Workhorse - Mettler Toledo
Contents
1. If the travel distance is more than 50 miles from Mettler Toledo LLC authorized service location or if the work is requested by the Purchaser to be performed outside of the normal working hours Purchaser agrees to pay Exact Equipment or it s authorized Service Distributor their standard premium for such hours and travel expenses REMEDIES AND DAMAGES If equipment or apparatus sold shall fail to conform to the contract of sale including but not limited to the warranty of Mettler Toledo LLC Purchaser s sole and exclusive remedy shall be at the sole option of Mettler Toledo LLC to repair or replace any non conforming equipment or apparatus or parts thereof 19 1 Workhorse User s Guide METTLER TOLEDO For your notes 19 2 TOLEDO Service INTERNET Quality Management System certification Development production and auditing in accordance with ISO9001 Environmental management system in accordance with 15014001 Worldwide service Our dense service nelwork among the best in the world ensures the maximum availability and lifespan of your product Conformit Europ ene This label is your guarantee that our products conform to the latest guidelines On the Internet You can find important information about our products and services as well as our company quickly and easily at http www mt com and at www mt com METTLER TOLEDO 1900 Polaris Parkway Colu2. k ya kak X 13 2 Problems Without Error 0 5 a d k ke kek dl eW ek Raa n wa Ku nenne 13 6 Cleaning Maintenance L kk nnne nnne nnn nnne nnn nn 14 1 Cleaning 14 1 Daily and Weekly Cleaning 14 2 Weekly Only 14 2 Elevator Removal nnne nnn nnn nnne nennen nnne 14 3 Voice OPON i i syn Sise k ake k ka raveya keya kaya ka eke va dw ye Y kw ewa aa kU Ya du V Ke kU RAE RAE KWE 15 1 Automatic Weighing System Option L kk kkkkk erkek 16 1 Manually Clearing the Wrqpper eene 17 1 Printed Registered Film Option L eene 18 1 Wata n nya kena Tey UNTER TOTO RE VEY A KEWAN a WO DTP E ERAN CEY ERIT KERDE EA VAR AS EE 19 1 Chapter 1 Introduction Introduction The Workhorse is designed to be just what the name implies a workhorse Built from tough corrosion resistant materials such as aluminum stainless steel and industrial grade plastics the Workhorse is the most advanced automatic stretch wrapper available today But it s not just the material that make the Workhorse wrapper ready for the present and future It s the way the wrapper was designed to be operated Easy Using advanced electronic controls and on board self diagnostics the Workhorse is
3. Errors should only occur on wrappers equipped with optional printed registered film readers Errors that should only occur with an optional weighing System attached Error that should only occur with optional product exit photocell or weighing system Error should only occur on wrappers equipped with optional extended infeed Error should only occur on wrappers equipped with optional automatic upper ejector Errors that should only occur with an optional weighing System attached Error that should only occur with optional product exit photocell or weighing system Error code Chapter 13 Problems Causes Solutions Error Codes Error description and possible solutions 13 INCORRECT POSITION OF THE FOLDERS Press the start button on the operations panel 51 PRESS THE STOP BUTTON Remove any product that may be caught in the wrapping area Release the stop button and press start Using the T Handle relieve any possible bind in the wrapping area 14 SYSTEM CHECK REPORTS SENSOR FAULT SR2 Press the start button on the operations panel 51 15 SYSTEM CHECK REPORTS SENSOR FAULT G SR1 Press the start button on the operations panel 51 18 LOSS OF PROGRAMMED TLU VALUES Reprogram values 41 FILM FEED MOTOR NOT FUNCTIONING PROPERLY PRESS THE STOP BUTTON Remove any film that may be trapped in the film feed belts Press the start button on the operations panel 51 43 FIL
4. PRINTED FILM NOT POSITIONED PROPERLY Check the alignment of the film on the side indicated on the operations panel Check the alignment of the film eyespot to the photocell MACHINE INFEED PHOTOCELL BLOCKED Remove ALL packages from the infeed Clean machine photocell and reflector EXTENDED INFEED PHOTOCELL BLOCKED Remove ALL packages from the infeed Clean extended infeed photocell and reflectors AFETY PHOTOCELL BLOCKED emove ALL packages ean Safety photocells and reflectors IMPROPER MOVEMENT OF AUTOMATIC CARRIAGE Press the start button on the operations panel 51 IMPROPER MOVEMENT OF AUTO UPPER EJECTOR Verify that ejector is NOT locked into the up position Restart wrapper and reselect TLU PACKAGES NOT TRANSFERRING FROM EXTENDED INFEED PROPERLY Clean extended infeed photocell and reflector Remove any debris and clean package transfer belts Setthe infeed on off selector switch to 1 on and press the start button SAFETY PHOTOCELL BLOCKED Remove ALL trays from the infeed Clean the photocell and reflector Error code Chapter 13 Problems Causes Solutions Error Codes Error description and possible solutions 85 PACKAGE TOO BIG OR MACHINE PHOTOCELL ACCIDENTALLY BLOCKED Product hanging off tray correct placement of product in tray Select correct TLU number for tray size in use Remove any debris from infeed belts Clean infeed belts PACKAGES ON INFEED TOO
