
Press the HMI button (C) to go to the Recipe Select screen. Guide
The Guide screens contain instructions and pictures for all changeover points.
Press the arrows on the right and left sides (D) to advance to the next adjustment point screen.
Note:Depending on the number of
• adjustment points, there may be more than one Changeover Values screen.
Press screen in the lower right corner of the screen to return to the Changeover Map
Fig: 15 - Changeover Values Screen (E)
Fig: 16 - Changeover Map Screen
Fig: 17 - Example Changeover Guide Screen
Press the E-Stop.
From the Changeover Menu, go to the Recipe Select Screen (A).
Press the appropriate recipe to select the case size (B).
Press the Changeover Values button (C).
Check that the selected case size is displayed as the current case size. Begin adjusting the machine starting with the first changeover point using the instructions from one of the following sources:
a. The HMI Changeover Guide screens, accessed from the Changeover Menu (D) Use the arrows (E) to move through the changeover guide
The Changeover chapter of this manual. b. c.
The Changeover flipchart provided with the machine
Fig: 20 - Example Changeover Values Screen
Fig: 19 - Recipe Select Screen
Fig: 18 - Changeover Menu Screen
Fig: 21 - Example Changeover Guide Screen
C E
Press the Setup Menu icon (A) on the menu bar to open the Setup Menu Screen.
Press the menu buttons (B) to access screens to change operational modes, create and edit recipes, and view and edit configuration values. Machine specific screens may also be included
Configuration Values
Configuration values are variables for each case. These include timer and counter settings specific to the case size and dimensions.
Press the Setup Menu icon (C) on any of the setup screens to return to the Setup Menu
Maintenance login is required to edit configuration value setpoints (D).
Fig: 22 - Setup Menu Screen
Fig: 23 - Configuration Values Screen
Recipe New/Edit
The Recipe New/Edit screen is used to set up or copy recipes for a new case size. Maintenance login is required.
1. To add or change a recipe name, touch to select a recipe, then touch the edit button (A).
Add or change the recipe name and press Enter.
Press Yes in the popup (B) to confirm the change. Enter or copy changeover values for the recipe.
a. To enter values, press Enter Changeover Values (C) and edit the value for each changeover point.
b.
To copy changeover values from an existing recipe, press Copy Recipe Values (D).
• Use the arrows for the upper box (E) to scroll to and select the name of the recipe to copy from.
Use the arrows for the lower box (F) to scroll to and select the name of the recipe to copy to.
Press the copy button (G)
Fig: 24 - Recipe Edit Screen
Fig: 26 - Recipe Edit Screen
Fig: 25 - Recipe Confirmation Popup
Operation Mode
The Operation Mode screen allows the operator to place the machine in different operating modes. The current mode (A) is checked and also displayed at the bottom of the screen.
Control power must be off to change machine modes. The mode selection buttons do not appear until the E-Stop is pressed.
Manual Mode Automatic Mode Dry Cycle Mode
Maintenance Mode (if applicable)
This mode allows the operator to manually operate individual machine components. The Manual Control screen button (if applica- ble) only displays on the Setup Menu when the machine is in Manual mode.
This mode is used for routine production. This mode disables certain sensors, the vacuum and glue as needed to allow the machine to cycle automatically without product
This mode is used for diagnosing problems with the machine It jogs all axes at the same time with the capability to run cases without gluing them The Maintenance Control screen button only displays on the Setup Menu when the machine is in Maintenance mode
Select the Operation Mode screen from the Setup Menu.
E-Stop the machine. The mode selection buttons appear when control power is off.
Press the appropriate operation mode button.
Pull the E-Stop. The blue Machine Reset button lights.
Press the Machine Reset button.
Press the Cycle Start button to start the machine running in the selected mode.
Fig: 27 - Operation Mode Screen
Glue Setup Screen
The Glue Setup screen displays recipe and factory setpoints for different glue patterns.
Maintenance login is required to edit glue pattern recipe setpoints (A).
Manual Control
The Manual Control screen provides access to manual functions for areas of the machine. Control power must be on for the screen to be active. Follow instructions on the screen (A) to activate manual controls.
Press the side arrow (B) to go to the next Manual Control screen.
• The Drives switch (C) manually turns the material drive and exit conveyor motors.
• •
Press the Test Body Wrap Glue button (D) to test the operation of the body wrap glue.
The Pick and Kick buttons (E) are used to manually build a test box. See “Making A Box in Manual Mode” on page 5-11 for the procedure.
