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1436 Village Farms

1. 1 4 Figure 2 1 Pushing a Machine with a Forklift llle 2 5 Figure 2 1 Ground Connection 2 6 Figure 2 2 3 Phase Power Connection 2 6 Figure 2 3 Fittings for FRL Unit amp Lubricator 2 7 Figure 2 4 Air Lubricator 2 7 Figure 4 2 RESET Button 4 11 Figure 4 3 EMERGENCY STOP Button s 4 11 Figure 4 4 HMI and Chapter Organization 4 12 Figure 4 5 SERVICE CALL Screen 4 13 Figure 4 6 Main Control Screen 4 14 Figure 4 7 MACHINE ALARM Status Indicator 4 14 Figure 4 8 MACHINE ALARM Status Indicator 4 14 Figure 4 9 START STOP BUNON 6d dodi den hr Ee ot tr ORE e G Po Euler eed ee A 4 15 Figure 4 10 VALUE Button and Display RII 4 15 Figure 4 11 TRAYS PER SHIFT Display iod rg her Eon Ped em de dt pc Eon deu eer Rd ae 4 15 Figure 4
2. 4 25 4 111 PLG INPUTS Button ese rr C Raf Re ER e ES RO EUR RR EUR E d 4 25 4 12 PLC INPUTS SCREENS 4 26 4 12 1 PLC INPUT Status Indicators 4 26 4122 NEXT BON 4 26 4 12 8 PLC OUTPUTS ENGINEER Button 2 oo 4 26 4 13 PLC OUTPUTS SCREENS 4 27 4 13 1 PLC OUTPUT Buttons and Status Indicators 4 27 4 13 2 SERVICE CALL Button 4 27 4 13 3 REMOTE DEMAND Button 4 27 4 14 REMOTE DEMAND SETTINGS SCREEN 4 28 4 14 1 REMOTE DEMAND DELAY Buttons and Displays 4 29 4 14 2 EXTENDED HOPPER Button 0 nen 4 29 4 15 EXTENDED HOPPER 1 SCREEN 4 30 4 15 1 BEGIN HOPPER SEQUENCE DELAY ON TIME Button and Display 4 30 4 15 2 RPC LIFT DELAY ON TIME Button and Display 4 31 4 15 3 SIDE CROSS PUSHER DELAY ON TIME Button and Display 4 31 4 15 4 C
3. 4 38 4 18 3 OPENER SLIDE Buttons and Displays 4 38 4 18 4 RPC LOCK HAMMER Buttons and Displays 4 38 OPERATING PROCEDURES 5 1 GENERAL OUTLINE 5 1 5 2 MACHINE START ew r ard a EE ES Q a Rx QUQ Pee qu Q SE 5 1 5 3 LOADING TOTES J um ee a nn oe oe ch a en ce e S Te awe dud eb 5 1 5 4 PRODUCTION OPERATION ds aut dex ea au Oe ae eh wech make k wU K ur uQ ecc 5 1 RP 100 RPC Erector IPAC IPAC RP 100 RPC Erector 5 4 1 Starting the Machine 1 ee eens 5 1 5 4 2 Stopping the Machine lisse 5 2 5 5 SAFETY SYSTEMS AND FEATURES 5 2 5 6 FEATURES AND INSTRUCTIONS 5 2 5 7 SHUTDOWN PROCEDURE 32 2 59 2 2 9029 9 800 bau g ba hua Rae Dto Bedae Dein Q toten pe qon Docs 5 3 6 MACHINE SETUP 6 1 GUIDE BAIE ADJUSTMENT us deno rax ae clc be es Rear dex ue ac xc e 6 4 6 2 LOCK HAMMER LATERAL ADJUSTMENT 6 5 6 3 FLAP OPENER VERTICAL ADJUSTMENT 6 5 6 4 FLAP OPENER HORIZONTAL ADJUSTMENT 6 6 6 5 LOCK HAMMER SWING ADJUSTMENT 6 7 6 6 LOCK HAMMER LONGITUDINAL A
4. 2 7 9 17 shut off valve 1 3 2 7 VANWE 2 2 20 bos aa BR aan 1 3 MAIN DISCONNECT switch 1 3 main Power 1 3 9 16 maintenance chain tension 7 8 OA cR 7 8 WEEK uw ote ice E 7 9 IPAC RP 100 RPC Erector motor installation 2 6 specifications 9 16 N NEXT DUO xi 24 232008 um oe ames umasa 4 26 Nordson gregi M 1 3 Manlal M TT 1 3 O operating procedures 5 1 outfeed conveyor 1 4 P Password window 4 22 PLC INPUTS DURON aac xia luu uu oe eek oc s 4 25 PLC INPUTS button and status indicator 4 26 PLC Inputs screen 4 26 PLC OUTPUT button and status indicator 4 27 PLC Output screen 4 27 PLC OUTPUTS button 4 26 pneumatic specifications 9 17 precaution 1 2 R rear latis es einen ERE WA 2 5 REMOTE DEMAND button 4 27 4 29 REMOTE DEMAND DELAY OFF button and display 4 29 REMOTE DEMAND DELAY ON button and display 4 29 Remote Demand Settings screen 4 28 S safety standards 1 2 screens PLCInputs 4 26 PEG OU
5. 1 3 Installallon Seen gehn See Ge 2 2 5 electrical specifications 9 16 EMERGENCY STOP button 4 11 safety 1 1 specifications 9 16 engineering specifications 9 16 filter regulator unit 1 3 gom ae Hnm 2 7 fuse disconnect 2 6 Index G OEANMOUONS o dcs e ROS 1 4 GLUE OFF ON selector switch 9 16 ground wire 2 6 guard doors 1 4 GUa difi e e saioe P 1 1 1 4 removal 7 11 guide rail uUo nn 6 4 guid rals Suq a oe 6 4 hopper uas dex E Eee 6 4 6 7 HOLHIGIU zeugen een bee REA 1 3 I AT 1 3 I Installation 2 5 Interlock switches 1 4 J 1e E ETE TEENE E EENE GEBE s PE 3 8 JOG REV OFF FWD selector switches 9 16 L limit switches _ 9 16 lock out compliance 1 2 1 3 lubricator Die quM 2 7 M machine moving 2 5 2 5 PUSHING esca Bene uum 2 5 jr LT 9 16 SOCCO 9 16 SAUD T 7 11 machine specifications 9 16 main aif
6. 4 38 Figure 6 1 Infeed end Side Guide 6 4 Figure 6 2 Outfeed end Side Guide eee 6 4 Figure 6 3 RPC Lock Hammer Clamp Blocks cece 6 5 Figure 6 4 Flap Opener Vertical Adjustment 6 5 Figure 6 5 RPO W Wa ae wapu ga 6 6 Figure 6 6 Horizontal Adjustment Clamp Block 6 6 Figure 6 7 Lock Hammer Assembly 6 7 Figure 6 8 Lock Hammer Cylinder and Mount 6 7 Figure 6 9 Lock Hammer Longitudinal Adjustment 6 7 Figure 8 1 Vacuum Drive Cam Assembly 8 12 Figure 8 2 Cam Follower Linkage l l rr 8 12 Figure 8 3 Vacuum Assemblies nnana naana 8 13 yi IPAC RP 100 RPC Erector ACHINERT Vii IPAC RP 100 RPC Erector Preface PREFACE IPak Model RP 100 Tray Former are versatile and industry proven machines with unique mechanical tray forming technology They are designed and built to withstand the rigors of continuous heavy duty industrial applications The RP 100 Tray Former
7. KA wmnalle Plastic Container retor ISSUE DATE MAY 2011 m MACHINERY Village Farms Serial Number 1436 1437 Operation and Service Manual Designed and Manufactured by IPak Machinery Wexxar Packaging Inc Unit 1 14211 Burrows Road V Lii ds rar h Richmond BC Canada V6V 1K9 C y Phone 604 940 8073 Fax 604 940 8074 er www ipakmachinery com Email sales ipakmachinery com a division of Pro Mach lt IPAC RP 100 RPC Erector 1 1 N I TABLE OF CONTENTS PREFACE HOW TO USE THIS MANUAL iud arae auqa Don ded Ec dr d E nio e on iren da od 1 IX SAFETY 1 1 SAFETY CONSIDERATIONS 1 1 1 2 SAFETY STANDARDS u ge ee eom Q RC a bout kS pure ee w de ee 1 2 1 3 GENERAL PRECAUTIONS ue ac icd oa oe cuca eee ee a ae wa s a ue CR rar Mes E er 1 2 1 4 LOCK OUT GOMPLIANGE u au 00 000010 ERO wkd weak Roe dox a 1 3 1 5 COMPRESSED AIR 1 3 1 6 ELECTRICAL POWER au une aan neh sd dnos ie bea S d bur Eg ee ea wQ a 1 3 1 7 HOT MELT GLUE SYSTEM 1 3 1 8 OUTFEED CONVEYOR 1 4 1 9 GUARD DOORS 1 4 1 10 SAFETY INTERLOCKS eee Rh rre 1 4 1 11 CAUTIONARY LABELS e r
8. 2 X11 3227 CONVEYOR TOP PLATESPACER 4 3 X11 3228 CONVEYORCHAINRAIL 4 4 X11 3229 CHAINRAILSUPPORTBAR 4 6 X11 3231 INNERINFEEDRAIL RH 1 8 X11 3233 OUTERINFEEDRAILIH 1 xo fara CENERCONV MOUNTEAR 2 20 20 2195 ASSY IDLE SHAFT INFEED CONV 21 29 1761 ASSY MOTOR 1HP GEARBOX 30 1 22 X29 1765 ASSY HOPPER GATE AND CYC PROPRIEIARY AND NHDENTIAL TOLERANC ES UNLESS z THE INFORMATION CONTAINED ay T DRAWING S THE SOLE RB NC E PRO EC u du OTHERWISE SPEC IFIED WEXXAR Pac kaging Inc PROPERTY OF WEXXAR PACKAGING INC ANY REPRODUCTION DECIMAL IN PARTORASA WHOLE WITHOUT THE WRITIEN PERMISSON OF 3D SOLID DRAWING FRACTIONAL 132 WEXXAR PACKAGING INC IS PROHIBITED ANGULAR TITLE ASSY INFEED CONVEYOR 030 1 MATERIAL AS SHOWN DESCRIPTON X80 1023 0 75 OD X 125 L 13 32 ID_ 8 ES 4 2 2 NO EN 3179 6 X11 3180 LOCKERHAMMER si 8 X11 3182 LOCKER HAMMER SHAT 9 X11 3195 LOCKERMOUNTBARR 1 2 10 X11 3199 LOCKERMOUNTBARPLATERH 2 11 X11 3200 LOCKERMOUNTBARPLATERH 2 12 X11 3201 LOCKERMOUNTBARPLATECLAMP 4 X11 3327 LOCKER MOUNT CLAMP x10 6139 SPACERS BODXIS SDXUAL 4 15 200 1018 Cyl 158x 155 DACT C W ADJ CUSHION 4 16 2551 BEARING RETAINING ROLLER 8 17 272 749 ROD END FEMALE 7 16 NF HEAVY DUTY 4 ENTIA TO LERANC ES
9. 4 26 Figure 4 44 NEXT Button RR rrr 4 26 Figure 4 45 PLC OUTPUTS ENGINEER Button 4 26 IPAC RP 100 RPC Erector Figure 4 46 PLC Outputs Screens 4 27 Figure 4 47 PLC OUTPUT Buttons and Status Indicators 4 27 Figure 4 48 SERVICE CALL BUON EE Wire did 4 27 Figure 4 49 REMOTE DEMAND BUTTON 2022026 cona Ro bo ono ee a 4 27 Figure 4 50 Remote Demand Settings Screen 4 28 Figure 4 51 REMOTE DEMAND DELAY Buttons and Displays 4 29 Flgure d4 52 EXTENDED HOPPER BULIOLI uu u kr o rop rn ce nde bia a o e tede trm tae twee 4 29 Figure 4 53 Extended Hopper 1 Screen llli 4 30 Figure 4 54 BEGIN HOPPER SEQUENCE DELAY ON TIME Button and Display 4 30 Figure 4 55 RPC LIFT DELAY ON TIME Button and Display 4 31 Figure 4 56 SIDE CROSS PUSHER DELAY ON TIME Button and Display 4 31 Figure 4 57 CROSS PUSHER READY DELAY ON TIME Button and Display 4 31 Figure 4 58 CROSS PUSHER EXTENDED DELAY ON TIME Button and Display 4 32 Figure 4 59 CROSS PUSHER HOME DELAY ON TIME Button and Display 4 32 Figure 4 60 Extende
10. CAUTION Read and understand the safety instructions in the separate Nordson Manual supplied with your new machine The Hot Melt glue system operates at temperatures in the range of 350 F 175 C and contact with the hot glue will cause serious burns Always wear safety glasses and gloves when refilling the glue tank and be careful to avoid splashing Keep the tank lid closed at all times except when refilling the tank Remember that the glue applicator is very hot and that the glue is projected with considerable speed when the glue applicator is switched ON Be extremely careful when near Hot Melt material Even solidified material may still be very hot Always wear protective clothing which safely covers all exposed parts of the body 1 3 IPAC RP 100 RPC Erector Safety 1 8 Outfeed Conveyor Where used the outfeed conveyor systems on IPak packaging machines operate at moderate speeds Be sure to keep fingers well clear of all moving parts as the gearmotors develop substantial torque and do not stop easily Do not wear loose clothing or accessories e g neckties when operating IPak packaging machines 1 9 Guard Doors IPak takes your safety seriously offering the added benefit of safety guarding with interlock guard doors on all of our machines This guarding prevents operators from reaching into the machine during routine operation and maintenance 1 10 Safety Interlocks IPak is an industry leader in the incorporat
11. O THERWISE SPEC IFIED WEXXAR Pac kaging Inc PROPERTY OF WEXXAR PAC KAGING INC ANY REPRO DUC TION DECIMAL t 030 IN PARTOR AS A WHOLE WITHO UT THE WRITTEN PERMISSION 3D SOLID DRAWING WEXXAR PAC KAGING INC IS PROHIBITED FRAC TONAL 1 32 mE SEC E ASSY RPC DRIVE MATERIAL AS SHOWN DRAWN BY k nm X21 767 e fe l f 2 X1b3208 PUSHERUNEARSHAFI 2 3 113213 PUSHERUNEARBRG PIATE 1 4 X11324 PUSHERBOCK f1 L6 254 BEARING LINEAR 1 1 4 SELF ALIGNING 4 PROPRIETARY AND CONFIDENTIAL DIMENSIONS ARE IN INC HES TOLERANCES UNLESS i MR AEN UMORE BREE THIRD ANGLE PROJEK TON OTENE Te P WEXXAR Packaging Inc 3D SOLID DRAWING FRACTONAL ANGULAR IN PARTS RASA WHO LE WITHOUT THE WRITTEN PERMISSION OF 1 32 TITLE ASSY RPC PUSHER P N RPACKAGING INC IS PROHIBITED 030 1 DESCRIPTION ruis AS SHOWN DATE 10MARI1 aperoveney X21 766 m RE or X X Z O 10 BEARING LINEAR 1 SPB 16 NSK aves ropmowassew a fates m S sss PROPRIETARY AND CONHDENTIAL DIMENSIONS ARE IN INC HES TOLERANCES UNLESS HRD Packaging Inc ANGULAR 1 WHOLE WITHO UT THE WRITTEN PERMISSION OF RACTONAL 1 32 THLE ASSY PICK LIFT BEBEEEEEENE es N R PACKAGING INC IS PROHIBITED MATERAL AS SHOWN NO 4 x113222 ROTARYBIOCKPN 8 6 X11 3224 ROTARYBLOCKCY
12. 4 14 4 6 1 MACHINE ALARM Status Indicator 4 14 4 6 2 MACHINE WARNING Status Indicator 4 15 45 9 STAAI SIOP BU llOD 1x22 drania a beak be tugas be an ee Eon Oe oA 4 15 4 6 4 VALUE Buttons and Displays 4 15 4 6 5 TRAYS per SHIFT Display xix nun 53 mann nen REE EES REEL SE RS Eee 4 15 4 6 6 TRAYS PER MINUTE Display 22 u 000 wi un m a 00 REESE RHO In RAED EEE ann 4 15 4 6 7 Numeric Keypad Window 4 16 4 6 8 TRAY DEMAND Toggle Switch and Display 4 16 4 6 9 DUTY LANE Toggle Switch i uium atrae dc i ee ep tC eh SC CHR CC UR 4 16 4 6 10 JOG CONTROL Button 4 16 4 7 JOG CONTROL SCREEN mann 4 17 4 7 1 JOG REVERSE and JOG FORWARD Buttons 4 17 4 7 2 SENSOR Status indicator 4 18 4 7 3 MAIN CONTROL Button 4 18 4 7 4 SETUP Button asa sued 0 00 drame RR an an an na he CRT ER RC REES 4 18 42 8 SETUP SCREEN x22 2022 08 du a ee E do diera a ab a shee eut RC SE wer at qe an re 4 19 4 8 1 DRY CYCLE Toggle Switch
