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Kalamazoo Packaging Systems

Kalamazoo Packaging Systems

939-48-SR-LC Vertical Window/Panel Stretch Wrapper w/ 42 Safety Railing and Light Curtain.

7/11/2017

Operators Manual

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Kalamazoo Packaging Systems

Table of Contents Introduction 3 Warranty 3 Installation 3 Wrapping operation 4 Description of wrap cycle 5 Controls 5 AC Solid state drive settings 6-7 Film tension controller setting 7 Stretch wrap system adjustments 8 Maintenance 8 Lubrication 9 Chain tension 9 Trouble shooting 10 Machine layout 11 Tower assembly 12-14 Turntable assembly 15-16 Top Platen assembly 17-18 Subpanel 110/1/60Hz. 19-20 Control console assembly 21-22 Variable tension film delivery assembly 23-25 Safety Railing Layout 26-278 Wiring diagram (110/1/60Hz.) 29-35 Wrap timers settings 36 Programming Sheet 36 PLC Ladder diagram 37-47

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Kalamazoo Packaging Systems

Introduction

Congratulations! Your purchase of a Kalamazoo Model 939 Semi-Automatic Spiral Stretch Wrapping System will provide you with years of efficient stretch wrapping service. Your investment will ensure that your products will arrive cleaner, with less damage and pilferage at their destination at a lower cost to you.

Warranty

Kalamazoo Packaging Systems, Inc. (KPS) agrees to furnish the purchaser, without charge, F.O.B. the factory, any part found to be defective in either material or workmanship within one (1) year from date of shipment, provided the purchaser gives immediate notice of any defect and description of that defect to KPS. KPS reserves the right to inspect any defective part to verify the defect and to determine probable cause of same.

The liability of KPS under this warranty is limited to furnishing replacements for defective parts, and unless otherwise agreed to in writing, the purchaser shall bear the expense of installation.

Failure of equipment or parts due to abuse, misuse, neglect, incorrect operating techniques or power line drops or surges shall not constitute failure because of defective material or workmanship, and are expressly excluded from this warranty.

The above is the only warranty with no other guarantees which extend beyond the above and the seller disclaims any implications including but not limited to a warranty of merchantability.

Installation If the 939 stretch wrapper system, is to tall to ship assembled. (See Reassembling Manual.) For the purpose of in-plant movement by fork lift truck, pockets (6x2 tubes) have been provided in the machine base. To move the machine, carefully insert forks into the pockets provided.

DO NOT LIFT THE MACHINE AT ANY OTHER PLACE. USE ONLY THE POCKETS, COMPONENTS LOCATED UNDER THE TURNTABLE COULD BE DAMAGED.

Place the machine in the proper location. After the machine is properly located it can be bolted to the floor through the tabs provided. Position the Safety Railing per pages 26-27. Install the Light Curtains and Mirrors per pages 26-27. Install the Wraparound Ramp. The ramp may be bolted to the floor if desired. As shipped the turntable fixture stop position is perpendicular to the long axis of the machine. If desired, the orientation of the fixture may be changed 90 degrees by removing the fixture and the four bolts in the center of the turntable disc and manually rotating the turntable disc 90 degrees and then replacing the bolts and fixture. If another fixture orientation is desired, remove the two bolts from the ends of the fixture and loosen the center bolt. Rotate the fixture to the desired orientation and tighten the center bolt. Drill and tap the table top for the 3/8-16 NC bolts on each end of the figure.

Electrical Connection 110/1/60Hz. Plug system into a standard 110 volt outlet 20 AMP.

230/1-3/60Hz. and 460/3/60Hz. Connect power lines to the disconnect switch per wiring drawing.

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Kalamazoo Packaging Systems

Wrapping Operation 1 Normal start position; Film lift carriage-DOWN/ Platen arm - UP 2 Operator slides lower fixture to slightly less that the window width, centering on turntable, then sets window on the lower fixture. 3 Position top of window under upper fixture and lower the Platen Arm to stabilize window. (the Platen Arm has a limit switch that will automatically stop the Platen Arm.) 4 Operator applies edge protectors as required and attaches film to window by tucking between window and lower fixture. 5 Step outside of the Safety Railing!

