MATTRESSES WRAPPING MACHINE ME 105
Contents
1. F02 F03 A01 A02 A04 A20 A21 B83 C3 Acelerac Decelerac Referencia Mando Frecuencia Velocidad Velocidad Frecuencia terminal3 velocidad digital maxima VI portadora vac eoe 105 201 1 01 1250 0 8 412 V2 2 025 005 01 01 5 5 vo Or 380117 28977 1 7 9 is v4 Url 0 40 020 02 01 100 45 12 040 020 02 01 10 45 12 vo meo 0 40 040 02 01 50 25 12 V7 eee 040 040 02 o1 10 70 12 vg 2 040 040 02 01 100 25 70 12 02 VARIADOR PANASONIC VFO P01 POS P09 P15 Fr P32 22 P24 P64 Acc Decc F range Control Ref V Freq max Vel VO Vel V1 PWM PWMT Carrier vi a 1 5 10 V2 01 5 1 5 1 100 10 88895 002 001 5 1 51 11100110 v4 ves 002 5 35 10 vs 004 002 5 1 45 10 comer 004 004 FF 5 1 10 5 10 Vg eee 00 4 004 FF 5 1 10 23 75 10 va 004 004 FF 5 1 100 75 10 USER S MANUAL ME 105 36 WORLD BEAM QS18E Series Sets a threshold approximately 12 5 below the presented sensing condition see Figure 5 Any condition darker than the threshold causes the output2. SEAL BAR CENTER SEAL BAR CENTER CUTTER CENTER TOP BOTTOM a vsa D vs P BLOCK M1 SEAL BAR CENTER WHEELS M2 CUTTER CENTER RAMPS M2 SQ sam A ar BLOCK M2 SEAL BAR SIDE R CUTTER SIDER PRESS SIDE dt dt EA EX va P BLOCK M3 RIGHT SEAL BAR SIDE R CUTTER SIDER PRESS SIDE var eM vso VIII vai 21 E Y32 BLOCK M3 LEFT CLIENTE N2 de art culo Referencia Dise ado por Nombre de archivo Fecha Escala GLOBAL SYSTEM GROUP Merello Bolsas AYU 27 enero 2009 n d MERELLO ME105 MATTRESS WRAPPER MACHINE UN GOE NETE ROSSI IS E PNEUMATIC DISTRIBUTION 1 1 1 1 1 USER S MANUAL ME 105 29 Edici n L mina
3. Referencia Descripci n Cantidad al Interruptor magneto t rmico monof sico 6 A 1 2 3 Interruptor magneto t rmico monof sico 25 A 1 D Interruptor diferencial 2p 40A 30 mA 1 gl Interruptor general trif sico 2x40 A 1 fl fusible 010 25A 1 PLC Aut mata programable FPOR C32P 1 16 M dulo de salidas FPOR 2 1 cl c2 Contactor trif sico 24 VDC 25 A 2 1 2 Regulador 8000 W c potenci metro 500 Ohm 2 vl v7 Variador de frecuencia Mitsubishi FRA520S 0 4 KW 7 ml m7 Motoreductor trif sico 220 0 4KW i 20 7 FCO Fotoc lula autoreflexiva 70cm multitensi n 1 Fotoc lulas de barrera 5m multitensi n 1 2 Fotoc lula autoreflexiva 30 cm programable 1 D3 D4 Detector inductivo PNP 10 30VDC 2 S3 Detector inductivo SMC PNP 10 30VDC 1 55 Final carrera con rueda 1 51 2 4 6 7 Detector inductivo PNP 10 30VDC 4 ev20 32 Electrolv lvula neum tica 1 8 5 2 24 VDC 15 vent Electro ventilador con filtro 80 220 VAC 50 60Hz 1 1 tirador parada emergencia 1 2 pulsador parada emergencia 1 1 2 final carrera puerta NO 4 RS Rele de seguridad 24DC 1 USER S MANUAL 105 32 Mo __DESCRIPCON CABLE COLOR CAJA HIO 20NA HIO COMENTARIOS FCEL NUEVO X1 PUERTAM1 i X2 FCELTOPE X3 X4 AJUSTE X5 AJUSTE d X6 FCELCENTRAL X7 BARRA CENTRAL Micropulso ST X8 D BOBINA IN PU
4. FASE Plano ID Cant Descripci n 1 1 UCF205 16 Rodamiento tipo brida UCFL 205 1 2 UCP204 2 Rodamiento tipo puente UCP 204 1 3 1 1 Emisor fotoc lula Telemecanique XUK 2AKSNL2T 1 4 PPli 2 Puerta policarbonato humo 620x1120x8 1 5 BIS 4 Bisagra puerta polipropileno 1 6 FCBIS 2 Interruptor de seguridad Telemecanique XCSPL591 1 7 FCO 1 Detector fotoel ctrico Telemecanique XUK SAPANL2 1 8 PLACAI 2 Gu a de entrada inoxidable 1 9 BANDAI 1 Banda PVC NAB 10ELBV 2250X3115 1 10 UCPA206 4 Rodamiento tipo silleta UCPA 206 1 11 2 1 Motoreductor Bonfiglioli VF44 P1 20 P71 B14 B3 0 37KW 1 20 1 12 M1 4 5 3 Motoreductor Bonfiglioli VF44 P1 20 P71 B14 0 37KW 1 20 1 13 1 2 3 3 Electrov lvulas Univer 5 2 1 8 24 VDC 06250 1 14 CILO 2 Cilindro Univer ISO 32 80 D M fijaci n horquilla 1 15 1 1 Puerta policarbonato humo 620x1120x8 1 16 2 Cierre puerta bisagra ref 5608 1 17 1 1 Receptor fotoc lula barrera Telemecanique XUK 2APANL2R 1 18 GUBI 1 Gu a pl stico tubo acero 050 x 3050 1 19 RUIR 2 Rueda nylon acanalada 0200 1 20 D3 D4 2 Placa inoxidable detecci n medidas con inductivo 1 21 52 57 2 Tensor pl stico 212 con detector inductivo 1 22 RUL 8 Rodillo portabobinas 108 x 3050 1 23 2 1 Detector fotoel ctrico Telemecanique XUM SAPANL2 1 24 CIL1 1 Cilindro Univer ISO 32 160 D M fijaci n horquilla 2 1 PP2d 2 Puerta policarbo