13. RMATION CONTAINED IN THISDRAWING 1 THERWISE SPEC IFIED WEXXA PORN E Nea ENRE No M AM omini THIRD ANGLE PROJECTION D MERE ST FED RPackaging Inc m ASSY STACKER INFEED SECTION ANG ULAR MATERIAL AS SHOWN 2 DESC RIPTION 6 X22401 WLDMT INFEED GUIDE LH 1 8 X22 403 WLDMTTRAYGUIDERH 1 9 X122542 GUIDEBLOCKSPACER 22 2 4 4 zZ 10 11 12 1 1 15 16 17 202 729 HING E BAR 2 x 72 Piano Hinge WEXXAR Packaging Inc ASSY SIACKER LIFT SIOP INIA e 2 PROPRIETARY AND CONFIDENTIAL DIMENSIONS ARE IN INC HES TOLERANCES UNLESS THE INFORMATION CONTAINED IN THISDRAWING ISTHE SOLE IRD ANGLE PROJ EC TION OTHERWISE SPEC IFIED PROPERTY OF WEXXAR PACKAGING INC ANY REPRO DUCTION DECIMAL 030 IN PARTORASA WHOLE WITHOUT THE WRITIEN PERMISSION OF 3D SOLID DRAWING FRACTIONAL 132 WEXXAR PACKAGING INC IS PROHIBITED ANGULAR IE MATERIAL AS SHOWN em ned TIO monn X22410 we sr one AS SHOWN BETT Fi t ew ende IY DEED M ES He C a TRAP GUIDE LOWER MOUNT EJ mer soer enen 1 Ee JE an TRAP GUIDE CYL REAR MTG BL Ea E Ii p s 14 2022453 RO D END FEMALE 5 16 NF ES NRE 3D SOLID DRAWING FRACTIONAL Assy TRAP G UIDES STAC KER PROPRIETARY AND CONRDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING ISTHE SOLE PROPERTY OF WEXXAR PAC KAGING INC ANY REPRO DUC TION IN PART
14. The single arrow scrolls one line at a time while the double arrow scrolls one screen at a time Figure 4 29 SCROLL Buttons 4 21 iPAC RP 100 RPC Erector Controls 4 9 2 CLEAR Button Clear Touch the CLEAR button located at the bottom center Figure 4 30 CLEAR Button center of the Alarm History screen to erase accumulated alarm messages Authorized users may clear this data upon entering the password on the Keyboard that appears Note that touching this button will bring up a Password window 4 9 3 Password Window Touch the blank field in the Password window to bring up an Alphanumeric keypad window Type the required password 9300 To enter the password into the Password ee ee window touch the ENTER key Then touch the OK button If you enter an invalid password an error message will display Touch OK to remove the error message and input a valid password NOTE As soon as the password is entered and the OK button is touched the Alarm History screen will cleared Input password Figure 4 31 Password Window Keyboard Ej fa af af of ef eol ET me EEEHEEEEERERET EREEFEFHEEEBEES SRS ee ee ee cc cars SHIFT gt Figure 4 32 Alphanumeric Keypad Window 4 9 4 Alphanumeric Keypad Window Touch the buttons in the Alphanumeric Keypad window to set the username and the password into the field at the top of th
15. When this sensor is cleared another stack of unopened trays is moved by a crosspusher into positon ready to be advanced into the RPC Hopper The sensors and limit switches described above trigger a series of timers in the PLC which then trigger the following outputs Valve SV6 RPC Pick Output O 2 0 6 Valve SV7 Grip Swing Output O 2 0 7 3 1 4 Tray Advance and Opening As the tray is placed on the guide rails its presence is detected by the OUTFEED JAM sensor Input 0 0 12 The RPC Pusher then pushes the tray forward and into position for opening Two pairs RPC Openers then descend to the bottom of the tray After reaching the tray bottom the pairs separate one pair moving towards the leading end of the tray and the other to the trailing end The claw shaped tray openers slide under the folded end panels of the tray lifting their edges up off of the tray floor The lifting of the tray ends forces the tray sides to rotate upward into a vertical position Finally four RPC Lock Hammers located near the the tray corners swing outwards to impact the tray s end panels near the tray corners The tray opening sequence with the tray openers and hammers is initiated by the RPC PUSHER FWD limit switch Input 0 0 10 The impact of these hammers forces the four corners of the tray into their locked positions The tray remains on the guide rails at this location until pushed forward and out of the machine by the advance of t
16. hh 4 19 4 8 2 DRY CYCLE ACTIVE Status Indicator 22 ee 4 20 5 4 8 3 REMOTE DEMAND Toggle 4 20 4 8 4 REMOTE DEMAND ON Status Indicator 4 20 4 8 5 ALARM HISTORY Button 4 20 4 9 ALARM HISTORY SCREEN 4 21 BERE sans 4 21 24223 4 22 4 9 3 Password 4 22 4 9 4 Alohanumeric Keypad Window 4 22 4 9 5 TRAY RECORD SUMMARY Button 4 22 4 10 TRAY RECORD SUMMARY SCREEN 4 23 4 10 1 TOTAL NUMBER OF TRAYS Display rrr 4 23 4 10 2 TOTAL TRAYS PER SHIFT Button and Display 4 24 4 10 3 Total Trays Per Shift Confirmation Window 4 24 4 10 4 TRAYS per MINUTE Display 4 24 4 10 5 TROUBLESHOOTING PLC WO Button ne 4 24 4 11 TROUBLESHOOTING SCREEN
17. 12 TRAYS per MINUTE Display 4 15 Figure 4 13 Numeric Keypad Window lerra 4 16 Figure 4 14 TRAY DEMAND Toggle Switch and Display 4 16 Figure 4 15 DUTY LANE Toggle Switch 4 16 Figure 4 16 JOG CONTROL Button 4 16 Figure 4 17 Jog Control Screen u u uuu a od w 4 17 Figure 4 18 JOG REVERSE and JOG FORWARD Buttons 4 17 Figure 4 19 SENSOR Status indicator 4 18 Figure 4 20 MAIN CONTROL Button 4 18 Figure 4 21 SETUP Button neusten neuartiger 4 18 Figure 4 22 Setup Screen lille esee ehh 4 19 Figure 4 23 DRY CYCLE Toggle Switch 4 19 Figure 4 24 DRY CYCLE ACTIVE Status Indicator 4 20 Figure 4 25 REMOTE DEMAND Toggle Switch 4 20 Figure 4 26 REMOTE DEMAND ON Status Indicator 4 20 Figure 4 27 ALARM HISTORY Button 4 20 Figure 4 28 Alar
18. 4 1 Starting the Machine With the power turned ON and a blank hopper full of trays J Turn the JOG ON OFF button on the HMI screen to the OFF position 2 Touch the green START button on the HMI screen 3 1 IPAC RP 100 RPC Erector Operating Procedures The machine will now run automatically continually erecting trays If the machine is required to stop and start from a remote area or on demand by a conveyor system a remote switching device limit switch sensor foot pedal etc is required This switching device must be wired in the normally OPEN position Refer to the remote demand hookup on the electrical schematic diagram X100 E0044 The machine operation does not change when the remote switching device is connected 5 4 2 Stopping the Machine The machine will continually run until the machine is manually turned OFF by the operator or until the hopper runs out of folded trays To stop the machine manually touch the red STOP button on the HMI or stop the signal from the remote switching device The machine will run several cycles without picking any more blanks to ensure that all previous trays are cleared from the machine 5 5 Safety Systems and Features If a tote is blocking the PH 13 sensor or if any of the check timer setting conditions are not met a safety timer will time out and stop the machine To restart the machine 1 Depress the EMERGENCY STOP button 2 Remove the tote and any obstructions 3
19. ES UN THE INFORMATION CONTAINED on DRAWING IS THE SOLE THIRD ANGLE PROJECTION OTHERWISE SPEC IFIED WEXXAR Pac kaging Inc s PROPERTY OF WEXXAR PACKAGING INC ANY REPRODUCTION DECIMAL 030 IN PARTORASA WHOLE WITHOUT THE WRITIEN PERMISSION OF 30 SOLID DRAWING FRACTIONAL 132 WEXXAR PACKAGING INC IS PROHIBITED ANGULAR 1 THLE ASSY STAC KER FRAM E MATERIAL AS SHOWN DRAWN BY LL ETT D s je Por EMABH amwes X22 448 Uu WIWIWIWINININININININININ INTER I Rte e HP FI le ulas oolr e esI ti il 6 X12346 SIACKERUNEARMOUNTDUAL 1 8 XI29 6 54 5 4 9 xiz97 SPACER CYL 2 B x 9 S FLANGE MOUNT 1 7 16 17 202 300 LOCK COLLAR SPLIT3 4 ZINC PLATED PROPRIETARY AND CONHDENTIAL DIMENSIONS ARE IN INC HES TOLERANCES UNLESS ENG ERROR IE EREDE HIRD ANGLE PROJECTION OPEWE Scr WEXXA R Packaging Inc IN PARTORASA WHOLE WITHOUT THE WRITIEN PERMISSION OF 3D SOLID DRAWING FRACTIONAL 1 32 WEXXAR PACKAGING INC IS PROHIBITED o THLE ANGUS T UT ASSY STACKER LIFT MATERIAL AS SHOWN ETT D s gt px EMARH emees omas X247 s 1122617 STACKER INFEED CHAIN RAILGUDE gt s D02262 CHANRALMOUNINGEAR 3 s 02262 CHANRALMOUNTNG PLATE PRIETARY AND CONHDENTIA DIMENSIONS ARE IN INC HES TOLERANCES UNLESS IN PARTORASA WHO LE WITHOUT THE WRITIEN PERMISSION OF 3D SOLID DRAWING WEXXAR PACKAGING INC IS PROHIBITED FRACTIONAL PRO L
20. RP 100 RPC Erector Controls Main Control Figure 4 65 Hopper Screen 4 17 Hopper Screen The Hopper screen includes four timings for the machine s hopper Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the SETUP button in the bottom right hand corner to bring up the Setup screen secus E EOM Figure 4 66 SLIDE SWING Buttons and Displays 4 17 1 SLIDE SWING Buttons and Displays The first pair of the Hopper buttons and displays are those of the SLIDE SWING They indicate in milliseconds the start and stop times for the hopper s Slide Swing Touching the numerals of either of these touch sensitive values will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER Y button 4 35 IPAC RP 100 RPC Erector Controls e EE Figure 4 67 RPC PICK Buttons and Displays 4 17 2 RPC PICK Buttons and Displays The second pair of the Hopper buttons and are those of the RPC PICK They indicate in milliseconds the start and stop times for the hopper s RPC Pick Touching the numerals of either of these touch sensitive values will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new valu
21. SHAFTBAR 1 11 Xr2502 CROSS PUSH CYL SUPPORT 1 12 ya2 2514 CROSSPUSHER ROD END MTG 1 Eu Eu 2 3 2 3 2 1 1 1 1 1 1 1 1 1 1 2 X Z00 145 1 5 B x 28 S Rear Clevis w Cushion amp 1 Z01 396 LIMITSWITCH LOW OF ROLLER LEVER DC M12 702 542 BEARING LINEAR 1 SPB 16 NSK 202 751 ALIGNMENT C OUPLER 7 16UNF X12 2499 SPACER 1 OD X 0 938 L 13 32 ID 12 2583 SWITC H MOUNTANGLE l DIMENSIONS ARE IN INC HES TOLERANCES UNLESS IRD ANGLE PROJ ECTION OTHERWISE SPECIFIED 30 WEXXAR Pac kaging Inc 3D SOLID DRAWING FRACTONAL 1 32 ANGULAR 1 ASSY CENTER CROSS PUSHER DESERPTON ADDED 201 396 26APR11 PROPRIETARY AND CONRDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING ISTHE SOLE EXXAR PROPERTY OF W PACKAGING INC ANY REPRO DUC TION IN PARTORAS A WHO LE WITHOUT THE WRITTEN PERMISSION OF WEXXAR PACKAGING INC IS PROHIBITED MATERIAL AS SHOWN FINISH AS SHOWN DATE 23MAR11 APPROVED BY NO 1 2 3 5 7 X11 3259 RPCCROSSPUSHERSDEPLATE 2 X11 3200 CROSPUHERBACE 4 202 541 BEARING LINEAR 1 1 4 SELF ALIGNING 8 SPACER 1 OD X 3 313 L 13 32 ID 16 201 396 LIMITSWHCH LOW OF ROLLER LEVER DC M 12 10 11 12 13 14 15 DIMENSIONS ARE IN INC HES TOLERANCES UNLESS IRD ANGLE PROJECTION OTHERWISE SPECIFIED WEXXAR Pac kaging Inc 3D SOLD DRAWING FRACTONAL 1 32 ANGULAR 1 ASSY SIDE PUSHERS X21 759 DRAWN BY AYC DWG NO
22. Toggle Switch Dry Cycle For the purposes of troubleshooting machine operators may choose to operate the machine without any try blanks loaded Off This function is called the DRY CYCLE To enable the Dry Cycle operation touch the gray DRY CYCLE OFF toggle switch located in the lower center of the Setup screen The Figure 4 23 DRY CYCLE Toggle toggle switch will then change to the green DRY CYCLE ON Switch toggle switch at which point the machine can operate without any tray blanks loaded 4 19 IPAC RP 100 RPC Erector 4 8 2 DRY CYCLE ACTIVE Status Indicator When the machine is in DRY CYCLE operation a small DRY CYCLE ACTIVE status indicator appears below the DRY CYCLE toggle switch It will display in the same location on the Main Control screen 4 8 3 REMOTE DEMAND Toggle Switch Located in the lower right area of the Setup screen this toggle switch turns the REMOTE DEMAND sensor ON or OFF The REMOTE DEMAND sensor is used to halt machine operation if trays are not moving away from the machine on the downstream conveyor thus avoiding tray jams t also matches tray forming output to the rate of consumption by downstream processes To enable the REMOTE DEMAND sensor touch the gray REMOTE DEMAND OFF toggle switch which will then turn green and display the text REMOTE DEMAND ON 4 8 4 REMOTE DEMAND ON Status Indicator When t
23. UNLESS THE INFO PRO FRIETARY AND SOLE RB NC E PROJ EC u du O THERWISE SPEC IFIED WEXXAR Pac kaging Inc z PROPERTY OF WEXXAR PACKAGING INC ANY REPRODUCTON DECIMAL 030 IN PARTOR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF 3D SOLID DRAWING TILE ee ASSY RPC LOCK HAMMER DEECRPTON wana ASSHOWN REPLACE X80 0779 WITH X80 1023 AND X10 3358 WITH X10 6139 4 4 2011 FINsH AS SHOWN DATE 7 DWG NO X21 769 G s usus Tercommonsowon 1 PRIETARY AND CONHDENTIAL DIMENSIONS ARE IN INCHES TOLERANCES UNLESS PROPRIETARY AND CONHDENTIAL i Me NEN UPON ae REGRESS HRD ANGLE PROJ ECTON OHERMSE SGED WERXAR Packaging Inc t TTLE ASSY SIAC AE GUARDS IN PARTORASA WHOLE WITHOUT THE WRITTEN PERMISSON OF 30 SOLID DRAWING WEXXAR PACKAGING INC IS PROHIBITED FRACTIONAL ANGULAR MEM PART X22 299 X22 454 X22 455 X22 300 X22 402 X22 403 X21 060 X12 352X GEARBOXMOUNT X10 919 SPACER 1 OD X I L 11 32 1D X12 581 X12 582 X12 605 X12 974L X12 974R __CYLMOUNTCROSSBAR PLIATERH X12 980 X12 1585 X12 1611 X12 2518 X12 2520 X11 296A 2 278 2 430 2 435 2 548 2 616 2 618 2 881 SPROC KET H40P32 2 882 SPRO C KET H40B32 c w 1 1 2 Bore 05 006 MOTOR 208 230 460 3 1760 0 33HP 204 661 RATC HET HANDLE 1 2x1 2NC x1 202 675 CO LLARS Split 1 1 2 2 pc black 2 623 TAPER BUSHING H 1 1 2 gt lt lt NIN UJUI NIN BIN 3 PROPRIETARY AND CONHDENTIAL TOLERANC
