AIRPAD - MACHINE AP

Transcription

1 OPERATION INSTRUCTIONS AIRPAD - MACHINE AP CE Declaration of conformity We declare that the machine AP503 is in conformity with the following standard or standardised documents: 2006/42/EC, 2006/95/EC, 2004/108EC en/DS/ Original instructions Technical file at: M.Rauch FROMM System GmbH Neulandstrasse 10 D Achern R.Fromm Director FROMM Holding AG Hinterbergstrasse 26 CH Cham

2 Index Page 1 Safety instructions 3 2 Description of the machine 3 3 Technical data AP Operating elements 5 5 Control panel 5 6 Installation Moving the support to the working position Installation of foot and feeding unit Operating the machine Film rolls to lay in the dispenser Pulling in the film Taking out of the finished Airpads from the machine Film control Film processing Starting Turn on Setting the national language Program selection Starting Heating up of the machine Stopping the machine OFF key Emergency off (EMO) switch Stopping the machine by the control system Program chart Stored data Standard values for program data Entering and adjusting program data Program data Preselecting the number of cycles Machine data screen Display of consumption data Mechanical adjustments Brake of the dispenser unit Sliding clutch of the feeding unit Troubleshooting Pneumatic schematic PNS Key functions Chart forms Index numbers for language selection Warranty conditions and liability Appropriate use 27 page 2

3 1 Safety instructions AP Read these instruction carefully, until you use the machine. Security instructions for electric tools Attention! When using electric tools, certain general rules must be followed in order to prevent electric shocks, injury- and fire casualties. Do not use electric tools in a humid or wet environment. Through touching the electrical equipment endanger your security. Do not use electric tools close to burnable liquids or gases. Do not carry the tool by the cable and do not use the cable for pulling the plug. Protect the cable from heat, oil and cutting edges. When not in use and when doing maintenance work unplug the tool from the mains plug. Regularly control the plug, the cable and the housing for damages and have the damaged parts exchanged by an authorized service company. Regularly control available extension cables and replace any damaged ones. Attention! Only persons trained in the operation may operate this machine. 2 Description of the machine AP503 is a machine to produce individually defined air-filled protection and filling elements. The machine processes AIRPAD films according to FROMM s specification. The welding seams are made by a heat pulse. During each working cycle one, two or four Airpads in different sizes and with individually defined degree of filling are produced. The so produced Airpads are fed by a feeding unit up to a height of more than 2m. The rows are perforated and can be torn off from the Airpad panel without any instrument. The optional available bins can be attached to the machine as a buffer und dispenser. 3 Technical data AP Dimensions of the mounted machine Length: 1450mm (57"), with bin 2420mm (95"), with bin and arm mm ( ") Width: 797mm (31") (+170mm (7") to open the protection cover) Height: 2450mm (97") Height below bin arm: 1960mm (77") Dimensions of machine packed 2 packages Pallet: 1200mm X 800mm X 1450mm (47 X 32 X 57") Box: 700mm X 460mm X 790mm (28 X 18 X 31") Weight Machine complete: Feeding unit: Packaging: approx. 268kg (591lbs) without film rolls approx. 32kg (71lbs) pallet approx. 28kg (62lbs), carton approx. 11kg 20lbs), box for feeding unit approx. 11kg (20lbs) 2420 max enT1.fm page 3

4 Connected loads AP Because of the high starting current (> 2kW) the machine needs its own electrical fuse. Current supply: 230 VAC, 50/60 Hz, 16 A Power draw: 2.0 kva Power consumption: approx. 1.1 kwh Compressed air connection: Diameter of the tube : nominal width 10 / 3/8" Pressure: 4-6 bar / psi Air consumption: maximum 82 Nl/min / 2.9 cu.ft. per min. (during pad production) maximum 3.5 Nl / 0.12 cu.ft. per cycle Performance: cycles per minute depending from the pad size and type of film Noise The A equivalent continuous sound level at the operator s work place is typically 70 db (A). This value has been determined according to DIN T3 (11.85) Film material Caution! Only films released by FROMM may be used. Width of film: 420 mm / 16.5" Diameter of the film rolls: maximum 280 mm / 11" Length of film: between 500 and 1000 m / yd. depending on the gauges of film Core diameter of the film roll:76 mm / 3" Type of film: AIRPAD films according to FROMM s specification Film gauges to be processed:from to 0.08 mm / " Accessories Item No. Designation Remarks AP Pull in aid Delivered with the machine. N Adjusting pin To be for adjust the sliding clutch at the feeding unit and the brakes at the dispenser. Delivered with the machine. N Key (Switch cabinet) Delivered with the machine Bin APD50R0 Serves as a depot for the produced Airpads. Taking out of the Airpads from the top. (option) Bin APD50R1 Serves as a depot for the produced Airpads. Taking out of the Airpads from the bottom. (option) Arm APD50R2 For upgrading the bin , in case a later taking out of the Airpads from the top is desired. (option) AP Frame With this the arm can be mounted transversal to the bin. (option) AP Switch box To switch external ON and OFF. (option) AP Connection cable Connection to the switch box. (option) N Connection bench Basic module for an optical or acoustical signal transmitter. (option) AP Connection cable Connection for an optical or acoustical signal indication. (option) N Signal lamp For optical, external signal. (option) N Light bulb Needed for signal lamp N (option) N Alarm transmitter For acoustical, external signal. (option) AP Strand Is necessary when signal lamp N and alarm transmitter N are used simultaneously.(option) N Mounting flange Stand fastening for signal transmitter. (option) N Tube Needed for the mounting flange N (option) N Mounting flange Wall fastening for signal transmitter. (option) page enT1.fm