5. lower upper roll conveyor ne3 conveyor n 2 roll w U v w u4 va wa us ws y Jus M7 w we uz vI M8 w TA U v7 v vb U v8 v 12 1 1 E 12 L1 12 adjustment 1 adjustment 2 adjustment 3 ES 5 2 8 8 lateral lateral lateral n u Ut 1 w u w u 4 v w v3 v v2 2v Ma M2 w va W4 viv L1 12 L1 2 L 12 2 413 EM 43 EM2 A 6 7 Li 3 CLIENTE N de art culo Referencia Disenado por Nombre de archivo Fecha M Merello Bolsas AYU 27 enero 2009 ME105 MATTRESS WRAPPER MACHINE Tus POWER DISTRIBUTION Edici n 1 L mina 5 4 1 Cajti 0 24VDC Caj3 Caj2 2 CLIENTE N de art culo Referencia GLOBAL SYSTEM GROUP Dise ado Nombre de archivo F M Merello Escala Bolsas AYU echa 27 enero 2009 n d ME 105 MATTRESS WRAPPER MACHINE A Edicion Lamina ELECTRICAL DISTRIBUTION pe SE _ ian L1 I H USER S MANUAL 31 LIST OF DE MATERIALS
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8. e SYNCHRONIZING WITH PREVIOUS LINES the green light Y42 on the control cabinet lights when the machine is ready to accept a new mattress e SYNCHRONIZING WITH FOLLOWING LINES the mattress will not leave the machine if the input signal XB remains ON MANUAL USUARIO ME 105 6 3 LOADING OF THE FILM AND STARTING UP Place a roll of polyethylene max 150 Kg on the upper pair of rollers and other one on the lower pair keeping the correct side for welding NOTE some printed rolls will not join by the printed face due to the chemical treatment received The same could occur with re enforcement rolls for the top or bottom of the mattress because they will be join for the both faces If this kind of problem appears please ask your film provider For the correct guidance of the film see the figure attached The film surface tension depends on the adjustment of the passing trough lever This adjustment is the same for every kind of mattress and must be carried out with the lightest to be wrapped In order to give more tension to the final bag you can operate over the extra advance time on the keyboard see chapter n 5 When change a roll it is necessary to make a seal along the upper and lower rolls Pull the film trough the guides by hand or acting over the plastic lever and press the key CENTRAL SEAL see chapter n 5 After these adjustments press the START STOP button to put the machine
9. MATTRESSES WRAPPING MACHINE ME 105 INSTALLATION USER AND MANTENIANCE MANUAL MANUAL USUARIO 105 NOTIFICATION OF CE MARKING The Manufacturer MERELLO Ingenieros S L c Horcajo 20 nave 23 PINTO 28320 MADRID SPAIN Declare that the product mattresses wrapper machine ME 105 s n 1400 Has been developed in accordance with the European Directive 98 37 CE 22nd June 1 998 and shows compliance with the Normative EN414 EN292 EN1050 EN945 EN418 and EN1088 when used as directed by the appropriate documentation Signed Miguel Merello Arvilla industrial engineer Madrid June 2013 MANUAL USUARIO ME 105 3 MANUAL USUARIO 105 1 GENERAL MACHINE DESCRIPTION The machine ME 105 wraps automatically every kind of mattresses springs latex foam from polyethylene rolls The machine provides advance of the mattress trough the film and adjusts itself to the appropriate measures The finished mattress is ready to be stocked The machine is compound by the following elements NES Kop Co 22 80x1 E 6 BOX 2 BOX h MODULE 3 MODULE 2 MODUL
10. when activated the ramps on the 2 module ascend before sealing to avoid the film to retract on the mattress advance Is useful for sticky film e BUTTON AUTO MANUAL select between automatic adapt to the measures of the mattress or to continuous feed ignoring the measures EXIT TIME value that the 3 conveyor moves to make the mattress leave e MAX PRESS M3 the first value shows the maximum number of teeth that the press will count before activate the seal even if it is not mattress detected Is only for sizing purposes the second number shows the number of teeth already counted and helps to calculate the first e TIME PRESS M1 time in tenth of seconds during which the wheels over conveyor in Module n 1 push on the mattress to assure the traction After this time the wheels to avoid a shock against the conveyor Aprox 10 20 e DELAY PRESS M2 time in tenth of seconds during which the wheels over conveyor in Module n 2 wait to push on the mattress to assure the traction This permit the mattress to start advance during wrapping Aprox 10 20 MINIMUM LENGTH maximum advance of the measuring bar in module n 1 to avoid it to shock against the conveyor The mattress will be wrapped even if is littler than this Aprox 250 MANUAL USUARIO ME 105 16 e ADV EXTRA M3 value added to advance of the mattress to arrive to module 3 A bigger value provokes the mattress to advance more The right value makes the mattress to stop i