24. bring up the Setup screen Touch the NEXT button to bring up the Extended Hopper 2 screen Figure 4 54 BEGIN HOPPER SEQUENCE DELAY ON TIME Button and Display 4 15 1 BEGIN HOPPER SEQUENCE DELAY ON TIME Button and Display The first of the Extended Hopper buttons and displays is the BEGIN HOPPER SEQUENCE DELAY ON TIME button and display It indicates in milliseconds the delay time after which either of the hopper lanes recognizes that a tray stack is ready for lateral side pushing into the hopper s center lane Touching the numerals of this touch sensitive value will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER Y button 4 30 IPAC RP 100 RPC Erector Controls mroumdaiyontme MEERE Figure 4 55 RPC LIFT DELAY ON TIME Button and Display 4 15 2 RPC LIFT DELAY ON TIME Button and Display The second of the Extended Hopper buttons and displays is the RPC LIFT DELAY ON TIME button and display It indicates in milliseconds the delay time after the tray stack is ready for lateral side pushing before the stack is lifted in the hopper Touching the numerals of this touch sensitive value will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by to
25. responsibilities the operator must also be alert to the possible development of malfunctions An important factor in achieving optimum performance of the RP 100 system is the quality control of the trays The operator should be particularly alert to the condition of these trays 5 2 Machine Start Up Before the machine can start forming trays it must be powered up To do this 1 Turn ON the MAIN DISCONNECT switch and turn ON the air to the machine 2 Close all guard doors and ensure that all the EMERGENCY STOP buttons are not pressed 3 Press the RESET button on the control panel In this mode the machine will be powered up but will not be able to erect trays Before beginning production operation it is recommended that the operator slowly jog the machine until it has made a few cycles to ensure everything is operating smoothly To do this on the HMI 1 Touch the JOG button on the HMI screen 2 Touch the START button on the HMI screen The machine will move through the JOG cycle only while the START button is touched Ensure that all of the shafts and chains are rotating freely This mode can also be used when troubleshooting problems in the erecting section 53 Loading Totes Place the totes horizontally onto the extended hopper conveyor Ensure the stack is even all around and square The machine is equipped with a HOPPER FULL sensor and when it becomes clear the machine will stop 5 4 Production Operation 5
26. used in lieu of the wording caution risk of electric shock for any cautionary marking This symbol alerts you to general risks not associated with electrical pneumatic or mechanical operations or indicates that an action could cause equipment damage or affect the quality of the product To indicate that you must stop and read the instructions carefully the following symbol is used This symbol is used to alert you of an important step in operational sequence to note exceptions to normal machine operation or when special circumstances must be taken into consideration by the machine operator Throughout this manual you will find the following four special text formats he names of all buttons keys sensors switches displays and status indicators are capitalized boldfaced and placed in single quotes For example Press the START button The value in the SPEED display is not touch sensitive All machine component status terms operations functions display values and features are capitalized and boldfaced For example The case separator returns to the UP position e When referring to HMI Human Machine Interface display screens and windows we use initial capitals boldface and single quotes For example return to the Main Menu screen Touching the LOGIN button will bring up the Login window When referring to Sections in this manual we italicize the link and use single quote
27. 100 Automatic Tray Former and Stacker are automatic machines designed to open and stack RPC trays When functioning the machines form and stack the trays at a constant speed upon demand without requiring further operator input All motions of the RP 100 Automatic Tray Former are controlled by a PLC Programmable Logic Controller which is located in the main control panel Optical proximity sensors are used to detect the position of the machine s components and the trays being formed Interlock switches are used to ensure that all guarding is secure while the machine is in operation The buttons and touchscreen on the electrical control panels form the operator interface and provide the input signals to the PLC The PLC then decides upon the next stage of the machine s operation and sends electrical signals to the machine s electric motor and the pneumatic and solenoid valves that activate the machine s various components Sensors Switches Buttons Sense current machine status user inputs and sends information Pneumatic System PLC Analyses input and sends instructions about which pneumatic valves need to be opened closed Moves the machine components into their next state 3 1 Sequence of Operation 3 1 1 Startup Because the EMERGENCY STOP buttons and guard doors are wired together in series all guard doors must be closed and EMERGENCY STOP buttons must be pulled out for the machine to ene
28. 5 IPAC RP 100 RPC Erector Machine Setup Clamp Block T 6 4 Flap Opener Horizontal Adjustment Figure 6 5 RPC Pusher Figure 6 6 Horizontal Adjustment Clamp Block 5 Pull the RPC pusher out as far as possible towards the outfeed end of the machine 6 Place an opened tray on the guide rails with its trailing end touching the RPC pusher block See Figure 6 5 7 Locate the flap opener assembly holding the flap openers which are turned towards the infeed end of the machine Loosen the four caphead screws which secure it 8 Slide the assembly towards the infeed end of the machine until the flap openers are touching the inner side of the trailing minor flap 9 Tighten the four caphead screws which secure the flap opener clamp block 10 Loosen the caphead screws which secure the second flap opener assembly 11 Slide it away from the first flap opener assembly until it touches the inner side of the leading minor tray flap 12 Secure the caphead screws which secure the second flap opener assembly 6 6 IPAC RP 100 RPC Erector Machine Setup Cylinder Cylinder Rod End Figure 6 7 Lock Hammer Assembly Figure 6 8 Lock Hammer Cylinder and Mount 65 Lock Hammer Swing Adjustment 1 Locate the four lock hammer cylinders secured to their mounting weldments See Figure 6 8 2 Using a 1 2 wrench loosen the two capscrews which secure each of the four lock hammer cylinders on the mounting weldments 3 Exten
29. 53 Start Stop Time mec Main Control Figure 4 71 Fold Lock Screen 4 18 Fold Lock Screen The Fold Lock screen includes four timings for the machine s tray folding and tray locking mechanisms Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the SETUP button in the bottom right hand corner to bring up the Setup screen MENTI NESSUN Figure 4 72 RPC LOCK POSITION Buttons and Displays 4 18 1 RPC LOCK POSITION Buttons and Displays The first pair of Fold Lock buttons are those of the RPC LOCK POSITION They indicate in milliseconds the start and stop times for the RPC Lock Touching the numerals of either of these touch sensitive values will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER yY button 4 37 IPAC RP 100 RPC Erector Controls sviz openerum EHE EON Figure 4 73 OPENER LIFT Buttons and Displays 4 18 2 OPENER LIFT Buttons and Displays The second pair of Fold Lock buttons and are those of the OPENER LIFT They indicate in milliseconds the start and stop times for the Opener Lift Touching the numerals of either of these touch sensitive values will bring up a ten key keypad Touch the numerals of the keypad to se
30. D S see scar cedrus qm des uawan ku mapu aap 4 27 Remote Demand Settings 4 28 SERVICE CALL button 4 27 single solenoid valves 9 17 SOIVENIS 1 2 specifications electrical 9 16 engineering 9 16 machine 9 16 pneumatics 9 17 START button 9 16 switches CYCLE OFF ON 9 16 GLUE OFF ON 9 16 Index INIEHIOCK ss amp 4 armani 1 4 JOG REV OFF FWD 9 16 MAIN DISCONNECT 1 3 T theory of operation 3 8 TOTAL TRAYS MINUTE display 4 24 transport SKIS uuu bee ence reer wees 2 5 TROUBLESHOOTING button 4 24 V vacuum cups pneumatic specifications 9 17 VALUE button and display 4 15 valves mainair 1 3 main air shut off 1 3 2 7 W windows 4 22 4 X21 712 WLDMTRPCLOWERFRAME RH 1 6 X21714 WLDMT RPCLEG AL 1 8 X21716 WLDMTLRPCLEGCR 2 9 X21717 WIDMT RPC LEGDR 1 9 23 X21 060 WELDMT FRAMEFOOT 8 28 X11 3210 PICKMOUNTNGPLATE 4 X11 3240 CENTER BEARING SUPPORTBAR A X11 3244 CENTER BEARING SUPPORTBA
31. DJUSTMENT 6 7 7 MAINTENANCE 7 1 DAILY MAINTENANCE en 7 8 7 2 WEEKLY MAINTENANCE 7 9 7 3 MONTHLY MAINTENANCE 2 m ann 7 9 7 4 EVERY THREE MONTHS 7 10 7 5 ANNUAL MAINTENANCE 7 10 7 6 GUARDING REMOVAL 7 11 8 TROUBLESHOOTING B VACUUM SYSTEM Ls an en xeu ae ne eh ed aud uku s sess sab a 8 12 8 1 1 Vacuum Cups Do Not Move 8 12 8 1 2 Vacuum Cups Do Not Impact Bottom Of Blank 8 13 8 1 3 Vacuum Does Not Turn ON 8 13 8 1 4 Vacuum Turns ON But Is Weak 8 14 9 ENGINEERING SPECIFICATIONS 9 1 GONIROL STATION zu 22 22 asus su nude giai ed Robe PESE muka akui qasa oS Q S Q aca 9 16 10 SPARE PARTS KIT 11 INDEX RP 100 RPC Erector ACHIWERT IPAC RP 100 RPC Erector LIST OF FIGURES Figure 1 1 Locked Out MAIN DISCONNECT Switch and Air regulator Assembly 1 3 Figure 1 2 Safety Interlock ee ha 1 4 Figure 1 3 Warning Labels 0 0 0 ccc
32. Disengage the EMERGENCY STOP button 4 Press the RESET button on the contro anel 5 Touch the green START button on the HMI screen There are five guard doors on the machine and two EMERGENCY STOP buttons If any door is opened or an EMERGENCY STOP button is pressed the machine will immediately stop Power will be removed from the PLC and the main air will shut off To restart the machine 1 Close the guard door and or turn and pull out the EMERGENCY STOP button 2 Press the RESET button on the control panel 3 Touch the green START button on the HMI 5 6 Features and Instructions The machine is equipped at the factory with guards to protect the operator from drive units pinch points and electrical circuitry It is important to turn the MAIN POWER DISCONNECT switch on the machine to the OFF position before removing any guarding lt is important for all guarding and safety devices as manufactured and installed at the factory to be re installed after maintenance and prior to start up of the machine All guarding must always be in place while the machine is operating 0 2 IPAC RP 100 RPC Erector Operating Procedures Extreme caution should be taken while making adjustments with the guards off 5 7 Shutdown Procedure At the end of each production day the following shutdown procedures are necessary 1 Clean up the machine and operating area 2 It is suggested that all daily maintenance proce
33. EXXA PORN D Nea ENRE Na Ne AM Memini THIRD ANGLE PROJECTION O MERE SIT FED RPackaging Inc m ASSY STACKER INFEED SEC TION ANGULAR MATERIAL AS SHOWN
