Stretch Packaging Machine Operating Manual

Operating Manual

Stretch Packaging Machine

Type MSK Tensiontech

MSK Tensiontech

Commission Number: 441600

MSK Hungary Gépgyártó Bt. Vágóhíd út 39,

Nyírbátor 4300, Hungary Phone +36 42 511

100 • Fax +36 42 511 155 http://www.msk.hu

http://www.msk.hu/

Operating Manual

MSK

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After-sales Service

MSK Covertech, Inc.

4170 JVL Industrial Park Drive

30066 Marietta, Georgia

USA

Phone (+1) 770 928 1099 (central office)

Fax (+1) 770 928 3849 (customer service)

OPERATING MANUAL:

Stretch Packaging Machine Type MSK Tensiontech

© 2012 by MSK Verpackungs-Systeme GmbH

Technical amendments reserved.

MSK Verpackungs-Systeme GmbH is working constantly to further develop and improve its

products. Please appreciate that modifications are possible in the scope of supply in the form,

configuration and engineering at any time. No claims can be derived from the information, fig-

ures and descriptions in this operating manual.

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Operating Manual

MSK Tensiontech Table of Contents

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1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.3 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.4 Copyright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.6 Obligations of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.7 Liability disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.8 Manufacturer's address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.9 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.10 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.2 Demands on personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.4.1 Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.4.2 Safety devices on the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.5 Safety precautions for maintenance and troubleshooting . . . . . . . . . . . . . . . . . 27

2.5.1 Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.5.2 Electrical/electronic installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.5.3 Electric welding operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.5.4 Testing in accordance with the Occupational Safety and Health Administration (OSHA)29

2.6 Noise measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2 Description of functions (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.3 Sequence of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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3.3.1 Sequence of functions in film feeder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.3.2 Functional sequence pick up film, stretch and fit . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.4 Description of assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4.1 Baseframe (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4.2 Film rack (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.4.3 Film feeder head (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.4.4 Wealing bar and Hood Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.4.5 Suction Tubes (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.4.6 Hood Wrapper (4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.4.7 Centering device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.4.8 Control console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.4.9 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.5 Safety Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.5.1 Emergency STOP circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.5.2 Safety pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.5.3 Safety fence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.6 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.7 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.7.1 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.7.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.7.3 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.7.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.1 General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.2 Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.3 Electrical ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.4 Pneumatic ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.6 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.7 Film data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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5.2 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5.3 Handling during transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.3.1 Center of gravity and lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.3.2 Transport of pallets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.4 Unloading and unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.5 Handling of packaging materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.6.1 Storage of packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6 Installation and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65


6.2 Qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.3 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6.4 Pneumatic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6.5 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.6 Safety fence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6.7 Installation plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7.1 Inspection before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.1.1 Inspection points: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.2 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

8 Operation of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8.1 Operation of MSK packaging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8.1.1 Generally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8.1.2 Layout of the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

8.1.2.1 Main Screen Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

8.1.3 Inspection before placing into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

8.1.4 Placing into operation for the first time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

8.1.5 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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8.1.5.1 Manually moving conveyors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

8.1.5.2 Manually adding a pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

8.1.5.3 Further manual functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

8.1.5.4 Manual functions of the centering frame (CF) . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

8.1.5.5 Manual functions of the Tensiontech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

8.1.5.6 Manual function General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

8.1.5.7 Manual Hooding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

8.1.5.8 Manual function of the Film Supply (FS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.1.5.9 Manual function of the Hooding Frame (HF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

8.1.5.10 Manual functions of the Film Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

8.1.6 Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

8.1.7 Moving to normal position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

8.1.8 Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

8.1.9 Adjust the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8.1.10 Select the pallet information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8.1.11 Switching off the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.2 Overview of the operating elements on the control cabinet/control console 101

8.3 Insertion of the film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

8.3.1 Film reel changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

8.3.2 Threading in the film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

9.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

9.2 After-sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

9.3 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.4 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.4.1 Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.4.2 Control of electric equipment pursuant to BGV A3 . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.4.3 Lubrication and maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

9.5 Maintenance of the MSK Tensiontech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

9.5.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

9.5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

9.5.3 General visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

9.6 Further maintenance work on the MSK Tensiontech . . . . . . . . . . . . . . . . . . . . 122

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9.6.1 Bearing roller (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

9.6.2 Bearing rollers 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

9.6.3 Lateral Guide rollers 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

9.6.4 Alignment of the hood applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

9.6.5 Toothed belt replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

9.6.5.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

9.6.5.2 Disassembly of the upper toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

9.6.5.3 Disassembly of the lower toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

9.6.5.4 Assembly of the lower toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

9.6.5.5 Assembly of the upper toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

9.6.5.6 Tightening of the toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

9.7 Replacing the Sealing bars on the MSK Tensiontech. . . . . . . . . . . . . . . . . . . . 135

9.7.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

9.7.2 Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

9.7.3 Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

9.7.4 Final Steps After Mounting Wealing bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

9.8 Maintenance of the motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

9.9 Maintenance of the pneumatic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

9.10 Maintenance of the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

9.11 The alignment and maintenance of the flap conveyor . . . . . . . . . . . . . . . . . . . 143

9.11.1 Screws for alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

9.11.2 Warning (signs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

9.12 Maintenance of the conveyor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

9.13 Maintenance of the centering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

9.14 Maintenance record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

10.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

10.1.1 Personal preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

10.1.2 Preparations for remedying faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

10.1.3 Steps before switching on again after faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

10.2 General information on troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

10.3 Faults and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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10.4 Printout of the error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

10.5 Further faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

10.5.1 General Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

10.5.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

10.5.1.2 Load not centered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

10.5.1.3 Gate in safety fence open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

10.5.1.4 Emergency stop tripped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

10.5.1.5 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

10.5.2 Stretch film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

10.5.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

10.5.2.2 Film tears during stretching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

10.5.2.3 The film hood is not drawn optimally over the goods to be packed . . . . . . . . . . 166

10.5.2.4 The film is not cut off cleanly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

10.5.2.5 Film is not or not completely sealed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

10.5.2.6 The film jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

11 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

11.1 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

12 Annex Manufacturers' Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

12.1 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

12.2 Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

12.3 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

12.4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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1 General

1.1 Foreword

This operating manual is a major asset for the safe and successful operation of the

packaging machine. It contains important information on operating the packaging ma-

chine safely, properly and efficiently. Observance of this information will help to avoid

dangers, repair costs and standstill times, and to increase the reliability and service

life of the machine.

All figures and drawings in this operating manual serve for the general illustration of

the machine and are not binding for the machine design in detail.

The operating manual must be available at the packaging machine at all times. It must

be read and observed by all persons engaged to work on or with the machine,

e.g.:

– Operation,

– remedying faults during operation,

– care,

– service (maintenance, inspection, repair) and/or

– transport

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1.2 Warnings

The following warnings are used in the present operating manual:

DANGER

A DANGER symbol draws attention to an impending dangerous situation.

If the hazardous situation is not prevented, this will result in death or severe injury.

Follow the instructions in this warning to avoid the danger of serious injury or even

death.

WARNING

A WARNING symbol draws attention to a potentially dangerous situation.

If the hazardous situation is not prevented, it can result in death or serious injury.

Follow the instructions in this warning to avoid the potential danger of serious injury or

even death.

CAUTION

A CAUTION symbol draws attention to a potentially dangerous situation.

If the dangerous situation is not avoided, it may lead to minor or moderate injury.

Follow the instructions in this warning to avoid the danger of injury.

ATTENTION

A ATTENTION symbol draws attention to potential machine damage.

Material damage may occur if the dangerous situation is not avoided.

Follow the instructions in this warning to avoid the risk of material damage.

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NOTE

A NOTE draws attention to additional information that simplifies the operation of the

packaging machine.

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1.3 Explanation of symbols

Warnings and prohibitions are marked in this operating manual with symbols.

The following symbols are used in the present operating manual:

Symbol Meaning

General warning

Danger of electric shock

Danger from falling objects

Danger from tipping objects

Environmental hazards

Danger from pressurized lines or compo-

nents!

Danger of pinching

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Symbol Meaning

Danger of crushing

Danger of cuts

Danger due to pulling in or catching

Danger of burning due to hot surfaces

No access to persons with heart pace-

makers

Access to indicated areas forbidden

General information

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1.4 Copyright

This operating manual must be treated as confidential. It may only be used by author-

ized staff.

NOTE

The operating manual forms part of the machine and must be

passed on to the new owner if the machine is sold.

All documents are protected in the sense of the Copyright Act.

The disclosure and reproduction of documentation, in whole or in part, as well as the

exploitation and communication of its content shall not be permitted unless expressly

stated otherwise. Infringements of this obligation are criminal offences and incur an

obligation to pay damages.

We reserve all rights for the exercise of industrial property rights.

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1.5 Warranty

Read these operating instructions carefully and in full before operating the packaging

machine!

The manufacturer assumes no liability for damage or operating malfunctions resulting

from failure to observe the operating manual.

The operating company has to supplement the operating manual with operating in-

structions on the basis of national regulations on accident prevention and environmen-

tal protection, including information on supervision and notification requirements with

respect to special operating circumstances, e.g. regarding organization of work, work-

ing processes and staff deployed.

In addition to the operating manual and the regulations on accident prevention appli-

cable to the country and place of use, the recognized technical rules for safe and pro-

fessional working also have to be observed.

The warranty shall become void, for example, in the event of:

• Inappropriate use

• Use of other than the approved equipment

• Incorrect connection

• Attachments not belonging to the scope of supplies and services

• Use of non original spare parts and accessories

(Non-original spare parts must be approved by MSK before installation)

• Conversion, if this has not been harmonized with MSK’ to modification

• Failure to perform prescribed maintenance operations

• Failure to observe prescribed maintenance intervals

The owner of the machine is recommended to conclude a maintenance contract with

MSK Verpackungs-System GmbH. This will ensure that the machine is serviced reg-

ularly by our service personnel and that necessary wear and spare parts are available

without long delivery times. The machine will have standard 1 year warranty period

starting on the day of machine acceptance.

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1.6 Obligations of the operating company

The packaging machine may be a source of danger if it is not operated correctly or if

it is operated in an incorrect condition!

The operating company is under the obligation to operate the machine only when it is

in a safe and proper state. The operating company has to secure hazardous areas that

exist between MSK machines and the customer's own equipment.

The operating company has to appoint and instruct responsible staff:

• Employ only trained or instructed staff.

• Clearly set out the responsibilities of the staff with regard to operation, set-up, maintenance and repair.

• Regularly check that staff are safety conscious and aware of hazards and are ob- serving the operating manual.

• Before starting work, staff assigned to work with/on the machine must have read

and understood the operating manual, in particular the chapter "Safety", as well as

the relevant regulations.

• The operating manual and relevant regulations have to be stored in such a way that they are accessible to operating and maintenance staff.

• Define the responsibilities for the machine and authorize the operator to reject un-

safe working instructions from third parties!

Generally valid legal and other binding regulations on accident prevention and envi-

ronmental protection have to be observed and instructed, in addition to the operating

manual.

NOTE

The machine owner is recommended to draw up operating in-

structions adapted to the general regulations and conditions.

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1.7 Liability disclaimer

To the best of our knowledge and belief, all technical information, data and instructions

on machine operation contained in this operating manual are correct at the time of

printing, taking into account our present understanding and experience.

We reserve the right to make technical modifications in line with the further develop- ment of this machine covered by this operating manual. In such cases no claims can

be derived from the information, figures and descriptions in this operating manual.

We shall not be liable for damage or operating malfunctions that result from operating

errors, inappropriate repairs or the non-observance of the operating instructions. We

expressly state that only original spare parts and accessories approved by us may be

used. This also applies to the components of other manufacturers that have been

used.

The installation or use of non-approved spare parts (the original spare parts listed on

the spare parts list provided by MSK) and accessories and any unauthorized retrofits

and modifications are not permitted for safety reasons and will void any liability of MSK

Verpackungs-Systeme GmbH for consequential damage or injury.

MSK Verpackungs-Systeme GmbH is liable for possible errors or omissions, to the ex-

clusion of additional claims entered into within the framework of the warranty obliga-

tions undertaken in the contract. Claims for damages, on whatever legal grounds,

shall be excluded.

Description and illustrations is specific to the machine. However, it may not used for

spare parts order. Drawings and graphics may not be in scale.

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1.8 Manufacturer's address

MSK Hungary Bt.

4300

Nyírbátor

Vágóhíd út 39.

Hungary

Phone (+3642) 511-100

Fax (+3642) 511-155

E-mail [email protected]

www.msk.hu

After-sales Service

MSK Covertech, Inc.

4170 JVL Industrial Park Drive 30066 Marietta, Georgia

USA

Phone (+1) 770 928 1099

Fax (+1) 770 928 3849

mailto:[email protected]


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1.9 Declaration of conformity

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1.10 Introduction

NOTE

The present operating manual contains instructions on commis-

sioning and for ensuring safe and reliable operation, as well as on

bridging prolonged standstill times up to re-commissioning.

NOTE

The operating personnel are obliged to work with the necessary

care and attention and to observe the safety regulations. This

means that the installed safety and protection installations must

not be removed or modified. Obvious changes and damage must

be reported to the responsible person immediately. In exceptional

cases, modifications to safety installations may be carried out

only by personnel authorized by MSK Verpackungs-Systeme

GmbH.

Initial commissioning is carried out by one of our specialists fitters who will explain the

machine to the operating personnel in detail. Detail questions can be clarified on site

during the instruction and the explanations should be recorded in the operating man-

ual. After commissioning, record all important data and work related to the packaging

machine in an operating logbook.

Observe the information and recommendations in the operating manual and comply with the maintenance measures recommended by us. They are a precondition for a

long service life.

After every cleaning of the machine with grease-dissolving cleansing agents, protect

all bare metallic parts again with lubricant!

Ensure that all bearings affected by the cleaning are subsequently thoroughly lubricat-

ed again!

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2 Safety

2.1 Intended use

The MSK Tensiontech packaging machine is intended exclusively for the packaging

of the products specified in the purchase contract with the dimensions and weights

specified there. Every other form of use of the machine cannot be considered as an intended use and

is not permissible!

WARNING

Danger from use for other than the intended use!

If not used for its intended purpose or used in any other way, the

packaging machine may be or become a source of danger!

► Employ the packaging machine only for its intended use!

► Observe the methods of operation described in the operating

manual!

The manufacturer/supplier shall not be liable for damage resulting from use for non- intended purposes. The user/operating company alone shall bear the risk.

2.2 Demands on personnel

DANGER

Danger due to electrostatic charges for persons with heart pacemakers!

Persons with heart pacemakers are at risk due to electrostatic

charges caused by the film!

► Persons with heart pacemakers must not come anywhere

near the packaging machine!

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NOTE

Work on/with the machine may only be performed by persons au-

thorized to do so based on their training and qualification. Further-

more, such persons must have been trained by the operating

company.

Persons undergoing training or instruction or persons undergoing general education

may only be allowed to work on the machine under the constant supervision and con-

trol of an experienced person!

Persons who are under the influence of drugs, alcohol or medication that affects their

reaction capabilities must not be permitted to carry out work on the machine.

Connection, set-up, maintenance and repair work may only be carried out by qualified

and authorized specialist staff.

Persons working with power-operated machines or equipment must ensure that they

do not endanger themselves or others by the movements of such machines or equip-

ment.

The machine owner may only entrust working with power-operated machines or

equipment with dangerous movements to persons who are qualified to operate such machines/equipment, and

• who can carry out the work independently and safely, or

• have been previously instructed in the use and are under the supervision of a person experienced in this work.

This machine may cause hazards if it is operated inappropriately by untrained staff or

if it is not used for its intended purpose.