5 4 Operating elements View from the operator s location Feeding unit Protection cover Manometer Pressure regulator EMO - switch Control panel Mainswitch Compressed air connection with filter at the rear Dispenser 5 Control panel enT1.fm page 5

6 6 Installation The carrying out of work at the electrical equipment of the machine is only allowed for educated and qualified persons. The machine may only be operated in dry, dust free rooms where sufficient natural or artificial aeration is assured. The room temperature should be stable and between 5 C (41 F) and 35 C (95 F). Pay attention to a solid horizontal mounting. Mount the wheels. The brake wheels to the side of the dispensing unit. Lock the brakes in any case. 6.1 Moving the support to the working position - Remove the protection caps (screwdriver for recessed head screws) - Loose screws at the support (hexagon socket spanner SW6). - Push the support to working position. - Tighten screws. - Mount the protection caps. Protection caps Support in transport position Support in working position 6.2 Installation of foot and feeding unit - Assemble the profiles for the feet with the connection elements. - Screw the assembled profiles to the machine. - Fasten middle profile top edge (X1) in level with guard-plate top edge (X2). - Put feeding unit on the support frame. Attention! The safety noses must be glide into the profile openings. - Screw the feeding unit with the support frame together ( 4 screws M8 x 25 + security rings + groove stones). - Install cover and stripper. - Connect motor. - Connect connection cable at the proximity switch, fix the cable with the cable clips and the cable strappers. - Screw together ground wire at the antistatic brush and foot. - Hang the bin (option) to the machine. Attention! The machine may be connected to the mains supply only by means of the cable respective plug delivered. Make sure that the mains voltage and frequency correspond to the data on the manufacturer s nameplate. The compressed air must be free of oil, water and dirt. The air is connected at the filter AP page enT1.fm

7 4 x N x N AP AP x N x N N N x N x N x N AP AP N AP AP AP mm (15.8") AP AP x N x N AP X1 X2 4 x N x N x N x AP x AP enT1.fm page 7

8 7 Operating the machine 7.1 Film rolls to lay in the dispenser - Film roll to lay on roll with brake and roll. - Observe the following: seen from the front side the upper roll (A) must run counter clockwise during unwinding seen from the front side the lower roll (B) must run clockwise during unwinding the new film rolls must have room temperature 7.2 Pulling in the film Keep the protection cover closed. Turn on main switch. When the control system is in the automatic mode: A A switch to manual mode by means of the key Caution! Observe unwinding direction! Film roll B B Balance unit Pulling in the film A Open the protection cover. Lift the upper transport roll by loosening the star grip screws. Roll with brake Roll Push the pull in aid with the glue lines in running direction backwards under the air tube over the lower brush between the longitudinal welding jaws between the transport rolls and between the transversal welding unit. (The storage place of the pull in aid are behind the dispenser) Film (A) has to path through under the above balance unit, over the right deflection roller of film checking than press against the glue lines of the pull in aid. Warning! Never grip into the running machine! Upper transport roll Star grip screw Pull in aid Air tube Protection cover Lower brush Deflection roller with film checking A Longitudinal welding jaws Lower sealing lip Transversal welding unit Guard-plate Push the pull in aid with the film inserted completely through the machine. Remove pull in aid. page enT1.fm