11. STOP mode e Seal C make a seal on the central bar Seal L make a seal on the side bars Belts advance of conveyor n 2 y 3 Film retro of the film rollers Adv L advance of movable seal bar Adv 2 retro of movable seal bar The rest of the information on other screens show parameters that can be changed To change a value touch it directly Then a keyboard appears on the screen and let you write the new value press ENTER for finish If the value is not between the acceptable ranges the display will reject it DATA MENU TOTAL production e ALTERNATE BUTTON LAT CUT when activated the excess of film on lateral seals is trimmed during the seal cycle ALTERNATE BUTTON LAT SEAL when activated the seals on the 3 module lateral seals are made on each bag When deactivated the mattress leaves the machine directly from the first seal e ALTERNATE BUTTON PRESS M1 M2 M3 when activated the press on the 3 module descends to approach the edges of the mattress and increase the adjustment of the bag before sealing They can also be cancelled by the remote input X3 so e ALTERNATE BUTTON bef aft when BEFORE and PRESS M2 are activated the puller on the 2nd module release before seal to avoid wrinkles When AFTER and PRESS M2 are activated the wheels keep connected to ensure that the mattress is not catch by the sealing bar e BUTTON PARAMETER give access to the parameter menu see below e
12. change state the presented condition In Light Operate mode the presented condition is the Output OFF condition In Dark Operate mode the presented condition is the Output ON condition To change the Light Dark Operate setting see page 5 Darkest Single Most Light no signal Presented saturated Recommended for applications where only one condition is known for example a stable dark Condition signal background with varying lighter targets or when maximum excess gain is required Figure 6 Dark SET Light Operate shown lee Press and hold push button 2 4 seconds Single pulse remote line T Sensor waits for sensing condition Push Button Power LED OFF Output LED Slow flash 1 Hz Remote Line Power LED OFF Output LED Double flash Present sensing condition Five click push button Present sensing condition Five pulse remote line Power LED Flashes 3x then ON Green Output LED OFF then ON or OFF depending on output state Sensor returns to RUN mode with new settings Accepted Power LED OFF Output LED Slow flash 1 Hz Sensor returns to wait state ready for sensing condition Not Accepted Initial Output LED condition is simultaneous with Power LED 3 flash Banner Engineering Corp Minneapolis MN U S A 4 PIN 136564 rev www bannerengineering com
13. cuadro ST USER S MANUAL ME 105 USER S MANUAL 105 34 ss e es feweu ncn BEBO 11111111 51 16121114 81 44104811 feso mimo 1 su uonoeuoo uonoeuoo LEE TL TL I i jejs ET J 1 1 fuom Ig xoa 2121112172 poscere PEPE gt pam frete Fen Elia sapo oso Doo mera Ea pos poses ro pessoa s s e e zv 9992 ese efe D LT he 425 iS hod ave ao fefe funuo far 2 2 juom 21111118 11111 PL XO serv DEDO peo poe 7 os e efe fo onm 1 EE ESI ESI 9 fo pejor o OTE 50 Exprrs 515 5151515 nz n aaa po Popopopopopopopessee _ Peers PEIPER 222 4 HIMIVIS IEEE H3MO1 LANISVO 35 ME 105 USER S MANUAL VARIADOR OMROM JX
14. or more people The doors of the machine should remain closed When a door is opened the cycle stops and waits for the START STOP button The machine detects automatically the arrive of a new mattress and put the conveyor to move so therefore no objects must be put on it to avoid obstructs and accidents The cuts are made by blade which could cause injuries in hands and arms The operation of exchange must be realized protected with gloves The seals are achieved by heating The wrong use of the bars can cause burn on hands or arms 4 The machine is intended for wrapping mattresses The use for wrapping other kind of things can result in injuries or accidents MANUAL USUARIO ME 105 19 DEVICES 9 gt ss mau ma MC 50535 3ALLINGNI TIT TIS SOTIW XE MOSNIS MUNANI OTT T 3S SOTIW MN AN 20 ME 105 MANUAL USUARIO 89000 HOSNIS IA LINANI 8v39 Iuv3 3NISN3 LEVO HOSNIS X08339 2 YOAJANOI 2 TOT 7 3N SOT3M 00T Z IN SOTAIN 501 2 35 50131 TOI C 35 SOT3IN 201 2 35 SOT3IN 201 2 35 SO T3IN TOT T 3S SOTIIN 001 2 35 50134 21 105 MANUAL USUARIO 53553811 VN 55384 O0T E 3N SOT3IN 6 7 _ 22 105 MANUAL USUARIO 9 LIST OF MATERIALS