Fig: 28 - Glue Setup Screen
Fig: 29 - Manual Control Screen
Fig: 30 - Manual Control Screen #2
Each of the hand icons (F) on the machine map displays a manual controls pop-up window (G) for that area of the screen. Press the X (H) to close the pop-up.
Home buttons (I) are provided to send servos to the home position.
Arrow buttons (J) run conveyors forward or reverse and move components up and down Tandem buttons (K) run two conveyors simultaneously
Optional Functions
The Optional Functions button on the setup menu opens the Machine Status screen
Use the arrows (L) to adjust the machine speed.
Fig: 32 - Manual Controls Pop-Up Windows
Fig: 33 - Machine Status Screen
Fig: 31 - Manual Control Screen - active
I/O Menu
Press the I/O Menu icon (A) on the menu bar to open the I/O Menu screen. Press the buttons (B) to access the Sensor Map and Description screens, and the Output Test screen.
Sensor Description
The sensor description screens explain the function of each sensor.
Press the side arrow (C) to go to additional sensor description screens.
Fig: 34 - I/O Menu Screen
Fig: 35 - Sensor Description Screen
Sensor Map
The Sensor Maps show all the sensors on the machine. As the machine operates the sensors on the map change color as they activate or deactivate.
Press one of the sensor icons (A) on the initial sensor map screen to display sensor maps for the body wrap bundle feed, forming section or conveyors.
Press the I/O Menu icon (B) on any of the sensor screens to return to the I/O Menu.
Fig: 37 - Sensor Map Screens
Fig: 36 - I/O Menu Screen
Output Test
The Output Test screen allows the operator to manually energize the solenoids controlling the pneumatic mechanisms of the machine.
Maintenance login is required. Follow the instructions (A) to enable the output test buttons
The information button (B) opens a popup window additional instructions
To close the popup window, press the X in the upper right corner (C).
When the output test buttons have been enabled, press a button to activate the indicated mechanism (D).
Fig: 38 - Output Test Screen
Fig: 39 - Reset Steps Popup Window
Press the Alarm Menu icon (A) on the menu bar to open the Alarm Menu screen. Press the buttons (B) to access alarm and message screens.
Alarm History
The Alarm History lists the alarms that have occurred on the machine
Press the Alarm icon (C) on any of the screens to return to the Alarm Menu.
Use the directional arrows (D) to scroll up or down the list.
Press the Trash Can icon (E) to clear the Alarm History Maintenance login is required
Fig: 40 - Alarm Menu Screen
Fig: 41 - Alarm History Screen
Alarm Status
The Alarm Status screen is a data collection screen that accumulates the frequency and cumulative time the current alarm was active.
Use the directional arrows (A) to scroll up or down the list.
Press the Trash Can icon (B) to clear the Alarm Status.
Alarm Descriptions
The Alarm Descriptions screen provides a menu of fault information screens.
Press the alarm button (C) to open a fault screen with troubleshooting steps for the selected alarm.
The information screen describes the steps for correcting the fault and resuming operation. Press the icon (D) to return to the Alarm Descriptions screen.
Fig: 42 - Alarm Status Screen
Fig: 44 - Example Alarm Information Screen
Fig: 43 - Example Alarm Description Screen
Maintenance Menu
Press the Maintenance Menu icon (A) on the menu bar to open the Maintenance Menu screen. Press the buttons (B) to access maintenance screens.
Press the trash can (C) to clear the case counter
Maintenance Setup
The Maintenance Setup menu displays a list of scheduled maintenance tasks for the machine (E). A maintenance login is required to make any changes.
Press the Maintenance icon (D) on any of the screens to return to the Maintenance Menu.
When scheduled maintenance tasks are due, the Maintenance icon (F) appears at the top of the screen. The tasks are displayed on the Required Maintenance screen.
Fig: 46 - Maintenance Setup Screen
Fig: 45 - Maintenance Menu Screen
Adding Maintenance Tasks
In addition to the facto tasks, there are five additional spaces for customer configured maintenance tasks. Maintenance login is required to add tasks
Add a task as follows:
1. Press an blank maintenance task name (A) and enter a task name on the keypad that appears
2.
Enter a schedule for the task.
a. b. Press the first schedule button (B) to enter the number. Press the second schedule button (C) to select the unit of time.
3. When the task has been created, press the on/off toggle (D) to turn the task On.
Required Maintenance
The Required Maintenance screen dis- plays a list of maintenance tasks that are due to be completed. Use the direction arrows to scroll through the list (E).
