Bandall OPERATING INSTRUCTIONS

Bandall OPERATING INSTRUCTIONS

SUPPLIER : Bandall international Marconiweg 9a 3442 AD Woerden The Netherlands Tel.: +31 348 431520 Fax: +31 348 431480 E-mail: info@bandall.com Internet: www.bandall.com MODEL : Bandall 24/32/40/48 Machine no. : Date of construction :

TABLE OF CONTENTS OPERATING INSTRUCTIONS Chpt. Contents Page Operating conditions 1 Marks 3 1 Connecting the Bandall 4 2 Prepare for use 5 3 Feeding the material into the machine 6 4 Changing the parameters 8 Explanation of the screens 9 4.1 Auto-start on/off 10 4.2. Installing the start time 11 4.3. Extra tension on/off 12 4.4. Markreader (option) 13 4.5. Extra screen on/off 14 4.6. Change sealing temperature 15 4.7. Change sealing time 16 4.8. Cool time 17 4.9. Press on/off (option) 18 4.10. Press starting time 19 4.11. Press release time 20 4.12 Change the feed length 21 4.13. Change feed-in speed 22 4.14. Set Motor acceleration 23 4.15. Set Motor deceleration 24 4.16. Slide open time 25 4.17. Faster in-feed 26 4.18 Save machine settings 27 4.19 Load machine settings 28 4.20 Programme code 29 5. Error list 30 Wiring diagram Plc board III touch screen 34 Drawing with partslists 35-39

1. OPERATING CONDITIONS The operating location of the machine must meet a number of requirements. The ambient circumstances may influence the quality of the banderole, the capacity, and the life span of the machine. OPTIMUM Temperature: 10 C - 30 C Atmospheric humidity 10-90% Ventilated location Solid, even basis UNFAVOURABLE Extremely dusty location Humidity Presence of gases and vapours CONNECTIONS Avoid multiple wall sockets and extension cords The plug must be fixed in the wall socket The plug must be grounded Voltage fluctuations have to be less than 10%. 1

SAFETY The machine is only to be turned on by the main ON/OFF switch The machine has to be switched off before attempts are made to remove the hoods The head of the sealing mechanism can be heated up to 220 C. Great caution is required during cleaning work. Do not touch moving parts while the machine is switched on. Ensure that dirt, dust, foil and paper remnants do not fall into the machine. Switch the machine off during long breaks. OPERATION, MAINTENANCE, REPAIR The use of the machine is restricted to the banding of dry products that fit in the arch. The machine is only to be operated by staff members who have been instructed by the supplier. Maintenance and repair may only be executed by qualified personnel. Do not use any water and/or corrosive detergents when cleaning the machine. Any alterations of the machine, which are executed during the warranty period without notification of the supplier, may influence the warranty. 2

MARKS If the marks are worn of, or if they have become illegible, they have to be replaced by the user. where meaning right hand side undercarriage top net-entrance right hand side undercarriage bottom manometer working pressure front undercarriage left bottom connection foot pedal front undercarriage left middle diagram guide rollers front table right manometer tape tension top table plate left clamping danger back undercarriage left bottom air connection back undercarriage middle top electricity danger 3

1. CONNECTING THE BANDALL First connect the machine to a pressured air supply with a minimum of 6 Bar and a maximum of 12 Bar airpressure. The pressured air must be dry and clean. In order to make the connection a female 1 /4" ORION connector is required. The use will be approximately 56 liters of air of 6 Bar per minute for a rate of 30 bands per minute (see fig. 1). Use the electrical cable supplied to connect the machine to an earthed socket. The voltage is 220-240 Volt 50 Hz. The connection value is 500 Watt. Ensure the cable is placed where it will not hinder the user of the machine and is free from any moving parts, such as the roll holder with rolls. Hand and Foot Operation When using the foot pedal (for connection see fig. 2) then the overview of the programme must be consulted. Switch on the main switch. The display shows: Fig. 1 Fig. 2 Cut material Manual reverse feed Manual forward feed Lift contra roller/left upper clamp Feed in material and/or to run screen Actual temperature seal head Product counter The loaded programme Pulse counter during jogging 4