15. to change state In Light Operate mode the presented condition is the Output ON condition In Dark Operate mode the presented condition is the Output OFF condition To change the Light Dark Operate Single setting see page 5 Condition signal Recommended for applications where only one condition is known for example a stable light background with varying darker targets or in retroreflective applications Figure 5 Light SET Light Operate shown Press and hold push button 2 4 seconds Single pulse remote line T Sensor waits for sensing condition Push Button Power LED OFF Output LED Slow flash 1 Hz Remote Line Power LED OFF Output LED Double flash Present sensing condition Four click push button ttt a Present sensing condition Four pulse remote line Fr T TY T LIT Tt Power LED Flashes 3x then ON Green Output LED OFF then ON or OFF depending on output state Sensor returns to RUN mode with new settings Accepted Power LED OFF Output LED Slow flash 1 Hz Sensor returns to wait state ready for sensing condition Not Accepted Dark SET Sets a threshold approximately 12 5 above the presented sensing condition see Figure 6 Sensor positions E threshold 12 5 above Any condition lighter than the threshold causes the output to
16. 5 2 Gu a lineal HIWIN LGR15 con patines LGH15 3 8 9 PP3 4 Puerta policarbonato humo 910x880x8 3 10 PM3Z14 4 Engranaje Pi n M3 Z 14 3 11 CP3 2 Carcasa protecci n lateral lado cuchillas 3 12 CIL11 4 Cilindro Univer ISO 40 400 D M fijaci n horquilla 3 13 CIL7 4 Cilindro Univer ISO 40 320 D M fijaci n horquilla 3 14 UCPA206 4 Rodamiento tipo silleta UCPA 206 3 15 M6 1 Motoreductor Bonfiglioli VF44 P1 20 P71 B14 B3 0 37KW 1 20 3 16 55 1 Final de carrera electro mec nico rueda 045 MANUAL USUARIO ME 105 24 Plow de desdiere 2 Fose 26 ME 105 MANUAL USUARIO Piom de desdiere 3 Fose Embobadora de colchones 104 ME 105 MANUAL USUARIO BOX 1 MODULE 1 B 8 e uj 8 t D e bj gt O E CLIENTE N de art culo Referencia Nombre de archivo Fecha Escala Disenado por F GLOBAL SYSTEM GROUP M Merello Bolsas AYU 27 enero 2009 n d MER Q ME105 MATTRESS WRAPPER MACHINE INGENIEROS S L ER 222 ELECTRICAL DISTRIBUTION WF 1 EU es E BARRIER 1 WHEELS M1 BLOWERS M1 as gt TT BLOCK M1
17. E 1 Module n 1 Mattress In feed receive the mattress put it on position for wrapping and measures the length for adjust the corresponding sealing bars distance The machine detects a new mattress automatically and starts moving the in feed conveyor This module contains the upper and lower rolls of film For sincronice with in feed lines Y15 output is ON when the machine is ready Module n 2 middle sealing receive the enfold mattress from the previous module seals all along and separates the bag from the rolls cutting it by blade Module n 3 lateral sealing receive the wrapped mattress from the previous module seals both sides cut the waste of film by blade and give the mattress away Control cabinet keeps the electrical and electronic components that provide the control of the machine A screen allows the man machine dialogue input parameters and show error messages The position at modules 1 2 and 3 are measured by contact free devices that allow the machine to know the exact position at every moment as well as to move to the rigth position without reset The machine complies with safety requirements of CE as expressed on last chapter TECHNICAL DATA AERIAL NOISE 70 dB A WEIGHT MODULE 1 1 400 Kg WEIGHT MODULE 2 800 Kg WEIGHT MODULE 1 1 600 Kg MANUAL USUARIO ME 105 5 2 MACHINE INSTALATION Every element of the machine has its own adjustable legs that allow the installation in any surface Main j
18. ERTA M1 d libre SALIDA OCUPADA cuadro S DET BOBINA SUP 5 cuadro S SETA morado cuadro S libre cuadro S BARRA SOLDAR MEDIO o NAJN p w iN un gt w PUERTAS 2 caja3 DET RUEDA caja3 DET PRENSA caja3 CARRO PRESENTE r cuadro ST APILADOR ARRIBA cuadro ST COLCHON DENTRO cuadro ST BANNER PROGRAMABLE INDUCTIVO CILINDRO AUTORREFLECIVA BALLUFF OS uv jun a n p Y PWM AJUSTE2 cuadro MESA 1 MARCHA cuadro PWM AJUSTE3 cuadro AJUSTE1 ADEL 3 cuadro AJUSTE1 ATR S cuadro RODIL SUP ADEL cuadro RODIL SUP ATR S morado cuadro RODIL INF ADEL RODIL INF ATR MESA 2 MARCHA 4 5 6 MESA 2 RAPIDO cuadro MESA 3 MARCHA cuadro 7 8 9 termina en caja3 4 5 6 0 2 ADEL cuadro 4 2 3 AJUSTE2 ATR S cuadro AJUSTE3 ADEL morado cuadro 10 11 12 termina en caja3 1 2 3 AJUSTE3 ATRAS cuadro CERRAR BARRERA cajal d PRENSA M1 SOPLADOR M1 BAJAR CENTRO SUBIR CENTRO SUBIR CENTRO AB CORTAR CENTRO rado cajal d MESA2 RETRO cuadro Y28 PRENSA M2 Y29 SUBIR RAMPAS Y2A MOTOR PULLER Y2B BAJAR LADOS Y2C CORTAR LADOS Y2D BAJA PISONES SUBIR PISONES 5 APLICAR CALOR APLICAR CALOR L cuadro SEMAFORO VERDE cuadro S SEMAFORO ROJO r cuadro S SUBIR APILADOR cuadro ST ACTIVAR FRENO cuadro ST TOPE COLCHON morado cuadro ST BAJAR APILADOR