6 Make sure the Light Curtain Reset and the Film/Platen Reset blue lights are on.

1) If the Film/Platen Reset blue lighted button is not on.

A) Make sure the E-stop button is pulled out.

B) Push the Film/Platen Reset blue lighted button.

2) If the Light Curtain Reset blue lighted button is not on.

A) Make sure the E-stop button is pulled out.

B) Make sure the light curtains is not blocked.

C) Push the Light Curtain Reset blue lighted button.

7 Select program Short or Tall. If you cannot reach the top of the product to cut the film, select the

Tall program and the film carriage will return to the bottom home position.

8 Operator starts wrap cycle by pushing the CYCLE START button.

Note: The system automatically senses window wrap

height with a switch on the film carriage.

9 When system has completed its automatic wrap cycle the operator cuts the film.

10 The operators need to support the product and push down on the Platen RAISE foot switch petal .

The Top Platen load stabilizer will raise and the window can be removed.

In program SHORT the film carriage will automatically return to the bottom home position went

the Platen RAISE foot switch petal is pushed.

11 End of wrap cycle.

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Kalamazoo Packaging Systems

External Controls (located on console)

1 E-Stop: Stops all function by shutting off the main control relays and the PLC. (If the E-STOP button is pushed, it must be left off for 30-45 sec. so the AC Drives can shout down.) 2 Cycle Start: Energizes the system. Starts the automatic wrap cycle. 3 Light Curtain Reset: Resets the Light Curtains Safety Relay after the curtain has been

broken and/or the E-Stop button has been pushed. 4 Film/Plate Reset: Resets the Film carriage and Platen carriage Safety Relay after the E-Stop

button has been pushed. 5 Cycle Stop: Stop all function and reset the PLC. 6 Programs: Selects the program that best suits the window being wrapped. 7 Film Raise: Manually raises the film carriage. 8 Cycle Interrupt: Interrupts the cycle but does not reset timers. 9 Table Jog: Manually operates Turntable only. 10 Film Lower: Manually lowers the film carriage.

Foot Controls 1 Platen Raise, Left Pedal: Manually raises the top Platen Arm. (The film carriage will automatically return to the home position in program SHORT). 2 Platen Lower, Right Pedal: Manually lowers the top Platen Arm.

Description of Wrap Cycle 1 Operator initiates the wrap cycle by pushing the CYCLE START button. 2 Turntable soft starts. 3 Film tension comes on gradually. 4 After bottom reinforcing wraps the Film carriage starts up, travels until carriage switch senses

proper height. 5 (Program Short) Film carriage stops and than the turntable will decelerate and index to the home position. 6 When operator raises top Platen, the Film carriage will return to the down home position

automatically.

*If (Program Tall) is selected on the control console, the system will wrap to the bottom position before the Turntable will decelerate and index to the home position.

Internal Controls (located inside of the cabinet)

1 Film Tension: Can be adjusted for proper film tension for different types and gauges of film. Located over the Film Tension controller (top right hand side). 2 Film Lift Speed fast: Can be adjusted to change film overlap on program short and tall. located on the Film Lift AC Drive keypad. Factory set at 45Hz. 3 Turntable Speed Fast: Can be adjusted to change the Turntable speed in

program short and tall. Potentiometer located on the Turntable AC Drive keypad. Factory set at 60Hz. 16 RPM.

To Program the Ac Drives. (see pages 6-7)

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Kalamazoo Packaging Systems

Telemecanique ATV 12 AC Drive Programming To change a parameter in the AC Drive. 1. Press the Jog Dial to get into the parameter you would like to change. 2. Turn the Jog Dial to change the code. 3. Press the Jog Dial to enter into the code. 4. Turn the Jog Dial to change the value. 5. Press the Jog Dial to enter the value.

939-48 Platen Carriage Drive rdy ConF ACC Acceleration 2.5 dEC Deceleration 0.1 HSP High Speed 60.0 bFr Motor Frequency 60 Full drc tUn Auto Tune yes SFr Switching Frequency 2.0 Ctt Motor Control Type PErF StA Frequency Loop Stability 10% Fun AdC tdC1 Auto DC Injection Time 2sec.