5. Chapter 13 Problems Causes Solutions Problems Without Error Codes Package has holes in the bottom or bottom is burnt Sealing plate temperature too high Decrease the sealing plate temperature see Chapter 10 Package open on both ends or under package on both sides Improper TLU for the tray being run excessive product height insufficient film length programmed Use the correct TLU or one for slightly larger tray Note If excessive height is the cause have an authorized technician increase the film length value for that TLU on the next visit Packages open on one side a Film reel not in proper position b TLU in use is not correct for product being run c Packages not being placed properly on the infeed a Adjust film so that it is correctly positioned for that side of the wrapper ensure that the arbor locking handle is engaged and tight b Use a suitable TLU See fault 4 c Place packages straight and centered on the infeed Packages open lengthwise on the bottom a TLU in use is incorrect for that tray b Film is not wide enough a Select an appropriate TLU b Change fhe film reel to a wider roll of film Film is loose on product a TLU in use is incorrect for tray b Film reel is too narrow a Select an appropriate TLU b Change the film reel to a wider roll of film 13 7 Workhorse User s Guide 13 8 Fault Product rolls out of wrapping area when ejected Cause a b
6. Width 54 5 Height 52 Infeed Height 31 5 2 Discharge Height 41 0 2 Minimum Doorway Opening Requirements For Installation Type bonis zs 56 25 15 40 00 15 47 00 Dimension only with infeed and discharge fully removed nfeed disconnected and secured to the front panel of the wrapper discharge NOT removed Shipping Weight Package Specifications Film Chapter 3 General Information amp Specifications Approx 840 Ib Wrapper Only Package Orientation Longest tray dimension perpendicular to package travel Minimum Maximum Package Dimensions MIN MAX A Width 5 16 B Length 5 1 10 2 Height 0 5 6 0 IMPORTANT NOTE Not ALL packages within these dimensions will run through the wrapper For example a tray that has ALL of the MAXIMUM 16 wide 10 Long and 6 high dimensions may not wrap because the maximum film width may not cover the entire package 50 100 gauge stretch film 3 D core 9 maximum O D 2 film arbors standard Automatic select Minimum maximum dimensions MIN MAX Roll Width 14 2l Pulled Length 9 3 4 27 102 25 70 3 3 Workhorse User s Guide METTLER TOLEDO For your notes Chapter 4 Wrapper Parts and Controls Main Components 4 Wrapper Parts and Controls On the next several pages the main parts of the Workhorse and the layout of the keyboard can be found T
7. z d Solution Fuult Trays cri ejected from Cause a c z Solution d c o Excessive film or poorly positioned film reel Product too high in tray top heavy Upper ejector height not set properly TLU in use is incorrect for tray in use Use a narrower film on that side be sure that film reel is positioned properly Re arrange product in tray to be more stable Set upper ejector to the proper height See sec 11 Select an appropriate TI ush when folders the wrapping area Tray big for product Film width is too large TLU in use is incorrect Seleci Seleci Selec LU move to tuck the film or when trays are being on the tray or that tray for that tray a tray that is closer to the size of the product being run an appropriate an appropriate TI LU change the film reel to a narrower roll of film LU for that tray 14 Cleaning Chapter 14 Cleaning Maintenance Cleaning Cleaning Maintenance There are two basic types of cleaning the procedures that should be performed on a daily basis at the end of production and those that should be performed weekly which are slightly more in depth The regularity of this cleaning schedule was based on SUPERMARKET MEAT ROOM use PERFORM THE CLEANING MORE OFTEN AND THOROUGHLY WHEN THE WRAPPER IS LOCATED IN A PACKING PLANT The WorkhorseG is NOT a washdown ma
8. CHECKING THE FILM THREADING DIAGRAM EITHER IN THIS MANUAL OR ON EACH SIDE OF THE WRAPPER Position the roll of film front to back using the numbered guide found on the cover behind the film roll Most rolls of film will be placed between the 0 and the 2 on the guide depending on film width and position on the film transport belts Note On Z version wrappers there is a film roll stop on each side and on X version wrappers there is a film roll stop on the 1 side for film positioning These stops should 7 2 Chapter 7 Film Installation Installing Film on the Workhorse be set so that the greatest amount of film will be carried by the film belts that transport the film into the wrapping zone Lock the film roll into the proper position with the lever on the end of the arbor 7 3 Workhorse User s Guide 7 4 Lift the Dancer Bar as shown and lock it in the up position by sliding the locking clip inwards WHEN THE WRAPPER IS ON THIS WILL ALLOW THE FILM ARBOR BRAKE TO DIS ENGAGE AND ALLOW THE ROLL OF FILM TO SPIN FREELY IF THE WRAPPER POWER IS NOT ON THE BRAKE WILL NOT DIS ENGAGE Open the distributor cover Depending on which side and press on the distributor release handle DO NOT USE EXCESSIVE FORCE Chapter 7 Film Installation Installing Film on the Workhorse Thread the film into place in the distributor as shown on the threading diagram over the idler and under the dancer PL
9. CLOSE Increase distance between packages as they are placed on infeed Product hanging off tray correct placement of product in tray Remove debris from infeed and or clean infeed belts CARRIAGE PHOTOCELL OBSCURED DURING OPERATION Remove ALL packages from the infeed Remove any film that may be caught in the belts Clean the photocell and reflector PACKAGE TOO SMALL OR MACHINE PHOTOCELL ACCIDENTALLY BLOCKED Use a larger tray Clean infeed belts and or remove any debris clean machine photocell and reflector 19 PACKAGE READ BY MACHINE PHOTOCELL BUT NOT BY SAFETY PHOTOCELL Remove ALL packages from infeed Remove any debris on infeed and clean machine photocell and reflector 19 Clean infeed belts A PRODUCT EXIT PHOTOCELL BLOCKED Remove any packages from the sealing belt Press the start button on the operations panel 51 Clean photocell and reflector 100 101 see sec 16 INCORRECT MOTION FROM SCALE UP DOWN BELTS Press start button SCALE ERROR Reset weighing system and press the start button Use the wrapper in Wrap Only mode 13 5 Workhorse User s Guide Problems Without Error Codes 13 6 Error code Error description and possible solutions 93 PACKAGE WEIGHED BUT NOT LABELED Check and Reset Weighing and Labeling system Use the wrapper in Wrap Only mode 95 LABELING SYSTEM ERROR Check and Reset Weighing and Labeling system Use the Wrapper