19. T HEAT CENTER time in tenth of second during which power is applied to the central MANUAL USUARIO ME 105 14 welding bar This value will be reduced by the temperature compensation system see below The amount of power can be regulated in the control cabinet Pl Valor aprox 25 50 NOTES gt The grosser the film is the higher this value must be Too high power values will reduce the Teflon covers life Too high values will increase the cycle time e T COLD CENTER time in tenth of second after heating during which the bar stay down to allow the film to solidify Aprox 10 40 e T HEAT LATS time in tenth of second during which power is applied to the lateral welding bar This value will be reduced by the temperature compensation system see below The amount of power can also be regulated in the control cabinet P2 Valor aprox 30 60 e WAITING CENTER time in tenth of seconds that the mattress is waiting for the bar of Module 2 to open Aprox 5 10 e WAITING SIDES time in tenth of seconds that the mattress is waiting for the bars of Module 3 to open Aprox 5 10 e TIME CUTTER CENTER the first value is the time in tenth of seconds that the central cutter will wait to activate aprox 5 The second the time during which the blade travel trough the film in the central bar to separate the bag After this time the blade will back to its position Aprox 20 30 TIME CUTTER S the first value is the time in tenth of seconds t
20. Tel 763 544 3164 USER S MANUAL ME 105 37 3 JAY dA OLNIININILNVIN NOIOVTVISNI NOIVOISINENT SVZ3ld ONNLHVM 141 8 ONNHIINHOS ILSITUILZIVSHA N3lL3H1N3 NOLLVTIVLSNI NOLLVOIIHANT S33H9V13G 84944 SAG 31511 3ONVN31NIVIN NOLLVTTVLSNI NOILVIIHANT 1511 SLHVd 3HVdS NOIZNILNNVIN 3NOIZVTTVISNI INOIZ OISINVOIN IG LLHVd WISIN INOLLAGIY TIOITDLINOS 38 ME 105 USER S MANUAL 01 28 02 2 2 10 118681 2 08 01 8 6 2 55 04 2 55 06 2 00 08 110 9 2 61 01 Es A 39 t9uSuel p utor 5129510 gnuo ip mouy 91 89 09 6 89 0b 61 88 06 8 19 82 8 92 01 1 8009 80091 9009 80091 0009 81 28 02 21 29 02 11 88 81 6 08 01 9 6N13 9069 9009 2029 0029 809 51 25 02 e 6 06 01 172218 ei esgova 2069 1089 0029 809 6 06 18 ER sjuowojnoy sBuueag maujasng el OL Oc LL 8 Gl vi 9 L v 22 8 l Le 9c ME 105 USER S MANUAL jaded ue ajsa ep seujbpd eu pionipab saidedyy jne 15 e A ojuerquie jap sewajqosd 50 3 juep eddrug eig VA uoo vs anos eqneiuas
21. ct bag TERMICAL ADJUSTMENT OF THE SEALS By varying the sealing parameters the machine can join any kind of film The criterion depends on the final goal higher speed A power Y time heating V time cooling Jess electrical energy more duration of covers power time heating more esthetic seals A time cooling thicker film V power time heating time cooling very inelastic film Y time cooling A time waiting ADJUSTMENT OF THE BAG The final adjustment of the bag to the mattress depends on several points how long the mattress advance over the central seal bar how strech is the film during the tie up The fastest way to change the bag adjustment is by acting on the first point directly on the keyboard In the line EXTRA ADVANCE change the value cents of second that the mattress will advance over the seal bar Note that a too low value can provoke the mattress to be catch by the bar The stretch of the film must be between two limits no too high because can broke the join at one or both sides and no too loose because can present unwinding problems Note that the stretch is a combination of the position of the lever the relative speed of the film respect to the advance of the mattress adjustable by inverter and the relative speed of the film respect to the bar when moves down For initial adjustment keep the speed of the rolls as similar as posible to the advance of mattress watch the lever angle to stabi
22. e mattress being in feed WITH OUT WHEELS 1 select whether or not the wheels on the 1 module are going to work The wheels are intended to catch the mattress against the conveyor for assure the advance trough the machine WITH OUT WHEELS M2 idem for second module BEFORE LATER ACT WHEELS M2 select when the wheels on the second module must be deactivated BEFORE the welding bar means more adjusted bags and less wrinkles AFTER the welding bar can be necessary with very light mattresses WITH OUT SEAL SIDES select whether or not the up and down sides of the mattress are going to be sealed Normally they must to be but in special cases rolling bags foam they must to be opened The machine controls the sealing temperature by software