Press the menu buttons (F) to go to the Clean, Lubricate or Inspect menus to access information screens about performing the required maintenance tasks.
When a maintenance tasks has been completed, scroll to select it and press the Complete button (G) to clear it from the list
Fig: 47 - Customer Configurable Tasks
Fig: 48 - Required Maintenance Screen
Maintenance History
The Maintenance History screen displays a list of completed maintenance tasks. Use the directional arrows (A) to scroll up or down the list.
Press the trash can (B) to clear the maintenance history. Maintenance login is required.
Clean, Lubricate, Inspect
The Clean menu button on the Maintenance Menu opens a menu of points that require cleaning for the specific machine.
Lubricate and Inspect menu buttons open similar menus for lubrication and inspection points.
Press a menu button (C) to open an information screen that provides instructions for cleaning, lubricating or inspecting that point.
Press the side arrow (D) to return to the menu.
Fig: 51 - Example Clean Point
Fig: 50 - Example Clean Points Menu
Fig: 49 - Maintenance History Screen
Press the Help Menu icon (A) on the menu bar to open the Help Menu screen. Press the buttons (B) to access machine documentation and contact information.
Press User Manual, Wire Schematic or Pneumatic Schematic to open the document in a PDF viewer.
To exit the viewer, press the X in the upper right corner (C).
If the schematic is oriented incorrectly, press the Rotate button (D) to turn it clockwise 90 degrees until it is correct
PDF Viewer
Fig: 52 - Help Menu Screen
Fig: 53 - Pneumatic Schematic in PDF Viewer
Training
Press the Training button on the Help Menu to open the Training Menu.
Press the buttons (E) to access instructions for machine operations
To close the popup window, press the X in the upper right corner (F).
Fig: 54 - Training Menu Screen
Fig: 55 - Start Steps Popup Window
General Lubrication
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 containing higher concentrations of dust, dirt or debris may need to be wiped down and lubricated more frequently.
Excess or spilled lubricants can cause package damage Spilled lubricants must be cleaned up to prevent slips or falls by personnel which may result in serious injury Over lubricating is harmful to most components.
Lubricate lead screws, sprockets, connecting chains and gear racks weekly, or after each 40 hours of continuous use. Use lubricants B,C, and D respectively.
Note:
Note: Not
e: Not e:
Bearings on the feed wheel assemblies and discharge conveyor are factory sealed and need no further lubrication.
Check and fill the air line lubricators on a daily basis. Use SAE 10 non-detergent oil only. Use of automotive type or detergent oils will damage the seals throughout the pneumatic system.
Refer to the glue manuals for proper air line lubricator adjustments.
Over time shafting may experience a build-up of contaminants. When necessary, clean shafting with a light oil saturated rag only.
CAUTION
Use of solvents may damage seals and cause premature failure of linear device.
Mandrel and Blocker Section Operations Manual
Location Lubrication Schedule
Vacuum Pull
Down Hoppers
Vacuum Pull
Down Hoppers
Motor Driven
Components
Motor Driven
Components
Die Compression
Section
Die Compression
Section
Mandrel and Blocker Section
Cylinder Rods
Kicker Vee Guides
Gear Boxes
Drive Chains
Die Frame Cam Bearings
Die Frame Cam Bearing Slots
Bearing Rods And Linear Bearings
Linear Guides
BF30-2AS Bliss Former
Refer to manufacturer’s data included with this manual
Weekly or after 40 hours of operation
Weekly or after 40 hours of operation
Weekly or after 40 hours of operation
Weekly or after 40 hours of operation
Lubricant Codes
10wt. SAE non-detergent oil
Lithium soap-based grease (medium consistency)
Silicone lube spray (if possible with pinpoint applicator)
As listed in the gear motors manufacturers data as supplied with this manual or a gear oil which meets AGMA #7 Compound Spec.
Aerosol chain and cable lubricant.
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 Materials
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. When prompted, enter 2 for the Service Department. Select the appropriate number for the service branch you would like to contact when prompted
•
•
• Service Parts: Enter 1.
Service Technical Support: Enter 2
Service Scheduling Coordinator: Enter 3
• Service Engineering Quote Team: Enter 4.
Part Replacement
Determine if part removal is absolutely necessary before disassembling any portion of the equipment Refer to Troubleshooting for more information
Safety
Before performing any machine adjustment or maintenance, close the Pneumatic Energy Isolating Valve and the Electrical Disconnect. Follow your company’s lock out tag out procedures.