Generally valid legal and other binding regulations on accident prevention and envi-

ronmental protection in addition to basic health and safety requirements have to be

observed. The operating company has to instruct its staff accordingly.

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2.3 Safety precautions

Observe the following instructions for accident prevention when operating the packag-

ing machine:

• Only operate the machine if it is in a proper state.

• Do not remove or disable safety devices.

• Before commissioning, inspect the machine for visible signs of damage and faults!

Report any changes (including changes in the operating behavior) to the respon-

sible department/person immediately! If necessary, immediately stop and secure

the machine!

• Have adjustments and/or maintenance work carried out by authorized personnel.

• Replace worn or damaged parts.

• Use only suitable maintenance tools.

• After completing repairs, install all safety devices again and check their electrical

and mechanical function.

• When switching on and off, observe control indicators as described in the

operating manual!

• Before switching on or starting the machine, ensure that no-one can be endan- gered by the machine!

• The machine owner must ensure that the machine is only used when it is in a safe working condition, and that all applicable safety requirements and regulations are

observed.

• Keep the operating manual accessible at all times.

• Any failure to observe the safety precautions given in this operating manual may

lead to material damage, injury or even death.

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2.4 Safety devices

2.4.1 Basic information

Check the safety equipment and locking devices on the device for safe operational condition.

Operate the machine only when all the safety devices are installed and fully functional!

The owner or operator of the machine is responsible for the proper operation of the

machine!

NOTE

Warning/danger signs are installed on the machine for the protec-

tion of the operating personnel. Observe these signs.

Replace damaged or illegible warning/danger signs immediately.

2.4.2 Safety devices on the machine

The packaging machine is equipped with the following safety devices:

• Safety fence

• Gates in safety fence with safety switches

• Safety light barriers

• Emergency STOP switches

• Lockable Air vent

• Safety pins (see Fig. 9.10)

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2.5 Safety precautions for maintenance and troubleshooting

2.5.1 Basic information

Replace hoses at the specified or appropriate intervals, even if they show no safety- relevant faults!

• Intervals specified or indicated in the operating manual for recurring checks / in-

spections shall have to be observed!

• Workshop equipment appropriate to the work is absolutely essential for carrying out maintenance measures.

• Work on electrical equipment of the machine may only be carried out by a qualified

electrician or by instructed persons under the supervision of a qualified electrician

and in accordance with the electrical engineering regulations.

• The adjustment, maintenance and inspection activities and deadlines stipulated by

MSK Verpackungs-Systeme GmbH, including information on the replacement of

parts / assemblies, have to be observed! These activities may only be carried out

by appropriately authorized qualified personnel.

• Inform the operating personnel before starting maintenance work and other spe-

cial operations!

• Where necessary, close off the whole area where maintenance is being carried

out.

• If the machine is switched off completely for maintenance and repair work, it must

be secured to prevent restarting.

• Retighten bolts loosened during maintenance and repair work and secure the bolts

with bolt locking compound (e.g. Weicon AN 302-43 (blue)) "medium strength"!

• If the removal of safety installations is necessary for maintenance and repair work,

these must be installed again and their proper function assured immediately after

completion of the maintenance and repair operations.

• Ensure safe and environmentally safe disposal of process media, materials and re-

placed parts!

• Ensure adequate lighting for all work.

• Only MSK spare parts or spare parts approved by MSK may be used.

• Wear appropriate protective clothing during maintenance work.

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2.5.2 Electrical/electronic installations

DANGER

Danger of electric shock!

Contact with live leads or components poses a risk of serious in-

jury or even death!

► Work on electrical/electronic components or assemblies may

only be carried out by qualified electricians in accordance with

the electrical engineering regulations.

► Before working on electrical equipment, isolate this equip-

ment and secure to prevent restarting!

► Cover neighboring live parts!

► Inspect the machine at regular intervals. Remedy any faults or

malfunctions discovered immediately. Switch off the machine until the faults have been remedied.

► Faults discovered on electrical machines/assemblies/equip-

ment must be remedied immediately. If these faults pose an acute danger, the machine, assembly or equipment must not be used until the faults have been remedied.

► Machine parts on which inspection, maintenance and repair

work is to be carried must - if prescribed - be disconnected from the power supply. First check the disconnected parts that they are really no longer live, then ground and short-circuit the parts and isolate any neighboring live parts!

► If work on live parts is necessary, have a second person

standing by who can turn off the master switch with voltage trip in the event of an emergency.

► Inform the operating personnel before starting the work.

Before starting any work on electrical installations, turn off the master switch and secure it with a padlock to prevent it from being turned on again. In addition, hang a

warning sign on the master switch for the duration of the work.

Close off the working area during the work and put up a warning sign. Use only insu-

lated tools for the work!

When working on high-voltage assemblies, connect the power supply lead to earth af-

ter switching off the power and short-circuit the components, e.g. capacitors, using a

grounding rod!

Fuses must not be repaired or bridged. Use only specified fuses with the prescribed

amperage!

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2.5.3 Electric welding operations

NOTE

No welding operations may be carried out on the machine!

If electric welding is carried out on machines or equipment connected mechanically

and hence electrically conductively to MSK machines, take the following precautions.

• Clean the packaging machine of dust and flammable substances.

• Unplug or disconnect electronic equipment installed on the machine.

• Lay the ground connection of the welding equipment directly alongside the welding point and ensure proper contact.

Insure the welding current does not short the ground.

2.5.4 Testing in accordance with the Occupational Safety and Health Adminis-

tration (OSHA)

In the event of a combination or installation of machines/plants or equipment from dif-

ferent manufacturers or suppliers and after modification of products supplied by us

with intervention in the electrical equipment, the machine owner must carry out a pre-

cise examination in accordance with the applicable Occupational Safety and Health

Administration (OSHA) and the applicable electrical engineering regulations before

the installation is switched on.

Should you have any questions, please contact MSK Verpackungs-Systeme GmbH.

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2.6 Noise measurement

Measuring conditions:

The measurement was performed in accordance with DIN 45635, Part 28, Class 2 at

the manufacturer's works.

Measuring equipment:

Brüel & Kjaer integrating sound level meter, Type 2236, Serial No. 1928183

The sound level meter was tested before and after the measurement.

Acoustic calibrator: 94 dB, 100 Hz, Type 4231, Serial No. 1914997

Measurement result

The A-weighted equivalent continuous sound pressure level at the operator's place of work is 75 dB(A).

DANGER

Danger caused by noise!

Depending on the local conditions, a higher sound pressure level

may occur that can lead to noise-induced hearing loss!

► Wear ear protectors where higher sound pressure levels exist

(>85 dB(A)).

NOTE

The measurement was performed at the manufacturer's works.

The sound pressure level is dependent on local conditions and

may be higher or lower at the installation location of the machine.

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MSK Tensiontech Design and Function

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3 Design and Function

3.1 Overview

5

7

1

4 2 3 8

10

6 11

9

Fig. 3.1 Overview of assemblies

1 Baseframe

2 Suction jaws

3 Lifting carriage for tensioner frame

4 Tensioner frame

5 Film feeder head

6 Clamping corners with catch wheels

7 Welding beam with 10-blade knife

8 Film rack

9 Tensioner frame lift motor

10 Film reel (buffer rolls)

11 Safety pin

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3.2 Description of functions (general)

The packaging film (film tube) is transported from the film rack (8) until the film tube is

level with the underside of the suction jaws (2). The film is picked up and fixed by

means of the suction fan. Then the film reel (10) swings out and receives the full length

of the film hood. The film is then welded with the welding beam (7) and cut off above

the seam. The suction jaws moves outwards, thereby opening the film tube. After the film hood is opened, it is transferred to the "hood fitter", consisting of tensioner

frame (4) and lifting carriage (3). The film hood is thereby held on the four clamping

corners (6) and subsequently stretched outwards. After stretching to the necessary fit-

ting dimension, the tensioner frame moves downwards and the film hood is drawn

over the load.

3.3 Sequence of functions

3.3.1 Sequence of functions in film feeder head

Fig. 3.2 Film feeder head

1 Film A

2 Film B

3 Film magazine/film reel

4 Suction fan

5 Suction jaws

Fig. 3.3

The film reel goes into root position.

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Fig. 3.4

The film is transported until the film tube has passed the suction jaws. Then the suc-

tion jaws swing into the middle.

Fig. 3.5

The suction fans start, the film is picked up and thus fixed.

Fig. 3.6

The film is transported, the film reel/film magazine is activated to move backwards and

receives the whole hood.

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Fig. 3.7

When the film reel has reached the rear position, the welding beam closes. The film is

welded and cut off above the seam by the knife. The welding beam remains closed.

Fig. 3.8

While the suction jaws move outwards and thus open the film tube, the film reel goes into root position.

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3.3.2 Functional sequence pick up film, stretch and fit

Fig. 3.9

The film hood has been opened, the hood fitter is ready to receive the hood.

Fig. 3.10

The clamping corners move inwards. The tensioner frame is then raised and the

clamping jaws enter the opened film hood.

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Fig. 3.11

The clamping corners are moved outwards.

Fig. 3.12

The reap wheels are actuated to the clamping corners and start to collect the film.

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Fig. 3.13

The film hood continues to be collected.

Fig. 3.14

Shortly before the film is completely collected, the welding beams are opened and re-

lease the film hood.

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Fig. 3.15

When the hood has been collected, the clamping corners move outwards and stretch

the film hood. During this process, the next film can be transported between the suc-

tion jaws again.

Fig. 3.16

The film hood is stretched to the fitting dimensions. The tensioner frame then moves

downwards and the film hood is pulled over the top corners of the pallet.

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Fig. 3.17

When the clamping corners have reached the underside of the pallets, the clamping

corners move inwards. The reap wheels are opened. The reap wheels can also be rotated backwards and assist in the removal of the film from the clamping corners.

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Fig. 3.18

The tensioner frame has pulled the film completely over the pallet and moves upwards

again. Above the pallet the clamping corners move inwards and the pallet can be

transported away. The next pallet can enter the station and the tensioner frame is

ready to receive the next film hood.

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3.4 Description of assemblies

5

7

1

4 2 3 8

10

6 11

9

Fig. 3.19 Tensiontech assemblies 3.4.1 Baseframe (1)

The baseframe (1) is a steel frame construction and serves to support all the machine

assemblies. It is designed such that is can absorb the static and dynamic loads of all

the machine assemblies. The baseframe is anchored to the floor.

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3.4.2 Film rack (8)

CAUTION

Danger due to pulling in or catching!

There is a danger of being pulled in between the film drive wheel

and the film roll!

► Do not reach between the film drive wheel and the film roll!

► Wear work clothes with low tear resistance (see chapter 9.1)!

► Wear appropriate protective gloves!

The film rack (8) is located behind the baseframe and can hold one or more film reels

(A, B, ....). The film rack also comprises the film reel drives and a film buffer roller con-

troller. The packaging film (film tube) is drawn from the film rack into the film feeder

head (5).

A

Fig. 3.20 Film rack

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3.4.3 Film feeder head (5)

CAUTION

Danger of being pulled in or trapped!

There is a danger of body parts being pulled in between the rub-

ber roller (A) and the counter-roller (B)!

► Do not reach between the rubber roller and the counter roller!

► Wear work clothing with low tensile strength (see chapter 9.1)!


Two film drives are located in the film feeding head (Fig. 3.21). The motors each drive

one rubber roll (A) that is pressed against two counter rollers (B). The drives have

been designed so that they can pull the film tube from the film storage. The counter

rollers (B) arranged in pairs can be shifted by the pneumatic cylinders for format con--

version.

The drive conveys the film through the opened sealing bars as far as the suction jaws (C).

The film storage in the film feeding head is a linearly traversable construction and can

take up the entire hood length. In addition to the sealing bar for sealing the film, the

film feeding head also has a film knife to separate the completed hood from the film

tube.

A C E

B

F

D

Fig. 3.21 Film feeding head

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3.4.4 Wealing bar and Hood Storage

WARNING

Danger of injury due to sharp knives!

The film knife above the sealing bar in the film feeding head is ex--

tremely sharp. This poses a serious risk of cuts!

► Keep the knife cover closed!


Danger of burning!

CAUTION

The sealing bar at the packaging machine becomes hot during

operation! This poses a danger of burning!

► Touch the components only after the sealing bar has cooled

down!


The sealing bar consists of two welding rails (A) arranged in parallel. After the film

hood is taken up by the film storage, the sealing bar is closed. The sealing bar is then

switched on depending on the film thickness. After sealing is completed, the film knife

(B) moves along the film and cuts the completed film hood from the endless tube. The

sealing bar opens again after a certain cooling time.

B

A

Fig. 3.22 Sealing bar

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3.4.5 Suction Tubes (2)

Each of the two suction tubes is divided into two segments which makes it possible to

adapt the suction tubes to narrow and wide film formats. Each segment has its own exhaust fan.

The fans fix the film through negative pressure. The suction tubes then unfold, as

shown in Fig. 3.23, which opens the film tube.

The clamping plates (shown in Fig. 3.23 green) are then closed.

Fig. 3.23 Suction tubes

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3.4.6 Hood Wrapper (4)

The tension frame (4) is integrated into the base frame and can be moved vertically

up and down by means of a lift motor (9). Arranged in the tension frame are four ad-

justable clamping corners with catch wheels that enter the opened film tube and pull

it into a rectangular form and ultimately stretch the film. After stretching the film, the tension frame is moved down over the pallet with the prod-

uct. Then the tension corners move together again so that the film surrounding the

product relaxes again. The tension frame is moved down again, the tension corners

move apart again, and the tension frame is moved upwards to its starting position

ready for the next working cycle.

The tension frame has counterweights in order to reduce the dynamic masses. These move up and down in the lift pole opposite the direction of movement of the tension frame!

For setup, maintenance or repair work and for when the emergency stop function is triggered the tension frame has automatic locking catches (2) that snap into the pro-

vided grooved strips.

In addition, bores and corresponding locking pins are provided on the lift pole to se-

cure the counterweights if maintenance needs to be carried out on the toothed belt,

for example.

The tension frame has a contour monitoring function (3) to prevent the tension frame

colliding with non-centered pallets. The path beneath the tension corners of the ten-

sion frame is monitored by means of light barriers and reflectors.

4 1 2

3

Fig. 3.24 Hood wrapper

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The tension frame has access steps (4). If you need to carry out maintenance work, the tension frame must be placed in the lowest position (maintenance position).

The frame is automatically lowered and the steps are positioned so that they are easy

to climb.

CAUTION

Danger of being injured as a result of falling!

There is a risk of falling from the tension frame!

► Only step on the tread plate (non-slip safety plate, corrugated

plate)!

► You must not tread on areas indicated with this symbol on the

tension frame!

► Do not step on the motors or tension corners!

► Wear safety boots and gloves!

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3.4.7 Centering device

The load is centered on the conveyor via an integrated pneumatic centering device. A

sonic sensor measures the height of the load in anticipation of preparing the stretch

hood. After a signal is given that the load is centered, it is transported via conveyor to

the stretch hooding station.

3.4.8 Control console

The control console is installed separately alongside the machine and contains all the operating and control elements for the operation of the machine in manual, setup and

automatic mode and the touch screen for the parameter displays and settings.

Fig. 3.25 Control console 3.4.9 Control cabinet

The installation of the switch cabinet depends on the conditions on site. The electrical

installations necessary for the control of the machine are housed in the control cabi-

net.

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3.5 Safety Mechanisms

WARNING

Danger if the safety mechanisms are not used correct-

ly!

The packaging machine can become a source of danger if the safety mechanisms are not used correctly or are by-passed!

► Operate the packaging machine only when all the safety

mechanisms are installed and functioning correctly!

