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MATTRESSES WRAPPING MACHINE ME 105

1. 3 5 M3 1 Motoreductor Bonfiglioli VF44 P1 20 P71 B14 0 37KW 1 20 3 6 S4 1 Detector inductivo RESCHNER M12 4mm 30VDC 3 7 LGRI5 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 fijaci n horquilla 3 13 CIL7 4 Cilindro Univer ISO 40 320 fijaci n horquilla 3 14 UCPA206 4 Rodamiento tipo silleta UCPA 206 3 15 M6 1 Motoreductor Bonfiglioli VF44 20 P71 B14 0 37KW 1 20 3 16 55 1 Final de carrera electro mec nico rueda 245 MANUAL USUARIO ME 105 24 de desdiere 2 Fose 26 ME 105 MANUAL USUARIO Piom de desdiere 2 Fose Embobadora de colchones ME 104 ME 105 MANUAL USUARIO 1 MODULE 1 8 N uj gt B t D e bj gt O CLIENTE de articulo Referencia Nombre de archivo Fecha Escala Disenado por F GLOBAL SYSTEM GROUP Merello Bolsas 27 2009 n d MER Q ME105 MATTRESS WRAPPER MACHINE INGENIEROS S L ER E ELECTRICAL DISTRIBUTION 1 BARRIER 1 WHEELS M1 BL
2. FASE Plano ID Cant Descripci n 1 1 UCF205 16 Bearing flange type UCFL 205 1 2 UCP204 2 Bearing bridge type UCP 204 1 3 1 1 Photocell barrier BANNER BOS 012C w mirror 1 4 2 Polycarbonate door smoked 620x1120x8 1 5 BIS 4 Polypropylene door joint 1 6 FCBIS 2 Safety switch Telemecanique XCSPL591 1 7 1 Photocell barrier auto reflexive BALLUF BOS 0123 1 8 PLACAI 2 Steel entrance plate 1 9 BANDAI 1 Conveyor belt PVC NAB 10ELBV 2000X3115 1 10 UCPA206 4 Bearing bridge type UCPA 206 1 11 M2 1 Motoreducer Bonfiglioli VF44 20 P71 B14 0 37KW 1 20 1 12 1 4 5 3 Motoreducer Bonfiglioli VF44 20 P71 B14 0 37KW 20 1 13 EV1 2 3 3 Electrovavle SMC 5 2 1 8 24 VDC G6250 1 14 CILO 2 Cylinder SMC ISO 32 80 D M 1 15 1 1 Polycarbonate door smoked 620 1120 8 1 16 MANI 2 Door latch ref 5608 1 17 FCle 1 Mirror photocell barrier 1 18 1 Steel plastic guide 050 x 3050 1 19 RUIR 2 Nylon wheel 200 1 20 D3 D4 2 Steel detector with inductive 1 21 52 57 2 Film tensor 220 with inductive 1 22 RUL 8 Roller for film 0108 x 3050 1 23 FC2 1 Photocell programmable BANNER QS18EP6DB 1 24 CILI 1 Cylinder SMC ISO 32 160 D M 2 1 PP2d 2 Polycarbonate door smoked 765x880x8 2 2 CIL4 2 Cylinder SMC ISO 40 320 D M 2 4 CP21 1 Guards sealing bar blade side 2 7 CP22 1 Guards sealing bar connections side 2 8 CIL3 2 Cylinder SMC ISO 63 400 D M 2 9 CIL6 2 Cy
3. 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 136564 rev www bannerengineering com Tel 763 544 3164 USER S MANUAL ME 105 39 El INIA JAY JA 1 NOIOVTVISNI NOIVOISINENT SVZ3ld 1 5 11SITUALZLVSYA N3lL3H1N3 NOLLVTIVLSNI NOILVOISINENT S33H9V13G S3931d SAG 31511 JONVN3 LNIVIA NOLLVTTVLSNI NOLLVOINENT 151 3HVdS NOIZNALNNVIN 3NOIZVTTVISNI 3NOIZVDIJIHSI1T IG LLHVd 157 DTHOLLOGDI l IOIDIINOS 40 ME 105 USER S MANUAL 01 28 02 LISE SL 2 08 01 uis 6 2 55 04 1 56 09 1 09 06 10 52 2 61 01 A 41 utor 5129510 gnuo ip 91 89 07 6 89 0P 61 66 06 8 21 60 8 92 01 4 8009 80091 9009 90091 0009 51 29 02 51 57 05 11 95 91 6 06 01 9 6N1
4. Then the mattress will advance up to the normal position to make the second seal e GAIN F 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 INSTRUCTION MANUAL ME 105 17 PARAMETER MENU ALTERNATE BUTTON PRESS when activated the wheels on the 1 module in feed conveyor descend to increase the pressure of the mattress against the belt avoiding it to slip ALTERNATE BUTTON RAMPS 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 T RETRO M2 time for the second conveyor to move backwards before sealing to increase the adjustment of the bag MAX PRESS 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 time in tenth of seconds during which the wheels over conveyor in Module n 1 push the mattress to assure the traction After this time the wheels up to avoid a shock against the conveyor Aprox 10 20 e DELAY PRESS 2 time in tenth of seconds during which the wheels over conveyor in Module n 2 wait to push on the mattr