9 Inserting film B AP Push the pull in aid with the glue lines in running direction backwards over the air tube under the upper brush between the longitudinal welding jaws between the transport rolls and between the transversal welding unit. Film (B) has to path through under the underneath balance unit, over the left deflection roller of film checking than press against the glue lines of the pull in aid. Push the pull in aid with the film inserted completely through the machine. Remove the pull in aid, align the films. Deflection roller with film checking Pull in aid Upper brush Transport rolls Upper sealing lip Protection cover Air tube Longitudinal welding jaws Transversal welding unit B A A Pull sufficient film out of the machine, feed the film underneath the feeding control cylinder and insert it centered through the conveyor belts of the feeding unit. Move the conveyor belts with the key combination + until the films are caught and the feeding control cylinder stays in a middle position (Sketch.) Films line up. Tighten the star grip screws. Close the protection cover. Switch over to automatic mode by pressing the key Feeding control cylinder During the next film change the new film can be stacked on the previous film and be pulled in. Pull in the new film until the glue line comes out of the machine enT1.fm page 9

10 7.3 Taking out of the finished Airpads from the machine The Airpads can be pulled off the bin at any time. Depending on the bin from the top or from the bottom. If the bin is completely filled, the PLC will switch off the Airpad production and it will start Airpad production again if certain Airpads are taken out from the bin. Basic menu E21: AUTOMATIC BIN FULL If a certain amount of Airpads is removed from the bin, the machine starts automatically. If the machine is restarted within 40 seconds after it has been stopped, in the display COOLING TIME will blink until 40 seconds since the stop command have been elapsed. If the machine is restarted later than 40 seconds after it has been stopped, the Airpad production will start immediately. 7.4 Film control The film control controls the film supply of the machine. Is one film missing, or the films are not correct pretensioned, the machine will be stopped (Error message E03). 7.5 Film processing The machine is delivered with the data of the films used by you. A correction of the stored values may be necessary in case of operating under extreme conditions. See point 8 for a description of this procedure. 7.6 Starting Turn on Close the protection cap. Unlock EMO switch. Check air pressure, pressure gauge must show 4 bar, if necessary adjust at the pressure regulator. In order to turn the adjustment knob it must be lifted up. Turn on main switch. The following message appears on the screen for 5 seconds: FROMM AirPad V. z.z If there is no error message: PROGRAM X.X* MANUAL OFF or PROGRAM X.X AUTOMATIC OFF The control system is in the basic menu. The program having been effective before the last turn off will always be indicated. With the key automatic mode. *X.X represents the program number being currently active. it can be selected between manual and page enT1.fm

11 7.6.2 Setting the national language AP The machine is set to the desired national language at their delivery. The language can only be changed in the automatic mode. Proceed as follows to change the language. Basic menu Insert password Enter the desired language according the chart PROGRAM X.X* AUTOMATIC OFF or PROGRAM X.X AUTOMATIC ON F? CODE * * * * * LANGUAGE 1 GB - English The selected language is indicated. under point 14 by means of the keys. Confirm with the key. The display changes to the basic menu. 7.7 Program selection The machine can store data of 45 different pad variants. The differences in the variants consist in size and the film material used for the airpads (see point 7.11 program chart). A new program can only be selected in the automatic mode when the machine stops. Proceed as follows to select a program: Basic menu Choose by means of the number keys or the keys the desired program number. Confirm with the key. PROGRAM X.X* AUTOMATIC OFF PROGRAM X.X AUTOMATIC OFF The active program number is blinking. The number can only be changed when blinking. The entered value is blinking. The number can only be confirmed when blinking. If the PLC doesn t accept a number it means that the program is locked. PROGRAM X.X AUTOMATIC OFF 7.8 Starting If the machine is restarted within 40 seconds after it has been stopped, in the display COOLING TIME will blink until 40 seconds since the stop command have been elapsed. If the machine is restarted later than 40 seconds after it has been stopped, the Airpad production will start immediately. The machine can be started only in the automatic mode. Press key PROGRAM X.X* AUTOMATIC ON After machine start must be an function check of dispenser unit and feeding unit! The film must be skintight inserted into the machine. *X.X represents the program number being currently active enT1.fm page 11