► The procedures described in the operating manual must be

observed!

3.5.1 Emergency STOP circuit

ATTENTION

Material damage caused by misuse of the emergency

stop circuit!

Frequent emergency stops result in high mechanical loads and

hence to increased wear of the machine.

► Operate the emergency STOP button only in the event of an

impending danger.

► Before entering the safety fence area, stop the machine via

the "Start/Stop automatic" (see chapter 8.1.8), as opening the safety fence gates results in an immediate stoppage of the machine as for an emergency stop.

The emergency stop switch is located on the machine control console. Press the

emergency stop switch immediately in the event of danger situations. This stops all

machine movements. In some cases movements performed by pneumatic cylinders

stop only when the piston has reached the end of its stroke.

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CAUTION


Parts of the machine may still be live even when the emergency stop switch has been pressed!

► Do not touch live parts and leads!

► Observe the instructions in the operating manual!

In order that the fault can be localized and after its elimination the machine can con-

tinue to be operated in automatic mode after pressing the emergency stop switch, the

controller in the control cabinet/control console and the switch cabinet lighting and

ventilation are not necessarily disconnected from the mains power supply. All motors

are disconnected from the power supply by means of main contactors.

NOTE

Note that the frequency converters the drive the motors require a

further 60 seconds before the voltage has dropped below 65 V!

NOTE

Emergency stop will keep the machine pressurized.

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3.5.2 Safety pin

WARNING

Danger from uncontrolled movement/dropping of the tensioner frame!

The tensioner frame can become a source of danger if the safety

installations are not used correctly or are by-passed!

► Switch off the machine.

► Insert all safety pins before carrying out work on the tensioner

frame, lifting chain, counterweight or clamping element on the motor shaft!

► Observe the instructions in the operating manual! Observe the

instructions in the operating manual!

Fig. 3.26 Safety pins

Insert the safety pins protecting all maintenance work below the tensioner frame or

during maintenance work requiring the replacement or disconnection of the lift chains!

The safety pins are located on both sides of the baseframe for the tensioner frame;

these must be used to additionally support the tensioner frame to prevent it dropping

during maintenance work. Move the tensioner frame to its uppermost position. Insert

the safety pins up to the stop (roll pin).

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ATTENTION

Risk of damage to the lift motor!

As the lift motor has to move the whole weight of the tensioner frame (the counterweights are resting on the lower pins), the lift

motor can be damaged if it is operated incorrectly!

► Move the motor only by brief actuation of the preselector but-

ton!

3.5.3 Safety fence

The machine is hermetically surrounded by a safety fence. The packaging area of the

machine can only be entered via gates in the fence switch monitored limit switches.

ATTENTION

Machine damage caused by frequent emergency stops!

During operation of the machine, opening the safety fence gates

trips the emergency stop function and stops the machine. Fre-

quent emergency stops result in high mechanical loads and




NOTE

Under no circumstances may the system be operated without ful-

ly functional Safety fences!

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3.6 Rating plate

The rating plate can be found on the frame of the hood fitter and contains the following

information:

– Manufacturer

– Machine type and variant

– Serial number

– Year of manufacture

– Electrical connection data

– Required air pressure

– Max. height of the product to be packed in mm

ATTENTION

Property damage due to disregarding the maximum

permissible quantities!

Failure to comply with the maximum values specified on the type

plates can result in severe damage to the system.

► Comply with the connection data for the power supply.

► Comply with the maximum load height

► Do not exceed or drop below the maximum air inlet pressure.

3.7 Scope of supply

Apart from the scopes of the Tensiontech mentioned in the description of the assemblies, the scope of supply of the packaging machine also includes the following:

3.7.1 Documentation

– Operating manual

– Spare parts catalogue

– Documentation from manufacturers of bought-out parts

– Hand-held welder (optional)

3.7.2 Accessories

3.7.3 Tools

No special tools are required for setup, service and maintenance. This work can be

carried out with standard tools (metric tools).

3.7.4 Spare parts

For further information, see chapter 11 Spare parts.

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MSK Tensiontech Technical Data

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4 Technical Data

4.1 General machine data

Machine type MSK 371

Design 1-format

Packaging capacity 80 pallets/hour

with a film thickness of 100 micron

Machine installation location heated shop

Ambient temperature min. 30° F (-1° C)

max. 100° F (37° C)

Ambient relative humidity 60%

4.2 Sound pressure level

Measuring surface sound pressure level Lp to DIN 45641 Part 1

< 75 dB(A)

4.3 Electrical ratings

Mains supply voltage (IT grid)

3 x 480 V, PE

Mains frequency 60 Hz

Control voltage inputs/outputs 24 V/DC

Brake voltage of the motors 120 V/AC

Rated current 61 A

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4.4 Pneumatic ratings

Required air pressure 72.5-87 psi (6 - 7 bar)

Air consumption 200 litres/pallet

4.5 Dimensions

Machine height 197” (5000 mm)

Machine width 76” (1930 mm)

Transport height in the area of the MSK Tensiontech

23.6” (600 mm)

Pallet height min. 40” (1016 mm)

max. 78” (1981 mm)

see installation plan

Pallet format:

A

B

C

D

E

40 x 48” (1016 x 1219 mm) 40 x 48” (1016 x 1219 mm)

42 x 48” (1067 x 1219 mm)

42 x 42” (1067 x 1067 mm)

48 x 42” (1219 x 1067 mm)

4.6 Weight

Machine weight approx 4.8 t

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4.7 Film data

Film type(s) Side pleat tube

Film width max. 55.1” (1400 mm)

Film dimensions (tested) 35 x 34,3” (890 x 870 mm)

Film thickness (tested) 100 micron

Film reel diameter max. 39.4” (1000 mm)

Reel core inside diameter 6” (152.4 mm)

Film reel weight max. 2204.6lbs (1000 kg)

DANGER


Persons with heart pacemakers are at risk due to electrostatic charges!



NOTE

Film should be validated prior to its use and make necessary pa-

rameter adjustment.

If films from other manufacturers or of other qualities are used,

the parameters may have to be modified.

NOTE

The danger for persons with pacemakers depends on the ESD values of the film.

(ESD = electrostatic discharge).

Ask the film manufacturer about the ESD value of your film. Use only film with low ESD values.

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MSK Tensiontech Transport and Packaging

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5 Transport and Packaging


WARNING

Danger from suspended loads!

Suspended loads represent a source of potential danger due to

falling or uncontrolled swinging!

► Never stand or walk under suspended loads!

► Ensure that there is no-one in the danger zone during trans-

port.

► Observe the information on the intended lifting points!

► Do not attach ropes to protruding machine parts or to parts at-

tached with eyebolts! Ensure that the lifting equipment is se-

curely attached!

► Secure the lifting equipment to prevent unintentional loosen-

ing, e.g. use hooks with hook locks.

► Use only approved hoists and lifting gear with a sufficient

load-bearing capacity!

► Observe the maximum lifting capacity of the crane.

► Do not use split or frayed ropes and slings!

► Do not lay ropes and slings over sharp corners and edges, do

not knot or twist, use edge protectors.

► Ensure that the angle of inclination of the lifting equipment

does not exceed 60°.

► Transport by crane may only be carried out by trained and au-

thorized persons.

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WARNING

Risk of falling due to eccentric center of gravity!

The center of gravity of loads may not always be in the middle. If

the lifting equipment is not correctly attached, the load may tip

over and cause serious or even fatal injuries! There is also a risk

of tipping on uneven floors or due to objects lying around.

► Observe the markings on the loads!

► Attach the crane hook so that it is above the center of gravity!

► Carry out a careful test lift and observe whether the load tips!

If necessary, adjust the attachment point of the hook!

► Remove all objects lying around before transport.

ATTENTION

Damaged caused by improper transport!

Considerable material damage can be caused by improper trans-

port!

► Do not pull the load at an angle, twist or scrape along the floor.

► Remove all objects lying on the floor before transport.

► When unloading the packages on delivery and during in-

house transport, handle the packages carefully and observe the symbols and instructions on the packaging!

► Remove the packaging only shortly before installation!

Observe the following additional points during transport:

After transport, raise the crane hook and do not leave it hanging at head height. When

working with multiple personnel, define the meaning of signals in advance and

raise the load only after receiving the agreed signal.

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Wear the following protective equipment at all times during work:

Close-fitting work protection clothing with a

low tearing resistance

Safety shoes or boots with steel toecap

and oil-resistant safety sole

Working gloves as protection against

injury

Goggles to protect the eyes from flying

parts and liquids

Safety helmet as protection against injury

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5.2 Transport inspection

Inspect the delivery immediately on receipt for completeness and transport damage.

NOTE

If the following instructions are not followed in the event of dam-

age, the insurance cover may be lost.

In the case of obvious and visible transport damage, proceed as follows:

• If damage is even suspected, sign for receipt only conditionally (e.g. on the freight

document), indicating the suspected damage.

• In the case of goods transported in containers, ensure that container and locks or

seals are examined by responsible persons from the shipping or transport compa-

ny. If containers are damaged or locks and seals are broken, are missing or differ

from those indicated on the freight documents, sign for receipt only conditionally,

indicating the suspected damage, and keep the damaged or wrong locks and

seals.

• Ensure claims for damages against third parties. Request the shipping company, other freight carrier, transport companies, warehousing companies, customs and

port authorities

• to make a joint examination of the damage,

• to certify the damage,

• to assign liability in writing and describe the damage in detail, in the case of ob-

vious visible damage before acceptance of the delivery, in the case of damage

not visible from the outside immediately on discovery.

• Determine and observe periods for complaint.

NOTE

Report all flaws or damage immediately on discovery. Claims for

damages can only be made within the prescribed periods for

complaint.

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• Take measures to minimize the damage that has occurred and to prevent further

damage.

• Contact the damage inspector nominated in the insurance documents without delay; he will assess the damage and provide advice on claiming damages against

third parties and on measures for minimizing the damage.

• Do not change the condition of the delivery and its packaging until the arrival of the

damage inspector, insofar as this is not necessary to minimize the damage or pre-

vent further damage.

• Report the insurance claim to the insurance company without delay and transmit

the full claim documents at once in order to expedite the claims settlement (at the

latest in sufficient time before the expiry of any periods of preclusion and/or limita-

tion relating to the compensation claims against third parties).

5.3 Handling during transport

5.3.1 Center of gravity and lifting points

NOTE

Information on center of gravity and lifting points of the individual

assemblies and components can be found in the chapter Mainte-

nance.

5.3.2 Transport of pallets

Pallets must be secured to prevent slipping during transport.

Transport of pallets with the crane

Loads attached to pallets can be transported by crane under the following conditions:

• Crane and lifting tackle must be suitable for the weight of the loads.

• The operator must be authorized to operate the crane.

Lifting:

• Attach ropes, straps or multi-point slings to the pallet.

• Check that the load cannot be damaged by the lifting equipment. If necessary, use

other lifting equipment.

• Start transport.

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Transport of pallets with the fork-lift truck

Loads attached to pallets can be transported by fork-lift truck under the following con-

ditions:

• The lifting capacity of the fork-lift truck must be sufficient for the weight of the trans-

port units.

• The driver must be authorized to drive the fork-lift truck.

Lifting:

• Insert the forks of the fork-lift truck between or under the legs of the pallet.

• Insert the forks so far that they protrude on the opposite side of the pallet.

• Ensure that the pallet cannot tip over with an eccentric center of gravity.

• Raise the load and start the transport.

5.4 Unloading and unpacking

The individual packages have been packed to withstand the expected transport con-

ditions. Only environmentally safe materials were used for packaging.

The packaging is intended to protect the individual components against transport damage, corrosion and other damage until they are installed. Therefore do not dam-

age the packaging and unpack the parts only shortly before installation.

5.5 Handling of packaging materials

Dispose of the packaging materials in accordance with the applicable statutory provi-

sions and local regulations.

ATTENTION

Environmental damage can be caused by improper dis-

posal!

Packaging materials are valuable raw materials and in many cas-

es can be used again or expediently processed and recycled!

► Dispose of packaging materials in an environmentally safe

manner!

► Observe the applicable local waste disposal regulations! If

necessary, engage a specialist company to dispose of the packaging materials!

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5.6 Storage

Packaging/storage

The measures for storage and packaging are dependent on the storage time and stor-

age location.

A corrosion inhibitor provides adequate protection during storage and installation in a

well ventilated machine room/ship and road.

For storage outdoors, the machine must be protected from the weather by watertight

tarpaulins or tear-resistant plastic film. Protect the tarpaulins/plastic film against me-

chanical damage.

Adequate ventilation must be ensured under the tarpauliln/film. Inspect the tarpaulins and corrosion protection at regular intervals.

Remedy any damage discovered immediately. Remove any corrosion that may have

occurred and renew the corrosion inhibitor.

External corrosion protection

• Clean or wash down bare unpainted machine parts.

• Allow cleaned parts to dry and then coat with a drying corrosion inhibitor.

ATTENTION

The machine paint must not be dissolved by the cleaning or washing agent!

During corrosion protection of the machine, the paint may be at-

tacked!

► Use only suitable washing agents!

► Observe the manufacturers instruction for use, safety and

disposal regulations!

Removal of corrosion inhibitor

The measures for removal of the corrosion inhibitor must be observed and carried out before commissioning!

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5.6.1 Storage of packaging material

Store the packaging material under the following conditions:

• Do not store outdoors.

• Store dry and dust-free.

• Do not expose to aggressive media.

• Protect from direct sunlight.

• Prevent mechanical vibrations and damage.

• Storage temperature -1 to 37° C (30° F to 100° F)

• Maximum relative humidity 60%

• If stored for longer than 3 months, check the general condition of all parts and the

packaging at regular intervals. If necessary, refresh or renew the corrosion inhibi-

tor coating.

NOTE

In some cases instructions on storage going beyond the points

described here may be provided on the packaging. These instructions must be observed accordingly.

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6 Installation and Connection


DANGER


Contact with live components poses a risk of serious injury or

even death!

► Before starting work, switch off the electric power supply and

secure to prevent it from being switched on again!

WARNING

Danger of injury from improperly performed installation and commissioning!

Improper installation and commissioning can result in serious per-

sonal injury or material damage!

► Before starting work, ensure that you have sufficient space!

► Handle open, sharp-edged components with care!

► Pay attention to cleanliness and orderliness at the place of

work! Loose components and tools lying around are a potential cause of accidents!

► Install all components correctly. Observe the prescribed bolt

tightening torques! Secure the bolts with bolt lock tight (e.g. Weicon AN 302-43 (blue)) "medium strength"!

► Secure components so that they cannot fall down or fall over!

► Operating elements of the emergency stop system must be

freely accessible!

► Operate the machine only when all the safety devices, e.g.

emergency stop switch, light barriers and safety fence are installed and fully functional!

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Wear the following protective equipment at all times during installation and commissioning:






injury


parts and liquids


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6.2 Qualification of personnel

The operating personnel must have the necessary qualification and authorization for

the operation of a packaging machine.

Before commissioning the machine, the operating personnel must familiarize them-

selves with the special features of this machine.

Initial commissioning is carried out by one of our specialist who will explain the ma-

chine to the operating in detail. Detail questions can be clarified on site using the op-

erating manual and the explanations should be recorded in the operating manual.

Work on the electrical installation may only be carried out by qualified electricians.

NOTE

The MSK packaging machine may only be transported and in-

stalled under the direct supervision of authorized MSK personnel.

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!"

#

$%&' (

##

6.3 Foundations

NOTE

The MSK packaging machine must not be operated until it is

properly anchored to the floor!

The foundation for the packaging machine must consist of concrete slab for dowel an-

choring with a concrete quality of C15 and a thickness of at least 6” (150 mm). If the

machine is installed on a concrete ceiling.

