Operation Manual QP Rotary OPP Labelling Hot Melt Full Updated [PDF]

Zitiervorschau

ROTARY OPP HOT MELT LABELLING MACHINE

TO BE THE BEST, ONE STOP PACKAGING AND FILLING SUPPLIER

Operation Manual

© Emec Packaging Solutions Sdn Bhd No 4, Jalan Gangsa , Kawasan Perusahaan Telok Panglima Garang 42500 Kuala Langat Phone +603 5033 5804 • Fax 603 3168 090

PACKAGING, FILLING, WEIGHING

Table of Contents 1. 2.

Acknowledgement ........................................................ 1 General Information ...................................................... 2 i) ii) iii)

3. 4.

Product Warranty .......................................................... 3 Health & Safety Procedures ......................................... 4 i)

5. 6. 8. 9. 10. 11.

Check the Shipment ............................................................. 2 Instruction Manual ................................................................ 2 Safety procedures, Precaution and Safety Symbols ............ 2

Safety Precaution Sign & Symbols ....................................... 4

Technical Specification ................................................ 6 Machine Layout and Drawing ..................................... 10 Operation ..................................................................... 10 Maintenance ................................................................ 22 Troubleshooting .......................................................... 44 Spare Part List ............................................................. 45 i)

Electrical and Mechanical ................................................... 45

12. Rotary OPP Hot Melt Labelling Diagram ....................... 46 i) ii)

Control Panel Layout .......................................................... 46 Schematic Diagram ............................................................ 46

PACKAGING, FILLING, WEIGHING

1. Acknowledgement

T

hank you for choosing Rotary OPP Hot Melt Labelling Machine . Our machines and equipments are manufactured with latest technology and tested prior delivery. Full testing will be done at site during commissioning.

We use high quality and reliable components such as PLC, Indicators and Load Cells. We also use standard pneumatic cylinders, solenoid valves and fittings that are easy available. In addition, our machine and equipments comes with 1 (One) year warranty on electronic parts and manufacturing defects. Like any other machine, proper use of the machine with regular preventive maintenance and service will increase the machine and equipment lifespan and potentially avoid unnecessary breakdown and costly downtime. If in doubt, please do not hesitate to contact our Sales or our engineers for more information. All information and specification in this manual are correct at the time of printing. Inline with our corporate mission to provide "Quality Products With Affordable Price", we reserve the right to make changes in engineering design, materials specification, and component brand and automation system at any time without giving prior notice.

Manufactured and supplied by : EMEC PACKAGING SOLUTIONS

No 4, Jalan Gangsa, Kawasan Perusahaan Teluk Panglima Garang,42500, Kuala Langat,Selangor Darul Ehsan, Malaysia. Tel: +603 5033 5804 Fax: 603 3168 0900 Website : www.emec-corp.com Email :[email protected]

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2. General Information i)

Check the Shipment

The first thing to do when received your machine/s and equipments is to check it and ensure that the contents conform to the shipment list/advise/documents. EMEC inspects all equipment prior shipment, but it cannot guarantee that the merchandise reaches the user intact. Therefore, the machine, equipments and any other items when received should be checked and in the event the item / s question did not conform to the specification and / or is missing, contact the transportation company, shipping agent and the manufacturer immediately. ii)

Instruction Manual

Generally, Instruction Manual should include in the shipment unless notified. We reserved the right to modify the design and / or manufacturing specification of our products as required, devoid of any obligation on our part to adapt any product supplied prior to such alteration and without giving any prior notice. Read the Instruction Manual thoroughly before installation, operation, repair or service and it should be made available easily for the technical, machine maintenance and operators to access when needed. iii)

Safety procedures, Precaution and Safety Symbols

Read and remember to observe all the SAFETY PROCEDURES, PRECAUTIONS and descriptions mentioned for general safety of the operators, service technician and foreman.

CAUTION

WARNING

DANGER

PROHIBITION

REMARKS

IMPORTANT 2

3. Product Warranty Warranty right varies from country to country, but it is the general intention of our corporation, EMEC PACKAGING SOLUTIONS SDN BHD, to offer customers a (1) one-year warranty on this product from the day of installation and commissioning. In some countries, consumer protection legislation state that your dealer or agent is responsible for offering a warranty and as such, please refer to your local dealer. The product (if defective) should be notified immediately in formal for verification and to be checked by EMEC Packaging Solutions Sdn. Bhd. technical team. This warranty only applies to product failures due to defective materials and or workmanship. It will be rendered invalid if, upon inspection is found that the product was:

• Wrong application against specification and machine design • Mishandled or damaged due to carelessness / accident by operator • Unauthorized modification or repair • Poor or No maintenance If the machine or equipment is still under warranty, then EMEC will take the responsibility to repair or replace at the discretion of EMEC and then returned to the customer at no extra cost.

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4.

Health & Safety Procedures

Read this Instruction Manual thoroughly to understand the operation procedures, safety and preventive maintenance. Allow qualified and trained technician to do inspection, maintenance or repair work. Fail to do so with result shock circuit, damaged electronic instruments, serious or fatal injury. i) Safety Precaution Sign & Symbols

CAUTION Always remember to SWITCH OFF the MAIN POWER and AIR SUPPLY before doing any maintenance or repair work.

CAUTION Earth wire must be properly connected to prevent electrical shock. Earth wire - Green or Yellow Green color wire.

CAUTION DO NOT use any sharp object or metal to press push buttons switch or setting Indicators, Touch screen or any electrical instruments.

WARNING Some products are HOT and under HIGH working PRESSURE. DO NOT open any hose, pipelines or valve when in RUNNING MODE.