12 7.9 Heating up of the machine AP The machine is producing Airpads after starting. In order to produce good quality Airpads immediately, during the first 10 cycles the welding jaws are heated up more according to a table stored in the PLC. After that the machine continues working in the normal mode. The values for the normal mode are stored in menu F1 as program data, they can be changed as described under 8.1 Program data. How much more the different welding circuits are heated up during the first 10 cycles can be adjusted in a separate menu Stopping the machine The operator can stop the machine in two different ways: OFF key Press key The started cycle will be terminated. The machine stops. PROGRAM X.X* AUTOMATIC OFF Emergency off (EMO) switch In case of emergency the machine can be stopped by actuating the Emergency off switch. The machine stops immediately, all parts except the control system are disconnected from the power supply. The welding jaws are going in start position. After having repaired the failure, the emergency off (EMO) switch must be unlocked by turning it to right. If the emergency off (EMO) switch is unlocked after a very short time, the display will show the error E20. The error message must be reset by means of the key. E06: COVER OPEN OR EMERGENCY STOP PROGRAM X.X* AUTOMATIC OFF E20: INVERTER FAULTY PROGRAM X.X AUTOMATIC OFF Stopping the machine by the control system The machine will be stopped automatically by the control system if an irregularity or an error in the program running is recognized. The display in the basic menu gives a hint to the error cause as long as it is persisting. See also chart under point 10. If the machine has been stopped by a short-time error and the control system is in the basic menu, OFF is blinking on the display. The tripping error can be displayed by pushing the key. Basic menu Push key The error message must be reset by means of the key. PROGRAM X.X* AUTOMATIC OFF (blinking) E13: LOW AIR PRESSURE PROGRAM X.X AUTOMATIC OFF (blinking) The blinking OFF prompt must be acknowledged by pressing the key or. * X.X represents the program number being currently active. page enT1.fm

13 7.11 Program chart 45 programs are available. Airpad XXL One Airpad per cycle over the whole film width. Program 1.0 Pad length 160 mm / 6 1/4" Film type PE / PE Film thickness 65µm Program 1.1 Pad length 80 mm / 3 1/8" Film type PE / PE Film thickness 65µm Program 1.2 Pad length 80 mm / 3 1/8" Film type PE / PE Film thickness 65µm Program 1.3 Pad length 60 mm / 2 1/3" Film type PE / PE Film thickness 65µm Program 1.4 Pad length 40 mm / 1 9/16" Film type PE / PE Film thickness 65µm Program 1.5 Pad length 160 mm / 6 1/4" Film type PA / PE Film thickness 42µm Program 1.6 Pad length 80 mm / 3 1/8" Film type PA / PE Film thickness 42µm Program 1.7 Pad length 80 mm / 3 1/8" Film type PA / PE Film thickness 42µm Program 1.8 Pad length 60 mm / 2 1/3" Film type PA / PE Film thickness 42µm Program 1.9 Pad length 40 mm / 1 9/16" Film type PA / PE Film thickness 42µm Program 1.10 Pad length 160 mm / 6 1/4" Film type PE / PE Film thickness 45µm Program 1.11 Pad length 80 mm / 3 1/8" Film type PE / PE Film thickness 45µm Program 1.12 Pad length 80 mm / 3 1/8" Film type PE / PE Film thickness 45µm Program 1.13 Pad length 60 mm / 2 1/3" Film type PE / PE Film thickness 45µm Program 1.14 Pad length 40 mm / 1 9/16" Film type PE / PE Film thickness 45µm Airpad XL Two Airpad per cycle over the whole film width. Program 2.0 Pad length 160 mm / 6 1/4" slit Film type PE / PE Film thickness 65µm Program 2.1 Pad length 80 mm / 3 1/8" slit Film type PE / PE Film thickness 65µm Program 2.2 Pad length 80 mm / 3 1/8" unslit Film type PE / PE Film thickness 65µm Program 2.3 Pad length 60 mm / 2 1/3" unslit Film type PE / PE Film thickness 65µm Program 2.4 Pad length 40 mm / 1 9/16" unslit Film type PE / PE Film thickness 65µm Program 2.5 Pad length 160 mm / 6 1/4" slit Film type PA / PE Film thickness 42µm Program 2.6 Pad length 80 mm / 3 1/8" slit Film type PA / PE Film thickness 42µm Program 2.7 Pad length 80 mm / 3 1/8" unslit Film type PA / PE Film thickness 42µm Program 2.8 Pad length 60 mm / 2 1/3" unslit Film type PA / PE Film thickness 42µm Program 2.9 Pad length 40 mm / 1 9/16" unslit Film type PA / PE Film thickness 42µm Program 2.10 Pad length 160 mm / 6 1/4" slit Film type PE / PE Film thickness 45µm Program 2.11 Pad length 80 mm / 3 1/8" slit Film type PE / PE Film thickness 45µm Program 2.12 Pad length 80 mm / 3 1/8" unslit Film type PE / PE Film thickness 45µm Program 2.13 Pad length 60 mm / 2 1/3" unslit Film type PE / PE Film thickness 45µm Program 2.14 Pad length 40 mm / 1 9/16" unslit Film type PE / PE Film thickness 45µm enT1.fm page 13