Fig. 6.1 Machine anchoring

NOTE

If the concrete quality cannot be guaranteed, use chemical an-

chors!

6.4 Pneumatic connection

A compressed air supply line with 1/2” is required for the operation of the MSK pack-

aging machine. The owner of the machine must ensure an adequate compressed air supply. For details of the necessary pneumatic pressure, refer to the chapter 4 Tech-

nical data. It should be at least 65.3 psi (4.5 bar).

The compressed air must be sufficiently dry; if necessary, install an air drier.

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6.5 Electrical connection

DANGER



jury or even death!

► Work on electrical/electronic components or assemblies may

only be carried out by qualified electricians in accordance with the electrical engineering regulations.




► Inspect the machine at regular intervals. Remedy any faults or

malfunctions discovered immediately. Switch off the machine

until the faults have been remedied.

► Faults discovered on electrical machines/assemblies/equip-

ment must be remedied immediately. If these faults pose an acute danger, the machine, assembly or equipment must not be used until the faults have been remedied.

► Machine parts on which inspection, maintenance and repair

work are to be carried out must - if prescribed - be disconnected from the power supply. First check the disconnected parts that they are really no longer live, then ground and short-circuit the parts and isolate any neighboring live parts!

► If work on live parts is necessary, have a second person

standing by who can turn off the master switch with voltage

trip in the event of an emergency.

► Inform the operating personnel before starting the work.

The owner of the packaging machine must provide MSK Equipment with a supply lead

of adequate cross-section and amperage. For details of the rated power, refer to the chapter 4 Technical data.

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6.6 Safety fence

WARNING

Risk of injury from failure to observe the safety installa-

tions (safety fence)!

Failure to observe the safety installations can result in serious personal injury or material damage!

► Operate the packaging machine only with installed safety

fence and safety light barriers!

The safety fence prevents unintentional entering of the danger zone. The MSK safety

fence gates are equipped with corresponding safety switches that cause the packag-

ing machine to stop immediately if the gates are opened.

WARNING

Risk of injury from unauthorized use of the safety in-

stallations (safety fence)!

Unauthorized use of the safety installations can result in serious

personal injury or material damage!

► Ensure in accordance with BGV A3 that no unauthorized per-

son can close the opened safety fence gates! (For more information please refer to the CD.)

► During repair, maintenance and cleaning work, ensure that

the safety fence gates cannot be closed inadvertently.

► Fasten open safety fence gates to the safety fence using a

padlock

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ATTENTION








NOTE

Under no circumstances may the system be operated without ful-

ly functional safety fences!

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6.7 Installation plan

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7 Commissioning

DANGER



charges!



NOTE

The danger for persons with pacemakers depends on the ESD

values of the film.


Ask the film manufacturer about the ESD value of your film.

Use only film with low ESD values.

NOTE

The operating personnel is obliged to work with the necessary

care and attention and to observe the safety regulations. This

means i.e. that the installed safety and protection installations

must not be removed or modified. Obvious changes and damage

must be reported to the responsible person immediately. In ex-

ceptional cases, modifications to safety installations may be car-

ried out only by personnel authorised by MSK Verpackungs-

Systeme GmbH.

Initial commissioning is carried out by one of our specialist, who will explain the pack-

aging machine to the operating personnel in detail. Detail questions can be clarified

on site using the operating manual and the explanations should be recorded in the op-

erating manual.

Observe the information and recommendations in the operating manual and comply

with the maintenance measures recommended by us. They are a precondition for a

long service life with a consistently high profitability of your packaging machine.

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7.1 Inspection before commissioning

NOTE

Before switching on the packaging machine, always check that

the machine and safety installations are in a safe and proper con-

dition!

7.1.1 Inspection points:

• The proper condition of the whole machine, in particular its safety devices and pro-

tective installations.

• No-one may be in the safety area of the machine inside the safety fence.

• The safety fence gates must be closed and locked.

• There must be no loads or loose objects on infeed conveyor.

7.2 Initial start-up

NOTE

The packaging machine must be inspected and accepted by an authorized MSK fitter before the initial start-up.

All functions must first be performed in manual mode. For this, switch on the machine

as described in the following chapters.

Select all functions in turn. Check the proper performance of the function and monitor all the indicator lights and watch for any error messages.

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8 Operation of the Machine

8.1 Operation of MSK packaging system

8.1.1 Generally

The MSK packaging system is controlled from the operating panel / control cabinet,

provided with an Panel View 700.

The design of the MSK control panel is contained in chapter 8.2 and a overview of

manual functions is contained in chapter 8.1.5.

Fig. 8.1 Allen-Brandley PV 700 Touch Panel

ATTENTION

It must be ensured that the protective doors are not opened un-

necessarily during the operation of the MSK packaging system.

The movement of the MSK packaging system then jolts to a stop,

which has a lasting negative effect on the strength and service life

of the components. In this case, the operator should wait until the

MSK packaging system has completed the cycle and the system

can be switched off.

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ATTENTION

Danger of malfunctions!

Simultaneous touching of more than one operating object on the display can result in unintentional actions!

► Always touch only one operating object on the display!

NOTE

Do not use sharp or pointed objects to operate the touch panel in

order to avoid damaging the plastic surface of the touch screen!

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8.1.2 Layout of the panel

The Control Panel PV 700 (see Fig. 8.1), with which the MSK packaging system can

be controlled, has touch screen LCD-display. The function keys can be activated by

touching the screen. PV 700 has a basic screen and sub screens for the controlling of

the MSK packaging system.

The basic menu (see Fig. 8.2) in which the main function touch buttons of the MSK

packaging system is shown.

Fig. 8.2 The basic menu

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8.1.2.1 Main Screen Buttons

The”HOME” button direct you back to the Main Screen.

The”UP” button direct you back to the page, which is higher in the hierarchie.

The”BACK” button navigates you to the former page.

The”MAINT” button opens the maintenance screen. - Here you can check the I/O status, change passwords, set up the shifts and

check the maintenance schudle of your MSK machine.

The”STATS” button navigates you to the counters.

The”RECIPE” button directs you to the job setup menu. - Here you can change or set all parameters for your MSK machine.

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The”SETUP” button opens the setup menu. - Here you can restart the HMI.

This is an information display shows you which machines are actually in the reference position (reference position = green).

Mode of the machine (Manual / Auto / Stop).

- Cycle stop: - Machine finishes last procedure before it stops - Press Start/Stop button

- Stop: - Process will not be finished - Press deselect Automatic then press Start/Stop

-Start Automatic: - Press Automatic and then Start/Stop

-Start Manual: - Deselect Automatic - Press Manual

Semi-Automatic functions for hooding and preparing the next film tube.

Semi-Automatic functions to drive the all machines to its home position.

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Manually add a pallet to the line.

Fault Menu. 8.1.3 Inspection before placing into operation

ATTENTION

Before switching on the system, the MSK packaging system must be checked for proper condition.

Check list:

1. The entire system, especially its safety devices, is in proper working order.

2. No persons are allowed to be in the danger zone of the system inside the protection guards.

3. The doors of the protective guards must be closed.

4. No parts may be on the conveyors. (e.g.: repair tools)

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8.1.4 Placing into operation for the first time

ATTENTION

An MSK installation engineer must always conduct an accep-

tance test before placing the MSK packaging system into opera-

tion for the first time.

First, operate all functions of the system individually. The system must be switched on

as described in the following paragraph, in order to do this. Select all functions one

after the other. Check that the sequence is correct. Remedy any defaults, errors and

malfunctions.

When starting up the MSK packaging system, carry out the following steps:

1. Set the main switch on the control cabinet to "I" (ON)

2. Switch on the control voltage

3. Open the compressed air supply

4. Close the doors of safety guards and check that nobody is inside the safety light beam area

5. Pull-out the Emergency Stop buttons

6. Press the buttons "Unlocking"

7. Switch into the automatic mode as described in Chapter 8.1.8.

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8.1.5 Manual mode

ATTENTION

Risk of collision of the hood applicator!

During lowering of the hood applicator in manual mode it can col-

lide with goods to be packed not standing centered on the pallet!

► Move the goods to be packed back (if possible) to the pallet

centering unit and have the goods centered again automatically. If the goods cannot be moved back, transport the pallet using the manual functions to the next removal station!

► Monitor the individual sequences of movements!

For operating in manual mode follow these steps:

1. Open the compressed air supply.

2. Switch on the master switch.

3. Switch on the control voltage (key switch) to ”On”.

4. Press the control voltage ”On” button, which at the same time is the release button, and then press the ”Release safety guards” button (if fitted).

5. Activate the ”Manual” function.

6. The various individual functions can be selected in the visual display in text or graphic mode.

7. Press ”Preselect On ”button to execute the corresponding function. Where a

text display is being used, press the ”Enter” key to execute the corresponding

function.

Activate the manual function

The menu in which the manual functions can be separately selected is activated by

touching the "Manual" function key .

You can jump one by one or in tens in the desired menu for the manual functions of

the machine parts by pressing the corresponding touch buttons.

Note: In order to prevent faults different preselection functions may be locked in

defined conditions.

After pressing continuously the "Preselection Switch On" button the function will be

activated.

De-activating the manual function

The manual function is de-activated by stop pressing the "Preselection Switch On"

button.

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8.1.5.1 Manually moving conveyors

1. Press “Start/Stop” for a cycle stop

- In this case the machine finishes the process (cycle)

2. Press the “Manual” button (inside / outside)

- Depends on which conveyors you want to move

- Use the buttons of “Inside Safety Area” if conveyors are inside the safety fence

- Use the buttons of “Outside Safety Area” if conveyors are outside the safety

fence

3. Select the conveyors, which you want to move by clicking on them

- Selected conveyors are highlighted light green and have the caption

“Manual ON” - Select multiple conveyors by clicking on multiple conveyors

- If you have selected a conveyor the REV / DOWN buttons will appear

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4. Select REV / DOWN to move the conveyor(s)

5. In manual mode you are responsible for the positioning of the pallet!

Pay attention to: - Other pallets

- Muting areas

- The centering position

- The positioning at the hooding position

- The positioning at the Gusset sealer position

8.1.5.2 Manually adding a pallet

– Press the insert pallet button.

– Select an insert-position by clicking on one of the positions

– Insert the pallet information

8.1.5.3 Further manual functions

Activate the manual mode inside the safety area:

Select the machine center, which you would like to control manually:

- Centering (see chapter 8.1.5.4)

- Tensiontech (see chapter 8.1.5.5)

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8.1.5.4 Manual functions of the centering frame (CF)

The centering frame has the Open/Close centering bars manual function.

Open the control of the device with the blue button:

Fig. 8.3 Manual function of the centering frame

1. Pneumatic Stopper: UP/DOWN:

With this manual function you can move the pneumatic stopper up and down.

2. Centering bars: OPEN/CLOSE:

With this manual function you can open and close the centering bars.

Use the control buttons on the HMI to activate the highlighted part.

Confirm and start the movement with the Preselect on button on your operator desk.

Fig. 8.4 Preselection on button

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8.1.5.5 Manual functions of the Tensiontech

This menu is displayed when the selector switch Manual/Automatic on the operating

console has been set to Manual mode and the Tensiontech has been selected.

Fig. 8.5 Manual Function - Main screen

1. General Functions:

Opens general manual functions like:

- Maintenance positions

- Semi-automatic hooding

2. Film Supply (FS):

Opens a bigger view of the film supply head (FS) where you can select manual

functions for devices on the FS (see chapter 8.1.5.8).

3. Stretch Hooding Frame (SHF):

Opens the manual functions for the stretch hooding frame SHF

(see chapter 8.1.5.9).

4. Film Rack:

Opens the manual functions for the film rack (see chapter 8.1.5.10).

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8.1.5.6 Manual function General

Fig. 8.6 Manual Function - General 1

1. FS to MAIN (Home) Position:

Drive film supply to the general maintenance position.

2. FS to UPPER MAIN. position:

Drive film supply to the upper maintenance position.

3. FS to LOWER MAINT. position:

Drive film supply to the lower maintenance position.

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8.1.5.7 Manual Hooding

Fig. 8.7 Manual Function - General 2

Select Format A/B:

With these buttons you can select the film format.

1. Drive film to end of suction tube:

Drive the film to the lower end of the suction tube.

2. Store film tube length in film supply head:

Prepare the hood inside film for covering.

3. Open film tube with suction tubes:

Open the film for the bagging.

4. Weld and cut film hood:

Close the welding bars and cut the film.

5. Move SHF up to film take-over position:

Drive the stretch hooding frame up to film gather position.

6. Gather film with reapwheels:

Gather the stored film hood from the film supply head.

7. SHF down to TOP stretch cycle start point:

Drive the stretch hooding frame down to top stretch cycle start point and

stretch the film.

8. Manually hood load:

Pull the film hood over the pallet.

9. SHF back up to start position:

Drive the stretch hooding frame back to the initial start position (Home)

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8.1.5.8 Manual function of the Film Supply (FS)

Fig. 8.8 Manual function - Film Supply

1. Welding Bars:

Open the manual functions for the welding bars.

2. Suction Tubes:

Open the manual functions for the Suction tubes.

3. Hood Storage:

Open the manual functions for the Hood storage.

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Hood Storage

Fig. 8.9 Manual function - Hood Storage

1. Hood Storage: INSIDE/OUTSIDE:

With this manual function you can control the storage of the film inside the

head. There is a roller moving to an inside or outside position to collect or re-

lase film.

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Welding Bars

Fig. 8.10 Manual function - Welding Bars

1. Weld the film:

Weld the film manually (create the sealing to close the bag).

2. Welding bar: CLOSE & CUT:


3. Welding bars: OPEN/CLOSE:

Open / Close the welding bars.

4. Knife: LEFT/RIGHT:

Cut the film.

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Suction Tubes

Fig. 8.11 Manual function - Suction tubes

1. Film clamps: OPEN/CLOSE:

Open / Close the film clamps at the side of the suction tubes to hold the film while

the suction tubes open.

2. Vacuum: ON/OFF:

Start / Stop the suction tubes.

3. Suction tube: OPEN/CLOSE:

Open the film by lifting the suction tubes.

(see first picture on the right side)

4. ST (trans): IN/OUT:

Move the two suction tube tracks apart / together

to open the film tube.

(see second picture on the right side)

5. Left ST (long): IN/OUT:

The two suction tubes drive apart on the track on the left side.

6. Right ST (long): IN/OUT:

The two suction tubes drive apart on the track on the right side.

7. ALL ST (long): IN/OUT:

The two suction tubes drive apart on the track on both sides.

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8.1.5.9 Manual function of the Hooding Frame (HF)

Fig. 8.12 Manual function - Hooding Frame

1. Stretch Hooding Frame: UP/DOWN:

Drive the Hooding frame up and down.

2. Stretch Hooding Frame: UP/DOWN <Without Interlock>:

Drive the hooding frame up and down without any interlock.

That means the operator is responsible to check if the frame collidates with an-

other machine part.

3. HF - Manual Functions:

This button opens further manual functions for the stretch hooding frame, es-

pecially for the film gather functions.

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Tension Corners

Fig. 8.13 Stretch Hooding frame - Tension Corners

1. Reapwheel: OPEN/CLOSE:

With this function you can open and close the reapweels.

2. Reapweel spin: FORWARD/REVERSE:

Whit this manual function the reapweels can be spin forward and reverse.

3. Reapwheel position: TOP/MIDDLE/BOTTOM:

With these functions the reapweel can be positioned to the top, moddle and

the bottom of the tensin corner.

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8.1.5.10 Manual functions of the Film Rack

Fig. 8.14 Manual function - Film Rack

1. Drive film Format D/E:

With these buttons you can manually drive the film rolls of the film rack to release the tensionon the film supply hood.