10. MAIL FIRST CLASS PERMIT NO 414 COLUMBUS OH POSTAGE WILL BE PAID BY ADDRESSEE Mettler Toledo LLC Retail Quality Manager MTWR P O Box 1705 Columbus OH 43216 USA NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES Please seal with tape 10 11 12 13 Contenis General Information amp Specifications 3 1 Dimensions Supply Voltage Installed Power Tolerance Of Installed Power Dimensions Wrapper Only Dimensions Minimum Doorway Opening Requirements For Installation Shipping Weight Wrapper Parts and Controls Main Components Power Controls Control Panel Overview of Operation Machine Operation Trays and Film Tray Sizes Tray Dimensions and Film Size Film Installation Installing Film on the Workhorse Film Overtravel and the Film Retqine 8 1 Wrapping Speeds lt lt sa kaka enne niu kak da kaka sawa yak annu 9 1 Sealing Plate Temperature and Adjustmen t 10 1 Upper Ejector and Adjustment 11 1 Stopping the Wrapper and End of Production 12 1 Problems Causes SOlUt OIS kk nennen nnn 13 1 ENT ON COGS MC ses yaya kav ceken kaka
11. time Re insert the elevator into the wrapper by reversing the above procedure Be SURE that the elevator is firmly seated on it s locating pins towards the front of the wrapper and into the locking levers toward the rear of the wrapper Lock the elevator into place by pressing down on the locking levers 95 Be sure that the chamfered edges of the locking blocks face upward see drawing below before pressing down on the levers The elevator should now be about 3mm 1 8 inch below the infeed polycord belts Close the inspection door MUST REST BELOW BELTS tt et Jw DO NOT POWER WASH THE ELEVATORI 14 3 Workhorse User s Guide EXACT EQUIPMENT For your notes 15 Chapter 15 Voice Option Voice Option The Workhorse wrapper may be equipped with optional voice prompts These voice prompts can be programmed by the installing or maintaining technician to operate in one of two different modes Automatic If the wrapper were 10 go into an error condition the voice prompt would automatically be heard along with the error number being displayed in area 61 on the operations panel Manual Should an error occur the wrapper would simply show the error number in area 61 on the display the operator would then need to press the voice button 56 on the operations panel to hear the appropriate voice prompt Note These messages have been pre recorded and then stored in the wrapper s
12. version wrappers DO NOT TRY TO OVERFEED OR FORCE PACKAGES INTO THE WRAPPER AT LESS THAN THE GAPS LISTED ABOVE THE WRAPPING SPEED WILL BE LOWER THAN MAXIMUM BECAUSE OF INCREASED ERRORS 05 amp 86 9 1 Workhorse User s Guide METTLER TOLEDO For your notes Chapter 10 Sealing Plate Temperature and Adjustment 0 Sealing Plate Temperature and Adjustment SAFETY WARNING HE SEALING PLATE OF THE WORKHORSE CAN REACH TEMPERATURES AS HIGH AS 355 F 180 C EVEN AFTER THE MACHINE HAS BEEN TURNED OFF THE SEALING PLATE W1LL REMAIN HOT FOR SEVERAL MINUTES USE CAUTION WHEN WORKING AROUND THE SEALING PLATE o adjust the temperature of the sealing plate simply rotate the control knob urning the knob clockwise will increase the heat urning the knob counterclockwise will decrease the heat On X configuration wrappers the temperature control knob is mounted on the operator s or front end of the wrapper On Z configuration machines including the inline configuration the control knob will be mounted on the rear end of the machine Q AAA Co 10 1 Workhorse User s Guide METTLER TOLEDO For your notes 10 2 11 Chapter 11 Upper Ejector and Adjustment Upper Ejector and Adjustment The upper section of the ejector of the Workhorse can be adjusted to accommodate very high profile packages By using the aluminum knob 81 located at the base of the upper ejector the height c
13. 4 1 Registered Film Mode Active Side 1 ndicators for Currently Selected Wrap Scale Mode ref section 4 7 Wrap Only The Only Possibility when no Scale System is Attached Ey Wrap AND Weigh 4 5 Exact Workhorse User s Guide 4 6 Weigh Without Wrap Packages Sent Through Wrapper Without Feeding Film Manual Scale Exposes Scale Grid and Stops ALL Motors to Allow the Scale to be Used as a Hand Scale ndicators for Current Speed Selection Packages Minute Errors Where Calling For a Service Representative is Recommended Indication that the Preventive Maintenance Interval has been Reached and Your Local Service Company Should be Contacted Chapter 5 Overview of Operation Machine Operation 5 Overview of Operation Machine Operation The following step by step procedure is a description of the basic operation of the wrapper Each individual operation will be described in detail in the pages to follow Operation Chapter Be sure the operator is familiar with all necessary safety precautions as 2 described in Chapter 2 Check the wrapper for any obstructions or product left anywhere in on or 14 around the wrapper that may affect it s use Verify the STOP button is depressed 4 Push the black button on the main power switch to turn the main power on Allow some time for the sealing plate to warm up and adjust with the 10 t