For more information on removing parts, refer to the General Subassembly drawings included in the packet of drawings accompanying this manual. The bubble numbers on these drawings identify replaceable parts.
1. Before reassembling, wipe all parts with a clean dry cloth. Apply the proper type of lubricant to each working part, if necessary, being careful not to over lubricate.
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 manual. You can purchase the RSP at any time.
Part Ordering Procedures
Replacement Parts
Pearson Packaging Systems will provide replacement parts for most components on your machine, including standard parts purchased from outside vendors.
To order any part, provide the following information:
Machine serial number
Pearson part number
Quantity required
Description
Purchase order number
Shipping instructions.
Warranty Replacement parts
To order parts under warranty, follow the steps above and provide the following information:
a.
b.
c d e f.
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)
Shipping instructions.
A Parts Replacement Return Authorization Number will be issued to accompany and identify the return. Parts must be returned within 30 days to remain under warranty.
The defective part will be returned to the vendor for evaluation. If the defective part is determined to be covered under the warranty, the new purchase order will be credited.
Bill Of Material
The Bill of Material (BOM), used to find part numbers and/or bubble numbers, is a listing of parts and purchased components used to assemble this machine
The following instructions explain the layout of the BOM:
Titles and Columns
The column headings shown on each page of the BOM include Level, Sub Part/Rev, Part Description, Position, Quantity and Manufacturer/Manufacturer’s Part Number
Level
Parts for the main machine are grouped under the main and sub assemblies that make up the machine. Examples of main assemblies include Guards (GRD), Electrical (ELE), and Modules (mechanical sections; MOD). Examples of sub-assemblies include Mechanical (BSA), Electrical Assembly (ASM) and Electrical Panel (PAN). Individual parts may be listed under a main assembly but most are listed under the sub-assemblies. Level designations are Level 1 – Main Assemblies, Level 2 – Sub 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 Packaging Systems, 800-732-7766.
Part Description
A brief description of the part, its size, color, material, etc.
Position
This column shows the bubble (position) number of a sub part with reference to the Assembly Drawing This space is filled with an asterisk if no bubble number appears on the print
Quantity
Indicates the total quantity of parts required.
Manufacturer/Manufacturer Part Number
Each part will have the manufacturer listed. Purchased components will also have the manufacturer’s part number listed.
Assembly Drawings
3-D Assembly drawings are provided with the machine documentation. These drawings (dwf) represent the base machine configuration in fabricated parts. For machines that are built with alternate fabricated parts (i.e. stainless steel, anodized, etc) refer to the computerized Bill of Material for the alternate fabricated part numbers
Abbreviations
Approx.: CSL: FBA: Fig.:
FOLF:
Hi-Cap Mag:
HP: hr:
HSC: HZ: KD: max : min: opt: Para or PH:
Half Slotted Case Hertz Knocked Down Maximum Minimum Optimum ¶: Paragraph Phase
PMMI: psi:
RSC: SCF: std.: typ: Approximately Constant Scoreline Fibre Box Association Figure Full Over Lap Flap High Capacity Magazine Horsepower Hour
Packaging Machinery Manufacturer’s Institute Pounds per square inch
Regular Slotted Case
Standard Cubic Foot
Standard
Typical
Glossary
Air Prep Unit: The air prep unit consists of a Lock out Valve, integral Filter Regulator, 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. The Exhaust Valve will immediately dump the air from the system when a jam occurs, or when an Emergency Stop button is pressed.
Constant Scoreline: The machine’s constant, that when setting up, or conducting changeovers, is essential to locate the case and/or carrier material in a specific location for the equipment to operate consistently
Cylinder Cushions: Cylinder cushions control the smoothness of the end of the stroke. Adjust the cushion so there is no hard stop and not much, if any, bounce. If a cylinder is allowed to bang or slam to a stop, the internal cushion seal will wear out. You will then need to replace the seal before you can make any further cushion adjustments.
Cylinders: Pneumatic cylinders are used to accomplish movement of parts
Electrical Dump Valve: Safety valve that dumps air downstream of valve Air downstream of valve is called “dumped air ” Air between Manual Dump Valve and Electrical Dump Valve is called “undumped air ”
Flow Controls: Flow control valves are used to control the amount of air to a component, affecting the speed at which the component reacts. Fuses: An electrical safety device consisting of, or including a wire or strip of fusible metal that melts and interrupts the circuit when the current exceeds a particular amperage.