2. Welding bar: CLOSE & CUT:


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8.1.6 Maintenance Menu

Fig. 8.15 Maintenance Main Screen

1. PLC Input status:

This button opens the PLC input status screen.

2. Password Setup:

This button opens the password setup menu.

3. Working Shift Setup:

In this menu you can find the counters.

The totals counter displays the number of packed pallets since commissioning

of the MSK packaging machine. The shift counter displays the number of

packed pallets per day (or since the last set of the counter). The daily counter can be set to zero with the button RESET. The totals counter cannot be reset.

4. Preventive Maint. Schedule:

This button opens the maintenance schedule menu.

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8.1.7 Moving to normal position

NOTE

The manual function “Automatic to start position” ”Nr. 25” is only

avalible in the menu for manual functions!

With the manual function "Automatic to start position" "Nr. 25" the MSK packaging sys-

tem can be moved to start position, if this function is activated by pressing continuous-

ly the "Preselection Switch On" button.

NOTE

If you can not move the MSK packaging system to start position

check the faults. In case of a fault at first clear the fault before

moving the MSK packaging system to start position.

Move the MSK packaging system to this start position before switching over to auto-

matic mode.

Always move the MSK packaging system to start position before shutting down the

system.

Normal position:

The following describe the normal position:

• The stretch frame is in its upper position (not the film pick-up position)

• The welding bars are open

• The stretching corners have been moved to the center

• The reap wheels have been actuated to the outside (they are not resting against the strechting corners)

• The suction jaws are open

• The film magazine has been retracted

• The knife is to the left or the right

The starting position must always be estabilshed before switchig to automatic opera-

tion.

Moving to the start position

The diferent machines can be moved into start positin by touching the corresponding function tuch buttons:

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8.1.8 Automatic mode

Activate the automatic function

To activate the automatic function, following conditions must be obeyed:

1. The control voltage must be switched on, and there may not be an error mes-

sage activated!

2. The machine must be in start position - acknowledged by the green "Start

position" indicator at the manual screen.

By touching the touch button "Automatic", the automatic function can be activated, ac-

knowledged by the lit green "Automatic" touch button.

De-activate the automatic function:

The automatic function is interrupted immediately by touching the Manual" or "Auto-

matic" touch buttons.

NOTE

It is recommended to let the machine finish its cycle.

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8.1.9 Adjust the parameters

The menu to change the hood parameters can be activated by touching the “Hood”

touch button.

Here the user must enter the password. Only when the password is entered cor-

rectly, is it possible to open the parameter screen.

In the middle of the screen a variable is displayed, which allows you to select which

pallet parameters should be changed.

After the desired pallet has been chosen, the menus for the speeds or the timers can

be selected by touching the cursor keys.

When the submenu for the speeds or the timers selected, the actual values are dis-

played.

To change a value, touch the desired number.

When all parameters that should be changed were adjusted, the touch button “Back”

should be touched until the startmenu has been reached. Or, the “parameters menu”

can be closed by touching the “Exit” touch button

8.1.10 Select the pallet information

When a palet has not been recognized properly, the pallet information can be changed

by PV 700.

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8.1.11 Switching off the machine

Always move the MSK packaging system to normal position before shutting down the

system. As an exception to this rule, the stretch frame must be moved to its lowest position in the following cases:

• If maintance work is to be carried out on the strech frame

• When the MSK TENSIONTECK is being prepared for possible transportation.

ATTENTION

Components inside the control cabinet will still be on even after

the MSK packaging system has been switched off.

In addition certain frequency converters take a further 60 seconds until the voltage has

dropped below 65V. Shut off the compressed air supply and open the quick-relase

valve on the pneumatic conditioning unit (compressed air will escape from the ma-

chine).

ATTENTION

Some pneumatic equipments are still pressurized even after the

compressed-air supply and the bleeding function of the pneumat-

ic system have been blocked.

ATTENTION

Before entering the danger zone, ensure that the padlock on the

master switch cannot be removed by other persons, e.g. with a spare key.

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8.2 Overview of the operating elements on the control cabinet/control

console

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8.3 Insertion of the film

8.3.1 Film reel changing

• Before the replacement, switch off the automatic mode! (see chapter 8.1.8)

• The film shaft (1) has bearing surface of "S-grün" at both ends.

• Rise the film drive (2) and remove the film shaft (1) from the film rack.

• Loosen the clamping lever (4a) and remove the collar (4) from one end of the film shaft (1). Pull off the empty reel core (5).

• Push the film shaft (1) into the new film reel, push on the collar (4) and secure with clamping lever (4a). If both the left-hand and right-hand collar were removed, en-

sure that the film reel is positioned exactly in the middle.

• Load the film reel carefully into the film rack, ensuring the film is loading to unwind

in the correct direction. Taking care not to damage the S-grün blocks at the ends

of the film shaft.

• Check the center position of the film reel in the film rack again.

"

#$ !

#

%

Fig. 8.16 Film rack

• Take the “old” and the “new” film, and seal it together in across the whole film

width. There should be no gap on the sealing to prevent the air going into the new

film tube.

• After the roll replacement and sealing, switch into manual mode, select “FS Head”

program group, and locate the “Drive film roll A“ function (or the corresponding film

format).

• Activate the manual function to transport the film over the system.

• Where the film is sealed by the film roll change, cannot be used for packaging, it

must run over the system. Use the “Drive film roll” manual function to drive the film

until the sealed point run over the system.

• When the sealed point is transported over the system, move the machine to home

position (ATS Home).

• Now, the machine is ready for production.

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8.3.2 Threading in the film

CAUTION

Risk of injury from moving machine parts!

Risk of injury when the machine is started!

► Before switching on the machine, ensure that all persons have

left the safety area!

► Close and lock the safety fence gates!

• Clear out the covering place conveyor (make the Tensiontech conveyor empty).

• Switch into manual mode, and lower the head to the lower maintenance position.

• Unwind approx. 20 - 23 feet (6 - 7 meters) of film from the film reel by hand. at the same time lift the film drive by switching the pneumatic switch on the film rack.

• Thread the leading end of the film tube under the guide roller (1), under roller (2),

over guide roller (3), under buffer roller (4) and up over guide roller (5).

• Thread the film tube over roller (6) under the eccentric disc that prevents the film from slipping back and then under roller (7) towards the film feeder head.

• Then thread the film under guide roller (8). Raise the film brakes with the pneumat-

ic switch located next to it, and thread the film over.

• Now, thread the film on the correct side of the rubber coated roll, down to the suc-

tion bars.

• Pull the film approx. 1.6 ft (0.5 m) under the suction jaws.

• Once you are ready, close all the safety doors, unlock the system.

• Move the machine to home position, using the ATS function in manual mode. The

film will be cut, and the head lifted to home position.

• Switch off the machine again as described in chapter 8.1.11 (master switch and

control voltage OFF, shut off compressed air supply). Open the safety door and

remove the film that has been cut off.

• Close the safety doors, and unlock the system.

• Now the machine is ready for production.

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Fig. 8.17 Film running diagram

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MSK Tensiontech Maintenance

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9 Maintenance


DANGER



charges!



DANGER


Contact with live components poses a risk of serious injury or even death!

► Before starting work, switch off the electric power supply and

secure to prevent it from being switched on again!

NOTE


values of the film.




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WARNING

Danger of injury from improperly performed maintenance!

Improper maintenance can result in serious personal injury or ma-

terial damage!

► Before starting work, ensure that you have sufficient space!

► Handle open, sharp-edged components with care!

► Pay attention to cleanliness and orderliness at the place of

work! Loose components and tools lying around are a poten-

tial cause of accidents!

► Install all components correctly. Observe the prescribed bolt

tightening torques! Secure the bolts with lock tight (e.g. Wei- con AN 302-43 (blue)) "medium strength"!

► Secure components so that they cannot fall down or fall over!

► Operating elements of the Emergency stop system must be

freely accessible!

► Operate the machine only when all the safety devices, e.g.

safety fence, light barriers and safety pins are installed and fully functional!

WARNING

Risk of injury from stored pneumatic energy!

Pneumatic energy may be stored in the machine that can lead to

uncontrolled movements of components and injuries!

► Before starting maintenance work, depressurize the pneumat-

ic system and secure it to prevent restarting! Only then start the maintenance work!

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WARNING

Risk of injury from sharp knives!

The film knife is very sharp. There is a risk of serious cuts!

► Wear suitable protective gloves.

► Leave the knife covers closed!

WARNING

Danger from falling loads!

Loosening the clamping element on the motor shaft without pre-

vious securing poses a serious risk of injury or even death from

the tensioner frame or counterweights dropping down!

► The clamping element may only be loosened when the ten-

sioner frame and the counterweight are secured with safety bolts (see Fig. 3.26) to prevent them from falling down!

CAUTION

Danger due to pulling in or catching!

In the following places, there is a risk of body parts being pulled in: - Between the film drive wheel and the film roll

- Between the rubber roller and the counter roller in the film supply head

- Between the toothed belt and the toothed belt wheels

► Do not reach between the film drive wheel and the film roll!

► Do not reach between the rubber roller and the counter roller

in the film supply head!

► Do not reach between the toothed belt and the toothed belt

wheel!

► Wear work clothes with low tear resistance (see chapter 9.1)!


CAUTION


Parts of the machine may still be live even when the emergency

stop switch has been pressed!

► Do not touch live parts and leads!

► Observe the instructions in the operating manual!

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Danger of burning!

CAUTION

The sealing bar at the packaging machine becomes hot during

operation! This poses a danger of burning!


down!


Crushing hazard!

CAUTION

Crushing point at the film drive in the film feeding head!

► The film drive may not be moved in manual mode if this puts

persons at risk!

► Do not reach between the rubber roll and the counter roller!

► Wear protective gloves!

CAUTION

Danger of tripping or slipping!

There is a risk of tripping or slipping on the pallet conveyors!

► Do not step on the pallet conveyors!

► If you have to step on the roll conveyor in order to carry out

maintenance work, place the foot plate on the roll conveyor

first!

CAUTION




plate)!


tension frame!

► Do not step on the motors or tension corners!


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Wear the following protective equipment at all times during maintenance work:






injury


parts and liquids


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9.2 After-sales service

Our After-sales Service is available for technical information.

Furthermore, our employees are always interested in new information and experience gained in practice and which could be of value for the improvement of our products.

MSK Covertech, Inc. 4170 JVL Industrial Park Drive

30066 Marietta, Georgia

USA

Phone (+1) 770 928 1099

Fax (+1) 770 928 3849

Manufacturer's address

MSK Hungary Bt.

4300

Nyírbátor Vágóhíd út 39.

Hungary

Phone (+3642) 511-100

Fax (+3642) 511-155

E-mail [email protected] www.msk.hu



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9.3 Operating personnel

The operating personnel must have the necessary qualification and authorisation for

the maintenance of a packaging machine.

Before carrying out maintenance on a special machine, the operating personnel must

familiarise themselves with the special features of this machine.

Instruction in the machine-specific requirements/characteristics can, if necessary, be

carried out on behalf of the machine owner in the training centre of MSK Verpackungs-

Systeme GmbH.

Work on the electrical installation may only be carried out by qualified electricians.

9.4 Maintenance schedule

9.4.1 Scheduled maintenance

Profitable operation of the packaging machine is not possible without "scheduled

maintenance".

The "scheduled maintenance" is thereby based on the performance of inspections and measures as outlined in the following lubrication and maintenance schedule. Param-

eters here are:

• Indications of wear values,

• assessment criteria and

• function checks

In order to uphold the warranty, any extension of the intervals must be agreed upon

with MSK Verpackungs-Systeme GmbH.

No legal claims can be derived from the information provided by us.

9.4.2 Control of electric equipment pursuant to BGV A3

The control of non-stationary and stationary electrical devices, facilities and equip-

ment pursuant to BGV A3 constitues a responsibility of theoperator for the equipment.

The control shall be performed on an annual basis. (For more information please refer

to the CD.)

Source: www.bgva3.de

http://www.bgva3.de/

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9.4.3 Lubrication and maintenance chart

Maintenance Wee k

Mon ths

Ye- ars

Cyc- les

Maintenance medium

Visual inspection of 1

All moving parts 1

Energy supply chains 1

Bump stops 1

Movable cables 1

Adjustment of chain tension, if required. 1

Inspection of bolts tightness, proximity switches and pho-

toelectric barriers 1

Photoelectric barriers and reflectors

Should the control LED flicker on one of the photoelectric

barriers, then the reflected luminous flux is insufficient. If the flickering cannot be eliminated by cleaning the photo-

electric barrier and the reflector, then the alignment of the

two devices to each other must be checked and correc-

ted if necessary.

1

Inspection of fuses, signal lights and fuse elements (fuses shall only be replaced by fuses of identical values).

1

Inspection of the “S-grün” blocks at the ends of the film

shaft. 1

Cleaning 1

The entire area of the unit to be swept clean. 1

In the switch box, cleaning of the AC unit. 1

In the case of motors cooled by ambient air, there must

be proper access provided for the cooling ribs at all times. The cooling air routes in the area of the motors must be

kept clean.

1

Lubrication of drive- and conveyor chains.

Chains installed by MSK do not require extensive main-

tenance. A re-lubrication interval of 3 to 6 months is re-

commended subject to operating hours.

2 Chain lubricant e.g.

- SYN-Setral-54NF

- Fluid-Setral SHT 260 MT

Control of Chain tension (slackness of chain approx

1% of the center distance), tighten if necessary. 1

Junctions of conveyor chains and rolls of object (film,

wood, glass, etc.) to be released. 3

Pulley levers and stoppers (if available)to be checked for ease of movement, to be lubricated and, if necessary,

replace the spring.

3

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Maintenance Wee

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Cyc- les

Maintenance medium

Oil in motors and drives to be checked every 3,000

operating hours, (no longer than every 6 months) 1 Gear oil e.g.

- FINA Pontonic

- FINAHydran CIN 46

- ARAL Vitam DE 46 Oil to be changed in motors and drives every 12,000

operating hours, or if operated fewer hours then every 3

years.

3

Pneumatic equipment

Pneumatic hoses and screw joints to be checked for

tightness. 1 Leakage spray

Test on the maintenance unit:

a) Water separator to be checked and condensate

water to be discharged.

b) Sinter filter of the maintenance unit to be checked

and cleaned if necessary.

1

Filter silencer to be cleaned. 6

Maintenance of the Sealing bars. Teflon tape to be clea-

ned. If necessary, teflon tape, heating tape and silicone

rubber to be replaced.

Drive shaft (rubber wheels) to be cleaned

1 Teflon tape to be cleaned with silicone

water.

Check the Decagonal blade (film knife) on the linear

drive in the sealing bar; to be rotated if necessary. 1

On the Linear drive (Festo) the degreased surface of the

guide rail or belt system to be lubricated. 3

Lubrication of the Linear guides. 1 Grease:

Lithiumgrease no. 2 Oil:

-Turbine oil ISO VG32 to 68 or

identical types

Film end position control (bracket at the front of the film pliers) to be checked for free movement, if necessary

spring(s) to be replaced.

1

Toothed belts to be checked at the pivoting beams and

film grippers for voltage and external damage, if neces-

sary to be retightened or replaced.

1

Toothed belts to be checked at the lifting carriage for ex-

ternal damage. 3

Dirt deposits on the toothed belts to be removed. 1

S-green guide on the counterweight to be checked for

abrasion, and to be replaced if necessary. 3

Vulkollan wheels (in the film feeder head and the stretch

hooding frame) to be checked for wear. 3

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Maintenance Wee

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Maintenance medium

Checking that the bolts are securely fastened at the toothed belt clampings:

- at the inspection window in the pillars, the bolts to be

checked for being securely fastened at the counterweight

(counterweights are at the bottom when the lifting car-

riage is at the top).