14 Airpad Four Airpad per cycle over the whole film width. Program 4.0 Pad length 160 mm / 6 1/4" slit Film type PE / PE Film thickness 65µm Program 4.1 Pad length 80 mm / 3 1/8" slit Film type PE / PE Film thickness 65µm Program 4.2 Pad length 80 mm / 3 1/8" unslit Film type PE / PE Film thickness 65µm Program 4.3 Pad length 60 mm / 2 1/3" unslit Film type PE / PE Film thickness 65µm Program 4.4 Pad length 40 mm / 1 9/16" unslit Film type PE / PE Film thickness 65µm Program 4.5 Pad length 160 mm / 6 1/4" slit Film type PA / PE Film thickness 42µm Program 4.6 Pad length 80 mm / 3 1/8" slit Film type PA / PE Film thickness 42µm Program 4.7 Pad length 80 mm / 3 1/8" unslit Film type PA / PE Film thickness 42µm Program 4.8 Pad length 60 mm / 2 1/3" unslit Film type PA / PE Film thickness 42µm Program 4.9 Pad length 40 mm / 1 9/16" unslit Film type PA / PE Film thickness 42µm Program 4.10 Pad length 160 mm / 6 1/4" slit Film type PE / PE Film thickness 45µm Program 4.11 Pad length 80 mm / 3 1/8" slit Film type PE / PE Film thickness 45µm Program 4.12 Pad length 80 mm / 3 1/8" unslit Film type PE / PE Film thickness 45µm Program 4.13 Pad length 60 mm / 2 1/3" unslit Film type PE / PE Film thickness 45µm Program 4.14 Pad length 40 mm / 1 9/16" unslit Film type PE / PE Film thickness 45µm The following values are stored in these 45 programs. Preblow time Transversal welding time Longitudinal cutting time Longitudinal welding time Cooling time Length Air pressure Determines the time of blowing in air prior to the stroke movement. Determines the heating time of the transversal welding jaws and as a result the quality of the transversal welding seam. Determines the heating time of the three longitudinal cutting jaws and as a result the quality of the longitudinal cutting seam. Determines the heating time of the longitudinal welding jaws and as a result the quality of the longitudinal welding seam. Determines the duration of the cooling time after welding. The welding jaws remain closed during the cooling time. The correct cooling time is decisive for the quality of the welding seams. Determines the length of the Airpads. Only the values 160, 80, 60 and 40 are possible. Adjusts the pressure for blowing up the Airpads. page enT1.fm

15 7.12 Stored data The machine stores the data of 45 different user programs. The stored programs have been tested, recorded and enclosed to the machine before delivery. The programs newly defined by the user must be taken down in the charts under point Standard values for program data The values in the following charts are standard values. Refer to the data sheet enclosed for the values being valid for the machine respectively see the newly defined programs in the charts under point 13. Airpad XXL Progr.- No. Preblow time Transversal welding time Longitudinal cutting time Longitudinal welding time Cooling time Length Air pressure mm 2,40 bar mm 1,20 bar mm 1,20 bar mm 0,80 bar mm 0,65 bar mm 2,15 bar mm 1,20 bar mm 1,20 bar mm 0,65 bar mm 0,50 bar mm 2,40 bar mm 1,05 bar mm 1,05 bar mm 0,70 bar mm 0,60 bar enT1.fm page 15

16 Airpad XL Progr.- No. Preblow time Transversal welding time Longitudinal cutting time Longitudinal welding time Cooling time Length Air pressure mm 2,2 bar mm 1,0 bar mm 1,0 bar mm 0,8 bar mm 0,4 bar mm 1,9 bar mm 1,0 bar mm 0,9 bar mm 0,65 bar mm 0,4 bar mm 2,2 bar mm 1,2 bar mm 1,0 bar mm 0,6 bar mm 0,3 bar Airpad Progr.- No. Preblow time Transversal welding time Longitudinal cutting time Longitudinal welding time Cooling time Length Air pressure mm 2,30 bar mm 1,10 bar mm 0,80 bar mm 0,80 bar mm 0,55 bar mm 2,00 bar mm 1,05 bar mm 0,75 bar mm 0,70 bar mm 0,55 bar mm 2,00 bar mm 1,00 bar mm 1,00 bar mm 0,65 bar mm 0,50 bar Insert these values in case of data loss and loss of the program listings (see point 8.1) Test the program afterwards. Mostly only the values for transversal welding time, longitudinal cutting time and longitudinal welding time (for the tightness of the pads) must be adapted. Record the new program data in the charts under point 13. page enT1.fm