34. HIFT Button and Display In the upper center of the Tray Record Summary screen is the TOTAL TRAYS PER SHIFT button and display This value is used to count the number of trays made since the display s value was last reset Touch the value in the display to reset the value to zero 3 Are You Sure You Want to Reset The Total Travs Per Shift Counter ww Figure 4 37 Total Trays Per Shift Confirmation Window 4 10 3 Total Trays Per Shift Confirmation Window When the value in the Total Trays Per Shift button and display is touched a confirmation window will appear Touch the YES button in the confirmation window to reset the Total Trays per Shift value to zero 4 10 4 TRAYS per MINUTE Display EIE Figure 4 38 TRAYS per MINUTE Display In the center of the Tray Record Summary screen is the TOTAL TRAYS MINUTE display This value indicates the machine s production speed in trays per minute This value is not touch sensitive and cannot be reduced or reset 4 10 5 TROUBLESHOOTING PLC Nusa ucc The TROUBLESHOOTING PLC I O button is found on the upper right area of the Setup screen to the right of the Figure 4 39 TROUBLESHOOTING TRAY RECORD SUMMARY button Touch the PLC Button TROUBLESHOOTING button to be taken to the Troubleshooting screen 4 24 IPAC RP 100 RPC Erector Controls RP100 TROUBLESHOOTING PLC Out
35. Inc FRACTONAL 1 32 L g 49 IN PARTORASA WHOLE WITHOUT THE WRITIEN PERMISSION OF 3D SOLID DRAWING WEXXAR PACKAGING INC IS PROHIBITED ANGULAR 1 ASSY HOPPER RPC TEM Y X11333 EXANGUARD C2 m2725 MAGNET CHANNEL 5 PROPRIETARY AND CONADENTIAL DIMENSIONS ARE IN INC HES TOLERANCES UNLESS Pa NOR C Dao NG me A eau TON THIRD ANGLE PROJ ECION O MEAW Sik FED WEXXAR Packaging Inc 3D SOLID DRAWING FRACTIONAL ANGULAR IN PARTORASA WHOLE WITHOUT THE WRITTEN PERMISSION OF 1 32 TITLE WEXXA ASSY GUARDS RPC N zd O PP N OO S Ul R PACKAGING INC IS PROHIBITED 030 1 MATERAL AS SHOWN Rev DESCRIPTION REPLACED 201 1275 WITH 201 396 26APR11 PROPRIETARY AND CONRDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF WEXXAR PAC KAG ING INC ANY REPRODUCTION IN PARTORASA WHOLE WITHOUT THE WRITTEN PERMISSION OF WEXXAR PACKAGING INC IS PROHIBITED MATERIAL AS SHOWN FINISH AS SHOWN L1 DXL3237 UPPER CENTER PUSHER MOUNT 3 2 X32900 CENTER PUSHER BRG PLATEBAR 2 3 D13291 CENTERPUSHERLOWERMIG 3 4 D13293 CENTERCR PUSHERUN SHAFT 2 5 Dxr324 PUSHRCYLREARCUVIS 1 6 D13295 CENERCROSSPUPSHR 1 7 D22495 CROSS PUSH UN BEARING PLA 1 8 x12 2496 CROSSPUSHUN BEARNG PLB 1 9 D22497 CROSSPUSHCYLMOUNTA 1 10 X250 CROSSPUSHUM
36. Inspect the chain tension ensuring that all chains are tight 3 Inspect the linear shafting for any foreign material that might be attached Carefully remove any particles while taking care not to score the shafts Maintenance IPAC np 100 RPC Erector Check the sensors for correct operation Clear any debris blockage and dust using only a soft cloth to prevent scratching 4 7 2 Weekly Maintenance 1 Check and refill the air lubricator Inspect all air cylinders on the machine They should move freely without binding or restrictions 2 7 3 Monthly Maintenance Lubricate all bushings cylinder pivots and rod ends where applicable IPAC RP 100 RPC Erector 7 4 Every Three Months 1 Using food grade grease and the two pumps of the grease gun grease the linear bearings in the vacuum section and the ram assembly Wipe away the excess grease 7 5 Annual Maintenance 1 Inspect all air lines for cracks and wear Replace them as necessary 2 Change the gearbox oil Maintenance n A 1 2 7 10 CHIWERT IPAC RP 100 RPC Erector Maintenance 3 Inspect all chains for wear Replace them if necessary 4 Inspect the bearings for wear and ensure that the set screws are tight 5 Grease the bearings Set Screw Lubrication Cap 7 6 Guarding Removal The machine is equipped at the factory with guards to protect the operator from drive units pinch points an
37. LPAE 2 8 X11 3358 ROTARY BLOCK BACKPLATE LH 1 9 X11 3286 ROTARY BEARING BLOCKRH 1 16 202 101 BALLBEARING 21DX11 8X3 8 4 17 202 749 ROD END FEMALE 7 16 NF HEAVY DUTY 18 06 101 SPRING HOLD DOWN ROLLER m PROPRIETARY AND CONHDENTIAL DIMENSIONS ARE IN INC HES TOLERANCES UNLESS Ros NONEM HED UNG s ep ANGLE PRO ECTON OTHERWEE E FED WEXXAR Packaging Inc 3D SOLID DRAWING FRACTIONAL ANGULAR IN PARTORASA WHOLE WITHOUT THE WRITTEN PERMISSION OF 1 32 TITLE WEXXA ASSY ROTARY FOLDER R PACKAGING INC IS PROHIBITED 030 1 ses ASSHOWN X21 729 WLDMT CAM LEVER LH X21 73 WLDMT CAM LEVER RH ITE N 2 PART NUM BER DESC RIPTION QTY 2 8 3 7 PROPRIETARY AND CONADENTIAL DIMENSIONS ARE IN INC HES TOLERANCES UNLESS Pa NOR PEKAS NG NC ANT Ran TON THIRD ANGLE PROJ ECION O MEAW SE SMAL WEXXAR Packaging Inc 3D SOLID DRAWING FRACTIONAL ANGULAR IN PARTORAS A WHO LE WITHOUT THE WRITTEN PERMISSION OF 1 32 Ame WEXXA ASSY CAM SHAFI M O 1 3 5 X11 01 VACUUM CAM AD B 1 1 1 RPACKAGING INC IS PROHIBITED 030 1 MATERIAL AS SHOWN V NIN ELL S 9 19 SPACER 1 OD X 4 100 L 1 4 TAP ROD END FEMALE 7 16 NF HEAVY DUTY 6 PROPRIETARY AND CONFIDENTIAL DIMENSIONS ARE IN INC HES TOLERANCES UNLESS MSS AREE N T AMEE THIRD ANGLE PROJECTION sssi WEAR Packaging
38. MAND toggle switch and display Touch the gray TRAY DEMAND DISABLED button to enable the tray demand feature which allows the machine to run a set number of trays Touching the value in the display will bring up a Tenkey Keypad window which will enable the operator to run a set number of trays Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER button 46 9 DUTY LANE Toggle Switch In the lower right of the Main Control screen is the DUTY LANE toggle switch Touchng the LH Lane Duty RH Lane Standby toggle switch will toggle the display from black to green and switch the duty lane from the left lane to the right lane The display changes to read Right Lane Duty Left Lane Standby and the machine draws the trays from the right hand lane when that lane is not empty When the right lane becomes empty trays from the right hand lane are automatically loaded Touch the green RIGHT LANE DUTY LEFT LAND STANDBY toggle switch to switch the duty lane back to the left lane 4 6 10 JOG CONTROL Button The JOG CONTROL button is located on the Main Control screen at the lower right when the machine is stopped Touch this button to open the Jog Control screen Controls TENKEY Figure 4 13 Numeric Keypad Window Tray Demand Disabled Figure 4 14 TRAY DEMAND Tog
39. ORASA WHOLE WITHOUT THE WRITTEN PERMISSION OF WEXXAR PACKAGING INC IS PROHIBITED ANGULAR j WLDMT STACKER CR PUSHER FR LH WLDMT STACKER SIDE GUDEMTG 4 4 X12 2481 SIDE GUIDE CLAMP 8 STACKER SIDE GUIDE LH 6 X12 2492 STACKER SIDE GUIDE RH CROSS PUSHER MTG BAR A 8 X12 2494 CROSSPUSHER MTG BARB 4 9 X12 2495 CROSSPUSH LIN BEARING PLA CROSS PUSH LIN BEARING PLB CROSS PUSH CYL MOUNTA CROSS PUSH CYL MOUNTB CROSS PUSH CYL MTG SPACER CROSS PUSH LIN SHAFT 42 313 LONG CROSS PUSH LIN SHAFTBAR CROSS PUSH CYL SUPPORT 1 CROSS PUSHER ROD END MTG CROSS PUSHER PLATE SIDE BACK GUIDE LH SIDE BACK GUIDE RH 700 1036 CYL 2 B 26 S TE QV ALIGNMENT COUPLER 7 16UNF BEARING LINEAR 1 SPB 16 NS 4 LIMITROLLER SWITCH OMRON SWITCH MOUNTANGLE SWITCH MOUNTANGLE TOLERANCES UNLESS chp ea Dr as oo _ WEXXAR Packaging Inc Se SOLID DRAWING FRACTONAL 132 IE T EI ASSY CROSS PUSHER STAC KER MATERIAL AS SHOWN DRAWN BY RS sd a pom uw Jmm bar 260 0 s pazass NFED SDE GUDE RAL MOUNT 4 8 X12 2620 STACKER INFEED CHAIN RAIL B 9 x122621 CHAN RAIL MOUNTING BAR o PRIETARY AND CONHDENTIA DIMENSIONS ARE IN INC HES TOLERANCES UNLESS IN PARTORASA WHO LE WITHOUT THE WRITIEN PERMISSION OF 3D SOLID DRAWING WEXXAR PACKAGING INC IS PROHIBITED FRACTIONAL PRO L RMATION CONTAINED IN THISDRAWING 1 THERWISE SPEC IFIED W
40. Operation and Service Manual was written to assist you in installing operating troubleshooting maintaining and repairing the machine properly This manual describes the standard features that are present in the RP 100 machine Please read the manual carefully as it contains the necessary information required to extend the service life of this machine to its fullest We recommend that this manual be kept with the tray former for future reference If any problems are encountered with the procedures contained in this manual please contact our Service Center before proceeding While every effort has been made to ensure the completeness and accuracy of this manual IPak assumes no responsibility or liability for any losses or damages resulting from the use of the information contained in this document Due to technical advances and improvements some of the information contained in this manual may be changed or modified without prior notice Also note that some of the components illustrated in this manual may differ slightly from your machine This document may not be copied or reproduced without the explicit written permission of IPak viii IPAC np 100 RPC Erector Preface How to use this manual Please study carefully the following information about the manual s format This symbol alerts you to a risk of personal injury due to mechanical or pneumatic operation This symbol indicates that an electrical hazard may be present It may be
41. R B X11 3248 ELECTRICAL PANEL MOUNT B X11 3249 ELECTRIC AL PANEL MOUNTA 34 X11 3212 CONVEYOR SHAFTMTG PLATE 6 X10 5124 SPACER Da PROPRIETARY AND CONADENTIAL DIMENSIONS ARE IN INC HES TOLERANCES UNLESS ien ANGLE PRO ECTON O WEXXAR Packaging Inc IN PARTORASA WHO LE WITHOUT THE WRITTEN PERMISSON OF 3D SOLID DRAWING FRACTONAL 132 WEXXAR PACKAGING INC IS PROHIBITED ANGULAR TITLE A FRAME RPC 030 1 po ee e 4 p21742 4 WLDMTOPENERCYLMTG REAR 2 6 X11 3192 OPENERLIFTARMSHAFTA 4 7 X113193 OPENERLFTARMSHAFTB 4 8 X11394 RPCOPRENER 4 9 Z00 1033 CYL 2 B X 3 S D ACT PIVOT C USH Cylinder 2 1 2 bore x 18 stroke SMC PRIEIARY AND NHDENTIAL TOLERANC ES UNLESS y ANGULAR 1 IN PARTORASA WHOLE WITHOUT THE WRITTEN PERMISSION OF FRACTIONAL 1 32 WEXXAR PACKAGING INC IS PROHIBITED ASSY RPC OPENER MATERIAL AS SHOWN N Pi D21223 womrorveanm i 2 X21 072X WLDMT IDLERSPROCKETTENSONER 1 4 x20 2180 ASSCMOTOR amp GEARBOX 1 IDLER 1 STANDOFF 6 x11 3149 DRIVEARMPMOTSHAFT 1 7 xir 3150 CONRODA 496259L 1 8 x11 3151 CONRODB 1225 14 9 X11 3153 SPACER 1 5 OD X 0 500 L 3 4 ID 17 z01 396 LIMIT SWITC H LOW OF ROLLER LEVER DC M 12 PROPRIETARY AND CONHDENTIAAL DIM ENSIO NS ARE IN INC HES TOLERANCES UNLESS E THE INFORMATION CONTAINED IN THIS DRAWING ISTHE SOLE DNS
42. ROSS PUSHER READY DELAY ON TIME Button and Display 4 31 4 15 5 CROSS PUSHER EXTENDED DELAY ON TIME Button and Display 4 32 4 15 6 CROSS PUSHER HOME DELAY ON TIME Button and Display 4 32 4 16 EXTENDED HOPPER 2 SCREEN 4 33 4 16 1 LEFT LANE and RIGHT LANE EMPTY DELAY ON TIME Buttons and Displays 4 34 4 16 2 HOPPER EMPTY DELAY ON TIME Button and Display 4 34 4 16 3 HOPPER NOT DETECTED DELAY ON TIME Button and Display 4 34 4164 HOPPER BUON pus ius uu bud RE E 4 34 4 17 HOPPER SCREEN 4 35 4 17 1 SLIDE SWING Buttons and Displays 4 35 4 17 2 RPC PICK Buttons and Displays hrs 4 36 4 17 3 GRIP SWING Buttons and Displays 4 36 4 17 4 HOPPER BOTTOM GATE Buttons and Displays 4 36 4145 FOLDZL OCK BUON u Suay EOS wu agua h puq UG S WR w W Rd wp ORE 4 36 4 18 FOLD LOCK SCREEN 4 37 4 18 1 RPC LOCK POSITION Buttons and Displays 4 37 4 18 2 OPENER LIFT Buttons and Displays
43. Signs amp Labels ANSI B155 1 2000 for Packaging Machinery CSA Z432 04 2004 Safeguarding of Machinery NEMA 12 UL listed standard electrical control General Precautions Your IPak machine is a rugged piece of industrial machinery It is equipped with various guards and other safety features but it must be treated with respect at all times to avoid the possibility of personal injury The following points are particularly important Do not operate the machine until it is completely set up and installed properly and you are familiar with its operation Do not operate the machine without guards and safety mechanisms in place and functioning Do not attempt to enter the machine for any reason while the air pressure is still ON Do not wear neckties jewelry loose clothing or other items that can get caught in moving parts or mechanisms near the machine Do not operate troubleshoot or maintain the machine while under the influence of any type of drug or alcohol Always observe all safety warnings and notices on the machine and in this manual Do not use solvents when cleaning or maintaining the machine All installation wiring must comply with applicable local codes 12 IPAC RP 100 RPC Erector Safety 1 4 Lock out Compliance The RP 100 is lock out tag out compliant on both the electrical and pneumatic main shut offs Both the MAIN DISCONNECT and the air regulator assembly can be locked out on our IPak tray formers Ens