- toothed belt clamp (clamp plate) to be checked at the lifting carriage.

(By the weight force of the lifting carriage the toothed belt

will be clamped).

1

Toothed belt pulley to be checked for tooth wear. 3

Toothed belt to be replaced. 6

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9.5 Maintenance of the MSK Tensiontech

Fig. 9.1 Maintenance schedule/machine overview

Insert the safety pins (see arrows) during all maintenance work requiring the replace-

ment or disconnection of the lift belts or clamping element on the motor shaft!

Safety pins provide the tensioner frame with additional support to prevent it from drop-

ping during maintenance work and are located on both sides of the baseframe. Move

the tensioner frame to its uppermost position for insertion. Insert the safety pins up to the top (roll pin).

When three safety pins have been inserted on each side, lower the tensioner frame

slowly and carefully in manual mode onto the upper safety pins. As the lift motor has

to move the whole weight of the tensioner frame (the counterweights are resting on

the other pins), move the lift motor only by briefly touching the preselector button. Oth-

erwise it can be damaged due to overloading!

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WARNING

Danger of injury due to improper maintenance!

Improper maintenance can result in serious injuries to persons or property damage!

It is prohibited to perform maintenance work on the hood wrapper,

such as replacing the toothed belt, if the hood wrapper is in the

bottom maintenance positions!

► To release the clamping plates at the toothed belt, or to re-

place the toothed belt, the hood wrapper must be in the top

maintenance positions!

► Comply with the descriptions on replacing the lift toothed belt

in chapter 9.6.5!

PLEASE NOTE

If you have to tread on the roll conveyor in order to carry out main-

tenance work, you must make it safe beforehand by placing a

suitable grate onto it!

ATTENTION

Risk of damage to the lift motor!

As the lift motor has to move the whole weight of the tensioner

frame (the counterweights are resting on the lower bolts), the lift

motor can be damaged if it is operated incorrectly!

► Move the motor only by brief actuation of the preselector but-

ton!

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Maintenance position of suction jaws

In the maintenance position 1 (refer to Fig. 9.2), it is possible to work comfortably on

the suction jaws and all other components underneath the film feed head.

Maintenance position of the film drive station

In the maintenance position 2 (refer to Fig. 9.2), it is possible to perform maintenance

work comfortably e.g. on the film drive station.

Start position Maintenance position 2 Maintenance position 1

Film drive station Suction tubes

Fig. 9.2 Maintenance positions

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Before the head of the MSK Tensiontech is moved into one of the maintenance positions, certain conditions must be complied with:

– Before any work may be started, first all automatic safety latches on the film feed

head, and on the hood applicator must be checked.

Fig. 9.3 demonstrates the correctly locked safety latch on the film feed head.

Fig. 9.3 Automatic safety latch, in locked position

– No personnel may stay in the danger zone underneath the MSK Tensiontech.

– There must not be a pallet placed on the hood applicator (should a pallet be placed

on the hood application spot, then remove it via the manual functions from the

equipment, refer to Chapter 8.1.5).

– Switch the unit to “Manual mode”, refer to Chapter 8.1.5

– Select the manual function “FS to LOWER MAINT. position”, refer to Chapter 8.1.5.6

– Perform the selected manual function via the button “Start manual function / Ma- chine Pre-selection” on the control panel.

– Wait for the equipment to come to a stand still.

– Shut down MSK Tensiontech.

– Enter the area via one of the safety doors.

– Secure the safety door against unintended closing with a padlock, so that no maintenance personnel will be accidentally locked inside the safety guard.

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Process relating to the function “Automatic movement to maintenance position

1” :

• The MSK Tensiontech is in the start position.

• The hood applicator slowly travels upwards.

• The hood applicator docks onto the film feed head.

• The hood applicator slightly raises the film feed head.

• Now the hood applicator carries the film feed head.

• Then the automatic safety latches are released on the film feed head

• Now the hood applicator and the film feed head are slowly moving downwards

• Shortly before reaching maintenance position 1 for the suction jaws, the hood ap-

plicator decreases speed

• The automatic safety latches on the film feed head will be closed, and will lock in

place at the dedicated openings.

• The hood applicator travels downwards, until the hooding frame almost rests upon

the conveyor.

• The automatic safety latches on the hood applicator are closed.

• The MSK packaging system reaches a standstill position, and the automatic move-

ment of the maintenance position is completed.

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Process relating to the function “Automatic movement to maintenance position

2” :

• The MSK Tensiontech is in the start position.

• The hood applicator slowly travels upwards.

• The hood applicator docks onto the film feed head.

• The hood applicator slightly raises the film feed head.

• Now the hood applicator carries the film feed head.

• Then the locking pins are released on the film feed head.

• Now the hood applicator and the film feed head are slowly moving downwards.

• Shortly before reaching maintenance position 2 for the film drive station, the hood

applicator decreases the speed.

• The automatic safety latches on the film feed head will be closed, and will lock in

place at the dedicated openings.

• The hood applicator travels downwards, until the hooding frame almost rests upon

the conveyor.

• The automatic safety latches on the hood applicator are closed.

• The MSK packaging system reaches its standstill position, and the automatic

movement of the maintenance position is completed.

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9.5.1 Lubrication

Lubricate the following points:

• All motors according to the manufacturers' specifications (see Annex Manufactur-

ers' documents)

• Chain for lifting movements every 30,000 cycles with SYN-SETRAL-54NF or

equilibrant

• Linear cylinder (see description of the linear cylinder in the Annex Manufacturers'

documents)

• Pneumatic cylinders and air conditioner (see Annex Manufacturers' documents)

9.5.2 Cleaning

The whole area of the packaging machine must be cleaned once a week with an in-

dustrial vacuum cleaner. Clean light barriers and reflectors once a week with a cloth.

NOTE

In the event of severe soiling, carry out cleaning at shorter inter-

vals.

9.5.3 General visual inspections

Inspect the following at least once a week:

All moving parts

• Energy supply chains

• Moving cables

• Hoses

• Indexing discs on the motors for flatness

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9.6 Further maintenance work on the MSK Tensiontech

NOTE

An adjustment of the bearing rollers is only necessary when the

hood applicator is displaced from its horizontal position.

3 2

4

1

Fig. 9.4 Adjusting bearing rollers and guide rolls

1 Bearing roller with adjustable axle (polyamide)

2 Bearing roller with rigid axle (polyamide)

3 Guide rollers with adjustable axle (guide rollers)

4 Lateral guide rolls (Vulkollan rolls)

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9.6.1 Bearing roller (1)

The carriage of the hood applicator can be realigned in the horizontal position with

the bearing rollers (1).

To accomplish this:

- Slightly loosen the lock nuts (A).

- Twist the eccentric bolt accordingly with the help of the auxiliary hole (B); in the

course thereof, ensure that the right and the left bearing roller are evenly twisted,

respectively.

- Retighten the lock nuts (A).

A B

Fig. 9.5 Bearing rollers

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9.6.2 Bearing rollers 2

The bearing rollers of the hood applicator may only be adjusted under light pressure

against the running surface of the main column.

Proceed as described in the case of the bearing roller (1).

9.6.3 Lateral Guide rollers 4

Having equidistance of the carriage on the two columns is very important. If the alignment changes, the distance between the switches must be adjusted within

0.1” (3 mm).

For this procedure, refer to the following Fig. 9.6.

- Move the carriage to lower position.

- Perform work simultaneously on both lateral guide rollers (4).

- Loosen the lock nuts (A).

- Twist the hexagon bolts (B) on both rollers to a position where the rollers do not fit

tightly any more.

- Align the hood applicator and carriage centrally (distance between carriage plate

and main column must be equal on both sides).

- Move both rollers by hand.

- Slightly tighten the hexagon bolts (B).

- Tighten the lock nuts (A).

- By displacement of the hood applicator, check if the guide rollers (B) are perhaps too

loose in other positions, readjust if necessary.

B

A

Fig. 9.6 Lateral guide rollers 4

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9.6.4 Alignment of the hood applicator

The bearing rollers on the tension frame are mounted on rigid axles and cannot be ad-

justed. The lateral guide rollers can be adjusted. The procedure is the same as that for the film supply head; see section 9.6.3.

CAUTION




plate)!


tension frame!

► Do not step on the rollers!

Use the wooden plate for maintenance (Fig. 9.7)! Make sure that the wooden plate is placed correctly!

The shafts of the rollers need to be in the gap of the steel hold- ers (A) which are screwed on the bottom of the wooden plate!


A

Fig. 9.7 Wooden plate

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It may occur that the tension frame is no longer in a horizontal position. This can be corrected by twisting the adjusting nuts at the toothed belt clamping.

Fig. 9.8 Tension frame

– Move the Tension frame to the lower maintenance position.

– place a level crosswise over the linear guiding rails (arrow) on the Tension frame, and check the horizontal position.

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1

2

Fig. 9.9 Toothed belt clamping

- Slightly release the lock nuts (1), but do not entirely remove them!

- Twist both adjusting nuts (2) evenly, in accordance with the desired position.

- Retighten lock nuts (1).

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9.6.5 Toothed belt replacement

WARNING

An improper procedure during the replacement of the

toothed belts can cause a life threatening hazard due to a

falling hood applicator or a toothed belt bouncing up!

The replacement of the toothed belt requires sound expert

knowledge and incorporates a certain risk. The work must be

carried out under safe working conditions carefully.

► We recommend having these maintenance procedures per-

formed by MSK mechanics.

Hazard due to fall!

WARNING

For work performed at certain heights, additional safety

precautions are required.

► We recommend the use of a mobile work stage, a so-called

“Cherry Picker”, in order to reach the upper assembly points of the MSK Tensiontech.

► Use fall protection!

NOTE

Faulty threaded rods on the toothed belt clamping must only be

replaced by threaded rods of the strength category 8.8.

NOTE

The toothed belt shall be subject to visual inspection on a regular

basis!

The toothed belts installed by MSK shall be replaced no longer than every 6 years!

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9.6.5.1 Preparation

• Cycle stop the centering conveyor and clean out products on the hooding convey-

or.

• The MSK packing system is in the start position.

• Report the entry of to the safety area at the touch panel and wait for sys-tem standstill.

• Enter the protective grid area through one of the safety doors.

• Insert two locking pins each per counterweight all the way up to the stop in the

corresponding holes above the counterweight (see Fig. 9.10).

Fig. 9.10 Locking pins for the counterweights at the hood wrapper

• All persons must leave the protective grid area; unlock the protective grid area and

switch the system to manual mode.

• Move the hood wrapper slowly upwards via manual functions until the counter-

weights lie on the bolts.

• Switch off the MSK Tensiontech with the master switch and secure against unin-

tentional reactivation.

The automatic safety catches at the hooding frame are extended and lock the hood wrapper.

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WARNING

Danger from falling loads!

A dropping hood wrapper is a source of mortal danger!

► First check the automatic safety catches at the hood wrapper!

► Fig. 9.11 shows a properly locked safety catch!

► Do not step under the hood wrapper if the safety catches are

not properly engaged!

• Visually inspect to see if all catches are positioned in the corresponding grooves

(see Fig. 9.11).

Fig. 9.11 Engaged safety catches

• Remove the four cover sheets at the guide pillars and check if both counterweights

are lying on the bolt. If that is not the case, use the manual function to further lift

the position of the hood wrapper until the counterweights are lying on the bolt.

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9.6.5.2 Disassembly of the upper toothed belt

- Mark the current position of the carriage on both sides of the lifting mast.

- Remove the four lock nuts (1) (see Fig. 9.12) on both sides of the threaded rods

of the toothed belt clamps.

1

2

Fig. 9.12 Toothed belt clamping

- Release the remaining four clamping nuts (2) evenly. In this way, the frame of the

hood applicators slightly lowers itself.

- Release the clamping nuts until the automatic safety latches are supported within

the slots.

- Release the bolts on the clamping plates, and remove the toothed belt from the

clamps.

Do not remove any of the bolts if the automatic safety catches are not lying

correctly in the slots!

- Also release the toothed belt clamping at the counterweight above, and remove the

toothed belt from the clamps.

- Repeat work on the second upper toothed belt.

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WARNING

Hazard of injury due to a falling toothed belt!

Falling toothed belts may cause injuries!

- Wear a suitable safety helmet!

- Do not step into the hazard zone!

- Inform other people near the hazard zone about the activity!

9.6.5.3 Disassembly of the lower toothed belt

- Release the skip protection at the drive roll; loosen both screws to do so (see arrow

in Fig. 9.13). The elongated holes make it possible to push the skip protection back far

enough.

Fig. 9.13 Skip protection

- The toothed belt can now be pulled downwards out of the deflector.

- Loosen the bolts to release the skip protection.

- Also release the toothed belt clamping at the counterweight, and remove the toothed belt from the clamps.

- Repeat the work for the second top toothed belt.

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9.6.5.4 Assembly of the lower toothed belt

- Cut the new toothed belt to the exact same length as that of the removed belt!

- Guide one end of the toothed belt under the released skip protection.

- Place one end of the toothed belt up over the sprocket; insert the teeth into the slots.

- Place the end of the toothed belt into the slots of the clamping plate on the counterweight. Use the same bolts again (or bolts of the same length). Secure the bolts with

screw fastening adhesive, e.g. WEICON AN 302-42 blue.

- Tighten the toothed belt manually.

- Place the other end of the toothed belt into the slots of the clamping plate on the hood applicator. Use the same bolts again (or bolts of the same length).

Secure the bolts with screw fastening adhesive, e.g. WEICON AN 302-42 blue.

- Tighten the clamping nuts.

- Repeat the work on the second toothed belt of the hood applicator.

9.6.5.5 Assembly of the upper toothed belt

- Cut the new toothed belt to the exact same length as that of the removed belt!

- Place one end of the toothed belt up over the free moving roller; insert the teeth into

the slots.

- Place the end of the toothed belt into the slots of the clamping plate on the

counter weight. Use the same bolts again (or bolts of the same length). Secure the

bolts with screw fastening adhesive, e.g. WEICON AN 302-42 blue.

- Tighten the clamping nuts.

- Repeat the work on the second upper toothed belt of the hood applicator.

9.6.5.6 Tightening of the toothed belt

- Start with the upper toothed belt.

- Tighten all four clamping nuts on the toothed belt clamping evenly. This will slightly

raise the head of the hood applicators.

- Twist the clamping nuts until the carriage is returned to the position marked at the

beginning.

- Check with a level if the carriage is attached to the toothed belt in a horizontal

position. If the carriage is not horizontal, adjust the position by the clamping nuts.

- Now tighten the lower toothed belt.

- Tighten both toothed belts by clamping evenly on the threaded rods.

(refer to Fig. 9.9).

- Pull the skip protections again, below the drive rollers, and screw them on tightly.

- Prepare the MSK Tensiontech for restart. Remove all tools and accessories (also

the chain hoist).

All personnel must leave the safety guard area. Close the safety guard doors.

Switch on the MSK Tensiontech, and lower the hood applicator to some extent in

the manual mode, until the counterweights do not rest upon the safety bolts any

more.

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- Enter the safety area through one of the safety doors.

- Remove the safety bolts of the counterweights; remount the cover plates on the

lifting mast.

- Restart the hood applicator, and lower it to the maintenance position.

- Switch off the MSK Tensiontech again.

NOTE

Strand frequency may only be checked by authorized expert staff.

NOTE

The toothed belts installed by MSK must demonstrate a strand

frequency of 36 Hz over a length of one meter (the distance

between the belt return wheel and the toothed belt clamping on

the carriage)

- Check the toothed belt tension with a strand frequency measurement device.