2. PREPARE FOR USE INSTALLING A REEL OF TAPE Turn the black knob counterclockwise to loosen it. Then remove the core of the old reel. Place a new reel on the holder in such a way that it unwinds as illustrated on fig. 3. Press the cardboard of the reel backwards as far as it will go. DO NOT PRESS on the tape to prevent it from being pushed off the core. Now turn the black knob clockwise until the reel is well fixed. Fig. 3 TENSIONING THE TAPE Before starting the banding procedure, the tape must be tensioned. Lift the guiderolls by hand (E) about 10 cm. The brake of the reel will now be released. Now turn the reel counterclockwise; thus winding the tape onto the reel. When the tape is tensioned, release rolls and reel; the reel unwinds a bit and is then stopped by the brake. A E The machine is ready for operation now. Fig. 4 5

3. FEEDING THE MATERIAL INTO THE MACHINE. A = Roll holder B = Infeed button C = Front positioning plate D= Display E = Band tension indicator F = Band tension adjustor G = Feed in buffer H = Band tension release I = Mark reader (optional) J = Foot pedal connection K = Rear positioning plate fig. 5 Before feeding in the material ensure that the end of the material is cut off straight and not folded. This will avoid problems when feeding in. Place the end of the material under the green in-feed button (B) and push down the green button. While holding down the green button press (this button can be found on the display (D)). until the material it is visible in the arch If the material is not immediately visible in the arch then immediately release the Carefully remove the material and start again with a newly cut end of material. button. Once the material has been fed in successfully, cut off the end of the tape by pressing Remove the cut off piece of material. If you are working with banding paper then this can stick to the seal plate - by pressing down on this tape it will be released. Feed the material around the arch by pressing Cont. op page 7 6

The display screen will automatically display the run screen. The machine is now ready to band a product. It is necessary to adjust the front (C) and rear (K) positioning plates to fit the product. The product should be placed in the left hand corner of the arch. If the band is too loose or too tight around the product then the tension can be adjusted by using the band tension knob (F). LEAVING THE RUN MODE There are various reasons for leaving the "run mode", e.g. - to stop the machine - to change material - to change product - etc. To leave the "run mode" press the button. You will then enter the feed-in screen. Remove the material by hand from the left corner of the machine and cut it off. Feed the rest of the material out of the machine. Change the material or product and start over at chapter 3 Feeding the material into the machine (page 6). 7

4. CHANGING THE PARAMETERS Within this chapter the extra possibilities offered by the Bandall machine are explained. These include: - using the additional options offered by a more detailed operating menu. - Saving and using various programmes - It is vital that this manual is read thoroughly to ensure that the machine functions well. To gain basic knowledge to use the basic functions of the Bandall then chapters 1, 2 and 3 of this manual must be read. Once you have taken delivery of the machine and switch it on then the main menu will appear on the display screen. For additional possibilities it is necessary to log in in the login screen. To enter the login screen press the "key" button. Type in the code 3516 to log in. This code is the standard code and has been installed by the supplier. An additional 4 tab pages will appear on the menu. Using these tab pages options can be switched on and off, and functions can be added to the users area. Following you will find a two-part explanation: A: Explanation of the screens (see page 9) B: Adjusting the parameters (see page 10-29) 8

EXPLANATION OF THE SCREENS The additional screens will be explained in detail below so that you can decide which functions you will make accessible to the user. Think about this before making any changes. In our experience the easy use of the machine is not always improved by making more options accessible to the user - what cannot be changed cannot be changed incorrectly. If you are confident in your user then of course he/she can be given the standard code. General The structure of the screens is as follows: At the top you will see the tabs. The tab that is lighter in colour is active. At the left of the screen the various function buttons are shown. Where a button is lighter in colour then that function is switched on. To the right of the numbers symbols show whether the function is on or off. 9

4.1. Auto-start on/off When the auto-start is switched off the machine will no longer automatically start once a product is placed in the machine. This function can be used together with a foot pedal, or manual use via the display. The foot pedal can be plugged into the foot pedal connection (see page 4), Proceed as follows: Once logged in, press the tab for the "extra screen" menu The following screen is shown. This is button 1: auto-start on/off. - if the button is lighter in colour then this function is switched on. If the button is darker then the function is switched off. - This can also be seen in the right hand column, where next to number 1 a means "on" and means "off". To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. PLEASE NOTE: If the machine has been programmed so that it can be manually operated using the display panel, then the run screen appears as follows Button for manual operation 10