5. the green light Y15 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 INSTRUCTION MANUAL ME 105 machine if the input signal X25 remains ON INSTRUCTION MANUAL ME 105 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 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 5 After these adjustments press the START STOP button to put the machine ready t
6. 4 RS Rele de seguridad 24DC 1 R Resistencia 1 Ohm 40W 1 USER S MANUAL ME 105 32 USER S MANUAL CONTROL CABINET ME 105 33 5 5 X0 NEW MATTRESS X1 DOOR X2 MATTRESS IN POSITION p o3 X4 LEFT PLATE DETECTOR 7 i X5 RIGHT PLATE DETECTOR PhCEL ADVANCE MATTRESS 4 I X10 LOWER ROLL BAR X11 DOOR Mld 1 ANALOGIC X3 MATTRESS BED SELECTOR X15 UPPER ROLL BAR X7 SEALING BAR CLOSED X12 SEALING BAR HALF CLOSED X17 EMERGENCY STOP gt 3 4 5 6 der O13 El 4 X20 DOORS M2 2 ANALOGIC i i 43 ANALOGIC X23 DETECTOR PRESS M3 6 6 X24 COUNTER PRESS M3 7 7 16 EMERGENCY CABLE 8 _ 8 L7 EMERGENCY CABLE 9 USER S MANUAL ME 105 24V pe FCO _ 52 Pp i l gt D4 1 57 58 59 L EN Et S6 HO EM2 L V0 1 V2 V3 V4 YO CONVEYOR 1 ADV _ gt Y13 CONVEYOR 1 2 FAST ADJUST 1 ADV Y2 ADJUST 1 RETRO Y14 ADJUST 2 ADV Y15 ADJUST 2 RETRO ADJUST 3 ADV Y12 ADJUST 3 RETRO Y4 ROLL BOTTOM ADV 1 r Y5 ROLL BOTTOM RETRO VS Y6 ROLL ADV Y5 ROLL TOP RETRO C23 Y7 CONVEYOR 3 ADV v7 eee AS Y11 CONVEYOR 2 ADV Y13 CONVEYOR 2 FAST 3 pq Y35 CONVE
7. Freq max Vel VO Vel V1 PWM PWMT Carrier vi 025 0 05 59 150 10 V2 025 005 5 1 50 1 100 10 0 25 0065 5 1 50 1 109 10 v4 040 020 5 1 45 10 040 020 5 1 45 10 yo 040 040 F 5 1 10 10 v7 m2 040 040 FF 5 1 100 35 75 10 Vg 040 040 FF 5 1 10 735 10 USER S MANUAL ME 105 38 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 output 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 Lig 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 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
8. SUBS SIA 23 106009 jueweinoy juewajnoy 205 dioi Je2edg masos pray deg 1 4S89 deo hoy JeaumuuoM 152245 aded pejokoas uo sabed pejuud BABY Sy dnoje vaste e sree 2150 ANA ojeuoDeso 2159 e IA Ip ejeuoDese PARO PISO P ANA 9109 uoo 01421409 ejeuoBese e AA einsniuo ip 014912405 esejopued ejeuoDeso eue uoo ojyoedog ejeuoBese e IA MNA 1 uoo 014919409 2 1 SA Jed euorziuent ui eyenBur g1oboog elley 105 yeusuuoM 2 SNA fay eyenbury deo 10 MHI 15196995 189510 emua ojeuy 1
9. juom IJ i XO serv Tre pr po peo poe 7 afefe ESJES EE EST Ez Ez 2529 OTE o 2 s s 9 5 5 4 _ vetetted 22088 222 2 15 LANISVO NIV 37 ME 105 USER S MANUAL VARIADOR OMROM JX F02 F03 A01 02 A04 A20 21 B83 C3 Acelerac Decelerac Referencia Mando Frecuencia Velocidad Velocidad Frecuencia terminal3 velocidad digital maxima 1 portadora 9E 5897 V2 2 025 005 01 0 5 5 12 Or ro 380117 28977 a v4 040 0 20 02 01 100 45 12 040 020 02 01 10 45 12 vo 0 40 040 02 01 50 25 12 7 0 40 040 02 o1 10 7 12 8 2 0 40 040 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
10. 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 INSTRUCTION MANUAL ME 105 status is moved to STOP After release it the energy appears again but the machine remain stopped until START STOP button is pressed Then the cycle will r
11. 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 Technical stop contact technical service INSTRUCTION MANUAL ME 105 13 01234 DATA The effect of the function keys is the following the machine should be in STOP mode 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 Bar 2 advance of movable seal bar gt 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 PRESS M3 ms NM ALTERNATE BUTTON LAT SEAL when ac
