AMP SmartWrapper 60 Manual

SmartWrapper 60
Overwrapping Machine
Operation & Setup Manual
Advanced Media Products, Inc.
Phone: [phone] Fax: [phone]
www.advancedmediausa.com

SmartWrapper 60 Operation Manual
Contents
Theory of Operation
1. Control System
1.1 Control Panel
1.2 Speed Adjusting
1.3 Cams & Levers
2. Feeding System
2.1 Hopper, Pusher & Box Lifter
2.2 Safety Device for Pusher (pre 2008)
2.3 Safety Device for Pusher (post 2008)
3. Overwrapping Film Feeding
3.1 Film Feeding
4. Tear Tape Feeding
4.1 Tear Tape Feeding
5. Film & Tear Tape Cutting
5.1 Film Cutting
5.2 Tear Tape Notch
6. Wrapping Parts Assembly
6.1 Wrapping parts descriptions
6.2 Wrapping parts adjustments
6.3 Side Sealers
7. Other Adjusting System
7.1 Film Length
7.2 Pusher Adjustment
7.3 Cutting Blade Adjustment
7.4 Rear Seal Folding Adjustment
7.5 Blade Height
7.6 Box Lifter Adjustment
7.7 Film side to side adjustment
7.8 Missing Disc Sensor
7.9 Change over instructions
7.10 Lubrication Guide
7.11 Replacement of Rear Seal Heater
8 Trouble Shooting Guide
8.1 Reference Data
8.2 Common Problems

1
Theory of Operation
The Smartwrapper 60™ is a single motor driven polypropylene over wrapping machine with the
built-in ability to add a tear tape for easy packaging opening. It is powered by 220 volt AC single
phase, consuming 2500 watts. The Smartwrapper 60 is adjustable to accommodate a package
size up to 30 mm high, 220 mm wide and 145 mm long. It is variable speed up to 50 pieces per
minute.
The machine utilizes a series of cams and levers to minimize the need for complex electrical
sensors and logic circuits. This allows the machine to run continuously with a minimum of
downtime for maintenance. No air is required.
The single motor drives a shaft with nine cams, each cam controls a function of the machine.
Levers running on the cams connect to the various parts of the machine to move the product
through the machine and wrap poly film around it.
The product to be wrapped is stacked in the hopper. The box lifters (one on each side of the
hopper) lift the stack of boxes, leaving one on the bottom to be pushed through the hopper exit
guides by the Pusher Bar.

2
The hopper exit guides set the box up to be centered down the product path.
A set of fingers reach up to pull a section of film down. When the finger reach the bottom the
cutting blade cuts the film. The box is then pushed under the brush and the film is wrapped
around the box. The box is pushed to the next station under the Box Float. The box float holds the
box in position as the rear folder comes down and folds the top flap of the film. The rear sealer
then rises up to fold the bottom flap and seal the rear of the box.
As the box is pushed through to the next station, the side folder fold the sides of the film up and
down respectively. The side tuckers tuck the small flap of film at the end. The box is then pushed
to the side heaters by another box coming down the product path. The side heaters move in and
touch the sides of the box to seal the film. The cycle keeps repeating until all boxes are wrapped.
Note! –The machine works best if the supplier of boxes and film do not change. This allows the
machine to be optimized for a particular box and will give the best results.

3
1. Control System
1.1 Control Panel
A B C D E
F G H I J K L M
N
A. Left Sealer Thermometer
B. Right Sealer Thermometer
C. Rear Sealer Thermometer
D. Tear Tape Sealer Thermometer
E. Cycle Counter
F. Manual Controller Socket
G. Manual /Auto Switch
H. Main Power Switch
I. Emergency Stop Button
J. Start Button
K. Stop Button
L. Side & Rear Sealer Heaters On/Off Switch
M. Tear Tape Heater On/Off Switch

4
N. Missing Disc Sensor On/Off (Optional)

5
Manual Controller
The manual controller will only function when the “manual/auto” switch is set to the manual
position (see previous page). Normal (Forward) mode can be controlled by pushing the “Start”
and “For” buttons simultaneously, Reverse mode can be controlled by pushing the “Start” and
“Rev” buttons simultaneously. The reverse mode is useful when a jam occurs to clear the broken
box from the product path.
Caution! - When using the manual control, all the safety switches are bypassed.
***The door safety switch and auto-stop safety switch are turned off when using the
manual control.***

6
1.2 Speed Adjusting
The speed of this machine is controlled by Inverter (Mitsubishi FR-S520S-1.5K)..
Mitsubishi Inverter FR-S520-1.5K
To adjust the speed
1. Turn the dial to adjust the desired frequency output to the motor. Turn the dial
clockwise to increase the frequency (and speed up the machine) or vice versa.
2. To save the new speed adjustment, press the set button.
Please note that the default setting is 65.0Hz, the approximate operating speed is 50
pcs./min.
CAUTION! –Running the Inverter faster than 65 Hz may damage motor and void the
warranty.