- Check the horizontal position of the hood applicator with a level, and adjust if

necessary.

- Tighten all lock nuts on the threaded rods of the toothed belt clampings.

- Prepare the MSK Tensiontech for restart. Remove all tools and accessories.

All personnel shall leave the safety guard area, close the safety guard doors, switch

on the MSK Tensiontech, and return it to the base position in the manual mode.

- Select and perform the function “Reference run” from the manual menu.

- Then switch the MSK Tensiontech to the automatic mode.

NOTE

As far as possible, please view the first packaging cycle.

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9.7 Replacing the Sealing bars on the MSK Tensiontech

WARNING

Danger of injury due to sharp knives!

The film knife in the film feeding head is extremely sharp. This

poses a serious risk of cuts!

► The knife may not be moved in manual mode if this puts per-

sons at risk!

► Wear appropriate gloves.

► Keep the knife cover closed!

Danger of burning!

CAUTION

The sealing bar at the packaging machine becomes hot during operation! This poses a danger of burning!


down!


Fig. 9.14 Film knife

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9.7.1 Preparation

• Cycle stop the centering conveyor and clean out products on the hooding convey-

or.

• Place the system into manual mode and move the film supply head to maintenance position 2 (lowest maintenance position).

• Switch off the control voltage.

• Turn off the main switch on the switch cabinet of the MSK system and enter the system via the grille safety gate.

9.7.2 Disassembling

• Disconnect the electrical connection for both sealing bars. To do so, pull the connector (pos. 1 in Fig. 9.15) out of the socket using the red handle.

• Release the locking levers (2). Each lever can be raised in order to make adjust-

ments.

1 2

Fig. 9.15 Electrical connection on sealing bar

• Now remove the sealing bar from its mount.

• Repeat the steps on the second sealing bar.

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9.7.3 Assembling

• Check the surface of both sealing bars for damage.

• Insert a sealing bar into the profile rail as shown in Fig. 9.16.

Fig. 9.16 Mounting a sealing bar

• Mount the sealing bar carefully. Make sure that the green guide plastic fits precise-

ly into the profile and is not damaged.

• Insert the sealing bar into the guide rail until it reaches the limit stop.

Fig. 9.17 Clamp piece

• Make sure that the clamp piece is inserted into the guide rail as shown in Fig. 9.17.

• Now tighten the black locking lever again.

• Reestablish the electrical connection by inserting the connector into the socket.

• Repeat the steps on the second sealing bar.

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9.7.4 Final Steps After Mounting Wealing bars

• Everyone must leave the safety area.

• Turn on the main power switch.

• Place the system into manual mode.

• In manual mode, move the MSK Tensiontech back into the starting position.

• Switch automatic mode back on.

NOTE

We recommend that you check the first few weld seams of the film hoods after changing the sealing bars!

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9.8 Maintenance of the motors

DANGER



even death!

► Before starting the maintenance work, switch off the electric

power supply and secure to prevent it from being switched on again!

The motors must be serviced in accordance with the manufacturer's specifications in

Annex Manufacturers' documents.

Should the stopping distance of the motors become too long, adjust or replace the brakes in accordance with the manufacturer's specifications in Annex Manufacturers'

documents!

Check the oil every 3,000 operating hours (but every 6 months at the latest).

Replace the oil in the motors and gearboxes every 12,000 operating hours, but every 3 years at the latest (see Annex Manufacturers' documents).

Externally cooled motors must have a free inlet of the cooling air to the cooling fins at all times. Keep the cooling air paths in the area of the motors clean at all times.

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9.9 Maintenance of the pneumatic equipment

CAUTION

Risk of injury from pressurized components!

Pressurized components of the pneumatic system can result in

injuries!

► Depressurize components before starting maintenance work!

► Observe the pressure gauges!

► Wear protective goggles!

Before starting work on the pneumatic equipment, depressurize the pneumatic system by actuating the hand lever on the compressed air conditioner.

- Check the pneumatic system (pneumatic hoses and hose fitting) for leaks (leak

spray).

- Checks at the air conditioner:

• Inspect the water trap (2) and drain the condensed water.

• Inspect the sinter filter (3) of the air conditioner and clean, if necessary.

The exact procedure for these two points can be found in the manufacturers' instruc-

tions in chapter 12 Manufacturers' documents).

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1 2 3

Fig. 9.18 Pneumatic air conditioner

1 Soft-start valve

2 water trap

3 Sinter filter

3. Exhaust air silencer

The filter/silencer cleans the collected exhaust air from the pneumatic control systems

and damps the exhaust air noise. Any condensation collects in the lower plastic cup

and can be discharged via the condensate drain.

NOTE

The manufacturer recommends the replacement of the filter car-

tridge after approx. 1000 operating hours.

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9.10 Maintenance of the electrical equipment

DANGER



even death!

► Before starting the maintenance work, switch off the electric

power supply and secure to prevent it from being switched on again!

► Maintenance work on the electrical installation may only be

carried out by appropriately authorised qualified personnel!

During the maintenance work, check the proximity switch priodically to make sure it is

properlly installed. Check the function of the AC unit on the control cabinet and all the

indicator lights.

Clean the light barriers and reflectors at regular intervals, depending on the degree of

soiling. Should the control LED on a light barrier blink, the reflected light flow is too

weak. If the blinking cannot be remedied by cleaning the light barrier and reflector,

check the alignment of the two components to one another and correct, if necessary.

Inspect the electrical cables for obvious signs of damage. Check that the electrical

connections are tight.

Clean electric devices from time to time to remove collected dust and dirt, as otherwise

leakage currents can occur.

Inspect fuses, signal lamps and safety elements (replace blown fuses only with fuses

of the same amperage).

Maintenance of the battery in the PLC, see separate description of the Control Logix

controller.

Furthermore, observe the maintenance instructions in the manufacturers' descriptions

in the Annex Manufacturers' documents.

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9.11 The alignment and maintenance of the flap conveyor

Below you will find a description how the knee angle must be adjusted to beware

accidents.

NOTE

Please do not walk on the flaps if it is not really necessary!.

Fig. 9.19 Flap conveyor knee setup

Fig. 9.19 show you an example of flap conveyor. The flap is in conveying position. The

sketch No.1 will show you that the knee angle is in the right position. The middle angle

must be over the dead point. In that position, the pneumatic cylinder could be pressure

less and the flap will not retract. Sketch No.2 and No.3 show you, the both wrong po-

sitions. If the knee angles are in that positions and the cylinder is pressure less the flap

will be retract.

Please check the position of the knee angle continuous, once per week.

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9.11.1 Screws for alignment

To fix all alignments use the counter nut on each screw!

B A

Fig. 9.20 Screws for alignment

Whit these screws (Fig. 9.20 (B)) you can adjust the flaps.

1. The flap must be in level with the middle string chain.

2. The knee angle must be adjusted in that way, that the knee is over the dead point (Fig. 9.19).

A mechanical end stop makes sure that the knee angle can not bend over!

If the knee angle is in the right position, but the flap is not in level with the middle string

chain, you must readjust the ball and socket joint which is connecting the knee an-

gle with the flap!

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9.11.2 Warning (signs)

A B

Fig. 9.21 Examples for marks

A: MSK part No.: 00123176 (Ø45mm) “Don not walk here!”

B: MSK part No.: 00072182 (Tape roll) “Danger area” To mark the sides of the flaps

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9.12 Maintenance of the conveyor unit

The conveyor drives shall be maintained in accordance with the data provided by the

manufacturer.

The chains shall be lubricated every 50,000 cycles by SYN Sentral 54 NF or

equivalent. Attention shall be paid to ensure sufficient chain tension (slackness of the

chain; approx. 1% of the centre distance), retighten if necessary.

For the tightening of the chains, release the lock nut (2), twist nut (1), moving the ten-

sion roller in direction (A), until the chain is sufficiently tight, then retighten lock nut (2).

Fig. 9.22 Tightening of chains

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9.13 Maintenance of the centering device

The chains shall be lubricated every 50,000 cycles by SYN Sentral 54 NF or

equivalent. Attention shall be paid to ensure sufficient chain tension (slackness of the

chain; approx. 1% of the centre distance), retighten if necessary.

For the tightening of the chains, release the lock nut (1), twist nut (2), moving the ten-

sion roller in direction (A), until the chain is sufficiently tight, then retighten lock nut (1).

2 1

Fig. 9.23 Tightening of chains

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9.14 Maintenance record

Assembly and commissioning

Assembly on: .......................... by: ..........................

Commissioning on: .......................... by: ..........................

Maintenance work and checks

Mechanics Electrical system

Date Signature Date Signature

Replaced parts

Mechanics Electrical system

Date Signature Date Signature

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Operating Manual

MSK Tensiontech Troubleshooting

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10 Troubleshooting


10.1.1 Personal preconditions

Troubleshooting may be carried out by persons who

• are authorized to do so on the grounds of their training and qualification.

• have been authorized to do so by the owner of the packaging machine.

DANGER





DANGER



jury or even death!




CAUTION

Risk of injury from pressurized components!

Pressurized components of the pneumatic system can result in

injuries!

► Depressurize components before starting maintenance work!

► Observe the pressure gauges!

► Wear protective goggles!

Work on the pneumatic equipment may be carried out by suitably qualified personnel with specialist know-how and experience in this field of work.

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10.1.2 Preparations for remedying faults

• Stop and switch off the packaging machine and secure to prevent restarting as de-

scribed in this operating manual.

• Secure enough work area.

• Inform the operating personnel.

10.1.3 Steps before switching on again after faults

• Cancel faults (reset).

• Check the safety installations.

• Check that the machine is functioning again correctly.

10.2 General information on troubleshooting

Leave enought space on the motor for cooling.

In the event of faults in peripheral systems (e.g. motors), observe also the manufacturers' documentation in the Annex to this operating manual.

If the cause of the fault cannot be determined despite intensive examination, contact MSK After-sales Service.

In this case, please have the following information available:

• Machine type

• Year of construction

• Serial No./Commission Number

The necessary information can be found on the machine rating plate.

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10.3 Faults and remedies

NOTE

An overview of the error messages that appear on the text display

in the event of faults can be found in the separate electrical doc-

umentation. Measures to be taken are shown together with the

corresponding error messages.

Before faults are remedied and cancelled, their cause must first be identified and rem-

edied! Observe the safety precautions given in chapter 2 and the cross-references to

the corresponding sections at all times!

When faults have been remedied, their remedy must be confirmed by the correspond-

ing preselector switch position or, if a text display is installed, with the function key "Clear".

Some error messages contain additional information and instructions. These can be

viewed by touching the button of additional information on the text display.

CAUTION

Danger in the safety area when the machine is switched on!

Troubleshooting inside the safety area can result in injuries when the machine is switched on!

► Switch off the machine before entering the safety area!

► Secure the machine to prevent restarting!

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10.4 Printout of the error messages

General

+GEN-F001: control voltage OFF +GEN-F002: E-stop operated at the main cabinet

+GEN-F003: E-stop operated at the control desk

+GEN-F004: E-stop operated - customer

+GEN-F005: E-stop operated - 4




+GEN-F009: Unlock safety guard

+GEN-F010: Reset emergency stop

+GEN-F011: unlock E-stop, area -3-

+GEN-F012: unlock E-stop, area -4-

+GEN-F013: fault at ASi network -1-



+GEN-F016: fault at DeviceNet network

+GEN-F017: control voltage 24V DC missing - P1, inputs

+GEN-F018: control voltage 24V DC missing - safety lightbeams

+GEN-F019: control voltage 24V DC missing - Outputs area 1, safety guard

+GEN-F020: control voltage 24V DC missing - Outputs area 2, E-stop

+GEN-F021: control voltage 24V DC missing - Outputs area 3

+GEN-F022: control voltage 24V DC missing - Outputs area 4

+GEN-F023:

+GEN-F024:

+GEN-F025: control voltage 230V AC missing - general

+GEN-F026: control voltage 230V AC missing - area -1-, safety guard

+GEN-F027: control voltage 230V AC missing - area -2-, E-stop

+GEN-F028: control voltage 230V AC missing - area -3-

+GEN-F029: control voltage 230V AC missing - area -4-

+GEN-F030:

+GEN-F031: Communication fault (Alliance)

+GEN-F032: ETH. Switch not OK

+GEN-F033: Safety guard door opened -SG1 / 1 ( Swingdoor )

+GEN-F034: Safety guard door opened -SG1 / 2




+GEN-F038: safety guard door opened -SG1 / 6



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+GEN-F049: safety lightbeam tipped - area -1-, pallet infeed

+GEN-F050: safety lightbeam tipped - area -1-, pallet outfeed







+GEN-F057:

+GEN-F058:

+GEN-F059: starting inverters - area -1-




+GEN-F063:

+GEN-F064:

+GEN-F065: motor protection tripp - general

+GEN-F066: motor protection tripp - area 1




+GEN-F070:

+GEN-F071:

+GEN-F072:

+GEN-F073: brake resistor thermocontact - general

+GEN-F074: brake resistor thermocontact - area 1 (hooding frame)

+GEN-F075: brake resistor thermocontact - area 2



+GEN-F078:

+GEN-F079:

+GEN-F080: circuit breaker tripp - general

+GEN-F081: frequency inverter tripp -general

+GEN-F082: frequency inverter tripp -area 1



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+GEN-F086:

+GEN-F087:

+GEN-F088:

+GEN-F089: thermal protection tripp - general

+GEN-F090: thermal protection tripp - area 1




+GEN-F094: ETHERNET Devices fault - Area 1

+GEN-F095: ETHERNET Devices fault - Area 2

+GEN-F096: PLC - HMI communication timeout

+GEN-F097: DeviceNet Slave fault -Add. 0
















+GEN-F113:

+GEN-F114:

+GEN-F115:

+GEN-F116:

+GEN-F117:

+GEN-F118:

+GEN-F119:

+GEN-F120:

+GEN-F121:

+GEN-F122:

+GEN-F123:

+GEN-F124:

+GEN-F125:

+GEN-F126:

+GEN-F127:

+GEN-F128:

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+GEN-F129:

+GEN-F130:

+GEN-F131:

+GEN-F132:

+GEN-F133:

+GEN-F134:

+GEN-F135:

+GEN-F136:

+GEN-F137:

+GEN-F138:

+GEN-F139:

+GEN-F140:

+GEN-F141:

+GEN-F142:

+GEN-F143:

+GEN-F144:

+GEN-F145:

+GEN-F146:

+GEN-F147:

+GEN-F148:

+GEN-F149:

+GEN-F150:

+GEN-F151:

+GEN-F152:

+GEN-F153:

+GEN-F154:

+GEN-F155:

+GEN-F156:

+GEN-F157:

+GEN-F158:

+GEN-F159:

+GEN-F160:

+GEN-F161: ASi Slave fault 1 / 0












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Film supply

+FS-F001: missing product information on covering place

+FS-F002: missing product information on place before

+FS-F003: compressed air pressure low or missing

+FS-F004: head not in start position

+FS-F005: knife is not in startposition

+FS-F006: rotation control hood storage

+FS-F007: position control hood storage

+FS-F008: temperature controller tripped

+FS-F009: welding bar is not closed

+FS-F010: welding bar is not opened

+FS-F011: rotary control suction tube adjustment transversal motor

+FS-F012: position control suction tube adjustment transversal motor

+FS-F013: suction tubes are not closed

+FS-F014: suction tubes are not opened

+FS-F015: timeout film welding (max welding time)

+FS-F016: rotation control suction tube adjustment longitudinal left

+FS-F017: position control suction tube adjustment longitudinal left

+FS-F018: rotation control suction tube adjustment longitudinal right

+FS-F019: position control suction tube adjustment longitudinal right

+FS-F020:

+FS-F021: reference drive, only slow speed possible!