17 8 Entering and adjusting program data 8.1 Program data In case of extreme operating conditions or change of the type of film, the program data must be modified respectively newly entered. This can only be done in the automatic mode. Times will be entered always in the program being currently active and displayed. Basic menu Insert password PROGRAM X.X* AUTOMATIC OFF or PROGRAM X.X AUTOMATIC ON F? CODE * * * * * P- X.X* BLOW TIME min 000 Y max 999 The indicated value Y can be changed by means of the numeral keys or the keys. The values are entered in milliseconds. The second line indicates minimum (min) and maximum (max) values. The value to be newly entered must be between these values. Too high or too low values are not accepted by the control system. The values for transversal welding time, longitudinal cutting time and longitudinal welding time may be modified only in small steps (max. 10ms). There is danger that the welding strips overheat in case of strongly increased values. The displayed value is blinking during entering. In case of a wrong input the entered value can be overwritten. You must press the key Display of F1 that the entered value is accepted by the control system. P- X.X* BLOW TIME min 000 Y max 999 The display changes to the next higher memory. The display changes to the next lower memory. If all inputs are terminated The display changes to the basic menu. *X.X represents the program number being currently active enT1.fm page 17

18 8.2 Preselecting the number of cycles AP The machine offers in the automatic mode the possibility to enter a certain amount of cycles, which are executed by the machine. One Airpad or one Airpad row is produced per cycle. Example: Basic menu PROGRAM X.X* AUTOMATIC OFF or PROGRAM X.X AUTOMATIC ON F? PROG X.X* min 0000 Y max 9999 Up to 9999 cycles can be preselected now by means of the numeral keys means endless production. The indicated value is blinking during the input. The entered value is stored. The machine stops after having executed the set number of cycles. At the next start the machine will produce the adjusted number. The preselection of the number of cycles can be done for each program seperately. The control system changes to the basic menu. 8.3 Machine data screen By pressing the key, the following data can be called in also in the manual or automatic mode. Basic menu PROGRAM X.X * MANUAL OFF or PROGRAM X.X AUTOMATIC OFF or PROGRAM X.X AUTOMATIC ON PADS n 0 SET UP n 0 If under menu F2 a number of cycles has been preselected, the first line will indicate the number of Airpads produced. In the second line the preselected number of cycles is indicated. TOTAL h:m :00 TOTAL PADS : The total producing time and the total number of the produced rows of airpads is indicated. The control system changes to the basic menu. *X.X represents the program number being currently active. page enT1.fm

19 8.4 Display of consumption data AP The consumption of Airpad film can be read out in the automatic menu as follows: Basic menu PROGRAM X.X* AUTOMATIC OFF or PROGRAM X.X AUTOMATIC ON FILM A: m FILM B: m FILM A shows the consumed film length in meter of the upper film roll (A), FILM B shows the consumed film length in meter of the lower film roll (B). F? *X.X represents the program number being currently active. The control system changes to the basic menu. 9 Mechanical adjustments 9.1 Brake of the dispenser unit The task of the brakes on the dispenser unit is to keep the film permanently tight between the dispenser unit and the transport shaft unit. At the start of the transport cycle the balance unit moves further up. At the end, the unit retracts under spring pressure. If the balance unit moves into the lower back position during the operation of the machine the brake must be tightened slightly. If the balance unit remains in the upper position the brake must be loosened slightly. The two brakes are individual to adjust. Adjusting the brake View from operator s location: Turn capstan nut clockwise (+) : Tighten the brake. Turn capstan nut counter-clockwise (-) : Loosen the brake. It is possible to use the adjusting pin N to turn the capstan nut enT1.fm page 19

20 9.2 Sliding clutch of the feeding unit AP The integrated sliding clutch of the feeding unit limits the tractive power of the feeding unit. Adjust the clutch in a way that sufficient tractive power is applied to the Airpad panel. If the force is too weak, the transport of the Airpad panel is insufficient. Adjusting the sliding clutch Warning! The sliding clutch is turning during operation. Turn capstan nut clockwise (+) : Tighten the sliding clutch Turn capstan nut counter-clockwise (-) : Loosen the sliding clutch + Use the adjusting pin N to turn the capstan nut Troubleshooting Only trained and instructed personnel is authorized to perform servicing and maintenance works! If the control system is in the basic menu, the following troubles will be indicated on the display as they occur. Error message Cause Repair E01: MOTOR 2M1 OVERLOAD E02: TRANSFORMER OVERLOAD a) The motor 2M1 is overloaded. The motor protection switch 2Q1 has tripped and turned off the machine. b) The motor protection switch is wrongly adjusted. One of the three welding transformers has been overloaded. The thermo switch of the transformer turns off. Switch off main switch and unplug the plug. Check respective mechanical section and motor and repair the failure. Reset motor protection switch in the switch cabinet, plug in the machine and switch on main switch. Check adjustment, correct if necessary. Set value see electrical diagram in the switch cabinet. Switch off the main switch and unplug the plug. Check if one of the teflon covers has burnt through or if there is a short-circuit at a cable connection. Check transformers. Repair the failure and plug in plug and switch on main switch again. page enT1.fm