12. stico 212 con detector inductivo 1 22 RUL 8 Rodillo portabobinas 2108 x 3050 1 23 FC2 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 policarbonato humo 765 880 8 2 2 CIL4 2 Cilindro Univer ISO 40 320 fijaci n horquilla 2 4 CP21 1 Carcasa protecci n lado cuchillas 2 7 CP22 1 Carcasa protecci n lado bornero 2 8 CIL3 2 Cilindro Univer ISO 63 400 fijaci n horquilla 2 9 CIL6 2 Cilindro Univer ISO 25 50 fijaci n horquilla 2 10 S3 1 Detector inductivo Univer 15063 2 11 PP2t 2 Puerta policarbonato humo 865 880 8 2 12 FCBIS 4 Interruptor de seguridad Telemecanique XCSPL591 XCSPL71 2 13 M7 1 Motoreductor Bonfiglioli VF44 20 P71 B14 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 NEOP2010 6 Tira de Neopreno autoadhesivo 20x10 1m 2 18 BL 1 Cuchilla trapezoidal 2 19 PBL 1 Portacuchillas 2 20 CILS 1 Cilindro sin v stago Univer 216 3050 51004163050 2 21 BANDA2 1 Banda NSL 10ELAV 2250X3115 2 22 RU2L 2 Rueda nylon 2200 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 NSL 10ELAV 2250X4035 4635 p EXTRA WIDE 3 4 PLACA3M 1 Rampa movil inoxidable
13. third conveyor when the mattress exceeds the corresponding size A bigger makes the third conveyor to start later Aprox 40 60 e SIZE M3 value relative to the distance between bars in module n 1 and bars in module 193 in order to calculate the necessary advance of the mattress A bigger value provokes the mattress to advance more The right value makes the mattress to stop in the beginning of the module n 3 Aprox 200 300 BIGGER SMALLER values to distinguish if two consecutives mattresses are the same length or not Minor is the negative difference under which the bar in module n 3 will need to re locate Mayor is the positive one If this value is big enough two different mattresses will be processed as if were the same length Aprox 6 6 BLOWER 1 the first number is the delay in tenth of seconds for the blowers in to be activated to help removing wrinkles The second time is the duration of the blow adjustable to avoid the bag hit the lateral bar e BLOWER M3 time in tenth of seconds during which the blower in is activated to help removing waste Aprox 10 20 e SIZE gt 2M the first value is the number that when exceeds provokes the machine to make two seals instead of one The second value show the wide of the present mattress and helps to calculate the first e ADVANCEI 22M shows the time in cents of second that the mattress will advance for make the first seal if the mattress is gt 2m previous point
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15. 3 is OFF the second when ON Aprox values 10 30 e LENGTH ADJUSTMENT time in cents of seconds that is subtract from the measure in Module n 1 to adjust the aperture of the bars in Module n 3 This adjustment can also be achieved by approaching or separating the inductive detectors of this parts A positive value will provoke a bigger separation in module n 3 Aprox 0 e ADVANCE PRESS M3 when equipped advance of the press in Module n 3 over the mattress to approach their faces and assure the traction After this advance the welding bar down to make the join Aprox 7 12 MEASURES MENU Default e BUTTON DEFAULT load the default parameters value Also allows to change the language of the messages SELECTOR select between automatic adapt to the measures of the mattress or not 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 INSTRUCTION MANUAL ME 105 16 e 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 e SIZE M2 value relative to the length of the second conveyor in order to activate the