4.2. Installing the start time Start time : this function is used when more time is required between placing the product in the machine and the start of the material being pulled around the product. For example, when an additional product is to be added or a stack is to be straightened by hand. Proceed as follows: Once logged in, press the tab for the "extra screen" menu The following screen appears: Here is button 2 "auto-start time" In the example above, at the right of the screen next to the 2 the "auto-start time" is set at 0.0 sec. If you press button 2, the following screen will appear. At the top right corner you will see the time currently programmed. This is shown in 0.10 of a second: if you choose value "4", then this is 0.4 seconds. Type in the new value and "enter" Now the screen below will appear. In the right hand column you will see that "auto-start time" (2) is now 0.4 seconds. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. 11

4.3. Extra tension on/off Extra tension on/off: You switch this function on if the highest band tension, with band tension adjustment (F, see fig. 5, page 6) is not high enough around the product Proceed as follows: Once logged in, press the tab for the "extra screen" menu The following screen appears. Here is button 3 "extra tension on/off" - If the button is lighter in colour then this function is switched on. If the button is darker then the function is switched off. - This can also be seen in the right hand column, where next to number 1, means "on" and means "off". To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. 12

4.4. Mark Reader (option) This menu is optional. If present, the external reel holder is fitted with a mark reader sensor. This option is used to position a preprinted text or sign. ATTENTION: When the outline of a product changes, the position of the text will change to!. This means that for products with different outlines you have to use different preprinted tapes. If the mark reader option is installed in your machine, then this button will appear in the "extra screen" and you can switch this function off to work with a non-printed material. If your machine has not been installed with this option then this button will not appear on the screen. Proceed as follows: Once logged in, press the tab for the "extra screen" menu The following screen appears: Here is button 4 "mark reader on/off" - If the button is lighter in colour then this function is switched on. If the button is darker then the function is switched off. - This can also be seen in the right hand column, where next to number 1 a means "on" and means "off". To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. PLEASE NOTE: If the button "mark reader on/off" does not appear in the menu above, contact your dealer. 13

4.5. Extra screen on/off This programmes allows you to give access to the user to additional functions. This refers to the functions: - Auto start on/off - Extra tension on/off Proceed as follows: Once logged in, press the tab for the "extra screen" menu The following screen appears: Here is button 6 "extra screen on/off" - If the button is lighter in colour then this function is switched on. If the button is darker then the function is switched off. - This can also be seen in the right hand column, where next to number 1 a means "on" and means "off". To leave this screen press the "key" tab. You will return to the main menu, which appears as follows: A new tab page appears at the top of the screen. This gives the user access to the extra functions. 14

4.6. Change sealing temperature The quality of the sealing depends on the right quantity of supplied heat. If more or less heat is required, the temperature of the sealing-head can be increased or reduced. DO NOT increase the temperature of the sealing head over 225 C. The teflon on the sealinghead can not take more than 225 C. If you want to supply more heat, increase the sealing time in menu 3. To change the temperature, select menu 7. Proceed as follows: Once logged in, press the tab for the "seal and press screen" menu The following screen appears. Here is button 1 "seal temperature" In the above example, at the right of the screen you will see "seal temperature (1) at 200 deg. C. If you press button 1 then the following screen will appear. In the top right-hand corner you will see the chosen temperature. The value is given in degrees C. If you type in the value "180" then this is 180 deg. C. Type in the new value and "enter" Now the screen below will appear. In the right hand column you will see that the temperature is now 180 deg. C. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. PLEASE NOTE: Guidelines: film is sealed at approx. 180 deg. C and paper at approx. 200 deg. C. Maximum 225 deg. C. 15