44. XT button in the bottom center of the screen to access the next PLC Inputs screen Figure 4 44 NEXT Button 4 12 3 PLC OUTPUTS ENGINEER Button PLC Outputs In the right center area of the Troubleshooting screen is the PLC OUTPUTS ENGINEER button Touch this button to Figure 4 45 PLC OUTPUTS access the first PLC Outputs screen The password is ENGINEER Button required to access this screen 4 26 IPAC RP 100 RPC Erector Controls 0 2 2 Left Lane X Pusher ight a 52 SV3 4 SV5 0 0 10 Conveyor Main VFD Forward 0 2 8 sv Hopper Botom Gate 5 8 z Trouble Trouble Main Control Shooting Main Control Figure 4 46 PLC Outputs Screens 4 13 PLC Outputs Screens The PLC Outputs screens display sixteen buttons Each of these buttons controls a PLC output directly Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the TROUBLESHOOTING button in the bottom right hand corner to return to the Troubleshooting screen 4 13 1 PLC OUTPUT Buttons and m RPC Lock Status Indicators Hammer SV14 To test any of the PLC outputs STOP the machine and Figure 4 47 PLC OUTPUT Buttons remove any unformed trays from the hopper Then touch the and Status Indicators button for that output When a button is touched it will illuminate and that machine component will function through i
45. ay On Time msec Main Control ovem Setup Figure 4 60 Extended Hopper 2 Screen 4 16 Extended Hopper 2 Screen The EXTENDED HOPPER 2 screen includes the remaining four timings for the machine s extended hopper Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the SETUP button in the bottom right hand corner to bring up the Setup screen Touch the NEXT button to bring up the next Extended Hopper 1 screen Figure 4 61 LEFT LANE and RIGHT LANE EMPTY DELAY ON TIME Buttons and Displays 4 33 IPAC RP 100 RPC Erector Controls 4 16 1 LEFT LANE and RIGHT LANE EMPTY DELAY ON TIME Buttons and Displays The seventh and eighth of the Extended Hopper buttons and displays are the LEFT LANE EMPTY DELAY ON TIME and the RIGHT LANE EMPTY DELAY ON TIME buttons and displays They indicate in milliseconds the delay time after the LEFT LANE RPC DETECT or RIGHT LANE RPC DETECT sensor is cleared before the that lane is recognized as having no trays and trays are taken from the opposite lane Touching the numerals of this touch sensitive value will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER 1 button Figure 4 62 HOPPER EMPTY DELAY ON TIME B
46. button should be pushed IN to STOP the machine in case of an emergency WARNING Any electrical or mechanical modifications to this equipment made without the prior written consent of IPak will void all warranties Unauthorized modifications can also result in personal injury death or destruction of the equipment 1 1 Safety Considerations IPak is proud to employ every conceivable precaution in the research and development of our tray formers We have become a world class leader in the packaging industry because of our adoption of the following best practices Fully automatic functionality requiring minimal operator interaction e Advanced safety guarding with keyed electronic interlock switches Lock out provision on electrical and pneumatic main shut offs ntegrated 24 volt DC power supply for safe low voltage operating controls e Intuitive cautionary labeling demonstrating electrical and mechanical risks 1 1 IPAC RP 100 RPC Erector Safety EMERGENCY STOP button shutdown with optional extra EMERGENCY STOP buttons PLC operated sequence and timer control 1 2 Safety Standards IPak observes the following safety standards 1 3 ANSI B151 1 2000 Safety Standards for Mechanical Power Transmission Apparatus CSA C22 2 1 02 0 M91 Canadian Electrical Code Part and Part II NFPA 79 Electrical Standards for Industrial Machines CSA C22 2 No 14 95 Industrial Control Equipment ANSI Z535 4 2002 Product Safety
47. d Hopper 2 Screen 4 33 Figure 4 61 LEFT LANE and RIGHT LANE EMPTY DELAY ON TIME Buttons and Displays 4 33 Figure 4 62 HOPPER EMPTY DELAY ON TIME Button and Display 4 34 Figure 4 63 HOPPER NOT DETECTED DELAY ON TIME Button and Display 4 34 Figure 4 64 HOPPER Button 4 34 Figure 4 65 Hopper Screen 1 hr 4 35 Figure 4 66 SLIDE SWING Buttons and Displays 4 35 Figure 4 67 RPC PICK Buttons and Displays 4 36 Figure 4 68 GRIP SWING Buttons and Displays 4 36 Figure 4 69 HOPPER BOTTOM GATE Buttons and Displays 4 36 Figure 4 70 HOPPER Button x X wee eae taeda 4 36 Figure 4 71 Fold Lock Screen 4 37 Figure 4 72 RPC LOCK POSITION Buttons and Displays 4 37 Figure 4 73 OPENER LIFT Buttons and Displays 4 38 Figure 4 74 OPENER SLIDE Buttons and Displays 4 38 Figure 4 75 RPC LOCK HAMMER Buttons and Displays
48. d each of the four cylinders out to their maximum extension point 4 Slide the each of the cylinders horizontally along the mounting weldments until their positions cause the lock hammers to be swing to exactly 1 2 degree past a vertical angle 5 Tighten the two capscrews on each of the lock hammers mounting weldments 6 6 Lock Hammer Longitudinal Adjustment 6 Place an opened tray on the side guides with the flap openers fully extended against the inner sides of the tray ends 7 Using a 9 16 wrench loosen the four caphead screws which secure each of the lock hammer assemblies See Figure 6 9 Figure 6 9 Lock Hammer Longitudinal 8 Slide each of the lock hammer assemblies to Adjustment positions such that with the lock hammers swung to their maximum rotation 1 2 degree past the vertical the edges of the lock hammers are pressed againt the inner edges of the trays end flaps NOTE The position of the lock hammer one one side of the machine must be exactly parallel with its match on the other side 9 Tighten the four caphead screws on each of the lock hammer assemblies 6 7 IPAC RP 100 RPC Erector Maintenance ACHBIMERT 7 MAINTENANCE Proper maintenance is critical in ensuring long lasting performance from the RP 100 Performing the following procedures will ensure that the machine will continue to run reliably for many years 7 1 Daily Maintenance 1 Sweep under and around the machine 2
49. d electrical circuitry An EMERGENCY STOP button must be pressed before removing any of the guarding It is necessary for all guards and safety devices as manufactured and installed at the factory to be re installed after maintenance and prior to STARTUP of the machine All guarding must always be in place while the machine is operating WARNING DO NOT operate the machine without the guards in place WARNING Extreme caution should be taken while making adjustments or size changes with the guards removed 7 11 IPAC RP 100 RPC Erector Troubleshooting 8 TROUBLESHOOTING NOTE Prior to referencing the troubleshooting guide ensure that you have properly read and understand Section 5 Operating Procedures ALL TROUBLESHOOTING STEPS THAT REQUIRE WORKING INSIDE THE ELECTRICAL PANEL OR REMOVING GUARDING SHOULD ONLY BE PERFORMED BY CERTIFIED MAINTAINANCE PERSONNEL 8 1 Vacuum System The vacuum system may not operate properly for many reasons If the vacuum system fails to pick a blank properly the reasons can be mechanical pneumatic or electrical The following section shows how to trouble shoot the vacuum system Refer to the vacuum assembly X21 1348 X21 1377 the electrical diagram X100 E0034 and the pneumatics diagram Cam Follower Rod Ends VACUUM ON Limit Switch Figure 8 1 Vacuum Drive Cam Assembly Figure 8 2 Cam Follower Linkage 8 1 1 Vacuum Cups Do Not Move If the vacuum c
50. dures outlined in Section 7 Maintenance be performed at this time 5 3 IPAC RP 100 RPC Erector Machine Setup 6 MACHINE SETUP The machine comes set up at the factory and should open trays without any problems However if the machine fails to open trays properly the machine setup may need to be adjusted The areas of the machine that may need adjusting are the guide rails the lock hammers and the flap openers The following procedures outline how to inspect and set up these areas of the machine 6 1 Guide Rail Adjustment If blanks are failing to be placed level on the guide rails or are not entering the tray opening section straight and square the guide rails may be incorrectly positioned To correct the positioning of the guide rails use the following procedure am 1 Figure 6 1 Infeed end Side Guide Figure 6 2 Outfeed end Side Guide 1 Place an open tray on the guide rails and inside the lock hammers See Figures 6 1 and 6 2 2 Using a 9 16 wrench loosen the four caphead clamp screws which secure each of the four side guide clamp blocks 3 Adjust the side guides so that there is a 1 16 gap between the inner edges of the two guide rails and the outer edges of the tray In doing so take care to ensure that the two guide rails are equidistant from the machine s longitudinal centerline 4 Tighten the sixteen caphead clamp screws 6 4 IPAC np 100 RPC Erector 6 2 6 3 Lock Hammer Lateral Adjust
51. e and close the keypad by touching the ENTER 7 button ceo E BEE Figure 4 68 GRIP SWING Buttons and Displays 4 17 3 GRIP SWING Buttons and Displays The third pair of the Hopper buttons and are those of the GRIP SWING They indicate in milliseconds the start and stop times for the hopper s Grip Swing Touching the numerals of either of these touch sensitive values will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER 1 button Figure 4 69 HOPPER BOTTOM GATE Buttons and Displays 4 17 4 HOPPER BOTTOM GATE Buttons and Displays The fourth pair of the Hopper buttons and are those of the HOPPER BOTTOM GATE They indicate in milliseconds the start and stop times for the Hopper s Bottom Gate Touching the numerals of either of these touch sensitive values will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER Y button 4 17 5 FOLD LOCK Button Fold Lock In the upper right side of the Setup screen is the FOLD LOCK button Touch this button to bring up the first Fold Lock screen Figure 4 70 HOPPER Button 4 36 IPAC RP 100 RPC Erector Controls RP100 FOLD LOCK 13 16
52. e numerals are displays Display and are not touch senstive The function of each will be made clear in the descriptions accompanying them 4 6 5 TRAYS per SHIFT Display Trays Shift In the upper right area of the Main Control screen is the 41 R SHIFT TRAY S PER SHIFT button and display Its value cannot IgM eiie ns be changed other than being reset to 0 Touch the value in this display to reduce the TRAYS PER SHIFT value to zero 46 6 TRAYS PER MINUTE Trays Minute ELE I Trays Minute Display Figure 4 12 TRAYS per MINUTE On the right hand side of the Main Control screen is the Display TRAYS PER MINUTE display It is not touch sensitive and cannot be changed by the operator 4 15 IPAC RP 100 RPC Erector 4 6 7 Numeric Keypad Window The numeric keypad is used to change the values of many of the displays on the machine s interactive screens Touching the numerals of any touch sensitive value brings up the Numeric Keypad window Touch the numerals to set the desired value in the field in the top of the keypad Touch the CLEAR button to delete any value entered Store the new value and close the window by touching the ENTER button Touch the CANCEL button to close the Numeric Keypad window without making any changes 4 6 8 TRAY DEMAND Toggle Switch and Display On the right hand side of the Main Control screen is the TRAY DE
53. e window Store the username and password and close the window by touching the ENTER button 4 9 5 TRAY RECORD SUMMARY Button pue In the upper left area of the Setup screen is the TRAY I f RECORD SUMMARY button Touch this button to bring up Figure 4 33 THAT RECORD the Tray Record Summary screen SUMMARY Button 4 22 IPAC RP 100 RPC Erector Controls RP100 TRAY RECORD SUMMARY 13 18 26 Main Control Figure 4 34 Tray Record Summary Screen 410 Tray Record Summary Screen The Tray Record Summary screen is used to check the total number of trays formed by the machine or or the machine s speed in trays per minute or to reset the machine s Total Trays Shift value Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the SETUP button in the bottom right hand corner return to the Setup screen Figure 4 35 TOTAL NUMBER OF TRAYS Display 4 10 1 TOTAL NUMBER OF TRAYS Display In the top of the Tray Record Summary screen is the TOTAL NUMBER OF TRAYS display This value indicates the total number of trays which the machine has formed The value changes automatically as each tray is made The value is not touch sensitive and cannot be altered or reset 4 23 IPAC RP 100 RPC Erector Controls Figure 4 36 TOTAL TRAYS PER SHIFT Button and Display 4 10 2 TOTAL TRAYS PER S