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17. 9920 uoo jeuobexay gt ep SIA SIA SIA peau J9A09 amero peau 205 19125 5910 uoo ede egn jexoeg 4 1 19 1 ejeyosioBe7 euobexay uajoeuod 2 reyoapgnjyosqy ejunp Buniuoig ejeequos Jeyoepjuuunz noyabajurz 009 2 19 10pejoueisiq euog uy UIS SIA amy ep ajalasquog 1 5 10 186085 Buweunus soGeyabny sabeyabny unr eleo uouonodeo uoyondey SIA 2 106009 esiojenua3 SIA worp eyanelo
18. MATTRESSES WRAPPING MACHINE 105 INSTALLATION USER AND MANTENIANCE MANUAL NOTIFICATION 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 1393 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 July 2012 INSTRUCTION MANUAL ME 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 ey 80x1 6 BOX 2 BOX MODULE 3 MODULE 2 MODULE 1 Module n 1 Mattress In feed receiv
19. OWERS M1 A BLOCK M1 SEAL BAR CENTER SEAL BAR CENTER CUTTER CENTER TOP BOTTOM vs 2 BLOCK M1 SEAL BAR CENTER WHEELS 2 CUTTER CENTER RAMPS M2 sam BLOCK M2 SEAL BAR SIDER CUTTER SIDER PRESS SIDE 4 EA P BLOCK M3 RIGHT SEAL BAR SIDE R CUTTER SIDER PRESS SIDE VIII e E Y32 BLOCK M3 LEFT CLIENTE N2 de art culo Referencia Dise ado por Nombre de
20. YOR 2 RETRO i2 5 V5 Y16 GREEN LIGHT RED LIGHT I O STACKER X25 CART PRESENT X26 MATTRESS IN STACKER X27 STACKER UP Y40 ACTIVATE STACKER Y41 ACTIVATE BRAKE Y42 HIDE STTOPER MATTRESS USER S MANUAL ME 105 35 Module 16EYT ES V1 V2 Y20 CLOSE BARRIER Y21 PRESS 1 Y22 BLOWER 1 Y23 DESCEND SEAL C TOP jg Y25 ASCEND SEAL C TOP Y26 CUTTER ASCEND SEAL BOTTOM Y24 RAMPS M2 11 Y10 PRESS M2 Y27 DESCEND SEAL LATERAL 12 Y30 CUTTER LATERAL 13 ASCEND PRESS M3 Y32 DESCEND PRESS M3 15 _ Y33 BLOWER M3 16 HEAT CENTRE Y37 HEAT LATERAL C2 USER S MANUAL ME 105 0 Ez ar 3 ev7 ev8 ev9 n 1 36 ss e fos feweu ncn Pt TTT fef lt lofe feso mimo 4 su uonoeuoo uonoeuoo LEE TL TL UL ET J fuom xoa 5 SYN parra ATT PEPE Elia save oso Ea pos poses s s v e zv foam 0900902230 4126 s ave ao pre 2 fefe funuo far 2 2
21. archivo Fecha Escala GLOBAL SYSTEM GROUP Merello Bolsas AYU 27 enero 2009 n d MERELLO ME105 MATTRESS WRAPPER MACHINE UN GE NETE ROSSI IS E PNEUMATIC DISTRIBUTION 1 I 1 T USER S MANUAL ME 105 29 Edici n L mina lower upper roll conveyor ne3 conveyor n 2 roll u4 va wa us 5 5 y Jus 7 w we uz M8 w WA v7 v vb U v8 v 12 v6 E 12 12 adjustment 1 adjustment 2 adjustment 3 2 5 8 lateral lateral lateral n u 101 v4 v w v3 v 2 2v Ma M2 w w3 U va W4 viv 12 2 L 12 2 413 EM2 6 7 Li CLIENTE de articulo Referencia Disenado por Nombre de archivo Fecha M Bolsas AYU 27 enero 2009 ME105 MATTRESS WRAPPER MACHINE Tus POWER DISTRIBUTION Edici n 7 Lamina M5M4M1 Cajti 0 24VDC Caj3 2 CLIENTE
22. de articulo Referencia GLOBAL SYSTEM GROUP Dise ado por Nombre de archivo F M Merello Escala Bolsas AYU echa 27 2009 n d ME105 MATTRESS WRAPPER MACHINE A Edicion Lamina ELECTRICAL DISTRIBUTION _ L1 I USER S MANUAL 31 LIST OF DE MATERIALS Referencia Descripci n Cantidad al Interruptor magneto t rmico monof sico 6 A 1 a2 a3 Interruptor magneto t rmico monof sico 25 A 1 D Interruptor diferencial 2p 40A 30 mA 1 21 Interruptor general trifasico 2x40 1 fl fusible 010 25A 1 PLC Aut mata programable FX1N 40MTDSS 1 16XY M dulo de salidas FX16 YET 1 1 2 Contactor trif sico 24 VDC 25 A 2 1 2 Regulador triac 8000 W c potenci metro 500 Ohm 2 vl v7 Variador de frecuencia Mitsubishi FRA520S 0 4 KW 7 ml m7 Motoreductor trif sico 220VAC 0 4KW i 20 7 FCO Fotoc lula autoreflexiva 70cm multitensi n 1 Fotoc lulas de barrera 5m multitensi n 1 FC2 Fotoc lula autoreflexiva 30 cm programable 1 D3 D4 Detector inductivo PNP 10 30VDC 2 S3 Detector inductivo UNIVER PNP 10 30VDC 1 S5 Final carrera con rueda 1 51 2 4 6 7 Detector inductivo PNP 10 30VDC 4 ev20 32 Electrolvalvula neumatica 1 8 5 2 24 VDC 15 vent Electro ventilador con filtro 80 220 VAC 50 60Hz 1 1 tirador parada emergencia 1 EM2 pulsador parada emergencia 1 PT1 2 final carrera puerta NO