4.7. Change sealing time The quality of the sealing depends on the right quantity of supplied heat. If more or less heat is required, the sealing time can be increased or reduced. DO NOT reduce the sealing time below 0,3 sec. This prevents the changing air pressure of the compressor from having to much influence on the seal. If you still want less heat, reduce the sealing temperature in menu 2. To change the sealing time, select menu 6. Proceed as follows: Once logged in, press the tab for the "seal and press screen" menu The following screen appears: Here is button 2 "seal time" In the above example, you will see at the right of the screen the "seal time"(2) is set at 0.4 sec. If you press button 2 then the following screen will appear: In the top right-hand corner you will see the chosen seal time. The value is given in 0.10 of a second: if you choose the value "6" then this is 0.6 seconds Type in your required seal time, followed by enter The following screen will appear: At the right of the screen you will see that the "seal time"(2) is now 0.60 seconds. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. PLEASE NOTE: In normal circumstances, the seal time must be set at 0.4/0.5 seconds. Maximum 5 seconds. 16

4.8. Cool time This is the seal cool time, the time that the clamps left and right of the seal unit will keep the material tensionless after the adjusted seal time. Then it is possible to let the seal cool down. Proceed as follows: Once logged in, press the tab for the "seal and press screen" menu The following screen appears. Here is button 3 "seal cool time" In the above example, you will see at the right of the screen the "seal cool time"(3) is set at 0.0 sec. If you press button 3 then the following screen will appear: In the top right-hand corner you will see the chosen seal cool time. The value is given in 0.10 of a second: if you choose the value "6" then this is 0.6 seconds. Type in your required seal cool time, followed by enter The following screen will appear: At the right of the screen you will see that the "seal cool time"(3) is now 0.60 seconds. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. 17

4.9. Press on/off (option) In this menu it is possible to switch the press, or another application that is connected to this exit, on or off. You could use this press to compress products just before they are banded. Proceed as follows: Once logged in, press the tab for the "seal and press screen" menu The following screen appears: Here is button 4 "press on/off" - if the button is lighter in colour then this function is switched on. If the button is darker then the function is switched off. - This can also be seen in the right hand column, where next to number 1 a means "on" and means "off". To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. PLEASE NOTE: If this button does not appear on the menu screen above, while your machine does have a press, then please contact your dealer. 18

4.10. Press starting time In this menu it is possible to adjust the time between the activation of the press, or another application that is connected to this exit, and the starting of the banding cycle. For example: you could use this time to press the air out of the product. Proceed as follows: Once logged in, press the tab for the "seal and press screen" menu The following screen appears. Here is button 5 "press start time" In the above example, you will see at the right of the screen the "press start time" (5) is set at 0.0 sec. If you press button 5 then the following screen will appear: In the top right-hand corner you will see the chosen press start time. The value is given in 0.10 of a second: if you choose the value "20" then this is 2.0 seconds. Type in your required press start time, followed by enter The following screen will appear: At the right of the screen you will see that the "press start time"(5) is now 2.0 seconds To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. PLEASE NOTE: If this button does not appear on the menu screen above, while your machine does have a press, then please contact your dealer. 19

4.11. Press release time In this menu it is possible to adjust the time between the end of the banding cycle and deactivation of the press. This time is used to hold the product by the press for a certain time to let the seal cool before the tension of the product is released on the seal. Proceed as follows: Once logged in, press the tab for the "seal and press screen" menu The following screen appears; Here is button 6 "press stop time" In the above example, you will see at the right of the screen the "press stop time" (5) is set at 0.0 sec If you press button 6 then the following screen will appear. In the top right-hand corner you will see the chosen press stop time. The value is given in 0.10 of a second: if you choose the value "20" then this is 2.0 seconds. Type in your required press stop time, followed by enter The following screen will appear: At the right of the screen you will see that the "press stop time"(6) is now 2.0 seconds. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. PLEASE NOTE: If this button does not appear on the menu screen above, while your machine does have a press, then please contact your dealer. 20