54. esem ened tabia Ena m 1 4 INSTALLATION 2 1 POSITIONING THE MACHINE RR hh rr 2 5 2 1 1 Selecting a Location for the Machine 2 5 2 1 2 Moving the Machine HER ER ua as asua ss nannten 2 5 0 1 CONNECTING THE ELECTRICAL SUPPLY 2 6 0 2 CONNECTING THE AIR SUPPLY 2 7 THEORY OF OPERATION 3 1 SEQUENCE OF OPERATION x zx Eug cR OE OR ee ed woh wed woke wed weed we 3 8 ON Sl ara a see m wash E q y ga meine basa men eae ee Pee ee E ee Be 3 8 312 Hopper lay nen ran inca nee enden nne na ern 3 8 3 1 3 Tray Positioning for Opening 3 9 3 1 4 Tray Advance and 3 9 9 1 9 Tray Stacking urn unm em so te nn Res ae et UR w a 3 10 CONTROLS 4 1 MAIN DISCONNECT SWITCH 4 11 4 2 RESET BUTTON seca ae cease out eee GRE RP CEREREM EEG ee E eee eee 4 11 4 3 EMERGENCY STOP BUTTON S 4 11 4 4 HMI AND CHAPTER ORGANIZATION 4 12 45 SERVICE CALI SCREEN 423 2431 xd Kersten tere en 4 13 4 6 MAIN CONTROL SCREEN
55. gle Switch and Display Hie iL St _ Raft Lane Day Lat Lane Sty Figure 4 15 DUTY LANE Toggle Switch Jog Control Figure 4 16 JOG CONTROL Button 4 16 ERIWERT IPAC RP 100 RPC Erector Controls Main Control Figure 4 17 Jog Control Screen 47 Jog Control Screen The Jog Control screen contains the JOG REVERSE and JOG FORWARD buttons In the lower area of the Jog Control screen twelve sensor status indicators show which sensors are activated during each step in the JOG CYCLE 4 7 4 JOG REVERSE and JOG FORWARD Buttons In the upper right and left of the Jog Control screen are the JOG REVERSE and JOG FORWARD buttons To jog the machne forward touch the JOG FORWARD button To jog the machne in reverse touch the JOG REVERSE Reverse Forward button Figure 4 18 JOG REVERSE and JOG FORWARD Buttons IPAC RP 100 RPC Erector 4 7 2 SENSOR Status indicator The SENSOR status indicators show which sensors are activated at each step as the machine is jogged in forward or reverse A blinking SENSOR status indicator means that there is no response from a particular sensor Touching the SENSOR status indicator will bring up the Error Identification screen with a photo of the sensor and its location on the machine Touching the photo will return the touch screen to the Jog Con
56. he REMOTE DEMAND sensor has been turned ON a small REMOTE DEMAND ON status indicator appears below the REMOTE DEMAND toggle switch It will display in the same location on the Main Control screen 4 8 5 ALARM HISTORY Button Located in the upper left hand corner of the Setup screen is the ALARM HISTORY button Touch this button to bring up the Alarm History screen Controls Figure 4 24 DRY CYCLE ACTIVE Status Indicator Figure 4 25 REMOTE DEMAND Toggle Switch Figure 4 26 REMOTE DEMAND ON Status Indicator Alarm History Figure 4 27 ALARM HISTORY Button 4 20 IPAC RP 100 RPC Erector Controls Figure 4 28 Alarm History Screen 49 Alarm History Screen The Alarm History screen displays the time date and identity of each alarm condition that the machine has experienced This screen is useful in determining common problems and can assist the operator in troubleshooting or making machine adjustments Touch the SETUP button in the bottom right hand corner of the Alarm History screen to bring up the Setup screen or touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen 4 9 1 SCROLL Buttons g The scroll buttons located at the right top and bottom of the screen are used to move up or down through a alarm history v messages
57. he next unopened tray 3 9 IPAC RP 100 RPC Erector Theory of Operation The sensors and limit switches described above trigger a series of timers in the PLC which then trigger the following outputs Valve SV11 RPC Position Lock Output O 2 0 11 Valve SV12 Opener Lift Output O 2 0 12 Valve SV13 Opener Slide Output O 2 0 13 Valve SV14 RPC Lock Hammer Output O 2 0 14 3 1 5 Tray Stacking As the tray arrives at the the infeed end of the stacker it is detected by the TRAY DETECT sensor If the CROSS PUSHER BACK limit switch has has signalled that the cross pusher is in its HOME position the lift cylinder activates and the tray is lifted up between two spring loaded side plates to make way for the arrival of the next tray underneath It is held at this level while the lift descends to receive the next tray When the tray stack has reached the number which has been preset in the tray opener s HMI the cross pusher activates and pushes the stack out of the outfeed end of the stacker The sensors and limit switches described above trigger a series of timers in the PLC which then trigger the following outputs Valve SV1 Cross Pusher Valve Output O 1 0 1 Valve SV2 Lift Cylinder Valve Output O 1 0 2 Valve SV3 Trapped Guides Valve Output O 1 0 3 3 10 IPAC RP 100 RPC Erector 4 CONTROLS Controls The control station is located on the front of the main control panel The station consists of
58. ics 1500DG1 5 02A for hopper gates Numatics UTNNO50 025 B for tray stop Numatics 2000DG3 02A for opener lift PIAK 28A1D CAAO for center hopper cross pusher 2 2 8 4 2 2 2 1 Numatics IPAC RP 100 RPC Erector Spare Parts Kit 10 SPARE PARTS KIT RPC 100 Village Farms e 3 zes BEARNG CAMFOUOWER s 14 10 1 IPAC RP 100 RPC Erector 11 INDEX A air requirements 9 16 air supply 2 7 installation 2 5 B buttons EMERGENCY STOP 4 11 E E 1 1 specifications 9 16 4 26 seo 344252555 esse 4 25 PLO OUTPUTS ized o RS haw er esas 4 26 REMOTE DEMAND 4 27 4 29 SERVICE canteen toe ersehen 4 27 START iterii auca aoaaa hg 9 16 TROUBLESHOOTING 4 24 buttons and displays REMOTE DEMAND DELAY OFF 4 29 REMOTE DEMAND DELAY ON 4 29 4 15 buttons and status indicators PEGINPE SENE 4 26 PEG seduce ara sate aed ee ere alae 4 27 C cautionary labels 1 4 compressed air 1 3 control panel 2 6 9 16 SalelV m 1 1 1 3 CYCLE OFF ON selector switch 9 16 D displays TOTAL TRAYS MINUTE 4 24 E electrical power
59. ion of advanced integrated safety guarding with key activated interlock switches on our IPak tray formers Opening any of the guard doors on the machine instantly disables all machine functions Figure 1 2 Safety Interlock 1 11 Cautionary Labels IPak provides cautionary labels for workplace hazards Please pay particular attention to the cautionary labels found on the machine DANGER THIS MACHINE STARTS AUTOMATICALLY DANGER DANGER THIS MACHINE MUST BE LOCKED OUT PRIOR TO SERVICING IPAK MACHINERY k DO NOT OPERATE WITHOUT GUARDS IN PLACE IPAK MACHINERY Figure 1 3 Warning Labels 1 4 IPAC RP 100 RPC Erector Installation 2 INSTALLATION The installation of the RP 100 RPC involves moving the compnents of the machine to an appropriate location reattaching all of the machine components connecting electrical power and supplying air to the machine The following section shows how to fully install the machine 2 1 Positioning the Machine 2 1 1 Selecting a Location for the Machine Select an appropriate location for the machine Ensure that enough room is provided next to the machine to load tray blanks access the guard doors and EMERGENCY STOP buttons remove formed trays and make machine adjustments Also ensure that there is enough room for the conveyor and that there is enough room to remove trays 2 1 2 Moving the Machine The safest way to move the assembled machine is by
60. ir filter is clean If it is dirty replace it with a new one If the problem still persists the PIAB vacuum unit may be faulty It should be replaced or repaired i a RP 100 RPC Erector Troubleshooting 8 15 PF HI H EBT 9 ENGINEERING SPECIFICATIONS IPAC RP 100 RPC Erector Engineering Specifications 9 1 Control Station The control station is equipped with START RESET and EMERGENCY STOP push buttons CYCLE OFF ON GLUE OFF ON and JOG REV OFF FWD selector switches The control panel provides an input for a remote demand sensor 240 Volt A C Three Phases 60 Hz 30A Standard Electrical Features Control Circuit 24 VDC 90 PSI 6 2 bar at main air regulator Machine Speed Up to 25 trays per minute Weight 3500 Ibs approx Machine Size Space Required 145 length x 62 width x 69 height 1 cu Ft Per cycle 90 PSI Air Requirements Allen Bradley 800 series 3 16 MAEHIME IPAC RP 100 RPC Erector Engineering Specifications One NAV4000 5DZ 3 2 single solenoid spring return for main air SMC dump Eight NVFS3120 5DZ 03T 5 2 single solenoid valves Eight NVFS3120 5DZ 03T 5 2 single solenoid valves 5DZ 03T 5 2 single solenoid valves FRL ASSEMBLY AC 50 DUO 3113 SMC NCA1D250 0700 XB5 for opener SMO NCA1D250 1800 XB5 for hopper cross pusher Numatics UTNN63 025 B for tray grip and tray stack lift Numatics 1500DG1 02A for hopper swings Numat
61. is running the wiring must be changed To do this simply reverse any two wires that are connected to the fuse disconnect Refer to the electrical schematic provided in the control panel and users manual for more detail on the electrical wiring 2 6 IPAC RP 100 RPC Erector Installation Main Air Shut Off Figure 2 3 Fittings for FRL Unit amp Lubricator 02 Connecting The Air Supply Main air must be supplied to the machine This can be done either by the client before the service technician arrives to set the machine up or by the service technician when he or she arrives to set up the machine The main air supply hose must be 37 ID or larger See Section 9 Engineering Specifications for other air requirements To supply main air to the machine 1 Connect the main air hose to the FRL unit See Figure 2 3 A 34 NPT fitting is required to connect the supply line to the FRL unit Ensure that the supply line has an inside diameter of at least 4 Pull Tab Lubricator m Resevoir aw Figure 2 4 Air Lubricator 2 Ensure that the lubricator is full of oil If the oil level is below the low level mark it must be filled with oil To add oil pull the tab Shown in Figure 2 4 twist the oil reservoir clockwise and then pull it down and off 3 Turn the main air shut off valve to the SUPPLY position IPAC RP 100 RPC Erector Theory of Operation 3 THEORY OF OPERATION The RP
62. lay indicates the amount of time in milliseconds that the machine will wait after the REMOTE DEMAND sensor has been blocked before the machine stops Under the REMOTE DEMAND DELAY ON button and display is the REMOTE DEMAND DELAY OFF button and display This button and display indicates the amount of time in milliseconds after the REMOTE DEMAND sensor has been cleared before the the machine will resume cycling Touching the numerals of either of these touch sensitive values will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER JY button 4 14 2 EXTENDED HOPPER Button Extended Hopper In the upper left area of the Setup screen is the EXTENDED l HOPPER button Touch this button to bring up the first Figure 4 52 EXTENDED HOPPER Extended Hopper screen Button 4 29 IPAC RP 100 RPC Erector Controls RP100 EXTENDED HOPPER 11 23 52 Delay On Time msec Main Control ove Setup Figure 4 53 Extended Hopper 1 Screen 4 15 Extended Hopper 1 Screen The Extended Hopper 1 screen includes the first six of the timings for the machine s extended hopper Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the SETUP button in the bottom right hand corner to
63. ls nee EMI Figure 4 58 CROSS PUSHER EXTENDED DELAY ON TIME Button and Display 4 15 5 CROSS PUSHER EXTENDED DELAY ON TIME Button and Display The fifth of the Extended Hopper buttons and displays is the CROSS PUSHER EXTENDED DELAY ON TIME button and display lt indicates in milliseconds the delay after the tray stack is cross pushed longitudinally before the cross pusher retracts to its home position Touching the numerals of this touch sensitive value will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER 1 button LaL MEME EDS Figure 4 59 CROSS PUSHER HOME DELAY ON TIME Button and Display 4 15 6 CROSS PUSHER HOME DELAY ON TIME Button and Display The sixth of the Extended Hopper buttons and displays is the CROSS PUSHER HOME DELAY ON TIME button and display It indicates in milliseconds the delay after the longitudinal cross pusher returns to its home position before it is ready to receive the next stack of closed trays Touching the numerals of this touch sensitive value will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER button 4 32 IPAC np 100 RPC Erector Controls RP100 EXTENDED HOPPER 17 23 22 Del
