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PSG-FT OWNERS MANUAL

AMS-120FS LABORATORY FITMENT SEALER

Developed by OLSON BROTHER ADVANCED MECHANIZED SYSTEMS exclusively for PPi TECHNOLOGIES GLOBAL

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Introduction

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The PSG FT fitment sealer is designed to seal fitments into film pouches. Seal jaw motion is monitored and controlled by an Allen Bradley PLC controller. A dual channel heater controller allows the two seal jaws to be monitored and controlled independently. The machine features sealed and/or shielded stainless steel ball bearings in the mechanism ensuring long life and minimal maintenance. The PSG FT can accommodate many different sizes and styles of fitments by fitting your machine with a correspondingly designed set of seal jaws and fitment holder. Refer to sections (5) and (8) for machine specifications and change parts technical data.

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Contents

1. How to use this manual 2. Machine operation 3. Recommended maintenance procedures 4. Safety 5. Specifications 6. Electrical diagrams 7. Replacement parts 8. Change parts specifications 9. Changeover procedures 10. Troubleshooting guide

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1. How to use this manual This manual is intended to give a basic outline of the operation of the PSG FT fitment sealer. If you do not feel comfortable operating this machine as described in this manual, contact PPi Technologies for further information and technical assistance.

2. Machine operation a. Setup

1. Remove contents of shipping crate and inspect for any damage. If any damage is found contact shipping company immediately.

2. Place machine in location and remove the six (6) table mounting bolts found in the table mounting brackets. Place table in position with countersunk bolt holes facing up. Fasten table with bolts.

3. Remove back cover (4 bolts). Facing front of machine, remove left side cover (4 bolts). 4. Tip machine onto right hand side and fasten the four (4) vibration dampening feet to the

machine bottom with supplied fasteners. 5. Place machine in upright position and fit it with required set of seal jaws and fitment

holder as described in section (9). 6. Replace all covers and safety shields and plug machine into power source as required in

specifications section (5). b. Controls and functions

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Fig.3 1. Refer to figures (2&3) for control panel layout and location.

a. (1) main power switch and emergency shut down. b. (2) powers up machine PLC. c. (3) on/off seal jaw heater controller. d. (4) ok/edit seal duration. e. (5) escape/save new value. f. (6) edit seal jaw temperature. g. (7) save new value. h. (8) increase value. i. (9) decrease value. j. (10) and (11) when pressed simultaneously initiate seal jaw cycle.

2. Powering up machine. a. Plug machine electrical cable into power source meeting machine requirements

outlined in section (5). b. Twist (1) main power switch clockwise until it pops out. c. Press (2) and green indicator light will turn on.

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3. Homing seal jaw mechanism.

Fig. 3.5 a. Power up machine. b. Be sure the table is placed in the fully in, locked position. PLC display will

indicate STATUS OK. c. Ensure crank position proximity sensor is oriented at a 45 deg. angle from

horizontal as shown in fig. 3.5. The position of the proximity sensor relates to the stop position of the seal mechanism. If the seal mechanism does not stop in the fully open position the crank proximity sensor may need adjustment.

d. Press (10) and (11) simultaneously to start cycle. Each time the seal jaw mechanism cycles, the homing position of the seal jaws is monitored ensuring that the seal jaws stop in the full open position allowing the fitment holder to pull out with the table freely.

4. Setting seal cycle duration: a. Power up machine. b. Press (4) two (2) times. c. Duration can be set from 0.4-9.9 milliseconds in 100 millisecond intervals. Set

desired value using (8) and (9) keys, then press (4) once. d. Press (5) to exit set duration mode and save entered value.

5. Setting seal jaw temperature: a. Press (3) on PLC to power up heater controller b. Press (6) till heater controller display shows SP1 for top jaw temperature setting

or SP2 for bottom jaw temperature setting. Set desired temperature with (8) and (9) keys then press (7) to save value. It is recommended that both seal jaws be set at the same temperature for most applications.