DANGER DO NOT open any SAFETY GUARD, DOOR OR MOTOR CHAIN COVER while machine is in RUNNING MODE.

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WARNING Wear SAFETY apparatus like protective eyewear, safety helmet and safety shoes to prevent injury.

WARNING Use HAIR CAP for SAFETY and Hygiene purpose. Long and WITHOUT hair CAP is Hazardous in production areas.

CAUTION Use ORIGINAL PARTS. DO NOT modified or use NON-ORIGINAL PARTS without consents.

WARNING DO NOT tamper, cutoff or bridged "Safety Device or Circuit" connection. Breached or fail to do so may cause short circuit, injury or loss of live.

CAUTION "Do Not Assume" all instruments using same power supply. It can be 380V AC 3 Phase or 230V AC Single Phase and 24V DC currents.

CAUTION NO WELDING should be perform on the machine. Welding can damage the Electronic Instruments or components.

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Safety Regulations 1). Do not wipe the vacuum drum while the machine is running. It must be wiped during shutdown. 2). Do not use a flammable solvent to wipe the cleaning vacuum drum, which will corrode the rubber. Jiangsu Ian recommends that you use special glue provided by hot melt adhesive manufacturers. (chemical solvents to avoid inhalation) 3). The storage area of the hot melt machine must be covered at any time, and there will be a pungent odor when heated. (Chemical solvent to avoid inhalation) 4). The equipment has a heating area and is marked with a safety mark to avoid burns. 5). The device is labeled with a safety mark (for reference only). Pay attention to safe operation. 6). When the machine is shut down for maintenance, the power supply is cut off on the panel to prevent the machine from accidentally pre-rotating. Second; device security protection settings 1). The equipment has a safety protection device. When the main engine runs and encounters the inverted bottle, the bottle will be bottled when the size of the star wheel passes. At this time, the device will automatically stop running. 2) When the cutter mechanism is stuck, the main motor torque limiter will automatically bounce and trigger the alarm to stop the main engine. 3). An emergency stop button is provided before and after the machine. (Emergency stop using emergency) 4). The device is equipped with a security alarm door, and the device automatically stops running when it is turned on. Kindly reminds you to read the instruction manual before operating the equipment. (Nonoperators must not operate this equipment)

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5. Technical Specification MACHINE TYPE

:

Rotating OPP Hot Melt Labelling Machine

MACHINE DIMENSION

:

3650mm x 1700mm x 2010mm

METHOD OF SPEED ADJUSTMENT

:

Uninterrupted – Adjust Rate

LABEL TYPE

:

BOPP, Paper-Plastic Composite Film, Paper Label

LABELLING STATION

:

12 per cycle

LABELLING SPEED

:

10000 – 12000 BPH

LABELLING ACCURACY :

±3mm

MAX LABEL WIDTH

:

200mm (standard width, can be adjusted)

MAX OUTER DIA. OF LABEL

:

600mm

PAPER CORE HOT MELT

:

152mm

LABELLING GLUE

:

Glue at both ends of each label with hot melt

GLUING TEMP.

:

120 ~ 160 C

PRODUCT TYPE

:

Round or square container made of plastic, metal & glass

AIR SUPPLY

:

5-6 bar / 72-88 psi

POWER SUPPLY

:

380V/60Hz/5000W, 3 phase

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Introduction to mechanical specifications:

1. Physical Dimension: 2700 x 1900 x 2100 cm. 2. Applicable Specifications 1. Number of rotating heads; 8 heads 2. Bottle type requirements; round, square, rectangular 3. Into the bottle direction; left into the right 4. Production Speed; 30-200 Bottles / Minute (According To The Bottle Type) 5. Voltage requirements; 380v, three-phase five-wire 6. Host power; 10kw 7. Label height; 5-190mm (up to the bottom of the bottle) 8. Cans diameter; 40-110mm 9. Label material; OPP, Composite Film, Pearl Film, Laser Film Anti-Counterfeiting Film.

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7. Mechanical power distribution 1. main motor power 2.2KW 2. fan power 1.5KW 3. delivery standard servo motor power 0.75KW 4. glue pump motor 90W 5. rack motor 180W (single rack) 8. Heating power distribution 1. Hot Melt Machine: 1.2KW 2. Spray Strip:100W 3. Rubber Roller 500W

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6.Machine Layout and Drawing 1. Overall layout

Label

Cutter Motor for Star Wheel

Infeed

Outfeed

Bottle Screw

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1. Enter the label method:

Cutter mechanism

Marking Station

Correction system

Tray 1

Note: The label has a diameter of 500mm, the inner diameter of the paper

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Replace the following changes according to different bottle types;

Replacement order : 1. Bottle Screw 2. Bottle Straight Plate (can be shared when the bottle position is close) 3. Star Wheel Guide Guard 4. Bottle Star Wheel 5. Out Of The Bottle Star Wheel 6. Bottles Of Drag 7. Stop Bottle Small Star Wheel 8. Labeling Vacuum Drum (multiple use according to the bottle type) 9. Labeling Brush 10. Gland Head (caps diameter, different shape, need to be replaced) replacement order

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1. Introduction to compressed air use

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2. Introduction to compressed air use