64. m History Screen 4 21 Figure 4 29 SCROLL Buttons 4 21 Figure 4 30 CLEAR IUD OD a acc ri pecore a ra hs ool oe ae P OUR oe ee ee ee 4 22 Figure 4 31 Password WindoW 4 22 Figure 4 32 Alphanumeric Keypad Window seleeee nenn 4 22 Figure 4 33 TRAY RECORD SUMMARY Button 4 22 Figure 4 34 Tray Record Summary Screen 4 23 Figure 4 35 TOTAL NUMBER OF TRAYS Display 4 23 Figure 4 36 TOTAL TRAYS PER SHIFT Button and Display 4 24 Figure 4 37 Total Trays Per Shift Confirmation Window 4 24 Figure 4 38 TRAYS per MINUTE Display serr IRR RR c 4 24 Figure 4 39 TROUBLESHOOTING PLC I O Button 4 24 Figure 4 40 Troubleshooting Screen 4 25 Figure 4 41 PLC INPUTS Button ene 4 25 Figure 4 42 PLC Inputs Screens 4 26 Figure 4 43 PLC INPUT Status Indicators
65. many of the HMI screens is a green MACHINE WARNING status indicator The screen changes to yellow during a warning state A message in the window indicates which of the machine s fault conditions has triggered the warning When the fault condition has been remedied the warning message will disappear and the green NO CURRENT WARNINGS status message will reappear 4 6 3 START STOP Button On the left hand side of the Main Control screen is the START button Touching this button starts the CYCLE of the machine to erect trays continually If the REMOTE DEMAND sensor is ON automatic tray erecting will stop when erected trays block the sensor on the outfeed conveyor and will resume when they move downstream away from the sensor Once touched the START button will be replaced with a STOP button Touching the STOP button stops the automatic machine cycle If the STOP button is touched while the machine is in the middle of a tray forming cycle the machine finishes forming the tray and then halts all further operation returning the mechanisms to their HOME positions 4 6 4 VALUE Buttons and Displays Figure 4 9 START STOP Button Throughout the remainder of the Controls Section of the manual the screen images includes VALUE symbols Any of these symbols with blue values are touch sensitive and Figure 4 10 VALUE Button and function as buttons Any with whit
66. ment Place a formed tray in the tray forming section with the RPC lock hammers lowered into the tray Locate the clamp blocks at each end of the RPC lock hammer assembly See Figure 6 3 Using a 9 16 wrench loosen the four caphead screws which secure the lateral adjustment of the clamp blocks Slide the lock hammer assemblies inward or outward to such a position as that the lock hammers when fully lowered straddle the seam lines between the inner edges of the erected tray minor and major flaps Retighten the clamp blocks Flap Opener Vertical Adjustment Place a formed tray in the tray forming section Locate and loosen the two caphead screws which secure the each of the flap opener assemblies in their vertical position See Figure 6 4 NOTE Only one caphead screw is shown in the photo Lower the flap opener assemblies so that the openers at their lowest point distort the floor of the RPC tray downward approximately 1 16 from its level position Retighten the four caphead screws Machine Setup 1 y 4 44 7 c De ES L E E m I lt c a ID E i cr gr gt m L gt 4 f Caphead Screws s E a PY im ucc A B Aw Figure 6 3 RPC Lock Hammer Clamp Blocks Caphead Screw N M EF ieee a TE p p x 1 a h Figure 6 4 Flap Opener Vertical Adjustment 6
67. osition and the CENTER OF BACK limit switch Input I 0 0 3 which signals that the Center Cross Pusher has returned to its home positon The sensors and limit switches described above trigger a series of timers in the PLC which then trigger the following outputs Valve SVO Left RPG Lift Output O 2 0 0 Valve SV1 Right RPG Lift Output O 2 0 1 Valve SV2 Left Side Cross Pusher Output O 2 0 2 Valve SV3 Right Side Cross Pusher Output O 2 0 3 Valve SV4 Side Swing Output O 2 0 4 Valve SV5 Center Cross Pusher Output O 2 0 5 3 1 3 Tray Positioning for Opening When the stack of trays is positioned in the RPC Hopper it is supported by the Front and Rear Hopper Gates The RPC Detect Sensor Input l 0 0 11 detects the bottom tray in the stack When this tray is detected two RPC Clamp Swings jam into holes in the sides of the second tray up in the stack Two Pick Lifts then grab the bottom tray The Hopper Gates then open to allow the bottom tray to be lowered and it is lowered down onto two guide rails The Hopper Gates then close the RPC Clamp Swings swing out of the holes in the second tray and it is allowed to fall down onto the Hopper Gates The two Pick Lifts rise to grab the next tray Their raised position is signalled by the PICK DOWN limit switch Input I 0 0 8 A HOPPER LOW sensor Input 0 0 13 is positioned on the side of the RPC Hopper a few inches above the RPC Detect Sensor
68. play instead of mechanical controls Many of these surfaces such as the START button operate as though they were mechanical buttons They will be referred to as buttons in this manual section IPAC RP 100 RPC Erector Controls MAIN CONTROL 13 12 18 Trays Shift Trays Minute Tray Demand Disabled Figure 4 6 Main Control Screen 4 6 Main Control Screen On the Main Control screen are buttons toggle switches and status indicators required for the basic operation of the machine The interactive controls on this screen include the START STOP button the TRAY DEMAND DISABLED button and display and the DUTY LANE toggle switch This screen also includes buttons which give the operator access to the Jog Control and Setup screens Figure 4 7 MACHINE ALARM Status Indicator 4 6 1 MACHINE ALARM Status Indicator At the top of many of the HMI screens is the green text machine MACHINE ALARM status indicator This status indicator changes to red during an alarm state A message in the status indicator indicates which of the machine s fault conditions has triggered the alarm When the fault condition has been remedied the alarm message will disappear and the green NO CURRENT ALARMS status message will appear Figure 4 8 MACHINE ALARM Status Indicator iPAC RP 100 RPC Erector Controls 4 6 2 MACHINE WARNING Status Indicator Below the MACHINE ALARM status indicator on
69. pushing it with a forklift When pushing the machine place a wooden or steel block on the ground across the rear legs Push against the block with the forklift Once the machine components are in the appropriate location remove the transport skis To do this lift the machine remove the bolts that are connecting the skis to the machine feet and lower the machine Figure 2 1 Pushing a Machine with a Forklift 2 IPAC np 100 RPC Erector Installation 0 1 Connecting the Electrical Supply Main power needs to be connected to the control panel when the machine is installed This machine requires 240V 3 Phase power at 60Hz Power must be wired to the machine before an IPak technician can begin setting up the machine Caution A certified electrician must perform the main power wiring of the machine DO NOT attempt the following procedure unless you are fully qualified Power Wires Figure 2 1 Ground Connection Figure 2 2 3 Phase Power Connection To connect power to the machine 1 Drill a hole in the side top or bottom of the control panel to send the main power wires through Install a strain relief or any other appropriate fitting and then send the main power wire into the control panel 2 Connect the ground wire to the grounding terminal block Figure 2 1 3 Connect the other three wires to the top of the fuse disconnect see Figure 2 2 Ifthe motor does not turn in the correct direction when the machine
70. puts PLC Inputs Engineer Main Control Figure 4 40 Troubleshooting Screen 4 11 Troubleshooting Screen On the center of the Troubleshooting screen are the PLC INPUTS and the PLC OUTPUTS ENGINEER buttons Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the SETUP button in the bottom right hand corner to bring up the Setup screen 4 11 1 PLC INPUTS Button PLC Inputs In the left center area of the Troubleshooting screen is the PLC INPUTS button Touch this button to access the first PLC Inputs screen Figure 4 41 PLC INPUTS Button 4 25 IPAC RP 100 RPC Erector Controls Figure 4 42 PLC Inputs Screens 4 12 PLC Inputs Screens The PLC Inputs screens display thirty six machine PLC Inputs status indicators Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the TROUBLESHOOTING button in the bottom right hand corner to return to the Troubleshooting screen 4 12 1 PLC INPUT Status Indicators When the machine is jogged through its cycle as each Figure 4 43 PLC INPUT Status machine input is triggered the corresponding PLC INPUT Indicators status indicator will be momentarily change from gray to yellow 4 12 2 NEXT Button Next Touch the NE
71. rgize when the START button is touched on the machine s HMI 3 1 2 Hopper Tray Supply The machine will begin to open trays if the following three conditions are met 1 the OUTFEED JAM sensor Input I 0 0 12 is clear indicating that there is not a backup of opened trays on the outfeed converyor 2 the LEFT LANE OF BACK Input 0 0 3 or the RIGHT LANE OF BACK Input 0 0 4 limit switches detect that the hopper cross pushers are back in position and ready to push a tray stack and 3 the RIGHT LANE RPC DETECT Input 0 0 7 or LEFT LANE RPC DETECT Input I 0 0 5 sensor detects that a conveyor has carried a stack of trays fully forward in one of the hopper lanes At this point a side pusher pushes the stack of trays into the center of the hopper If there are tray blanks ready to be fed from both of the conveyors the side pusher of the Duty Lane will push the trays across 3 8 IPAC RP 100 RPC Erector Theory of Operation When trays have been pushed into the center of hopper the correct positioning of the tray stack is sensed by the CENTER RPC DETECT LH and CENTER RPC DETECT RH sensors Input l 0 0 0 and Input 0 0 6 This triggers the Center Cross Pusher to push the stack of trays forward into the RPC Hopper The motion of the Center Cross Pusher is detected by the CENTER OF FORWARD limit switch Input 0 0 2 which signals when the Center Cross Pusher is at its fully extended p
72. s For example See Section 6 Operating Procedures e f you are using a PDF version of this manual you may jump directly to the referred section by clicking on the italicized text IPAC RP 100 RPC Erector Safety 1 SAFETY MUST BE READ PRIOR TO OPERATING WARNING The instructions in this manual are not intended to cover all of the details or variations in equipment or to provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred directly to IPak The RP 100 has safety features to protect you from injury while the machine is operating Guard doors equipped with interlock switches prevent you from entering the work cell while the case formation is in progress the machine will not run if one of these doors is open The control panel access door must also be closed in order for the machine to operate The perimeter guarding system surrounds the area known as the restrictive envelope and covers the entire range of possible machine motion For your safety you should never try to bypass the perimeter guarding system or enter the restrictive envelope while the machine is in operation Pressing an EMERGENCY STOP button immediately halts all machine operations by cutting off air supply and electrical power This