14. ACE THE LEADING EDGE OF THE FILM SO THAT IT IS EVEN WITH THE EDGE OF THE FILM COMB DO NOT THREAD THE FILM PAST THIS POINT When the film is in the proper position in the distributor close the distributor by pressing down FIRMLY on the top section be sure that it locks into place with a click Close the distributor cover by lifting slightly and pulling lightly outward on the center of the holding bracket Note Newer models DO NOT have Locking Latches simply lower the cover Pull outward on the dancer locking clip allowing the dancer to drop to it s normal position Arbor brake will engage If the Dancer Arm is NOT lowered the film when pulled will violently lift the arm causing the wrapper to enter Error 43 44 condition out of film and possibly damaging the locking clip he wrapper is now ready for use Release the STOP button and begin wrapping 7 5 Workhorse User s Guide METTLER TOLEDO For your notes Chapter 8 Film Overtravel and the Film Retainer Film Overtravel and the Film Retainer f for some reason the wrapper should go into a fault condition where a the sheet of ilm that has been pulled for a package is left in the machine and b another sheet of ilm is pulled the wrapper will detect this extra sheet of film and shut down with a film overtravel error Error 46 will be displayed for side 1 or error 47 for side 2 n the unlikely event that an overtravel occurs d outline s
15. M REEL 1 OUT OF FILM FINISHED OR TORN Check film reel 1 for film presence and proper placement Replace empty reel 44 FILM REEL 2 OUT OF FILM FINISHED OR TORN Check film reel 2 for film presence and proper placement Replace empty reel 45 UNUSED FILM PRESENT ON SIDE 1 OVERTRAVEL PRESS THE STOP BUTTON Open cover on the side indicated on the operations panel and Remove dll excess film 46 UNUSED FILM PRESENT ON SIDE 2 OVERTRAVEL PRESS THE STOP BUTTON Open cover on the side indicated on the operations panel and Remove dll excess film PRINTED FILM PHOTOCELL SIDE 1 MALFUNCTION Clean photocell and reflector 13 3 Workhorse User s Guide 13 4 Errors should only occur on wrappers equipped with optional printed registered film readers Errors that should only occur with an optional weighing System attached Error that should only occur with optional product exit photocell or weighing system Error should only occur on wrappers equipped with optional extended infeed Error should only occur on wrappers equipped with optional automatic upper ejector Errors that should only occur with an optional weighing System attached Error that should only occur with optional product exit photocell or weighing system Error code Error description and possible solutions 48 PRINTED FILM PHOTOCELL SIDE 2 MALFUNCTION Clean photocell and reflector 49
16. Opening ANY cover on the Workhorse MUST stop the wrapper in the event of an emergency or just to thread the film If opening a cover DOES NOT stop the wrapper CONTACT AN AUTHORIZED SERVICE REPRESENTATIVE IMMEDIATELY To release the stop button simply turn the button LIGHTLY CLOCKWISE In the direction of the arrow When production is finished for the day OR to clean the wrapper ALWAYS turn the main power to the Workhorse off This is done by simply press the RED button 40 on the main power switch The main power switch also has a provision for Lock out capability By lifting the yellow cover and sliding the cover into position the switch can be locked out using any OSHA approved locking mechanism 12 1 Workhorse User s Guide METTLER TOLEDO For your notes 12 2 13 Chapter 13 Problems Causes Solutions Error Codes Problems Causes Solutions When the wrapper is turned on the wrapper will perform a short self test to determine if here is a problem that should keep the wrapper from starting If no problem is found he numerical indicator at position 61 on the operations panel will show OO if a fault is found it will display an error amp to indicate what the problem is and section 62 of the display will indicate a general section of the wrapper where the fault exists see error chart below no fault is found the start button can be pressed which will initiate a short self iagnostic cycl
17. Workhorse Automatic Stretch gt lt Wrapper User s Guide Wrapping amp Labeling 64063805 Mettler Toledo 2012 No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording for any purpose without the express written permission of Mettler Toledo LLC U S Government Restricted Rights This documentation is furnished with Restricted Rights METTLER TOLEDO Attention Retail Quality Manager MTWR If you have a problem with one of our products or publications or just a suggestion on how we can serve you better please fill out this form and send it to the address on the opposite side of this page U S postage paid or fax it to us at 614 438 4355 Your feedback will help us to improve product performance quality and service Part Product Name Customer Feedback Part Model Number Provided By Customer Name Address Phone Number Fax Number Your comments Do not write in space below For METTLER TOLEDO use only Response if appropriate and corrective action taken Workhorse User s Guide 64063805 Replaces 17297000A METTLER TOLEDO is a registered trademark of MetlesToledo LLC 62012 Metler Toledo LLC Printed in USA FOLD THIS FLAP FIRST BUSINESS REPLY
18. a label for that package This is the cue for the scale belts to rise again and transfer the package on to the labeling station When the package passes in front of the labeling photocell 124 the package will then stop waiting for a label to be delivered to it Once the label is delivered and in the case of the RLA system the arm is at a safe distance away from the package as not to interfere with it s movement the conveyor will start to move again completing the labeling cycle 16 1 Workhorse User s Guide 16 2 tal 60 Scale no Film This mode works the same as the mode described Wrapper and Scale with only one exception the package will travel through the wrapper without film being issued to wrap it This mode is ideal for pre wrapped product that still needs to be automatically weighed and price labeled 6 Manual Scale When this mode is selected after a short pause the wrapper will drop the scales belts exposing the weighing platform The wrapper will then shut down all other functions and motors This will make the scale function the same as a basic back up scale where normal scale weighing and label delivery functions occur but no wrapping or transferring takes place at all Note To ensure proper and trouble free operation keep all photocells 100 122 and 124 as well as their respective reflectors 101 123 and 125 clean and free of debris 17 Chapter 17 Manually Clearing