The program on the machine has a temperature simulator that compensate the accumulative heat when is used a high rates This value increases proportionally during welding and decreases exponentially the rest of the time At any time the heating time programmed is reduced in function of the value of this simulation avoiding the raise of the temperature on bars By pressing the EMERGENCY STOP or pulling the EMERGENCY WIRE the energy is removed from the actuators every movements of the machine are cancelled and the machine status is moved to STOP After release it the energy appears again but the machine remain MANUAL USUARIO ME 105 9 stopped until START STOP button is pressed Then the cycle will
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24. hat the lateral cutter will wait to activate aprox 5 The second the time during which the blade travel trough the film in the side bars to separate the rest of film After this time the blade will back to its position Aprox 20 30 e XTRA ADVANCE time in cents of second while the mattress stays advancing over the central welding bar after the photocell detects it A higher value induces bigger advance before soldering and the bag will be looser Aprox values 0 5 3 0 T RETRO ROLLER time in tenths of second while the film rewind the excess of film after the mattress pass over the central welding bar A low value induces shorter movement before soldering and the bag will be looser Aprox values 0 0 1 5 e T RETRO BELT time in tenths of second while the mattress moves backwards after pass over the central welding bar A low can give an excess of film over the next mattress Aprox values 0 0 1 5 e PRESS M3 advance of the press in Module n 3 over the mattress to approach their sides After this advance the welding bar descends to make the seal Aprox 7 12 MANUAL USUARIO ME 105 15 PARAMETER MENU M e BUTTON UNSTICK provokes the machine to make a small movement of the rollers in order to unstuck the film for the next mattress e BUTTON STACKER provokes the machine to use the output stacker when available The button besides will make the machine stop when there is no chart or not BUTTON RAMPS
25. lizate and adjust the speed of the arm to the desired stretch The position of the central seal can be moved by changing one of the film stretch LONGITUDINAL ADJUSTMENT OF THE BAG When wrapping mattresses thicker than 10 cm the press compresses its top and bottom in order to approach the border before sealing leaving a better adjusted bag On depending on the kind of film and mattress to achieve this could be easier by keeping some distance between the mattress and the sealing bar This adjustment is made by fix side move the fix end on the module n 1 in order to approach or separate the mattress movable side change the data on the keyboard called LATERAL ADJUSTMENT bigger values provoke bigger separation or move the end detectors SPECIAL ADJUSTMENT WHEN USING BOOT SYSTEM In order to keep the same strenght on every roll is very recommendable to reduce the rolls speed a little This way the coneyor will help for unwinding the rolls avoiding different speeds Also the parameter Time retro roller can be increased with the same purpose MANUAL USUARIO ME 105 12 7 TOUCH SCREEN The touch screen is placed on front of the electrical cabinet and it allows the following functions e shows error and status messages e introduce different working modes e introduce control parameter e activate elements of the machine PASSWORD to operate other than the main screen a password will be requested There are 2 different pa
26. n the beginning of the module n 3 Aprox 0 00 3 00 BIGGER SMALLER acceptable error on the position of adjustment respect to the previous module Aprox 40 40 e BLOWER is the delay in tenth of seconds for the blowers in to be activated to help removing wrinkles Aprox 0 20 BLOWER M3 time in tenth of seconds during which the blower in M3 is activated to help removing waste Aprox 10 20 GAIN value center and sides that decreases the simulated temperature while not heating It is apply each two seconds subtracting a division of the value Temp value from the simulated temperature Aprox 8 15 e GAIN M value center and sides that multiply the distance when the adjustment moves to reach the measure on the previous module Aprox 8 15 TOTAL PRODUCTION shows the number of units processed by the machine from the first day to now MANUAL USUARIO ME 105 17 TEST MENU Give access to every output on the PLC for monitoring and modify some of them need to put the PLC in STOP mode to be accepted Useful for maintenance actions Also allow to change the language of the screen and messages AV AJ provokes the advance of the adjustment for initial setting RE AJ provokes the return of the adjustment for initial setting STACK provokes a cycle of the stacker when available MANUAL USUARIO 105 18 8 INSTRUCTIONS FOR SAFETY The load of the rolls is dangerous and need two