4.12. Change the feed length After having made a banding, new tape is inserted into the loop. Precisely enough tape is Inserted, to appear under the sealing plate. The right length of the tape can be adjusted by increasing or reducing the number of pulses. When this tape length is not adjusted properly, this can cause malfunction. Proceed as follows: Once logged in, press the tab for the "motor curve + slide open time + faster in-feed" menu The following menu appears: Here is button 1 "in-feed length" In the above example, you will see at the right of the screen the "in-feed length" (1) is set at 1765 pulses. If you press button 1 then the following screen will appear: In the top right-hand corner you will see the chosen in-feed length. You can type over this value by, for example, typing in 1750 followed by enter. (150 pulses is approximately 100mm) This choice must be confirmed. This can be done by pressing the diskette button on the screen shown here. The following screen will reappear: At the right of the screen you will see that the "in-feed length" (1) is now 1750 pulses. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. 21

4.13. Change feed-in speed You can set the maximum feed-in speed of the motor using the "maximum motor speed" button. This is set at 100%, and this is used to let the motor run as quickly as possible. The higher the value the quicker the motor runs (100% maximum). Proceed as follows: Once logged in, press the tab for the "motor curve + slide open time + faster in-feed" menu The following menu appears: Here is button 2 "maximum motor speed" In the above example, you will see at the right of the screen the "maximum motor speed" (2) is set at 100%. If you press button 2 then the following screen will appear: In the top right-hand corner you will see the chosen maximum motor speed. You can type over this value by, for example, typing in 90 followed by enter. This choice must be confirmed. This can be done by pressing the diskette button on the screen shown here. The following screen will reappear: At the right of the screen you will see that the "maximum motor speed" (2) is now 90%. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. 22

4.14 Set motor acceleration You can set the acceleration of the motor using the "motor acceleration" button. This is set at 100%, and is only used to allow the motor to accelerate as quickly as possible. The higher the value the quicker the acceleration (100% maximum). Proceed as follows: Once logged in, press the tab for the "motor curve + slide open time + faster in-feed" menu The following menu appears: Here is button 4 "motor acceleration" In the above example, you will see at the right of the screen the "motor acceleration" (4) is set at 100%. If you press button 4 then the following screen will appear: In the top right-hand corner you will see the chosen motor acceleration. You can type over this value by, for example, typing in 90 followed by enter. This choice must be confirmed. This can be done by pressing the diskette button on the screen shown here. The following screen will reappear. At the right of the screen you will see that the "motor acceleration" (4) is now 90%. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. 23

4.15 Set motor deceleration You can set the deceleration of the motor using the "motor deceleration" button. This is set at 100%, and is only used to allow the motor curve to run more slowly, allowing more accuracy. The lower the value the quicker the deceleration (100% maximum). Proceed as follows: Once logged in, press the tab for the "motor curve + lip open time + faster in-feed" menu The following menu appears: Here is button 5 "motor deceleration" In the above example, you will see at the right of the screen the "motor deceleration" (5) is set at 100%. If you press button 5 then the following screen will appear: In the top right had corner you will see the chosen motor deceleration. You can type over this value by, for example, typing in 90 followed by enter This choice must be confirmed. This can be done by pressing the diskette button on the screen shown here. The following screen will reappear: At the right of the screen you will see that the "motor deceleration" (5) is now 90%. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. 24

4.16. Slide open time The "slide open time" is used to programme the maximum time that the seal plate stays open, unless there is a product in the arch. This means that, when the slide open time is set at 2 seconds and you remove the product from the arch within 1 second, then the seal plate will close immediately, to avoid crushing. The programmed time is only reached when the sensor remains covered. If you programme the time in at 0.0 seconds then the seal plate will remain open until the product is removed and the product sensor is no longer covered (manufacturer's parameter). Proceed as follows: Once logged in, press the tab for the "motor curve + slide open time + faster in-feed" menu The following menu appears: Here is button 3 "slide open time" In the above example, you will see at the right of the screen the "slide open time" (3) is set at 0.0 sec. If you press button 3 then the following screen will appear: In the top right hand corner you will see the chosen time. You can type over this value by, for example, typing in a new time, followed by enter The value is given in 0.10 of a second: if you choose the value "20" then this is 2.0 seconds. The following screen will reappear. At the right of the screen you will see that the "slide open time" (3) is now 2.0 seconds. To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. 25