19. an be regulated NEVER set the upper ejector so that it does not AT LEAST touch the top of the product The main purpose of this part of the wrapper is to keep products and or trays in place during the wrapping cycle If contact with the package is not maintained it s possible for the package to fall back into the wrapping zone We recommend that the height of the upper ejector NOT be adjusted unless absolutely necessary Adjustment is usually unnecessary unless running large quantities of unusually high packages It s also possible fo raise the upper ejector and lock it into the raised position by lifting the mechanism and pushing on the handle of the locking pin 83 To lower the ejector from the up and locked position lift the ejector slightly and pull on the locking pin gently lowering the upper ejector ALWAYS remember to unlock and reset the upper ejector to the DOWN position BEFORE starting production 11 1 Workhorse User s Guide METTLER TOLEDO For your notes 11 2 12 Chapter 12 Stopping the Wrapper and End of Production Stopping the Wrapper and End of Production When it is necessary to stop the machine for any reason including emergencies simply press the STOP button 30 located on the right hand side of the weed It is always recommended that if the wrapper will remain idle for any length of time to also press the STOP button to avoid any possibility of an accidental start SAFETY NOTE
20. chine NEVER pour or spray water or any other liquid directly onto any part of the wrapper When a cleaning solution is called for use a mild soap and water solution on a cloth to wipe the wrapper down NEVER UNDER ANY CIRCUMSTANCES attempt any cleaning procedure until the STOP BUTTON has been pressed in and the MAIN POWER switch has been moved to the OFF position 14 1 Workhorse User s Guide Daily and Weekly Cleaning Weekly Only 14 2 Remove all product and or film debris from the Infeed conveyor and belts ALL Photocells and reflectors Film transfer belts Elevator Product exit rollers and belts Sealing Belt Only After The Belt Has Cooled Wipe down the following parts e Infeed conveyor and belts All covers Wipe down the ejector rollers Remove the elevator and clean thoroughly Elevator Removal Remounting Chapter 14 Cleaning Maintenance Elevator Removal Remounting BE SURE THE STOP BUTTON IS ENGAGED AND THE MAIN POWER SWITCH MOVED TO THE OFF POSITION Open the inspection door 23 and unlock the two locking levers e Lift the elevator and begin to pull it out through the opening Collapse all the mushrooms on the elevator by knocking them down by hand This will make it easier to extract the elevator through the opening Pull the elevator the rest of the way through the opening Clean the elevator thoroughly Do not immerse the elevator in water at ay
21. consists of mounted to fl activated by centimeters indicator on or side 2 Threading the film is o the film off a Cy or servi using TLU When a TI his value is selec nly slightly different than threading plain film Sim the regis ice manual pin 809000103 for printed film trial s lance is required contact Exact Equi ration mark eyespot and place the film as usua his option installed ilm Consult with your pment led the appropriate prin only on wrappers being used in central packing Registered Film option the wrapper ilm with a pre determined pattern This pai he same place on the package would then uthorized pecifications If additional photocells 132 and reflectors 13 I that are he wrapper near the film distributor on each side These photocells are number s that have a programmed film length value of 00 LU with ti he operations panel will illuminate 58 whether programmed for side 1 led film ply tear or cut into the film distributor MAKE SURE the eyespot travels THROUGH the photocell beam see illustration below The use and Manual part particulars of this option are explained further in the Workhorse Service number 809000103 18 1 Workhorse User s Guide METTLER TOLEDO For your notes 18 2 19 Chapter 19 Warranty Warranty Mettler Toledo LLC warrants equipment and apparat
22. e During this self test the wrapper will analyze it s functions and determine if there is a problem in need of correction If a fault is found the wrapper will stop indicating an error If no fault is found the wrapper is ready for use an error should occur use the chart found below and on the following pages to determine what the problem is a MPORTANT NOTE HE REMEDY PROCEDURES LISTED HERE SHOULD BE CARRIED OUT ONLY BY TRAINED AND QUALIFIED OPERATORS RST DEPRESS THE STOP BUTTON AND TURN OFF THE MAIN POWER SWITCH F THE PROBLEM CANNOT BE RESOLVED BY THE PROCEDURES LISTED CONTACT YOUR LOCAL AUTHORIZED SERVICE AGENT DO NOT ATTEMPT ANY REPAIRS OR DEFEAT ANY SAFETY DEVICE S 13 1 Workhorse User s Guide Error Codes Errors should only occur on wrappers equipped with optional printed registered film readers with an optional weighing system attached Error that should only occur with optional product exit photocell or weighing system Error should only occur on wrappers equipped with optional extended infeed Error should only occur on wrappers equipped with optional automatic upper ejector 3 Errors that should only occur with an optional weighing System attached A Emor that should only occur with optional product exit photocell or weighing system 13 2 Errors that should only occur The following li