27. nato humo 765x880x8 2 2 CIL4 2 Cilindro Univer ISO 40 320 D M fijaci n horquilla 2 4 21 1 protecci n lado cuchillas 2 7 CP22 1 protecci n lado bornero 2 8 CIL3 2 Cilindro Univer ISO 63 400 D M fijaci n horquilla 2 9 CIL6 2 Cilindro Univer ISO 25 50 fijaci n horquilla 2 10 53 1 Detector inductivo Univer 15 63 2 11 PP2t 2 Puerta policarbonato humo 865x880x8 2 12 FCBIS 4 Interruptor de seguridad Telemecanique XCSPL591 XCSPL71 2 13 M7 1 Motoreductor Bonfiglioli VF44 P1 20 P71 B14 B3 0 37KW 1 20 2 14 ESET 4 Bornero baquelita terminal resistencia 2 15 NICR408 6 ResistenciaNiCr 4x0 8 1m 2 16 CELO2010 6 Tira de Celotex ranurada 20x10 1m 2 17 2010 6 Tira de autoadhesivo 20x10 Im 2 18 BL 1 Cuchilla trapezoidal 2 19 PBL 1 Portacuchillas 2 20 CILS 1 Cilindro sin v stago Univer 16x3050 S1004163050 2 21 BANDA2 1 Banda PVC NSL 10ELAV 2250 3115 2 22 RU2L 2 Rueda nylon 0200 2 23 UCPA206 4 Rodamiento tipo silleta UCPA 206 2 24 UCFL205 4 Rodamiento tipo brida UCFL 205 3 1 PLACA3F 1 Rampa fija inoxidable 3 2 PRT 2 Plancha poliuretano recoge retales 3 3 BANDA3 1 Banda PVC NSL 10ELAV 2250X4035 4635 p EXTRA WIDE 3 4 PLACA3M 1 Rampa movil inoxidable MANUAL USUARIO ME 105 23 3 5 M3 1 Motoreductor Bonfiglioli VF44 P1 20 P71 B14 B3 0 37KW 1 20 3 6 54 1 Detector inductivo RESCHNER 12 4mm 30VDC 3 7 LGRI
28. ob during installation consists on leveling the machine and couple the different modules For this it is recommendable a burble level For electrical connections each module has cables to connect directly to the control cabinet and between them For more information see the scheme at the end of the manual The machine spends about 4 KW two phases electrical energy 220 VAC while seals and about 40 l min of dry clean compressed air at 6 bar INSTALLATION PROCEDURE 1 allocate the module n 1 on its final position and level 2 allocate the module n 2 besides the n 1 Put it to level and align both 3 bring the module n 3 near the n 2 leaving m of free space between both 4 connect cables C23 and C32 to box 3 following scheme attached 5 install the waste ramps 6 install the sealing bars 7 move the module n 3 to its final position besides n 2 Put it to level and align both 8 install the fix and the movable ascending ramps 9 install the lateral guards 10 install and plug the EMERGENCY WIRE 11 connect cables C2 and C3 to the control cabinet following the schemes attached 12 put the machine under voltage 220 VAC Don t forget the frame ground to earth 13 introduce a mattress and effectuate a complete cycle without film Verify everything works 14 put the upper and lower reels of film see section 3 and make a join between them 15 introduce a mattress See section 6 for fine adjustment
29. ready to work Please note that the machine will not work while any of the doors stay opened or the emergency stop is pressed The screen and lights will indicate this situation MANUAL USUARIO ME 105 7 ME 105 PLASTIC FILM INSTALLATION MANUAL USUARIO ME 105 8 4 CYCLE OF THE MACHINE As a safety measure CE the machine won t be ready to work after turn it ON until the START STOP button is pressed After this the green light on this button will remain ON and the machine will work while ON until a new acting over the button will be executed or an alarm will occur By pressing the START STOP button twice the machine will perform a step by step cycle which allows analyzing or introducing adjustments When the machine is turned OFF it loses any information about the actual cycle Due to that after turn it ON you should verify that there are not half wrapped mattresses on any of the modules The machine can vary between different working modes that can be selected on the screen and act in the following ways WITH OUT PRESS M93 select whether or not the press on the 3 module is going to work This press is intended to approach the borders of the mattress and increase the adjustment of the bag A special input X 3 is also provided for remote exchange of the press estate and can be wired from 24Vdc direct to the PLC When activated the second Xtra advance is applied instead of the first and the press is annulated for th