23. e 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 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 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 INSTRUCTION MANUAL ME 105 2 MACHINE INSTALATION Every element of the machine has its own adjustable legs that allow the installation in any surface Main job during installation consists on lev
24. eling 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 1 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 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 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 e SYNCHRONIZING WITH PREVIOUS LINES
25. ess to assure the traction This permit the mattress to start advance during wrapping Aprox 10 20 e TOTAL PRODUCTION shows the number of units processed by the machine from the first day to now INSTRUCTION MANUAL ME 105 18 TEST MENU EBEEEE ka EL E EA 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 INSTRUCTION MANUAL ME 105 19 8 INSTRUCTIONS FOR SAFETY The load of the rolls is dangerous and need two 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 The machine is intended for wrapping mattresses The use for wrapping other kind of things can result in injuries or accidents INSTRUCTION MANUAL ME 105 20 9 PART LIST
26. esume to the previous point first 175 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 INSTRUCTION MANUAL ME 105 5 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 CARE OF THE BLADES AND TEFLON COVERS The blades that cut the film are maintenance free and under normal situations last a l
27. 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 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 that 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 INSTRUCTION MANUAL ME 105 15 position Aprox 20 30 e XTRA ADVANCE time in cents of second while the mattress stays advancing over the central welding bar A higher value induces bigger advance before soldering and the bag will be looser The first value will be applied by the machine when X1
28. linder SMC ISO 25 50 2 10 53 1 Inductive detector Univer ISO63 2 11 PP2t 2 Polycarbonate door smoked 865x880x8 2 12 FCBIS 4 Safety switch Telemecanique XCSPL591 2 13 M7 1 Motoreducer Bonfiglioli VF44 P1 20 P71 B14 B3 0 37KW i 20 2 14 ESET 4 Baquelite resistance terminal 2 15 NICR408 6 Resistance NiCr 4x0 8 1m 2 16 CELO2010 6 Celotex base spline 20x10 1m 2 17 NEOP2010 6 Neoprene self adhesive 20x10 1m 2 18 BL 1 Trapezoidal blade 10 units 2 19 PBL 1 Blade base 2 20 CILS 1 Rodless cylinder SMC 16x3050 51004163050 2 21 BANDA2 1 Conveyor belt PVC NSL 10ELAV 2000X3115 2 22 RU2L 2 Nylon wheel 0200 2 23 UCPA206 4 Bearing bridge type UCP 206 2 24 UCFL205 4 Bearing flange type UCFL 205 3 1 PLACA3F 1 Steel fix ramp 3 2 PRT 2 Polyurethane plate for waste 3 3 BANDA3 1 Conveyor belt PVC NSL 10ELAV 2000X4635 INSTRUCTION MANUAL ME 105 21 3 4 PLACA3M 1 Steel movable ramp 3 5 M3 1 Motoreducer Bonfiglioli VF44 20 P71 B14 B3 0 37KW 1 20 3 6 S4 1 Inductive detector RESCHNER M12 4mm 30VDC 3 7 15 2 Lineal guide HIWIN LGR15 w bearing LGH15 3 8 9 PP3 4 Polycarbonate door smoked 910x880x8 3 10 PM3Z14 4 Rotative gear M3 Z 14 3 11 CP3 2 Guards sealing bar lateral side 3 11 CIL8 2 Rodless cylinder SMC 16x2300 51004162300 3 12 CIL11 4 Cylinder SMC ISO 40 400 D M 3 13 CIL7 4 Cylinder SMC ISO 40 320 D M 3 14 UCPA206 4 Bearing bridge type UCPA 206 3 15 M6 1 Motoreducer Bonfig