Cutter adjustment method; Position 1; fixed blade Position 2; static knife adjustment screw Position 3; disc-shaped shrapnel pressure is fast (locked) Position 4; static knife integral stroke adjustment screw No. 5 position; cutter roller negative pressure regulating valve 1). The first step is to tighten the fixing screw of the No. 1 position to a semi-elastic state, and then use the three adjustment screws of the stationary knife No. 2 position to push the pusher out. Note that the blade cannot touch the cutter roll and observe the 11

upper and lower gaps. It is about 1-2mm (the upper and lower gaps are basically the same). Finally, push the three adjustment screws back about 5mm. 2). In the second step, click the jog button on the operation panel and turn it slowly to make the rotary blade hit the stationary blade. At this time, the stationary knife will retreat as a whole, and after the rotating knife collides, the operation will stop. Then, tighten the No. 1 position platen screw. 3). The third step is to enter the control interface, click the Open

button to keep the device running. Then fine-tune the stationary knife stroke control screw counterclockwise. Listen to the knife collision sound. If there is a collision sound, click the

Open if the label can be cut.

button to feed the label into the cutter roll to see

The Problem that will appear when trying to cut the label is: A If the label has a uniform cutter mark but there is no cut, then the counter-clockwise fine adjustment of the No. 4 position stationary knife stroke control screw. Then divide the middle and lower sections to test the label, and observe that the label can be cut off. B If there is a knife mark above the label, there is no underneath. Then loosen the platen screw to a semi-tight state and finely adjust the bottom of the stationary knife. Conversely, if there is a knife mark under the label and there is no upper part, fine-tune the top of the stationary knife. Lock the blade screw and repeat the test until the label is cut. Note: Use the auxiliary blow pipe to blow the front end of the label attached to the cutter roll when the cutter roll is running at a certain position. (Blowing size can be adjusted according to usage)

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2. Rubber roller mechanism adjustment

1. As shown above; loosen the fixing screw at position 5 of the spray strip, adjust the vertical adhesion of the strip and the applicator roller, and then tighten the screw. 2. As shown above; the No. 2 position resistive U-shaped groove can control the amount of glue. 3. As shown above; the No. 1 position rubber strip prevents the glue from going up. 4. As shown above; the heating tube and the temperature sensing rod at position 3. 5. As shown above; the position of the 4th position scrapes the brass fast.

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1. As shown above; the rubberizing amount of the adjustment screw, adjust the fit of the spray strip and the rubberized roller to control the amount of glue on the surface of the rubberized roller. 2. Open the opening and closing handle to disengage the spray strip from the applicator roll. If it is turned into the label, it can be opened for cleaning. 3. Glue stroke adjustment cylinder is to adjust the distance between the rubber roller and the suction drum, and apply glue to the front and rear ends of the label.

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6. Labeling suction drum adjustment

1. In the first step, loosen the 6 M6 screws of the 2nd position tensioner, and the second part loosens the 2 positioning screws at the 1st position. At this time, the labeling drum can be rotated back and forth. In the third step, the labeling drum rear projection is moved to a position of about 1 mm behind the rotary blade as shown in the figure above, and the position 2 screw is fixed. The fourth step is to observe whether the labeling position of the labeling drum is suitable. When the labeling is performed, the label is basically flush with the front boss, and the rear end covers the tail end by about 1.5 mm.

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7. Indenter and bottle drag adjustment

1 As shown above; the head is adjusted perpendicularly to the center of the bottle. The first step is to prepare 1-2 two bottles. In the second step, loosen the 6 fixing screws above the rotating head. The third step is to rotate the head by hand to find the approximate position. The fourth step is to put the bottle into the bottle, the pressure head is lowered to press the bottle cap, and then fine-tuned.

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8. Into the bottle star wheel and bottle drag adjustment

1 Remove the 3 adjustment screws and remove the screws in the first step.

The second step is to rotate the star wheel so that the center of the star wheel is aligned with the center of the bottle, and the screws are pre-tensioned. It can be put into the bottle and watch the bottle smoothly and completely into the bottle. nine. 1 .screw and bottle star wheel adjustment.

1.1 When the bottle is replaced, the diameter changes. When adjusting the screw clamp bottle tightness, loosen the screw parallel adjustment screw, and rotate the stroke to open and close the handle to slightly clamp the bottle. (Note that the screw outlet face should be parallel to the star wheel guard inlet) 1.2 When disassembling, open the disassembly and opening handle and pull it outward. After loosening and removing the cantilever screw, pull out and the screw can be replaced.

2 .screw and bottle star wheel adjustment. 17

2.1 After the adjustment of the bottle star wheel and bottle drag is completed, the position of the screw and the star wheel can be adjusted. 2.2 Loosen the 2 adjustment stop screws to rotate the screw. Place a bottle in the screw. Slow jog operation When the bottle comes out of the screw, enter the star wheel, as shown above. 2.3 Jog operation, smooth bottle into the bottle, squeeze the bottle. 10. Labeling drum and bottle adjustment

1 the jog operation first makes the main shaft, the indenter, and the drum shaft three points basically in a straight line. 2 Turn the small machine power adjustment screw clockwise. At this time, the drum should be turned clockwise to make the other three points on the front strip into one line.

3 First adjust the small machine lift, so that the front strip is in the middle of the bottle labeling position. Then adjust the mobile small machine so that the front strip is in

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contact with the bottle.

11. Small drilling crew

As shown above; 1 small machine lift is used to adjust the bottle labeling position, when changing the height of the bottle type labeling position is used. 2 When the small machine moves forward and backward for labeling, the front drum of the labeling drum is in contact with the bottle, and the label can be taken away when rotated.

Chapter 3 Introduction to the Operation Panel ------

1. As shown above: Introduction to temperature controller 1 glue roller 2 glue machine 3 spray strip 4 cutter roller

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Set the temperature range: 1 rubber roller (150-200) depends on the ambient temperature, and hot melt adhesive. 2 glue machine (140-160) 3 spray strip (100-120) 4 cutter roller (30-50) The above temperature settings are based on actual conditions.