30. resume to the previous point first it s necessary to remove the causes of the problem and realize if the mattress need to be re introduced In this case the best is turn the machine OFF an the ON to start to work from the beginning By open any of the doors every movements of the machine are cancelled and the machine status is moved to STOP After close it the machine remain stopped until START STOP button is pressed Then the cycle will resume to the previous point The meanings of the lights are Green light the machine will accept a new mattress to wrap Yellow light blinking the machine is working at any point e Yellow light steady the machine has been stopped by the green button in the middle of a cycle e Red light blinking emergency stop is pressed or emergency wire is pulled or a door is opened or an alarm has occurred The screen shows the status e Red light steady emergency has been eliminated but the machine is not working until START STOP will be press ADJUSTMENT OF THE MEASUREMENT SYSTEM Every module on the machine has its own length measurement system which allows independent movement By means of this the new mattress can pass to next module even if the previous has a different length The measure system has a device that communicates the position to the PLC in analog 0 10VDC values If any car is out of position the value will be wrong and the machine won t work issuing an ERROR MEASURES message To rese
31. sswords that give access to 2 different levels 0000 allows access to the first DATA screen with frequent used parameters Value 1111 or 2222 allows to access to all the screens DATA PARAMETER and TEST The main screen shows the status message After an alarm occurs the message line explains the alarm that occurs The messages are Emergency stop even after it s been released Door opened even after it s been closed Inicializing while moving the machine to the initial position Ready the machine will accept a new mattress Working there is a mattress in feed Stopped the START STOP button was pressed and the machine is waiting Error on D3 D4 the length detectors D3 or D4 on M1 when included have been activated with no cycle They could be broken or to high sensibility Check the problem and press START STOP button to resume Error on S3 the movement of the central sealing bar hasn t reach the final position The reason could be the bar has catch a mattress the detector has moved a little down or the order to move didn t activate the electro valve Error on phase 2 the wrap of the mattress exceeds the time limit After check the problem move the mattress up to pass the sealing bar F3 key and press STAR STOP button to resume the cycle Measurement fail the measure is out of range Contact technical service MANUAL USUARIO ME 105 13 The effect of the function keys is the following the machine should be in
32. t the cars to the right position go to TEST screen and press AV AJ button By this the 3 cars will move forward recovering a in range position The reset the machine to let them find their home MANUAL USUARIO ME 105 10 5 MANTENIANCE EVERY WEEK remove the waste from the cutting cylinder case in order to avoid damages EVERY WEEK check the oil level on the compressed air filter Refill if necessary EVERY MONTH clean the air filter on the control cabinet EVERY MONTH test the differential switch by acting over the TEST button e CAREOFTHE BLADES AND TEFLON COVERS The blades that cut the film are maintenance free and under normal situations last a lot When the blade results damaged it s necessary to exchange for a new one For replace the blade dismount the cover untaught and pull carefully the old one and insert the new one The Teflon covers last between 30 000 and 100 000 processes depending on the gross of the film and the heat conditions When they are half used up silicone sprayed could help to last longer For covers substitution please use self adhesive 0 15 mm thick Teflon fabric e REPARATION OF RODLESS CYLINDERS REPAIR KIT air connection end caps Out seal strip inner seal strip shuttle MANUAL USUARIO ME 105 11 6 FINE ADJUSMENT Even though the machine has been tried at factory the final conditions can differ These are some different adjustment that allow to achieve the most perfe
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