21 Error message Cause Repair E03: FILM FEED a) One of the two film rolls has run out of film and the machine has been turned off. b) The film tension is to low. The deflection roller doesn`t turn during the transport. c) The maximum transport time has been exceeded. The PLC stops the transport. E04: FILM JAM A film congestion between the transport rolls and the transversal welding unit has occurred. The light barrier turns off the machine. a) The film sticked on transversal welding jaws. Replace film roll. Check the brakes of the winding-up device, perhaps the brakes are new to adjust, that the balance units skintighted the film. Check sensor and switch disk at motor 3M1. Replace defective parts. Open the protection cover. Pull out the film congestion in the transport direction by using both hands. Close the protection cover. Check welding times and eventually correct them until the film does no longer stick to the transversal welding jaws. b) The air pressure is to high. Check the air pressure. c) The preblow time is to long. Check the preblow time. E06: COVER OPEN OR EMERGENCY STOP a) The protection cover is open or the cover safety switch is not properly closed. Close the protection cover, respectively assure that the cover safety switch is properly closed. E07: PADS JAM FEEDING CONTROL CYL. E08: TEMP. SENSOR TRANSVERSAL WELDING E09: TRANSVERSAL WELDING E10: LONGITUDINAL CUTTING E11: LONGITUDINAL WELDING E12: FAILURE AIRPAD TRANSPORT b) The emergency off switch has been actuated. The proximity switches 6B6 or 7B2 do not change their status within 80cm transported film. Airpad jam in the outlet funnel. The NTC resistor built in the transversal welding jaw has been wrongly connected or is defective. The PLC has recognized that the transversal welding circuit has been heated up longer than programmed, or has not been heated up although programmed. The PLC has recognized that the longitudinal cutting circuit has been heated up longer than programmed, or has not been heated up although programmed. The PLC has recognized that the longitudinal welding circuit has been heated up longer than programmed or has not been heated up although programmed. Error in the area of the feeding unit AP The lower light barrier is not released within allowed time and the machine is turned off. Assure that there is no trouble, unlock the emergency off switch. Check function of the feeding control cylinder. Remove reason for the jam. Check cable connections. Replace defective parts. Check if the control system, the power switch, the relays or the transformer are defective. Replace defective parts. Check the fuses. Check if the control system, the power switch, the relays or the transformer are defective. Replace defective parts. Check the fuses. Check if the control system, the power switch, the relays or the transformer are defective. Replace defective parts. Check the fuses. Check function of the motor 2M1, Check traction of the conveyor belts, Check sliding clutch. E13: LOW AIR PRESSURE Error message immediately: No signal of the sensors 6B3 or 6B4; lower welding jaw unit not in home position; sensors defective or not properly adjusted. Check sensors and sensor adjustment, adjust or replace defective parts. Error message after the 3rd. stroke: The sensors 6B3 or 6B4 do not change their status after switching on the lifting valve within a certain time (welding jaws do not travel up). Provide sufficient air-supply for the machine. Check pneumatic system for air tightness. Check function of the lifting pistons. Check smooth running of the guides enT1.fm page 21

22 Error message Cause Repair E14: FAILURE POWER CONTACTORS E15: TIME FAILURE WELDING E16: USER PROGRAM DATA LOST E17: TEMP. SENSOR LONGITUDINAL CUTTING E18: TEMP. SENSOR LONGITUDINAL WELDING When switching on the machine, one of the relays 5K0 or 2K1 are closed. The machine can not be started. The PLC has heated up a welding circuit longer than allowed by an internal limit value. The machine switches off, on the PLC a red LED is lighting. Loss of data The NTC resistor built in the longitudinal cutting jaw has been wrongly connected or is defective. The NTC resistor built in the longitudinal welding jaw has been wrongly connected or is defective. Identify and replace defective relay. Push the red reset button on the PLC in the switch cabinet. If error appears again, replace PLC. Enter or reload program data. Check cable connections. Replace defective parts. Check cable connections. Replace defective parts. E19: TEMP. SENSOR AMBIEN TEMP. FAULTY The NTC resistor close to the lower film dispenser has been wrongly connected or is defective. Check cable connections. Replace defective parts. E 20: INVERTER FAULTY E 21: AUTOMATIC BIN FULL After short time switch off of the machine by the emergency stop switch. The inverter is giving out an error message. The bin is full. The PLC stops the Airpad production. The error message must by reset by means of the key. Identify error message at the display of the inverter. Check manual of inverter in the switch cabinet for further information. Take out the Airpads from the bin. The machine starts automatically. Signals for external control With utilization of external signal transmitter (option) can be perceive the following informations: E03 FILM FEED: Other failure: Flashing light, signal tone or both in 0,5 second interval. Flashing light, signal tone or both in 1,0 second interval. page enT1.fm