23. ection of the control panel 62 An LED overtravel has occurred on lention must be paid to the machine will light to indicate which side the MPORTANT The wrapper WILL NOT RUN UNTIL cleared he overtravel condition has been he electronics will not allow the wrapper to re start until the distributor cover on the side of the overtravel occurrence has been opened and the film removed This interlock has been installed to prevent damage to the wrapper by excess pieces of film becoming jammed in ihe film belts PRESS THE STOP BUTTON PRIOR TO ATTEMPTING FILM REMOVAL 8 1 Workhorse Service Manual METTLER TOLEDO For your notes Chapter 9 Wrapping Speeds Wrapping Speeds The Workhorse is capable of running at two different speeds packages minute Most trays will be programmed to run at 31packs minute but this speed can be changed at any time to 21packs minute by pressing the gt arrow button 55 on the control panel When the display indicators show a single arrow gt the speed is 21 packs minute When a double arrow displays gt gt the speed is 31 packs minute Slow speed is generally used for unusually high or unstable trays that would be a problem at the normal working speed of 31packs minute Maximum working speed is attained by placing the packages on the infeed with a 2 3 inch gap between packages for the X version wrappers b a 6 7 inch gap between packages for the Z
24. electronics the messages CANNOT be changed or altered by either the end user or the sali Lian eya LLL J 15 1 Workhorse User s Guide METTLER TOLEDO For your notes 15 2 16 Chapter 16 Automatic Weighing System Option Automatic Weighing System Option When the WorkhorseQ is installed with an automatic weighing system like the Exact RLA 971 system operations become slightly different A transfer system will be added to the wrapper s discharge that will make the system a complete wrapping and weighing system The wrapper s operating mode button 54 then becomes active and the wrapper can be used in anyone of the four following modes Wrapper Only In this mode the additional transfer section beyond the sealing belt becomes no more than an additional conveyor system and the packages transfer out of the wrapper without any further action E Wrapper And Scale In this mode following the wrap cycle the package will first be stopped on the sealing belt at the product exit photocell 100 for indexing onto the weighing platform 120 When the package leaves the sealing belt it then transfers over the weighing platform to the scale photocell 122 where the package will break the beam of the photocell The scale belts 121 will then drop placing the package down onto the weighing platform The scale will then weigh the package and then begin to deliver
25. he numbers that indicate the various parts will be used in subsequent sections of this manual Main Components 4 1 Exact Workhorse User s Guide Refit Description Main Power Switch Serial Identification Plate Reel arbor Indicator Lower Side Cover 1 Side Film Threading Diagram Fixed Film Transfer Belts Do not Move with Carriage Film Distributor Carriage Film Transfer Belts Move with Carriage Lower Ejector Pusher Pad Upper Ejector Assembly Folder Roller Plate Elevator Assembly Side Folder Plate s Exit Roller Assembly Exit Transfer Control Panel Mounting Position Varies with Wrapper Configuration Sealing Plate Thermostat On X version wrappers mounting is on the operator s Side on Z version wrappers on the opposite side Maximum Infeed Width Guide Used for Centering Trays on the Infeed Infeed Assembly Machine Photocell Reflector Triggers Wrap Cycle 20 Outfeed Transfer Belts Not Present with S Version Wrappers 21 Sealing Belt 22 Adjustable Legs 3ls lzlalslzlalololNlols l Jclsl ojoj 23 Elevator Access Door 24 Locking Slider for Dancer Tension Arm 25 Dancer Tension Arm 26 Lower Side Cover 2 Side 27 Diagnostics Box Port 28 Film Roll Positioning Guide 29 Film Arbor reel 30 Emergency Stop Switch 31 Distributor Cover 2 Side 32 Handle for Top Hood 33 Di
26. hermostat if needed If a scale system is attached select the needed operation mode w scale 4 16 wrap only etc Using the or buttons select the appropriate tray size 4 Be sure the film is present on both arbors properly threaded of adequate 7 size and in the correct position on the arbor Verify that ALL covers and guards are closed and in place Release the STOP button Press the START button on the control panel Place the trays centered on the infeed and begin wrapping After turning the main power ON if the STOP button is depressed the red display should display 01 and the red LED on the right of the infeed on the display 62 should be lit indicating the STOP button is engaged When the STOP button is released the display 61 should change to 00 and the LED on the infeed 62 should go out indicating Machine Ready Press the START button IMPORTANT Once the tray is placed on the infeed LEAVE IT ALONE NEVER push a tray or try to straighten it once it has been placed on the infeed The wrapper has safety interlocks that will stop the machine under normal circumstances should the package be severely misaligned 5 1 Workhorse User s Guide METTLER TOLEDO For your notes 6 Tray Sizes Chapter 6 Trays and Film Tray Sizes Trays and Film Most trays have a size number molded into the bottom of the tray this is generally the number that the ins