A jog button; for manual operation, handling mechanical problems, observing equipment operation. Click on the device to move it. Keep pressing and not releasing, the device will keep turning. It depends on how the operator operates. B Manual bidding; for manual operation, when the equipment is running (no longer automatically), press the manual bid to send a label. If you keep pressing it, you will always send the mark. It depends on how the operator operates. C color indicator light; used to observe whether the color code sensor works normally when the device is running the label. D glue roller indicator; used to observe whether the glue roller is working properly when the equipment is running and labeling. E Emergency stop button; used when an emergency stop occurs when there is a problem with the device. F power button; the indicator will light when turned on, indicating that the device is powered. G speed control knob; when the device is running and labeling, turn on the button. When the high-speed start sensor in front of the bottle detects that there is a bottle and the device maintains the high-speed operation labeling state, the production speed can be adjusted by the speed control knob. It cannot be adjusted at low speed.

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8. Operation 1. Operation screen introduction

1）

Device low speed start button.

2）

Melter start switch.

3） 4）

Control vacuum motor operation button Control the glue coating roller glue signal, apply the glue when the label is detected after opening, and the glue roller does not work after closing.

5） Control the feeding motor to run automatically. When the device is running after opening, the bottle sensor detects that there is a bottle and starts to send the label. After closing, it will not send the label. 6） 7）

8）

9） 10）

Stop mechanism switch button Control device high speed, low speed operation button

Adjust the pressure tightness between the indenter and the bottle. Turn on the maintenance light Click the parameter button to enter the parameter

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As shown above; 4 types of bottle type, corresponding to 4 different parameters, the internal parameters of the bottle type have been adjusted according to the user before leaving the factory. When replacing the bottle type, select the selection page as shown below

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1. Press and hold the button to confirm the parameter and enter the bottle type replacement prompt interface (as shown below).

Click

the button parameter to select the replacement.

4. Parameter modification page

5. The default values generated as shown above are as follows

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6. According to the actual label length, you need to adjust the following

parameters;

7.

Adjust the position of the label color punctuation

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Introduction of Sensors and Limit Switches of Various Parts of the Equipment 1. KEYENCE Keyence PZ-G42N sensor introduction Figure: As shown in Figure F, the PZ-G42N sensor has two control modes; 1) L into the light mode; the green light is always on, the red light is not on, when the bottle is turned off, the red light is on when the bottle is turned on, and the signal is output. 2) D non-light-in mode; red and green lights are always on, when the photoelectric switch shines on the passing bottle, the red light is off, and when the red light is on again, the signal is output. 3) MAX increases the detected signal strength and MIN attenuates the signal strength. (Adjusted according to the detected object)

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2. Panasonic Gods LX-101 sensor introduction Indicator light

Detection head

As shown in the figure; God sees LX-101 sensor two control modes; Note: Color code/color mode; according to different purposes, the COLOR item of NAVI mode should be used to set the color code/color mode before debugging settings. Color mark mode Detects the amount of light in the light receiving part of the illuminator Color mode Detects based on the color ratio of the detected object and is used to detect special colors

1） The start state RUN shows a light green light, press

the button three

times, the yellow light points to the COLOR position.

2） Used

to select mode

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3） Press

the

button three times to return to the start state. (The above

is the mode debugging option)

One; after selecting the color mode, press to TEACH

1) Move the label and press the button once for color will always blink.

the key once, the yellow light points

the detection point. The yellow

2) Move the label and press the key once to the darker position outside the detection point, waiting for the light green light to illuminate, and the setting is completed.

3) Pulling the label back and forth When the detection point passes the detection head, the orange indicator will flash once, and the sensor is set successfully. Second; after selecting the color code mode, press to TEACH

the key once, the yellow light points

1) Move the label and press the button once for the detection point, wait for the green light to illuminate and the setting is completed. 2) Pull the label back and forth. When the detection point passes the detection head, the orange indicator will flash once, and the sensor is set successfully. Note: The sensor detects a complete label. The detection point can only appear once from beginning to end. There can be no other colors like the color point in the middle.

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Equipment Operation Instructions 1.1 Boot operation precautions 1). Check compressed air (pressure is maintained at 0.4MPa-0.6MPa) 2). When turning on the power, you must wait for 40-50 minutes, and wait for the temperature of the heating part to reach the set value before starting the device. 3). Check if the hot melt machine needs to add glue. 4). Check if the marking direction is correct. 5). Check if there is a label in the rubber backing tank to block the rubber back hole, so as to prevent the glue from being unsmooth and blocked. 1.2 Operation process 1). Start the power switch, wait for 40-60 minutes, open the compressed air valve (the air pressure is kept above 0.4MPa), and then turn on the equipment normally after the above preparation is completed.

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Chapter 7 Causes and Treatment of Mechanical Failures 1.1 Incoming bottle star wheel abnormality: When the equipment encounters the inverted bottle, the star wheel is stuck and the torque limiter bounces. When the limit switch X16 detects the signal, the alarm is triggered and the main unit stops running. The touch screen will display “Incoming star wheel abnormality .. ”, and then rotate the star wheel to reset the torque limiter.

Click the button to eliminate the alarm. (The bottle star wheel alarm is the same as above)

1 into the bottle star wheel proximity switch, signal point X16 2 out of the bottle star wheel proximity switch, signal point X27

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3 bottle screw proximity switch, signal point X15

1.2 Host exception: 1 equipment running card bottle serious case 2 In the case of improper operation of the card cutter, the torque limiter under the cutter bounces, and when the proximity switch X17 detects the signal, an alarm is triggered.