+FS-F022: rotary control rubber coated roll

+FS-F023:

+FS-F024:

+FS-F025:

+FS-F026: rubber coated roll max running time

+FS-F027:

+FS-F028: filmroll is nearly empty -A-

+FS-F029: filmroll is nearly empty -B-

+FS-F030: filmroll is nearly empty -C-

+FS-F031: filmroll is nearly empty -D-

+FS-F032: filmroll drive timeout (max.running time)

+FS-F033: falling arrestor on head is not opened!

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+FS-F034: falling arrestor on head is not closed!

+FS-F035:

+FS-F036: Machine could not select the film, bacause film racks are bad

configuration +FS-F037: film format selection is not in -A- position (pneumatic)

+FS-F038: film format selection is not in -B- position (pneumatic)

+FS-F039: film format selection is not in -C- position (pneumatic)

+FS-F040: film format selection is not in -D- position (pneumatic)

+FS-F041: inverter tripp: rubber coated roll drive

+FS-F042: inverter tripp: filmroll drive

+FS-F043: inverter tripp: suction tube adjustment transversal drive

+FS-F044: inverter tripp: suction tube adjustment longitudinal-Left-

+FS-F045: inverter tripp: suction tube adjustment longitudinal-right-

+FS-F046: inverter tripp: suction tube blower

+FS-F047: inverter tripp: hood storage movement

+FS-F048:

+FS-F049:

+FS-F050:

+FS-F051:

+FS-F052:

+FS-F053:

+FS-F054:

+FS-F055:

+FS-F056:

+FS-F057: motor protection: rubber coated roll drive inverter

+FS-F058: motor protection: rubber coated roll drive -A/B-

+FS-F059: motor protection: rubber coated roll drive -C/D-

+FS-F060:

+FS-F061:

+FS-F062: motor protection: Rubber coated roll drive inverter

+FS-F063: motor protection: Rubber coated roll drive -A-

+FS-F064: motor protection: filmroll drive -B-

+FS-F065: motor protection: filmroll drive -C-

+FS-F066: motor protection: filmroll drive -D-

+FS-F067: motor protection: suction tube adjustment transversal inverter

+FS-F068:

+FS-F069: motor protection: suction tube adjustment longitudinal-left

+FS-F070: motor protection: suction tube adjustment longitudinal-right

+FS-F071: motor protection: fan inverter

+FS-F072: motor protection: fan -1-




+FS-F076: motor protection: hood storage movement inverter

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+FS-F077:

+FS-F078:

+FS-F079:

+FS-F080:

Hooding Frame

+HF-F001: safety scanning -1- occupied (interlock move down)

+HF-F002: safety scanning -2- occupied (interlock move down)

+HF-F003: film grippers are not in position

+HF-F004: frame is not in start position

+HF-F005: unlock falling arrestor

+HF-F006: reference drive, only slow speed possible!

+HF-F007: frame lifting belt/chain control -1-

+HF-F008: frame lifting belt/chain control -2-

+HF-F009: rotary control liftmotor hooding frame

+HF-F010: position control liftmotor hooding frame

+HF-F011: rotary control length adjustment

+HF-F012: position control length adjustment

+HF-F013: rotary control width adjustment -1-

+HF-F014: position control width adjustment -1-

+HF-F015: rotary control width adjustment -2-

+HF-F016: position control width adjustment -2-

+HF-F017:

+HF-F018:

+HF-F019: Gripper arm -1- lifted up!

+HF-F020: Gripper arm -2- lifted up!

+HF-F021: safety endswitch width adjustment -1- (over reference point)

+HF-F022: safety endswitch width adjustment -2- (over reference point)

+HF-F023: safety endswitch length adjustment (over reference point)

+HF-F024: safety endswitch liftmotor hooding frame at top (over reference)

+HF-F025: contour scanning -1- (length left)

+HF-F026: contour scanning -2- (length front)

+HF-F027: contour scanning -3- (length right)

+HF-F028: contour scanning -4- (length rear)

+HF-F029: film control sensor -1-




+HF-F033: safety endswitch liftmotor hooding frame at bottom

+HF-F034: frame falling arrestor is not working! (opening timeout)

+HF-F035:

+HF-F036:

+HF-F037:

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+HF-F038:

+HF-F039:

+HF-F040:

+HF-F041: inverter tripp: liftmotor hooding frame

+HF-F042: inverter tripp: length adjustment

+HF-F043: inverter tripp: width adjustment -1-

+HF-F044: inverter tripp: width adjustment -2-

+HF-F045:

+HF-F046:

+HF-F047:

+HF-F048:

+HF-F049:

+HF-F050:

+HF-F051:

+HF-F052:

+HF-F053:

+HF-F054:

+HF-F055:

+HF-F056:

+HF-F057: motor protection: liftmotor drive inverter

+HF-F058: motor protection: liftmotor -1-

+HF-F059: motor protection: liftmotor -2-

+HF-F060: motor protection: length adjustment drive inverter

+HF-F061: motor protection: width adjustment -1- drive inverter

+HF-F062: motor protection: width adjustment -2- drive inverter

+HF-F063:

+HF-F064:

+HF-F065:

+HF-F066:

+HF-F067:

+HF-F068:

+HF-F069:

+HF-F070:

+HF-F071:

+HF-F072:

+HF-F073:

+HF-F074:

+HF-F075:

+HF-F076:

+HF-F077:

+HF-F078:

+HF-F079:

+HF-F080:

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Pallet transport

+PT-F01: Conveyor at hooding place not in Position +PT-F02: Please check the positioning sensor to covering place

+PT-F03: Rotary control covering place conveyor

+PT-F04: Missing information at hooding place

+PT-F05: Missing information on centering place

+PT-F06:

+PT-F07:

+PT-F08:

+PT-F09:

+PT-F10: Pallet centering is not at back

+PT-F11: Pallet measuring finger is not at back (timeout)

+PT-F12: Pallet measuring finger is not at front (timeout)

+PT-F13: Pallet measuring long cylinder is not at home position (timeout)

+PT-F14:

+PT-F15: Position control Position control HMD lift

+PT-F16: Rotary control Rotary control HMD lift

+PT-F17: Turnarm -1- is not closed








+PT-F25: Turnarm -1- is not opened








+PT-F33: Pos.1 disconnect switch turned off

+PT-F34: Pos.6 disconnect switch turned off

+PT-F035:

+PT-F036: Inverter startup, please wait (Area 1)

+PT-F037:

+PT-F038:

+PT-F039:

+PT-F040:

+PT-F041: Inverter tripp - Covering place conveyor

+PT-F042: Inverter tripp - Centering place conveyor

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+PT-F043: Inverter tripp Height meassuring device

+PT-F044:

+PT-F045:

+PT-F046:

+PT-F047:

+PT-F048:

+PT-F049:

+PT-F050:

+PT-F051:

+PT-F052:

+PT-F053:

+PT-F054:

+PT-F055:

+PT-F056:

+PT-F057:

+PT-F058:

+PT-F059:

+PT-F060:

+PT-F061:

+PT-F062:

+PT-F063:

+PT-F064:

+PT2-F65: Inverter startup, please wait (Area 2, outside)

+PT2-F66: Inverter tripp - Conveyor Pos.1

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10.5 Further faults

10.5.1 General Faults

10.5.1.1 General

General fault can be caused. It should be pointed out here that a properly maintained machine is a precondition for its proper and reliable function (see chapter 9 Mainte-

nance).

10.5.1.2 Load not centered

CAUTION

Danger due to uncentered pallets!

Not centrically positioned pallets can cause severe damage to the

MSK packing system!

► Transport the pallet in manual mode to the next removal sta-

tion!

► Remove the pallet and set down in the upstream of pallet cen-

tering!

► Switch the system back to „Automatic“.

Contour monitoring ensures that only loads centered on the pallet are packed. Should

a load not centered on the pallet enter the hooding station due to a pallet fault or faulty

pallet loading, the machine will stop and an error message is displayed.

• Switch off the machine as described in chapter 8.1.11

• Reposition the load

• Leave the safety area and close the gates in the safety fence

• Restart the machine as described in chapter 8.1.4.

• Carry out contour monitoring again in manual mode

• If the load is now centered on the pallet, the machine can be switched to automatic

mode again

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10.5.1.3 Gate in safety fence open

Gates for safety fences supplied by MSK are equipped with a safety limit switch. If a

gate is opened, the machine switches off. Restarting is only possible when all the safe-

ty fence gates have been closed and the safety fence area has been enabled again

at the control console.

DANGER

Danger when standing in the safety area!

There is a serious danger if persons are allowed to remain in the safety area when the machine is switched on!

► Close the safety fence gates only when you are sure that no-

one is in the safety area inside the safety fence!

ATTENTION







the "Start/ automatic" (see chapter 8.1.8), as opening the safety fence gates results in an immediate stoppage of the machine as for an emergency stop.

NOTE

Confirm closing of the safety fence gates by turning the preselec-

tor switch to the corresponding position or by pressing the push- button!

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10.5.1.4 Emergency stop tripped

When the Emergency stop button is pressed, all movements of the machine are

stopped (pneumatic cylinders end their stroke on reaching the end position). For re- actions after tripping the Emergency stop circuit, see chapter 2 Safety.

10.5.1.5 Miscellaneous

If the fault cannot be exactly localized, the packaging machine must be brought to its

home position using the preselection function (see chapter 8.1.7) and automatic mode

started again. If the source of the fault cannot be identified or remedied, please contact

MSK After-sales Service.

10.5.2 Stretch film

10.5.2.1 General

DANGER





NOTE


values of the film.




In order to avoid faults in the film run, always pay attention to good film quality. The following are characteristics of good quality, i.e.:

– Low tolerance in the film opening dimension (>1” (25 mm))

– Low tolerance in the film thickness

– The film should be wound onto the reel with straight edges

– The film should not stick on the inside and in the side pleats (anti-blocking agent!)

Observe here also the general inspection and maintenance points in chapter 9.

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NOTE

Use only films from the same film manufacturer that MSK provided for commissioning and testing.

If films from other manufacturers or of other qualities are used,

the parameters may have to be modified.

10.5.2.2 Film tears during stretching

First check whether the film dimensions stipulated in chapter 4 Technical Data have been observed. If the film dimensions correspond to the specified values, the film qual-

ity is probably poor (visual inspection of the film for thin spots).

10.5.2.3 The film hood is not drawn optimally over the goods to be packed

A precondition for optimum fitting of the film hood over the pallet and load is the exact

alignment of all the elements of the packaging machine. This includes:

– Exact installation of the MSK packaging machine (in particular the MSK Tension- tech and the conveyor at the hood fitting station) according to the installation plan (see chapter 4 Technical Data)

– Horizontal positioning of the tensioner frame

– Correct threading of the film according to the film threading plan

– Properly centered film reel

If the MSK packaging machine is properly adjusted, check compliance with the specified load and film dimensions again (see chapter 4 Technical Data). Furthermore,

check whether the pallet is properly centered at the hood fitting station. If this is not

the case, the reason for this must be determined (e.g. a defective pallet) and the pallet

properly centered.

10.5.2.4 The film is not cut off cleanly

Inspect the 10-blade knife. If the cutting side is blunt, the knife can be turned and the

film cut with the other side of the knife.

WARNING

Risk of injury from sharp knives!

The film knife is very sharp. There is a risk of serious cuts!

► Wear suitable protective gloves.

► Leave the knife covers closed!

NOTE

It is expedient to always turn the 10-blade knife in the same direc-

tion (e.g. in clockwise direction).

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10.5.2.5 Film is not or not completely sealed

If the Teflon tape, the silicone rubber or the heater wire are damaged, replace these

parts. In addition, check the sealing bar pressure.

CAUTION

Danger from hot surfaces!

Touching the hot sealing bar can result in severe burns!

► Do not touch the hot sealing bar!

► Allow the sealing bar to cool down to < 140° F (60° C)!

► Wear protective gloves.

10.5.2.6 The film jams

First check whether the fold cutter is in the side fold of the film tube. The function of

the fold cutter is to open the side fold and to guide the film.

Fig. 10.1 Adjustment of the fold cutter

In addition, check the film threading against the film threading plan.

NOTE

Always pay attention to good film quality!

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Operating Manual

MSK Tensiontech Spare Parts

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11 Spare Parts

The complete spare parts list (spare parts are marked with E, recommended spare

parts with EE and maintenance parts are marked with W) gives an overview of all the

main parts installed in the machine with drawings and lists for the individual assem-

blies. As the delivery time for the motors can be up to 12 weeks, we recommend that you

have one of each type in stock.

When ordering spare parts, please indicate the designation, article number and desired quantity of the corresponding article.

The spare parts documentation for the individual components is arranged according

to the sequence of the components on the installation plan in chapter 6.7.

The MSK packaging machine consists of the following components:

• Pos. 1: Roller conveyor


• Pos. 3: Pallet-Centering system

• Pos. 4: MSK Hooding conveyor

• Pos. 5: MSK Tensiontech packaging machine MSK371


• Pos. 8: Electrical cabinet

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Operating Manual

MSK Tensiontech Spare Parts

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11.1 Spare parts list

Operating Manual

Annex Manufacturers' Documents MSK Tensiontech

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12 Annex Manufacturers' Documents

12.1 Motors

Article Manufacturer installed Type Present yes x

no -

Low-pressure fan Elektror in the carriage of the packaging

machine

D06 X

Drives SEW Lift motor of the packaging machine

X

12.2 Pneumatics

Article Manufacturer Installed Type Present

yes x no -

Valve/installation

island

Festo Pneumatic

controller of the packaging machine

CPE X

Cylinders Festo in the film feeder, hood fitter and

other pneumatic

installations

DHC, DSNU, Short-stroke

cylinders

X

DNCB X

ADN X

Linear cylinders Festo Film knife drive in

the welding beam of the film feeder

DGC X

DGP -

Valves Festo Pneumatic installa-

tion

5/2 and 5/3

way direc-

tional control

valves

X

Air conditioner Festo Pneumatic installations

MSB6-1/2

X

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12.3 Electrical Installation

Article Manufacturer Installed Type present

yes X

no -

Text display Siemens Switching cabinet/ Operating console

TP177B -

Excell Operating console PH IP67 -

Allen Bradley Switching cabinet/

Operating console

PV 700 X

PV 1000 -

Proximity switch Balluff Position detection

Pulse counting

BES M18 MI

-

Schönbuch IBCT 181506

181406

-

Telemecanique XS1-M18 -

IFM IGA M18 X

Truck BI5U M18 X

Frequency converter SEW Switching cabinet MOVITRAC

MC07B -

MDX61 -

Altivar Serie 31 -

Allen Bradley PowerFlex

40

X

PowerFlex

70

X

Safety emergency stop relays

Telemecanique Switching cabinet XPS-ECP

XPS-AR

XPS-AV

-

Allen Bradley MSR142R TP

X

Reflection light barriers

Sick Positionserkennung, Platzabfrage

WL 280 X

Safety light barrier Sick Light barrier for personnel protection,

monitoring of the safety

fence openings at the

inlet and outlet of the

packaging machine

M40Z X

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Article Manufacturer Installed Type present

yes X

no -

Control unit welding beams

Ropex Res 403 -

Res 406 -

Allen Bradley 900-TC16 X

Air conditioning system

Rittal Switch cabinet SK 3110 X

AS-i bus Siemens Packaging machine X

Hand-held welding tongs

HAWO Welding aid -

Polystar X

12.4 Lubrication

Article Manufacturer installed Type

Liquid grease Setral Lubrication of the chains 54 NF

Star guide rail

Rexroth Star – Film feeder head

– Fitting frame

Stretch Packaging Machine Operating Manual

Documents

Transcript of Stretch Packaging Machine Operating Manual