27. in Wrap Only mode 96 Remove Clean phi SCALE PHOTOCELL BLOCKED packages at sealing belt and scale platform otocell and reflector 122 amp 123 97 Remove Clean phi LABELING PHOTOCELL BLOCKED package s at labeling station otocell and reflector 124 amp 125 Remove 4 PACKAGES REMAINING AT PRODUCT EXIT PHOTOCELL packages at product exit photocell 100 101 sec 15 This is only a partial list and the solutions listed only suggest a possible course of action for more detailed information about a specific problem refer to the Chapter of this manual that deals with the particular part of the wrapper that is exhibiting problems Fault Cause Solution Fault Cause Solution The operations pi anel is not lit after turning the main power switch to the On position No main incomin g power Check the main power plug fo ensure that it is connected properly Packages are no a Sealing plate b Film too wide t sealed correctly loose film on the tray bottom femperature too low or long for tray being run a Increase the sealing temperature See sec 10 b Use the correct TLU for that tray use a narrower film on that side Reprogram the fil m parameters for that TLU Fault Cause Solution Fault Cause Solution Fault Cause Solution Fault Cause Solution Fault Cause Solution
28. ll width required Required Film Programmed Length Place the tray product to be wrapped on a flat surface With the 4 mark of the tape measure placed on a lengthwise edge of the tray Ref B measure the cover length of the tray plus 4 on the opposite lengthwise edge of the tray The TOTAL measurement at that point is the required programmed film length for that package in centimeters 7 Installing Film on the Workhorse Chapter 7 Film Installation Installing Film on the Workhorse Film Installation The Workhorse wrapper uses PVC stretch films from 50 100 gauge And accommodates 2 rolls of film one on each side of the wrapper from which if will automatically select via TLU or tray program The rolls of film must be installed in the correct fashion i e the correct size roll on the 1 and 2 sides and threaded properly for the wrapper to function normally Standard film positioning is the small roll of film is placed on the arbor marked 1 and the large roll is placed on arbor 2 This may be reversed if needed but remember to program the wrapper accordingly FIRST PRESS THE STOP BUTTON 7 1 Workhorse User s Guide With the Dancer Film Tension Arm in the DOWN position lift the lever on the arbor as shown If an empty roll of film is present remove the Slide the new full roll of film onto the arbor as shown BE SURE THE FILM UNWINDS IN THE CORRECT DIRECTION BY
29. mbus Ohio 43240 www mt com P N 64063805 METTLER TOLEDO is a registered trademark of Mettler Toledo LLC 2012 Mettler Toledo LLC 64063805
30. not only simple to use but simple to repair minimizing downtime and eliminating most routine service With a minimum of maintenance and care the Workhorse will provide the user with years of outstanding performance and satisfaction 1 1 Workhorse User s Guide Workhorse ZS Workhorse ZS with 90S90 Powered Conveyor and Model 707 Indexer Labeler Chapter 2 Safety Safety WARNING FAILURE TO ADHERE TO THE FOLLOWING INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE e Carefully read and understand the Operator s Manual The Workhorse uses an electrically heated sealing belt Use caution when working near the belt even after the wrapper has been turned off The Workhorse cycles through a complete wrapping operation when the package sensors are triggered Be aware of this and keep hands and clothing away from the moving parts of the wrapper when ihe power is on e NEVER attempt to defeat any of the various safety interlocks on the guards DO NOT attempt internal adjustments or repairs These must be performed by trained and qualified service personnel DO NOT allow water to enter the electrical enclosures Use caution when cleaning and disconnect the power REMEMBER the wrapper is a wipe down NOT a wash down machine NO ONE but qualified operators age 18 or older should operate the wrapper e DO NOT permit distraction of the operator while the wrapper is in u
31. scharge Cover s 34 op Hood 35 Distributor Cover 1 Side 4 2 Chapter 4 Wrapper Parts and Controls Power Controls Power Controls Main Power Switch Black Push Button When pushed ALL power to the wrapper is engaged and the machine is ready for use CAUTION DO NOT hei f safely lockout lock can be installed 4 3 Exact Workhorse User s Guide Control Panel Up TLU Selection Button Selects TLU s with a higher than The one displayed at position 57 TLU Display 4 4 Chapter 4 Wrapper Parts and Controls Control Panel Down TLU Selection Button Selects TLU s with a lower than 53 The one displayed at position 57 TLU Display Scale Wrap Mode Selection Button Operational ONLY when a Scale System is Attached Indication for wrap scale mode will 54 appear at position 59 Wrapping Speed Selection Button used to override the programmed or current wrap speed setting Indication for 55 current wrap Speed can be found at position 60 Selection Push button to Activate Deactivate Voice Mode Option in Automatic Mode OR Activate Voice Prompt when in On Demand Mode Active Only When Voice Option is Installed see explanation sec 14 4 TLU Selection Display Displays Currently Selected TLU Tray 57 Look Up numbers 58 Indicators for Printed Registered Film Operation With film reader option installed ONLY see sec 1
32. se DO NOT permit personnel with loose clothing ties or jewelry near the wrapper when in use e Maintain a firm footing in the area surrounding the wrapper DO NOT allow unqualified personnel to attempt repairs Switch the wrapper OFF when not in use Keep the wrapper clean and in good running order SWITCH OFF and LOCK OUT the wrapper before attempting any cleaning or maintenance DO NOT attempt to operate a damaged or a malfunctioning wrapper Use in accordance with the manufacturer s instructions DO NOT attempt to force oversized packages through or into the wrapper e Keep the area around the wrapper clean dry and free of obstructions e DO NOT use extension power cords Workhorse User s Guide METTLER TOLEDO For your notes Chapter 3 General Information amp Specifications 3 General Information amp Specifications Dimensions 26 Workhorse User s Guide Specifications Power Speed Dimensions 3 2 Supply Voltage 208 240 VAC 60 Hz Phase 12 5 amps dedicated circuit NEMA L15 20R Twist Lock receptacle required Installed Power 2500 Watts Tolerance Of Installed Power 5 Packages per Minute 30 Normal 21 selectable and or program to tray size Wrapper Only Dimensions Type 2 Depth 64