Disposal method; loosen the fixing screw at No. 1 counterclockwise, then adjust the screw at the No. 2 clockwise, press the jog button to operate the machine.

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Note: If the device is running repeatedly, the host abnormal alarm occurs several times, that is, the torque limiter above the main motor is too loose, need to be tightened, turn clockwise and adjust counterclockwise. It can be bounced when it is transferred to the card cutter, and it will not be bounced during operation. 1.3 Broken label: Before the labeling process, the label is disconnected, or the label is used up, triggering an alarm. Replace the finishing path and click

the button to eliminate the alarm.

1.4 Material rack shortage: When the X12, X13 rack sensor detects that the label is running out, the device goes from high speed to low speed, and the yellow indicator alarms.

1.5 high and low speed did not respond:The reasons are: 1 high speed switch is not open 2 high-speed start sensor X23 detection signal instability 3 back end betting bottle high speed off sensor X26 always has a signal 4 lack of material X12 or X13 alarm 5 sensor damage Treatment: Check one item for exclusion. 1 turn on the high and low speed control switch 2 check the high speed start sensor X23 to always have a signal 3 check the high speed off sensor X26 has no signal 4 Install the entire roll of labels so that the X12 and X13 remain signaled. 5 replacement sensor

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1.6 Stop bottle out of control:

1.The reasons are as follows: 1 The feed switch is not turned on. 2. Stop Bottle Release Sensor X24 And Gate Close Sensor X25 Detection Signal Is Unstable 3 Block Solenoid Valve Y5 Is Damaged Treatment: Check one item for exclusion. 1 open the feed switch 2 re-adjust the sensor signal 3 replacement solenoid valve 1.7 The cutting length error is greater than 2mm:

The reasons are: 1 label length setting is incorrect 2 The initial displacement value is set to be biased 3 label tension is too large 4 labeling drum superscript position is too large Approach: 1 set the correct label length 2 adjust the initial displacement value 3 replacement label 4 adjust the valve to reduce the negative pressure 1.8 color punctuation position is wrong: The reasons are: 1 label length setting is incorrect The 2-color sensor X3 detects that the signal is unstable. 3 labeling drum suction is too large, pull the standard. Approach: 1 set the correct label length plus 1mm 2 adjust the color sensor from the new 3 Adjust the cut point displacement value parameter each time the cut color point is at the same position

4 As shown below: In the case of the same length of the label, after changing the parameters, manually cut 3-5 labels, observe the change of the black point position of the label, and adjust to the position we want. 32

1.9 There is a deviation between the front and rear positions of the vacuum drum on the label: The reasons are: 1) the label tension is too large and the single label is not flat 2) labeling drum and cutter roll negative pressure adjustment is improper 3) Auxiliary blowing air volume is too large Adjustment method: i) Replacement label ii) Adjust the negative pressure valve to the applicable pressure iii) Reduce the amount of blowing air

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2.0 Uneven coating: The reasons are as follows: 1) 2) 3) 4)

The glue machine is short of material and the amount of glue is not enough. Glued roller surface has label jam. Scraping rubber sheet wear deformation. Labeling drum boss strips wipe.

Deformation approach: 1) 2) 3) 4)

Add hot melt adhesive block. Clear surface label. Replacement of the scraper board. Replace the labeling drum boss strip.

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2.1 Turning the standard: The reasons are as follows: 1) When the glue is applied, the glue is pressed against the vacuum drum too tightly. 2) Labels are too much glue On the 3 label, the front end of the vacuum drum is behind. Approach: 1) Micro adjustment of the glue roller and vacuum drum spacing.

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1) 2)

fine-tuning the tight scraping rubber sheet Loosen the vacuum drum and adjust it counterclockwise. Lock and test several labels to observe.

2.2 labeling is not tight: The reasons are: 1 too little glue on the front end of the label 2 The front end labeling position is wrong. 3 labeling curved plate and vacuum drum clamp bottle too loose Approach: 1) Fine-tuning loose squeegee. 2) Adjust the position of the big star wheel into the bottle. 3) Adjust the tightness of the label bending plate and the vacuum drum bottle 3.1 Labeling misalignment error is large (normally within plus or minus 1.5): The reasons are as follows: 1) The unevenness of the whole roll of labels. 2) Auxiliary blowing air volume is too large. 3) Labeling the curved plate, the bottle and the vacuum drum are not adjusted vertically. 4) Bottle deformation bottom is not flat Approach:

1)

Requires label manufacturers to do quality.

2) Adjust the amount of auxiliary blowing. 3) Adjustment mechanism to make the label bending plate, the bottle and the vacuum drum vertical. 4) Remove the deformed bottle.

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3.2 Labeling misalignment in the same direction: Processing method Adjust the left and right tilt of the cutter mechanism, fine-tune the screw clockwise, the cutter mechanism will tilt to the left, and the front end of the vacuum drum on the label will increase. The opposite is true. (The labeling error is affected by the height of the label on the vacuum drum boss) 3.3 Early bidding or late bidding: The reason is that the bottle sensor X7 detects the bottle's elapsed time and affects the bidding time. Treatment method: adjust the position of the bottle sensor X7 to the right angle.

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3.4 Label Cuts Constantly: The reasons are: 1) Cutting knife wear. 2) The stationary knife screw is loose and not perpendicular to the rotary knife. 3)

Static launch is not enough distance.

Approach: 1) Replacement blade. 2) Adjust the verticality of the push knife and the rotary knife. 3) Counterclockwise fine adjustment to control the screw pushed out by the stationary knife.