7
1.3 Cams & Levers
A B C D E F G H I
A. Pusher Bar
B. Clamp close/release (used for film wrap adjustments)
C. Box Lifter
D. Rear Sealer Folding Plate
E. Rear Folding Plate
F. Film Cutting Blade
G. Film Length
H. Sides Folding Block
I. Sides Sealers

8
2. Feed System
2.1 Hopper, Pusher & Boxes Lifter
Loosen the locking screws
to adjust the hopper for different
size products.
Pusher Bar (under safety cover)
WARNING! - DO NOT RUN
MACHINE WITHOUT SAFETY
COVER!
Box Lifter

9
2.2 Safety Device for Pusher (Pre 2008 Machines)
When products jam during the automatic mode, the machine will stop automatically and the Jam
Indicator will flash.
Jam Indicator
To restart the machine
1. Clear the jammed product.
2. Push the lever in the direction shown so that the mechanical safety device returns to its
original position. You will feel a click when it is fully seated.
3. Run the machine with the manual control to check that the settings have not changed so as
to avoid jamming again.
4. Press start to restart the machine.
Lever connected to pusher bar
(Push this direction to reseat after jam)
Micro Switch
Mechanical Safety Device

10
2.3 Safety Device for Pusher (Post 2008 Machines)
When products jam during the automatic mode, the machine will stop automatically and the Jam
Indicator will flash.
Jam Indicator
To restart the machine
1. Clear the jammed product.
2. The safety device will reset itself.
3. Run the machine with the manual control to check that the settings have not changed so
as to avoid jamming again.
4. Press start to restart the machine.
Lever connected to
pusher
Mechanical Safety Device
Micro Switch

11
3. Overwrapping Film Feeding
3.1 Film Feeding
Film Holder Film Tension Rollers Cutting Blade
Film Feeding Diagram
Film Feeding Direction

12
4. Tear Tape Feeding
4.1 Tear Tape Feeding
The tear tape feeding includes
1. Tear Tape Holder
2. Tear Tape Guides
3. Tear Tape Sealer
4. Position Adjusting Screw
2. Tear tape guides
1 Tear tape holder
3. Sealer
4. Position adjusting
screw
Tear Tape Feeding Diagram
IMPORTANT! Twist the tape to turn it upside down

13
5. Film Press & Tear Tape Cutting Assembly
Tear Tape Cutter
Tie Bar connected to
Tear Tape Cutter
Film feeds between
these plates
Film Press –Holds the
film from going
backwards
Film Guiding Plate
Cutting Blade
(upper)
Cutting Blade
(lower)

14
5. Film Press & Tear Tape Cutting Assembly (continued)
Adjusting Spring Upper Blade
NOTE! –Only adjust if film not cutting. Use caution when adjusting. You should go in 20°
increments or less, if you twist more than 20°, you may go past the correct setting.
Your locking nuts may vary from this picture.

15
5.2 Tear Tape Notch adjustment
Tear Tape Notch
Adjusting Notch vertically
1. Loosen the locking screw
2. Move the block vertically to
the desired position.
3. Relock the screw.
4. Adjust the tie bar to the
proper position for the notch
cut on the film.
Tie Bar Lock Screw Block
Adjusting Notch Horizontally
1. Loosen the lock screw
2. Move the column horizontally to
the desired position.
3. Relock the screw.
4. Adjust the tie bar to the proper
length
Lock Screw Column Tie Bar

16
6. Wrapping Assembly
6.1 Wrapping Parts Descriptions
Hopper Base Adjustment
Box Lifter Assembly
Guide block restrictor –
one end is set for DVD and
the other end is set for CD
boxes
Hopper Exit Guides –ensure the box is exiting from hopper straight, there is another one on the
other side.
Brush for CD box (two
pieces)
Brush for DVD box (three
pieces)
Lock nut for brush
assembly
Adjustment nut –set the
brush to touch the box
top, this gives friction to
the film wrap for proper
positioning.

17
6. Wrapping Assembly (continued)
Box Floater –this should just rest on the top of
the box
Locking nut for Box Floater
Spacer –change this for different size boxes
Adjustment Nuts for Box Floater
Rear Folding Blade –the pusher should stop
the box about 0.5mm past this part.
Side Tucker (brass colored piece) –This should
be 0.5mm away from box on each side.
Side Folders –These should be 1.0mm from
the box edge.
Side Sealers (under heat shield)–when in the
opened position they should be 1.5mm away
from each side of the box. When closed they
should touch the box.