4.17. Faster in-feed If the "faster in-feed" function is switched on, then the machine will feed the material into the arch once the banding process is complete, and not only once the seal plate is closed. This results in the ability to have a faster production process as the material is fed into the arch at the time that the product is removed from the machine. This means that the machine is ready for the next product sooner. This is an advantage for those machines that require more time to feed in the material. A possible disadvantage is where a product is still in the machine at the time that the material is fed in and the product bottom side is in the arch, resulting in a possible fault in the material in-feed. Proceed as follows: Once logged in, press the tab for the "motor curve + slide open time + faster in-feed" menu The following menu appears: Here is button 6 "faster in-feed" - if the button is lighter in colour then this function is switched on. If the button is darker then the function is switched off. - This can also be seen in the right hand column, where next to number 1 a means "on" and means "off". To leave this screen press the "key" tab. You now leave this login menu and return to the main menu. 26

4.18. Save machine settings This screen is used to save or to load programmes. When several different banding materials are to be used then it can be very useful to create a number of programmes listing the appropriate settings. Up to 19 programmes can be saved. It is also possible to load the manufacturer's settings, so that it is always possible to refer back to the original settings. Also, should there be a problem with the machine, it is possible to allocate a code to a list of settings. If these are then given to your dealer he may be able to see whether these settings allow for optimal use of the machine. The advantage of having such a list is that there can be no confusion about which parameters are under discussion. Also, if a typing error has been made then this will become evident. Additionally, a number of settings will be included in this code which do not appear in the screens. If an improvement is possible then your dealer can incorporate this within the code. This code can then be installed without needing to work through all of the screens. An incorrect parameter will not be accepted by the programme. Proceed as follows: Once logged in, press the tab for the "programme screen The following menu appears: Here is button "save programme" This button can be used to save any changes in the programme. The correct procedure to follow is: - Change parameters. Make a number of trial bands to test the parameters. - Go to the programme screen. - Select the required programme number by using the buttons. - Press the button and you will be asked if you are sure. - If you are sure press, if not then press. 27

4.19 Load machine settings Proceed as follows: Once logged in, press the tab for the "programme screen The following menu appears: - Select the required programme number by using the buttons. - Press the button and you will be asked if you are sure. - If you are sure press. The programme you have selected will now be in the run mode. 28

4.20 Programme code Using this button you can install a coded parameter list. Proceed as follows: Once logged in, press the tab for the "programme screen The following menu appears: Here is the button "code to programme - Select the programme that you wish to change. - Then press the button and you will be asked to confirm this choice. The following screen will then appear: Rows 0 to 9 appear in this screen - you can then check these rows against the list you have received from your dealer. It is also possible that you have received only one row. Choose the row that you wish to change (e.g. 4) by clicking on the row itself. The following screen will appear: Here you can type in your code.. Once you press this row will be saved and you will return to fig. 2. Once you have changed all the rows required, carefully check all rows Press to leave this screen. If you press then you will leave this screen without saving the changes you have made. 29

5. ERROR MESSAGES ON DISPLAY To reset an error push button on the error screen Name: Description: lcd and I/O card are not compatible. software cannot communicate because of difference in version. Reason/solution: call your dealer and give him the report and machine number. 30

Name : Description : Reason/solution: No communication. When more than 3 communication faults are made consecutively. Call your dealer and give him the report and machine number of the machine. Name : Description : Reason/solution: Synchronisation failure. Synchronisation of the parameters has failed. Call your dealer and give him the report and machine number of the machine. Name : Description : Reason/solution: Tape stuck. Tension leaver (H) is down. The adjusted band tension is too low for this type of machine. This should not be less than 0.2 Mpa. Check this at indicator (E). Check whether the air pressure to the machine is sufficient by reading this from the main air pressure indicator (M). This should be at 6 Bar. Name : Description : Reason/solution: Wagon not up. Wagon is down in the in-feed buffer (G). Secure the roll of material on the roll holder (A). Check whether there is sufficient air pressure to the machine. This should be 6 Bar. 31