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a. does not send the standard: The reasons are: 1 servoalarm 2 wiring loose 3 servo damage Approach: 1) Check the instructions and follow the instructions to deal with the problem. 2) check wiring 3) .replacement (maintenance) servo

Encoder adjustment 1) The encoder below the small machine does not need to be adjusted after the first adjustment is completed. (If you need to adjust the reason: there is an angle display on the touch screen. 1. When the angle is not displayed, the angle is not rotated by 360 degrees.) 2) Adjustment method; when the rotary knife and the stationary knife coincide, the angle can be adjusted to 230 degrees. 3.1 Electrical problems Please check the electrical drawings or contact the company after sales.

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2. Sensor and limit switch I/O meter

1 high-speed start sensor ----------------------- front-end has always been a high-speed operation of signal equipment 2 baffle release sensor ----------------------- The front end always has a signal stop bottle to open the supply bottle 3 bottle sensor ------------------------------ Check that there is a bottle into the start to send the mark 4 high-speed stop sensor ------------------------ back-end gambling bottle has been running signal equipment at low speed 5 baffle close sensor ---------------------- The back end bet bottle has a signal to close the stop bottle to stop the supply bottle 6 off-label sensor -------------------------------Detecting the label front-end label break stop device operation 7 rack sensor 1 ------------------------------ Detect the remaining label to stop high speed, alarm reminder to replace 8 rack sensor 2-----------------------------Detect the remaining label to stop high speed, alarm reminder to replace 9 color standard sensor ------------------------------ detection distinguishes the color point of the label 10 screw limit switch (located under the machine)--------------------- screw abnormal alarm when card 11 big star wheel limit switch (located under the machine)-------------------------big star wheel abnormal alarm when card 12 host limit switch (located under the machine) ------------------------ host abnormal alarm when card cutter

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PCL; I/O correspondence table

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9.Maintenance NOTE: A) During maintenance, be sure to turn power OFF B) Take special care not to mis-insert the Air Tube

GENERAL PRECAUTION Always keep the machine clean to prevent entry of dust or dirt. Carefully note dis- connector or poor contact, to be sure all Air Tubes are securely tightened. Ensure the electric power and air supply are OFF, when the machine is not operating.

PERIODICAL CHECK i)

Loose wiring, terminals and connectors

ii) Loose air tubes and connectors iii) Dust or dirt in ventilation holes iv) Panel compartment cleaning v) Panel surface cleaning vi) Air pressure reading vii) Electric supply voltage viii) System ERROR detection Alarm

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Maintenance Items Maintenance Content 1. Wipe the vacuum drum and the cutting blade daily with a clean cloth to keep it clean. 2.

For internal lubrication, add butter once a week (No. 0 lithium grease).

3. Remove the original oil with a clean soft cloth before applying the lubricant to the surface. 4.

Check all rotating belts for breaks or severe breakages in a timely manner.

5. Lubrication between the conveyor chain plate and the wearreducing strip shall be carried out to produce general products with lubricating oil or grease, to produce products with high food hygiene requirements, and to lubricate the conveyor chain plate and the wearreducing strip by means of circulating spray. 6. Check the amount of wear between the conveyor chain plate and the anti-friction strip after every 6 months of operation. If the wear is excessive, replace the anti-friction strip or the conveyor chain plate in time. Check the fixed state of the frequently disassembled parts every month, and whether the fittings are good, such as whether the screws are loose or not, and whether the bearings are loose. If the part is found to have rust spots, it should be immediately derusted, painted or rustproof. 7. Keep the surface of the machine clean and do not place other items on the machine. 8. If the glue machine is heated for more than 3 days for a long time, the hot melt adhesive will be carbonized and yellowish and black, and the new rubber block will be cleaned and replaced before production. 9. Power distribution boxes, motors, sensors and other electrical components are strictly prohibited from water or corrosive liquids. 10. The cable should not be placed close to wet or water and corrosive liquids to prevent premature aging of the cable insulation. 11. If you encounter difficulties during adjustment, repair or maintenance, please contact our customer service. 43

10.

Troubleshooting SYMPTOM

STOP switch no function

POSSIBLE CAUSE - STOP switch fault - PLC contact fault - PLC software interlocking - Wire open circuited -

Star Wheel stop frequently

-

Capper head not turning

START switch no function

Bottle get blocked on conveyor Overload protector is too loose Photoelectric sensor failure

-

Insufficient air supply

-

START switch fault PLC contact fault PLC software interlocking fault Wire open circuited

-

REMEDY -

Replace the switch Replace the PLC Restart power Reconnect wire

-

Adjust the bottles on conveyor Adjust the spring of overload protection to make it tight

-

Check the sensor, clean the optical head, as has been damaged is replaced.

-

Please set the air to 0.4-0.8 mpa

-

Replace the switch Replace the PLC Restart power Reconnect wire

44

11.