33. st of error codes includes a basic starting point for solving the problem that caused the error These solutions are mainly operator related Use the Chapter number that is lisi Error code ed above the solution to find more detailed solutions Error description and possible solutions 00 MACHINE READY Press the start button on the operations panel 51 01 STOP BUTTON IS DEPRESSED Release the stop push button by twisting lightly clockwise 30 02 AUTO SHUT OFF MACHINE NOT IN USE FOR 3 OR MORE MINUTES Press the start button on the operations panel 51 05 COVER OPEN Close ALL covers Place packages on infeed correctly Remove debris from infeed if present Clean safety photocells and reflectors 07 RESET Press the start button on the operations panel 51 08 FOLDER OR EJECTOR CABLE BROKEN Cable switch is open replace cable OR reset repair switch 09 PREVENTATIVE MAINTENANCE INTERVAL REACHED Press the start button and continue wrapping 11 INCORRECT POSITION OF CAM Press the start button on the operations panel 51 Unlock the cam motion using the T Handle INCORRECT POSITION OF THE ELEVATOR Press the start button on the operations panel 51 PRESS THE STOP BUTTON Remove any product that may be caught in the wrapping area Release the stop button Press the start button 51 Using the T Handle relieve any possible bind in the wrapping area
34. talling technician will use to program the wrapper with the correct amount of film stretch etc This is the number that should appear in the display position 57 in green To select any particular tray size simply press the 52 or the 53 button to display the desired TLU Tray Look Up Number Remember only the tray sizes that are currently active will be displayed That is if the tray sizes io be run are 2 4 8 10 12 25 and 10X14 displayed as 14 as there are only 2 digits available in the display then these will be the only tray sizes that will be displayed Your Authorized Service Agency can program additional TLU s if they are required 6 1 Workhorse User s Guide Tray Dimensions and Film Size 6 2 The following measurements need to be taken with the actual product present in the tray that is intended to be run on the wrapper As the Workhorse will only accept film length dimensions in centimeters we suggest the use of a tape measure with BOTH inch AND centimeter millimeter increments 1 inch 2 54 cm The dimensions that are taken and the dimensions actually programmed used may vary depending on such factors as Film stretch overall wrapper condition product height variance product pliability and tray quality A Required Film Roll Width Wrap a tape measure around the tray product widthwise Ref A The mark where the tape measure meets itself around the tray is the film ro
35. the Wrapper Manually Clearing the Wrapper The Workhorse wrapper with it s electronic controls and safety features is the most jam proof wrapper on the market today On occasion however jams DO occur Most jams can be manually cleared by simply removing the stuck package from the wrapping area CAUTION MUST ALWAYS BE EXERCISED NOTE ALWAYS press the Stop Button in and turn the Main Power switch to the off position prior to removing any product that has become stuck in the wrapper If the product is still un removable simply raise the dancer bar 25 and open the lower cover 24 to expose the main drive motor and the T handle Insert the T handle into the end of the motor and turn the handle COUNTERCLOCKWISE to relieve the jam Once the product is free remove the product remove the T handle from the motor return il to it s holder close the cover and lower the dancer bar The wrapper can now be restarted and is then ready for use 17 1 Exact Workhorse User s Guide METTLER TOLEDO For your notes 17 2 18 Chapter 18 Printed Registered Film Option Printed Registered Film Option This option is generally found operations Supermarket wrappers will not have When the Workhorse is equipped with the Prini has the capability of running be placed on each paci age of the same size in This option requires the use of specially printed fi service agen further assis The option
36. us sold against all defects in workmanship or materials for the following period s of time Workhorse Automatic Wrapper 1 year from date of shipment This warranty does not apply to expendable parts malfunctions caused by packaging supply failure conditions of misapplication abuse lack of maintenance improper installation or abnormal environmental conditions THE PROVISIONS OF THIS WARRANTY CONSTITUTE THE ONLY AGREEMENT BETWEEN THE PARTIES RESPECTING THE SUBJ ECT MATTER HEREOF THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION HEREIN INCLUDING THE WARRANTIES OF MERCHANT ABILITY AND FITNESS Mettler Toledo LLC shall in no way be liable for any losses costs forfeitures damages including loss of profits liabilities of the purchaser to it s customers or third persons liability of Exact Equipment to it s customers employees or other third persons and all other special incidental or consequential damages whether direct or indirect and whether or not resulting from or contributed to by the default negligence whether in manufacture or design or failure to warn on the part of Exact Equipment it s agents employees and subcontractors which might be claimed as a result of or use with or without an active malfunction or malfunction of the equipment or apparatus covered by this warranty or as a result of the failure of Exact Equipment to comply with or conform to any application terms or condition of sale
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