Crank position proximity sensor

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3. Recommended maintenance procedures a. The main mechanism crosshead bearing assembly should be lubed with NLGI class 1-2 grease or paste with high load additives such as OKS 250 every month of continuous operation. - To service crosshead:

1. Disconnect power cable from electrical power source 2. Remove the six (6) button head screws fastening the clear polycarbonate front shield to

the machine and set shield aside. 3. Using a clean towel, wipe away any buildup of old grease or debris from bearings and

contacting surfaces. 4. Apply a thin coat of fresh grease to bearings and contacting surfaces. Do not over

grease, only a thin surface coat is required. 5. Replace polycarbonate front shield and snug down fastening screws. Do not over tighten

screws as this could crack face shield. 6. Connect power cable and power up machine. Cycle machine several times to work fresh

grease evenly into mechanism.

4. Safety a. Before performing service of any sort on your PSG FT:

1. Be sure you are familiar with the functions and operations of your machine. 2. Always disconnect machine from all electrical power sources. 3. Allow heated surfaces to cool or serious burns could result. 4. Contact a qualified service technician if you do not feel able to perform the required

service. b. Locate and be sure to understand the safety symbols placed on your machine.

1. indicates hot surface that could cause burns.

2. indicates a pinch point that could crush body members.

3. indicates an electrical shock hazard. c. The PSG FT must be set up on a flat level surface that is able to support at least 75lbs. d. Never sit, stand, or place heavy objects on machine table as this could cause the machine to tip forward inflicting injury on the operator or others. e. The machine should be operated by only one operator at a time. f. Alteration of or disabling the double switch cycle start system could result in machine operator injury.

5. Specifications a. Electrical 1. Main power: 120VAC; 60Hz; 15A 2. Control power: 24VDC 3. Seal jaw heating elements: 120VAC; 500W; 6.3A fuse 4. Main control motor: 24VDC; 4A fuse

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b. Mechanical 1. Footprint: 12 wide, 14.645 long (25.645 overall length), 22 high 2. 6 seal jaw width 3. Sealing jaw clamping force: 56-83lbs. (Adjusted with screw shown in fig. 4)

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6. Electrical diagrams

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7. Replacement parts

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Ref. Picture No.

Part Description Part No.

1 Power up switch 120E110 2 Green status light 120E125 3 Yellow status light 120E126

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4 Emergency stop switch 120E132 5 1/32 Din dual channel heater controller 120H122 6 Cycle enable switch 120E112 7 Table safety position switch 120E135 - 8mm bore link bearings 120BR112 - 15mm bore cross head bearings 120BR115 - 25mm bore main crankshaft bearings 120BR118 8 0.375 bore rulon gas spring bracket bushings 120BU112 9 Crank position proximity sensor 120E140 10 Main mechanism linear bearings 120BL125 11 Table slide linear bearings 120BL126 - 0.500 x 6.000 500W heater element 120H125 - Heater fuses 120H128 - Main drive motor fuse 120E144

8. Change parts specifications

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9. Changeover procedures a. Disconnect machine from power source. b. Remove back and left hand side panels. c. Remove clear polycarbonate front shield. d. Remove front shield located under the table. e. Loosen the two fitment mandrel set screws shown in figure (4) and remove mandrel from

square socket. f. Loosen thermocouple set screw shown in figure (5) and pull thermocouple out of jaw. Be

sure to keep track of which jaw the thermocouple goes with. g. Loosen set screw on the front of the jaw. h. Loosen the two jaw screws, see figure (6), with appropriate Allen key and remove jaws from

machine pulling heating element out of jaw. i. Assembly is reverse of disassembly.

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Fig. 4

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Fig. 6

10. Troubleshooting guide

Problem Remedy Seal leaks around fitment -Seal jaw temperature too low, increase

temperature. -Seal cycle duration too short, increase seal cycle duration. - Seal jaws do not accurately match fitment profile, be sure jaws are accurately manufactured.

Table does not pull out completely -Fitment mandrel not mounted correctly. - Seal jaws not fully open, home machine mechanism (see section (2.b.3.)).

Seal jaws will not cycle when initiated -Table not fully in the in position (PLC display reads TABLE EXTENDED). - If table is fully in, table position switch may have malfunctioned.

Pouch film sticks to seal jaw -Temperature too high. -Heavy film adhesive layer, apply Teflon anti-stick seal jaw tape on seal jaws.

Lower seal jaw screws are fastened in a similar manner to bottom bar.

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