73. s illuminating when the switch is activated If the light does not illuminate then the limit switch may be faulty and should be replaced Ensure that the VACUUM VALVE output O 3 0 0 is being illuminated and that the output is sending 24VDC If it is not the PLC may be faulty and should be replaced If the output is working properly check the vacuum valve If the light on the valve solenoid does not illuminate check the wiring If the light does illuminate but the valve does not shift the valve may be faulty and should be replaced If the valve is shifting ensure that the airlines are not cracked or clogged Ensure that they are properly connected as shown in the pneumatic diagram 8 13 IPAC RP 100 RPC Erector Troubleshooting 8 1 4 Vacuum Turns ON But Is Weak If the blank will not pick but the vacuum is turning ON and the cups are moving properly the suction may be too low The vacuum should be strong enough that it is difficult to remove a blank from the vacuum cups To correct this problem 1 Check the air pressure at the main regulator to ensure that there is adequate air supply The machine requires 30 cu ft of air per minute at 100 PSI Ensure that the vacuum cups are not damaged or dirty Clean or replace them as necessary Ensure that the PIAB vacuum filter elements are clean and free of dirt If they are dirty clean them out with compressed air or replace them If the problem persists ensure that the main a
74. t the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER 1 button suos a Figure 4 74 OPENER SLIDE Buttons and Displays 4 18 3 OPENER SLIDE Buttons and Displays The third pair of Fold Lock buttons and are those of the OPENER SLIDE They indicate in milliseconds the start and stop times for the Opener Slide Touching the numerals of either of these touch sensitive values will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER 1 ETN Figure 4 75 RPC LOCK HAMMER Buttons and Displays 4 18 4 RPC LOCK HAMMER Buttons and Displays The fourth pair of Fold Lock buttons and are those of the RPC LOCK HAMMER buttons and displays They indicate in milliseconds the start and stop times for the RPC Lock Hammer Touching the numerals of either of these touch sensitive values will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER Y button 4 38 IPAC RP 100 RPC Erector Operating Procedures 5 OPERATING PROCEDURES 5 1 General Outline During normal operation the operator should maintain an adequate flattened trays In addition to the above
75. ter Organization The HMI Human Machine Interface touch screen uses a Main Control screen and the Jog Control screen for primary control The Setup Menu screen has eight subsections for adjusting and monitoring settings The reference numbers at the top right of the screens indicate chapter section numbers Setup Jog Control Main Control Note All other screens return to this Main Control screen Setup submenu Entry screen Tray Record Troubleshooting Service Summary nea THAYRECDRD SUMMARY RECORD SUMMARY mM TROUBLESHOOTING JELESHOOTING Remote Demand Settings Figure 4 4 HMI and Chapter Organization IPAC 45 SERVICE CALL Screen When the machine is turned on the opening screen displays a photo of the Wexxar factory and contact information Touch this screen anywhere to bring up the HMI s Main Control screen You can bring up this screen when the machine is not operating by pressing the SETUP button located at the lower right corner of any screen When the Setup Menu screen appears press the SERVICE CALL button to display the screen as shown in Figure 4 5 B 4 Giz We xar A C HI N E R Y TP 10104 Hordel OLI p O FOR PARTS amp SERVICE TOUCH SCREEN ANYWHERE Figure 4 5 SERVICE CALL Screen The RP 100 features an Allen Bradley HMI human machine interface touchscreen dis
76. the HMI screen the MAIN DISCONNECT switch the RESET button and an EMERGENCY STOP button 41 MAIN DISCONNECT Switch The MAIN DISCONNECT switch turns the main electrical power to the machine ON or OFF However no power is applied to any of the machine s electrically or pneumatically powered components The MAIN DISCONNECT switch can be locked in the OFF position for safety during maintenance operations 42 RESET Button Touch the RESET button to turn on the control power and provide power to the machine s electrically or pneumatically powered components 43 EMERGENCY STOP Button s The EMERGENCY STOP button immediately cuts off electrical and air supply to the machine and halts all operations regardless of whether a tray is positioned in the tray erecting process when the button is pushed IN Power is removed from the main air mechanisms Restarting the machine after an emergency stop is more complex than with a regular START Most likely the tray that was being formed will be wasted After clearing any tray jams or damaged trays the EMERGENCY STOP button should be released twisted and pulled out and the RESET button should be pushed for the machine to operate again Figure 4 1 MAIN DISCONNECT Switch Figure 4 2 RESET Button Figure 4 3 EMERGENCY STOP Button s IPAC RP 100 RPC Erector Controls MACHIME 44 HMI and Chap
77. trol screen 4 7 3 MAIN CONTROL Button The MAIN CONTROL buiton is located on the bottom left hand corner of many of the HMI s display screens Touch the MAIN CONTROL button to return to the Main Control screen 4 7 4 SETUP Button The SETUP button appears on the bottom right hand corner of many of the HMI s display screens Touch this button to display the Setup screen NOTE While the machine is cycling this button will not display Controls Figure 4 19 SENSOR Status indicator Main Control Figure 4 20 MAIN CONTROL Button Setup Figure 4 21 SETUP Button 4 18 IPAC RP 100 RPC Erector Controls RP100 SETUP 13 13 14 Tray Record Troubleshooting Summary PLC 0 Alarm History Service Call Extended Remote Demand Hopper Hopper Fold Lock Dry Cycle Mode Inhibited If Tray Blanks Detected In Magazine Main Control Jog Control Figure 4 22 Setup Screen 48 Setup Screen The Setup screen provides access to many features related to machine diagnostics and tuning and setting adjustments It also includes toggle switches for turning the dry cycle and remote demand features ON and OFF Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the JOG CONTROL button in the bottom right hand corner to return to the JOG CONTROL screen 4 8 1 DRY CYCLE
78. ts cycle If it does not function inspect and repair the component 4 13 2 SERVICE CALL Button service Call In the upper right hand corner of the Troubleshooting screen is the SERVICE CALL button Touch this button to bring up the Service screen which contains contact information for the IPak Service Department 4 13 3 REMOTE DEMAND Button Figure 4 48 SERVICE CALL Button Remote Demand In the upper left area of the Setup screen is the REMOTE DEMAND button Touch this button to bring up the Remote Demand Settings screen Figure 4 49 REMOTE DEMAND Button 4 27 IPAC RP 100 RPC Erector Controls RP100 REMOTE DEMAND SETTINGS 13 16 25 Main Control Figure 4 50 Remote Demand Settings Screen 4 14 Remote Demand Settings Screen The Remote Demand Settings screen is used to set the Remote Demand Delay ON and Remote Demand Delay OFF values Touch the MAIN CONTROL button in the bottom left hand corner of the screen to return to the Main Control screen or the SETUP button in the bottom right hand corner to return to the Setup screen 4 28 IPAC RP 100 RPC Erector Controls Figure 4 51 REMOTE DEMAND DELAY Buttons and Displays 4 14 1 REMOTE DEMAND DELAY Buttons and Displays In the top center of the Remote Demand Settings screen is the REMOTE DEMAND DELAY ON buttons and displays This button and disp
79. uching the ENTER JY button een Gee BE Figure 4 56 SIDE CROSS PUSHER DELAY ON TIME Button and Display 4 15 3 SIDE CROSS PUSHER DELAY ON TIME Button and Display The third of the Extended Hopper buttons and displays is the SIDE CROSS PUSHER DELAY ON TIME button and display It indicates in milliseconds the delay time after the tray stack is lifted in the hopper before the stack is cross pushed laterally into the center of the hopper Touching the numerals of this touch sensitive value will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER button Figure 4 57 CROSS PUSHER READY DELAY ON TIME Button and Display 4 15 4 CROSS PUSHER READY DELAY ON TIME Button and Display The fourth of the Extended Hopper buttons and displays is the CROSS PUSHER READY DELAY ON TIME button and display It indicates in milliseconds the delay after the tray stack is moved to the center lane before it is cross pushed longitudinally towards the tray erecting area Touching the numerals of this touch sensitive value will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER button 4 31 IPAC RP 100 RPC Erector Contro
80. ups do not move when the START button is pressed 1 Ensure that the vacuum shaft is rotating by slowly jogging the machine 2 If the cam does not rotate ensure that the chain and taper lock bushings are in place and that the keys and bolts are in the bushings are secured tightly See Figure 8 1 Tighten any loose fittings 3 If the cam is rotating but the vacuum assembly is not lifting inspect the vacuum assembly including the chain the rod ends rod end mount and the cam follower to insure that all components are properly attached IPAC RP 100 RPC Erector Troubleshooting Vacuum Adjustment Collars Figure 8 3 Vacuum Assemblies 8 1 2 Vacuum Cups Do Not Impact Bottom Of Blank If the vacuum cups move but do not impact the bottom of the blank 1 2 Lower the collars on the vacuum cups so that the vacuum cups lift up higher See Figure 8 3 If the cups still do not impact the blank adjust the stroke of the vacuum adjustment linkage by moving the vacuum rod end mount further away from the pivot See Figure 8 2 8 1 3 Vacuum Does Not Turn ON If the vacuum cups move properly but there is no suction from the vacuum system 1 Ensure that the limit switch actuator is making contact with the VACUUM ON limit switch If it is not adjust the position of the limit switch on the guide mount until the actuator makes contact with the switch See Figure 8 2 Ensure that the VACUUM ON input 1 0 0 1 light i
81. ure that you lock out the machine prior to performing any repairs or maintenance Figure 1 1 Lo cked Out MAIN DISCONNECT Switch and Air regulator Assembly 1 5 Compressed Air Compressed air is used to power the movement of many machine components You must ensure that the machine s main air solenoid valve is shut OFF before attempting to clear jams or make minor adjustments which require you to get close to the moving parts of the machine This air valve shuts OFF when the guard doors are opened or when the main power is switched OFF To safely carry out service or repair work on the machine a lockable main air shutoff valve is located on all IPak machines upstream of the regulator unit Padlock this valve in the OFF position for absolute safety during service work Always follow local lock out tag out regulations Always exercise caution when switching the compressed air back ON Stay well clear of all moving parts as they may move quickly when the pressure is reapplied Ensure that no person is in dangerous location when switching the compressed air ON 1 6 Electrical Power All Pak machines use electrical power Switch OFF the MAIN DISCONNECT switch on the control panel and lock it out before attempting service work outside of the control panel on the machine Before performing service work inside the control panel disconnect all electrical power to the machine customer supplied disconnect 1 7 Hot Melt Glue System
82. utton and Display 4 16 2 HOPPER EMPTY DELAY ON TIME Button and Display The ninth of the Extended Hopper buttons and displays is the HOPPER EMPTY DELAY ON TIME button and display It indicates in milliseconds the delay time after the HOPPER EMPTY sensor is cleared before the hopper is recognized as having no trays Touching the numerals of this touch sensitive value will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER JY button Rs BE Figure 4 63 HOPPER NOT DETECTED DELAY ON TIME Button and Display 4 16 3 HOPPER NOT DETECTED DELAY ON TIME Button and Display The tenth of the Extended Hopper buttons and displays is the HOPPER NOT DETECTED DELAY ON TIME button and display It indicates in milliseconds the delay time after which the hopper has been empty for a period of time set in the HMI Touching the numerals of this touch sensitive value will bring up a ten key keypad Touch the numerals of the keypad to set the desired value in the field at the top of the keypad Store the new value and close the keypad by touching the ENTER JY button 4 16 4 HOPPER Button f Hopper In the upper right area of the Setup screen is the HOPPER button Touch this button to bring up the Hopper screen Figure 4 64 HOPPER Button 4 34 IPAC

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