Spare Part List i)

Electrical and Mechanical

Item

Description

Model/ Part No

Qty

1 3 4 5 6 7 8 9 10

PLC Power Supply MCB MCB MCB Sensor HMI Servo Drive Inverter

Delta DVP40ES200R MEAN WELL EDR-120-24 Schneider 4 Pole 6A Schneider 1 Pole 10A 1 Pole 6A IFM203 FUJI TS1070i Delta ASD -A2-1021-B Danfoss VLT Micro Drive

1 1 1 3 2 1 1 1 2

45

12. Rotary OPP Hot Melt Labelling Diagram i)

Control Panel Layout

ii)

Schematic Diagram

46

0

1

2

3

4

5

6

7

8

9

A

EMEC Packaging Solutions Sdn Bhd PT 13532, Jalan Banting Pandamaran 42000 Pelabuhan Klang Selangor Darul Ehsan, Malaysia Tel No : +603 3168 6300 / +603 3165 1344 E-MAIL : [email protected] WEBSITE : WWW.EMEC-CORP.COM

B

(REG: 1213057-T)

Company / customer C

Project description

ROT OPP Hot Melt Labelling Machine BLOW MOULDING

Job number

Project name

BLOW MOULDING

Type

ROT OPP Hot Melt Labelling Machine

Place of installation D

Created on

18/7/2020

Edit date

21/7/2020

Number of pages

18

E

2 Date

18/7/2020

Edited By

WIN7

Approved By Revision Date of Revision

Reason of Modification

Approved Date

Project Name :

Project Description :

BLOW MOULDING

BLOW MOULDING

Company Name :

Page Description :

Job Number :

= CA1 + EAA

Remarks :

Page Page

1 1 / 18

0

1

2

3

4

5

6

7

8

9

A 200A

QF100

2.8:A /

L1

2.8:B /

L2

2.2:D /

L3

B

6

5

4

3

2

1

L1 / 2.2:A L2 / 2.2:B L3 /

2.2:D /

N

N / 6.0:B

2.2:D /

E

E / 9.1:B

1

3

5

FU1-3 16A

1

QF102 2

4

6

16A

2

C

13 1

2

COOLING FAN

5

TC1

1

6KVA 380V/200V

L3

N

E

2.2:B

2.2:B

2.2:B

3

4

M 1~

2

6

D

E

A

B

C

3.1:A

3.1:A

3.1:B

1

3 Date

20/7/2020

Edited By

WIN7

Approved By Revision Date of Revision

Reason of Modification

Approved Date

Project Name :

Project Description :

BLOW MOULDING

BLOW MOULDING

Company Name :

Page Description :

TRANSFORMER POWER SUPPLY

Job Number :

= CA1 + EAA

Remarks :

Page Page

2 2 / 18

0

1

2

3

4

5

6

7

8

9

A

2.4:E /

A

2.4:E /

B

2.5:E /

C

B 1

3

2

4

QF103 6A

PC1

L

C

PC3

PC4

PC5

/15.3:B

/14.3:B /16.3:B /17.3:B

N

FX5U-80MT

L1

PC2

16EYT

16EYT

4DA

4DA

PC6

PC7

4DA

4DA

N

TU1 200V

V+

V-

D

GS2110 GP1 +

5

4

4.2:B

9.0:E

-

E

2

4 Date

18/7/2020

Edited By

WIN7

Approved By Revision Date of Revision

Reason of Modification

Approved Date

Project Name :

Project Description :

BLOW MOULDING

BLOW MOULDING

Company Name :

Page Description :

POWER DISTRIBUTION

Job Number :

= CA1 + EAA

Remarks :

Page Page

3 3 / 18

0

1

2

3

4

5

6

7

8

9

A

4.8:A /

A

A / 4.0:A

4.8:A /

B

B / 4.0:A

4.8:B /

C

C / 4.0:B

B

1

3

3.2:E

9.1:E

9.3:E

4.8:B

5

Y0

Y4

0V

4.8:B

5

QF3

5

2

4

6

9.4:E

4.3:B

Y1

Y5

0V

4.3:B

QF4

C1

DICOM

OPC

PP

NP

DOCOM

CR

DICOM

OPC

PP

NP

DOCOM

CR

20

12

10

35

46

41

20

12

10

35

46

41

47

A2

CN1

VF1 MR-J3-E SERVO

CN1

AMPLIFIER CN1

U2 42

15

19

43

44

47

EMG

SON

RES

LSP

LSN DOCOM ALM

V2

W2

CN2

x1

D

RESET

ON

x2

X040 U2

FAULT

M 3

RIGHT LIMIT POSITION

STATION PROPULSION

W1

LEFT LIMIT POSITION

MOTOR 1.5KW

15

19

43

44

SON

RES

LSP

LSN DOCOM ALM

48

CODER EMERGENCY STOP

x2

V1

42 EMG

x1

CODER

U1

CN1

48

MOTOR 1.5KW CLAMPING SERVO

V2

W2

M 3

X041 FAULT

W1

CN2

RIGHT LIMIT POSITION

V1

C2

VF1 MR-J3-E SERVO

AMPLIFIER U1

B2

LEFT LIMIT POSITION

B1

/5.5:B 16A

6

RESET

4

ON

2

A1

C

3

9.1:E

5

EMERGENCY STOP

/5.1:B 16A

1

5.2:B

E

3

5 Date

20/7/2020

Edited By

WIN7

Approved By Revision Date of Revision

Reason of Modification

Approved Date

Project Name :

Project Description :

BLOW MOULDING

BLOW MOULDING

Company Name :

Page Description :

SERVO CIRCUIT 1

Job Number :

= CA1 + EAA

Remarks :