Gear Reducer: A mechanical component that changes the shaft speed of an electrical motor.
Glued Tabs: The glued joint of the case
Half Slotted Case (HSC): A type or style of case with folding bottom flaps, but without top flaps.
Knock Down (KD): A blank case in its collapsed or flat condition. Normally how material is shipped to customers for packaging processes.
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. The regulator reduces the air flow to a constant rate. This is done in order to protect the components of the machine by restricting the volume at which air enters the system and to maintain air pressure at a level suitable for the devices.
Manual Dump Valve: A pneumatic energy isolating valve, required by OSHA (29 CFR 1910.147). In the exhausting position, isolates the machine from incoming main air. To prevent accidental start-ups while cleaning or servicing the machine, this valve can be physically locked out and/or labeled with a warning tag while in the exhaust position.
Motor: A device that converts electrical energy into mechanical energy using forces exerted by magnetic fields on current-carrying conductors.
Open Depth: The inside dimension of the case, from the bottom of the case to the top of the open flaps.
Photocell: A sensor used to detect either carriers or cases. Used to indicate an action has been accomplished, and that another action can now take place.
Pushbuttons: A device for opening and closing or for changing the connection of a circuit.
Reflector, Photocell: A reflective disk or strip used with a photocell to reflect a beam emitted by the photocell.
Regular Slotted Case (RSC): A type or style of case. This case will have open flaps that remain in the open or upward direction during the packaging process.
Relays: An electromagnetic device for remote or automatic control that is actuated by variation in conditions of an electric circuit and that, in turn, operates other devices (as switches) in the same or a different circuit
RSC Tab Lock: A type or style of case. This case will have top flaps folded around the body of the case and held by tabs during the packaging process
Score Lines: The pre-positioned indentations or perforations.
Skewing: The placement of the glued joint and if the joint is properly positioned, maintaining the design specification of the case.
Slow Build Valve: Prevents a surge of high pressure air during machine start-up. During 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. The Slow Build Valve should be adjusted to reach full volume in 2 to 2.5 seconds, as the machine start delay pays out in 3.5 seconds.
Spring Loaded Ram Lock: If the machine start delay pays out before the slow build valve opens fully, the ram will try to fire; however, the lack of pneumatic pressure will prevent the ram lock from releasing. You must have full air pressure before the machine start delay pays out and the machine starts to cycle.
Switch, disconnect: A safety switch that, when turned to the “off” position, cuts the electrical power to the machine
Switch, limit: A mechanical sensor used to detect that an action has been performed. Part of the control circuit of the machine.
Switch, pressure type, bellows: A safety switch that detects the amount of air pressure being fed to the machine If the air pressure falls below a certain amount the machine will shut down
Switch, proximity: A sensor that, without making physical contact, detects the presence of a metal target, within a specified range
Switch, selector: An electrical control device that allows the activation of specific control circuits in the overall machine electrical program. Part of the control circuit of the machine.
Switch, safety, interlock: A two-part safety switch that allows the equipment to function properly when both parts are properly mated. If the two parts are disconnected (for example, by opening a guard door), power is removed from the machine.
Transformer: A device that reduces voltage in the control circuitry.
Valves: Pneumatic devices that direct the flow of air to and from other components (i.e., cylinders). Valves can be controlled electrically or mechanically.
Copyright © by Pearson Packaging Systems
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), without the prior written permission of:
Pearson Packaging Systems
W. 8120 Sunset Highway Spokane, WA 99224
1-800-732-7766 www.pearsonpkg.com
Pearson Packaging Systems strives to ship up-to-date, accurate manuals with our machines. However, continual product improvement does not make this possible. 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; fines or penalties for the violation of any federal, state, or local regulations.
Pearson Packaging Systems will not be responsible for the unsuccessful operation of any of its products that have been modified in any way by anyone other than an authorized factory representative
No patent liability is assumed with respect to the use of this information.
Most references to manufacturers or their products are registered trade names and are to be treated accordingly
Printed in the United States of America
Operator Message Boxes
Non-standard Options Overview
Machine Safety.
Machine Operation.
Troubleshooting
Preventive Maintenance
Service
2-2
2-2
2-3
2-3
2-3
Separate Glue Unit Disconnect............................................................3-1
In This Chapter 3-1
Option Overview.
Installation Procedures
Machine Safety.
Machine Operation.
Troubleshooting
Preventive Maintenance
3-1
3-1
3-1
3-1