Name : Description : Reason/solution: Band retreat. The band falls out of the arch when pulling back around the product. Material feeds in well but is not held securely at the end. Replace the rubber inlay to the left upper clamp. The in-feed length is too short. Ask your supervisor to increase the length. Or call your dealer and give him the report and machine number Name : Description : Reason/solution: Does not feed in within the time required. The machine cannot feed in the programmed length of material within the programmed length of time. Dirt around the transport axel/seal head. Switch the machine off so that the seal plate retreats. Try to carefully remove any remaining material. If the material does not feed in properly then call your dealer and give him the report and machine number. Name : Description : Reason/solution: Wagon not down. After a banding cycles the wagon is not down in the infeed buffer (G) within 4 sec. The reel holder does not turn smoothly. Reason: roll of material rubs against the frame. Name : Temperature time-out. Description : Programmed temperature is not achieved within 5 minutes. Reason/solution: Call your dealer and give him the report and series machine number. 32

Name : Description : Reason/solution: Mark not found. At the commencement of feeding in and with the mark reader function switched on, the printed mark cannot be read. Re-teach the mark reader sensor to recognise the mark. Name : Description : Reason/solution: Press. Press does not descend or ascend once requested. The press sensor has moved - this should be above the press cylinder. Check whether the red light is on if the press is at its uppermost position. If not, then you can remove the clamp with a small screwdriver and try to light the red light by sliding the sensor around. Name : Description : Reason/solution: Band not fed in properly. A sensor in the arch detects that the material has not fed in properly. Band curls and folds double. Correct the band position by hand. If this Error continues then, if possible, rotate the roll, cut the end off and feed in again. Name : Description : Reason/solution: Slide not closed. Slide is not complete closed. Material is caught between the slide and the but plate. Switch the machine off, open the slide and remove the material. 33

Wiring diagram Plc board III touch screen 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 J9 J8 J7 J6 J5 J4 1 2 2 1 4 3 2 1 J15 J10 J11 J14 11 10 9 8 7 6 5 4 3 2 1 Layout PLC. Board VIII J13 12 11 10 9 8 7 6 5 4 3 2 1 J12 12 11 10 9 8 7 6 5 4 3 2 1 J3 J2 J1 1 2 1 2 3 4 5 6 1 2 Con. Description color J1 230Vac input 1 Phase 230 VAC black 2 Nul black J2 230V Output 1 Phase freq.inv black 2 Nul black 3 Phase fan black 4 Nul black 5 Phase heater (switched) black 6 Nul black J3 230V power suply transformer 1 Phase 230 VAC brown 2 Nul blue J4 18Vac Input transformer 1 + red 2 - red J5 Outputs 1 1 Sealhead valve +24Vdc red 2 GND black 3 Sealhead valve +24Vdc red 4 GND black 5 Upper clamp left valve +24Vdc red 6 GND black 7 Wagon valve +24Vdc red 8 GND black J6 Outputs 2 1 Clamps valve +24Vdc red 2 GND black 3 Press valve +24Vdc red 4 GND black 5 Output 7 +24Vdc 6 GND 7 Output 8 +24Vdc 8 GND J7 Outputs 3 1 Busy +24Vdc brown 2 GND (common lamp) white 3 Error +24Vdc (red lamp) yellow 4 GND white 5 Ready +24Vdc gray 6 GND white 7 Standby +24Vdc (green lamp) green 8 GND white J8 Frequency inverter: Altivar 31 1 LI1 white 2 3 LI2 brown 4 5 AI2 green 6 COM yellow J9 Brake 1 Brake + 24Vdc (switched) brown 2 GND black Con. Description color J10 PT100 input (E10) 1 in red 2 in white J11 Encoder input 1 Anode LED black 2 Gnd. LED brown 3 24Vdc receiver (opto) orange 4 GND. Receiver red J12 Inputs 1 1 +24Vdc brown 2 Ingang E1 product sensor black 3 GND blue 4 +24Vdc brown 5 Input E2 wagon down black 6 GND blue 7 +24Vdc brown 8 Input E3 tension sensor blue 9 GND 10 +24Vdc brown 11 Input E4 external start white 12 GND J13 Inputs 2 1 +24V brown 2 Input E5 mark reader black 3 GND blue 4 +24V brown 5 Input E6 sealplate check sensor blue 6 GND 7 +24V brown 8 Input E7 press sensor blue 9 GND 10 +24V brown 11 Input E8 band in arch black 12 GND blue J14 Inputs 3 1 +24V 2 Input E9 free 3 GND 4 +24V 5 Input E11 free 6 GND 7 +24V 8 Input E12 free 9 GND 10 N/C 11 N/C J15 FlexBus J16 Display FlexBus J17 RS485 J18 RS485 (parallel to J17) 34