Page Page

4 4 / 18

0

1

2

3

4

5

6

7

8

9

A

5.8:A /

A

A / 5.0:A

5.8:A /

B

B / 5.0:A

5.8:B /

C

C / 5.0:B

B

1

3

4.7:B

9.2:E

9.4:E

5.8:B

5

Y2

Y6

0V

5.8:B

5

QF3

5

2

4

6

9.4:E

5.3:B

Y3

Y7

0V

5.3:B

QF4

C3

DICOM

OPC

PP

NP

DOCOM

CR

DICOM

OPC

PP

NP

DOCOM

CR

20

12

10

35

46

41

20

12

10

35

46

41

47

A3

CN1

VF1 MR-J3-E SERVO

CN1

AMPLIFIER CN1

U4 42

15

19

43

44

47

EMG

SON

RES

LSP

LSN DOCOM ALM

V4

W4

CN2

x1

D

RESET

ON

x2

X042 U4

FAULT

M 3

RIGHT LIMIT POSITION

STRETCH SERVO

W3

LEFT LIMIT POSITION

MOTOR 1.5KW

15

19

43

44

SON

RES

LSP

LSN DOCOM ALM

48

CODER EMERGENCY STOP

x2

V3

42 EMG

x1

CODER

U3

CN1

48

MOTOR 1.5KW FEED SERVO

V4

W4

M 3

X031 FAULT

W3

CN2

RIGHT LIMIT POSITION

V3

C3

VF1 MR-J3-E SERVO

AMPLIFIER U3

B3

LEFT LIMIT POSITION

B3

/4.5:B 10A

6

RESET

4

ON

2

A3

C

3

9.2:E

5

EMERGENCY STOP

/4.1:B 25A

1

9.0:E

E

4

6 Date

20/7/2020

Edited By

WIN7

Approved By Revision Date of Revision

Reason of Modification

Approved Date

Project Name :

Project Description :

BLOW MOULDING

BLOW MOULDING

Company Name :

Page Description :

SERVO CIRCUIT 2

Job Number :

= CA1 + EAA

Remarks :

Page Page

5 5 / 18

0

1

2

3

4

5

6

7

8

9

16A

QF5

A

6.8:A /

L11

6.8:A /

L21

6.8:B /

L31

2.8:B /

6

5

4

3

2

1

L11 / 6.0:A L21 / 6.0:A L31 / 6.0:B

N

N/

B

1

3

1

KM1 /10.8:E

C

2

4

1

5

/10.8:E

4

FR1 /11.5:B

3

1

KM2 2

4

1

5

/10.8:E

4

FR3 2

6

X44

/11.6:B

3

KM3 2

4

1

5

/10.9:E

4

FR4 2

6

/11.6:A

X46

1

3

2

4

1

5

20

2

6

X47

KM4

FR5 2

6

20

/11.6:B

D U6

M6 0.09KW/1A ROTATING CHAIN

V6

W6

M 3~

U8

M8 PE

2.2KW/4.8A BOTTLE COOLING

V8

W8

M 3~

U9

M9 PE

0.25KW/2A SUPERIOR EMBRYO

V9

W9

M 3~

U10

M10-1 PE

0.09KW/1A ORGANIZE EMBRYO

V10

W10

M 3~

U11

M10-2 PE

0.06KW/1A BOTTLE EMBRYO CULLING

V11

W11

M 3~ PE

E

5

7 Date

20/7/2020

Edited By

WIN7

Approved By Revision Date of Revision

Reason of Modification

Approved Date

Project Name :

Project Description :

BLOW MOULDING

BLOW MOULDING

Company Name :

Page Description :

MOTOR CIRCUIT

Job Number :

= CA1 + EAA

Remarks :

Page Page

6 6 / 18

0

1

2

3

4

5

6

7

8

9

A

7.9:A /

L11

L11 / 7.0:A

7.9:A /

L21

L21 / 7.0:A

7.9:B /

L31

L31 / 7.0:B

B 1

3

1

QF6 63A

3

1

QF7 2

63A

4

501

3

1

QF8 2

63A

4

502

3

1

QF9 2

63A

4

503

3

1

QF10 2

63A

4

504

3

1

QF11 2

63A

4

505

3

1

QF12 2

63A

4

506

3

QF13 2

63A

4

507

1

3

2

4

QF14 2

63A

4

508

509

C APR1

14.6:C /

A01+

A1(+)

A01-

A19(-)

14.6:C /

APR2

L1

14.6:C /

A02+

A1(+)

A02-

A19(-)

14.6:C /

T1

301

APR3

L1

14.6:D /

A03+

A1(+)

A03-

A19(-)

14.6:D /

T1

N1

302

APR4

L1

14.6:D /

T1

N1

303

A04+

A1(+)

A04-

A19(-)

14.6:D /

APR5

L1

15.6:C /

A05+

A1(+)

A05-

A19(-)

15.6:C /

T1

N1

304

APR6

L1

15.6:C /

T1

N1

305

A06+

A1(+)

A06-

A19(-)

15.6:C /

APR7

L1

15.6:D /

A07+

15.6:D /

N1

306

A1(+)

A07-

T1

APR8

L1

A19(-)

15.6:D /

A08+

A1(+)

A08-

A19(-)

15.6:D /

T1

N1

307

APR9

L1

16.6:C /

N1

308

A09+

A1(+)

A09-

A19(-)

16.6:C /

T1

L1

T1

N1

309

N1

D R11

R21

R31

R41

R51

R61

R71

R81

R91

R12

R22

R32

R42

R52

R62

R72

R82

R92

R13

R23

R33

R43

R53

R63

R73

R83

R93

R14

R24

R34

R44

R54

R64

R74

R84

R94

R15

R25

R35

R45

R55

R65

R75

R85

R95

E

6

8 Date

20/7/2020

Edited By

WIN7

Approved By Revision Date of Revision

Reason of Modification

Approved Date

Project Name :

Project Description :

BLOW MOULDING

BLOW MOULDING

Company Name :

Page Description :

HEATING CIRCUIT 1

Job Number :

= CA1 + EAA

Remarks :

Page Page

7 7 / 18