29. lioli VF44 P1 20 P71 B14 B3 0 37KW 20 3 16 S5 1 Switch detector with 245 wheel INSTRUCTION MANUAL ME 105 22 9 LIST OF MATERIALS 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 barrera Telemecanique XUK 2AKSNL2T 1 4 2 Puerta policarbonato humo 620x1120x8 1 5 BIS 4 Bisagra puerta polipropileno 1 6 FCBIS 2 Interruptor de seguridad Telemecanique XCSPL591 1 7 1 Detector fotoel ctrico Telemecanique XUK SAPANL2 1 8 PLACAI 2 Gu a de entrada inoxidable 1 9 BANDAI 1 Banda PVC NAB I0ELBV 2250X3115 1 10 UCPA206 4 Rodamiento tipo silleta UCPA 206 1 11 M2 1 Motoreductor Bonfiglioli VF44 20 P71 B14 0 37KW 1 20 1 12 1 4 5 3 Motoreductor Bonfiglioli VF44 20 P71 B14 0 37KW 1 20 1 13 EV1 2 3 3 Electrov lvulas Univer 5 2 1 8 24 VDC G6250 1 14 CILO 2 Cilindro Univer ISO 32 80 fijaci n horquilla 1 15 1 1 Puerta policarbonato humo 620 1120 8 1 16 MANI 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 250 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
30. o 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 INSTRUCTION MANUAL ME 105 ME 104 PLASTIC FILM INSTALLATION INSTRUCTION MANUAL ME 105 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 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 the
31. ot 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 INSTRUCTION MANUAL ME 105 10 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 perfect 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 time heating time cooling less electrical energy more duration of covers power time heating more esthetic seals A time cooling thicker film power Atime heating Atime cooling very inelastic film time cooling Atime 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
32. rd called LATERAL ADJUSTMENT bigger values provoke bigger separation or move the end detectors SPECIAL ADJUSTMENT WHEN USING BOOT SYSTEM INSTRUCTION MANUAL ME 105 11 In order to keep the same strenght every roll is very recommendable to reduce the rolls speed 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 INSTRUCTION MANUAL 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 passwords that give access to 2 different levels 7791 allows to access only to the first DATA screen with frequent used parameters Value 1977 allows to access to all the screens DATA and TEST The main screen shows the status message After an alarm occurs the message line explains the alarm that occurs These 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
33. tivated 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 INSTRUCTION MANUAL ME 105 14 ALTERNATE BUTTON PRESS 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 Don t use 1t with hard beds wood ALTERNATE BUTTON PRESS M2 when activated the wheels on the 2 module descend to increase the pressure of the bagged mattress against the belt avoiding it to slip e ALTERNATE BUTTON bef aft when BEFORE and PRESS are activated the wheels 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 BUTTON MEASURES give access to the measures menu see below CENTER time in tenth of second during which power is applied to the central 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 P1 Valor aprox 25 50 NOTES gt grosser the film is the higher this value must be gt Too high power values will reduce the Teflon covers life gt Too high values will increase the cycle time e T COLD CENTER time in tenth of second after
34. ttt a Present sensing condition Four pulse remote line TY 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 4 threshold 12 5 above Any condition lighter than the threshold causes the output to 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
35. 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 stabilizate 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 keyboa

MATTRESSES WRAPPING MACHINE ME 105

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