23 11 Pneumatic schematic PNS.1005 AP Y Y P Filter 2 Pressure regulator 0-10bar 3 Pressure control valve 4 3/2 way solenoid valve 5 Lifting cylinder 6 3/2 way solenoid valve 7 Air tube 12 Key functions Key Function ON key In HAND operation without function. In AUTO operation: start of production. OFF key Stops production, the started cycle will be brought to end. Acknowledges error messages. Selection key manual / automatic operation The key is only active when the machine is idle. Switches from manual to automatic operation when actuated. Program selection key After having pressed this button, a new unlocked program can be selected with the numeral keys or the keys. The program must be confirmed by the key. The program selection can be made only in Automatic - OFF operation. Call off key Calls off the total number of hours of production, the total numbers of cycles and the remaining number of cycles if the numbers of cycles to be produced has been selected enT1.fm page 23

24 Key Function Function key Calls in the memory in combination with the numeral keys. In menu F1 Programm data change to the previous parameter. Controls the conveyor belt, the transport rolls and the welding jaws in the manual operation in combination with the arrow keys. to Numeral keys Input of new values. The inputs must be confirmed with the key. Arrow keys Selection of values, programs and the language The inputs must be confirmed with the key. Arrow key In menu F1 Program data change to the next parameter. Return key Confirms all inputs. Cancellation key Returns from the memories to the basic menu. and simultaneously During manual operation: welding jaws move into welding position (only in case of closed protection cover). and simultaneously During manual operation: Conveyor belts of the feeding unit are running. (only with protection cover closed). During manual operation: film feed forward (only in case of closed protection cover). and simultaneously In the OFF mode: display of the last arisen error. The error message must be reset by means of the key. page enT1.fm

25 13 Chart forms Program data Airpad XXL Progr.- No. Preblow time Transversal welding time Longitudinal cutting time Longitudinal welding time Cooling time Length Air pressure Airpad XL Progr.- No. Preblow time Transversal welding time Longitudinal cutting time Longitudinal welding time Cooling time Length Air pressure enT1.fm page 25

26 Airpad Progr.- No. Preblow time Transversal welding time Longitudinal cutting time Longitudinal welding time Cooling time Length Air pressure Index numbers for language selection Language selection Index number Short-cut Language 0 SK Slovak 1 GB English 2 F French 3 D German 4 NL Dutch 5 E Spanish 6 S Swedish 7 FIN Finnish 8 P Portuguese 9 N Norwegian 10 I Italian 11 PL Polish 12 HU Hungarian 13 CZ Czech 14 SC Simplified Chinese 15 TC Traditional Chinese page enT1.fm

27 15 Warranty conditions and liability AP FROMM AIRPAD AG warrants all selled machines during a period of 24 months from the date of installation at the end-user's sight by the distributor, however, not later than 30 months from the date of shipment to the distributor of FROMM AIRPAD AG. The warranty includes all deficiencies clearly resulting from poor manufacturing or faulty materials. Damage claims as a result of production shutdowns and claims for damage to persons and to property resulting from warranty deficiencies cannot be asserted by the customer. The warranty excludes: wearing parts, deficiencies resulting from improper installing, incorrect handling and maintaining the tool, deficiencies resulting from using the tool without or with defective security- and safety devices, disregard of directions in the operation manual, arbitrary modifications of the tool, deficient control of wearing parts, deficient repair works of the tool. Use of consumable products not recommended by FROMM AIRPAD AG We reserve the right to modify the product at any time in order to improve its quality. 16 Appropriate use The Airpad machine AP503 has been designed to produce airpads exclusively. Use only films which are admitted by Fromm. The warranty / liability excludes: non appropriate use of the tool, disregard of directions in the operation manual, disregard of control- and maintenance instructions enT1.fm page 27