8 2 9 10 11 12 10 13 14 15 7 6 5 4 1 Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Description Motor pulley 21-T5-20 Pulley 21-T5-30 Cyl. upper left clamp Cyl. Clamps (cut and seal unit) Cyl. Seal head (cut and seal unit) Timing belt 475 mm Cut + seal unit complete Clamp left Cutter Isolation plate 1 mm Seal head Spring seal unit Clamp right PT 100 Heating cartridge number is the same as for 30 mm 3 30 mm Partnr. 239019005 239019006 233025043 233025039 233025038 243012003 280107000 280107104 245107007 289187001 287107001 248107004 280107105 2ET302630 2EV302620 50 mm Partnr. 280207000 280207104 245207007 289287001 287207001 248007004 280207105 2EV502620 77 mm Partnr. 280307000 280307104 245307007 289387001 287307001 248007004 280307105 2EV772620 102 mm Partnr. 280407000 280407104 245407007 289487001 287407001 248007004 280407105 2EV772620 35

12-12a 8-8a 10 2 3 14 13 11 5 1 9 7 Pos. Description 1 Motor 2 Upper clamp left 3 Seal plate 4 Cyl. sealingplate 5 Slide sealingplate 6 Fan 7 Freq. controller 8 Beltset BA 32 8a Beltset BA 24 9 Counter plate 10 Product sensor 11 Motor pulley 12 Front tablecover plate 12a Back tablecover plate 13 Timing belt 14 Pulley belt drive 15 Valve SMC Part number is the same as for 30 mm 6 30 mm Partnr. 2EA301810 260103010 287106100 2PC303830 241006002 2EV300610 2EF307050 2AS300590 2AS300240 2EP301880 222006005 2AP301850 280320201 280320202 2AT301970 2AP301910 233016005 15 50 mm Partnr. 4 77 mm Partnr. 102 mm Partnr. 287206100 2PC503830 260303010 287306100 2 x partnr. 30 mm 260403010 287406100 2 x partnr. 50 mm 2AS500590 2AS500240 2AS770590 2AS102261 2AS102274 36

1 2 3-3a 30 mm 50 mm 77 mm 102 mm Pos. Description Partnr. Partnr. Partnr. Partnr. 1 Seal plate catcher with groove 287007038 2 Main board touch screen machine 221026002 3 Touch Screen glass 221026003 3a Display touch screen complete 221026001 Part number is the same as for 30 mm 37

7 4 5 3 2 1 6 30 mm 50 mm 77 mm 102 mm Pos. Description Partnr. Partnr. Partnr. Partnr. 1 Belt tape feed 2AT301960 2 Motorpulley 2AM301850 3 Spacer 2AK301730 NA NA NA 4 Contra roller incl. bearings 2AA301790 2AA501790 2AA771790 2AA102179 5 Bearing contra roller 2AL301750 6 Bearing set tape feed NT 235007004 7 Feed-in button complete 2AB303520 2AB503520 2AB773520 2AB102352 Part number is the same as for 30 mm 38

1 2 3 1 4 5 8 7 6 30 mm 50 mm 77 mm 102 mm Pos. Description Partnr. Partnr. Partnr. Partnr. 1 Guide pin 6 mm 264183003 264283003 264383003 264483003 2 Guide pin 5 mm (u.c.l.) 264183004 264283004 264383004 264483004 3 Bearing push plate (u.c.l.) 6 mm 235011002 4 Push plate (u.c.l.) 280003903 5 Bearing push plate (u.c.l.) 8 mm 235011003 6 Guide pin 8 mm (cyl. u.c.l.) 264183002 264283002 264383002 264483002 7 Bearing F6800ZZ (drive shaft) 235021003 8 Drive shaft 264181000 264281000 264381000 264481000 Part number is the same as for 30 mm 39