Bosch Pack201hs User manual

www.boschpackaging.com

Client: Cadbury, Malaysia

Type: Pack201HS

Machine №: 8-114-406-036

Year of construction: 2015

These document are designed for purchaser of our machines only and may neither be

reproduced nor made know to third party without written approval

Instruction Manual

INSTRUCTION MANUAL

Robert Bosch Limited

Packaging Technology, Business Unit

Confectionary and Food

700/154 Moo 1 Amatanakorn Industrial Estate

Tambon Baankao, Amphur Panthong,

Chonburi 20160 Thailand.

Tel. No : +66 (0) 3846 5272

Fax No : +66 (0) 3846 5273



Instruction Manual



Machine

T

ype:

Cus

t

omer:

Machine Serial

N

o.



Order

N

o.



Pac

k201HS



Cadbury, Malaysia



8-114-406-036

P140047



Operation

and

maintenance

in

accordance

with

t

hese

instructions

is a

condi

-

tion of

t

he

guar

ant

ee.



This manual is

copyrighted

and is

supplied

solely for

t

he

purpose of

oper

at

-

ing and

maintenance

of

t

he

machine;

it

mus

t

not

be

provided to

or

made

available

to third

parties.

Manufacture

of any parts based on

this

manual

is

expressly forbidden

.



2012

Pack201 | Preface | Section 1 EN | 1

1

Table of Contents

1 Preface �� 3

1�1 General Information �� 3

1�1�1 Technical Assistance ��3

1�1�2 Instructions For Ordering Parts ��3

1�1�3 Disclaimer ��3

1.2 Machine Specications �� 4

1�2�1 Electrical ��4

1�2�2 Air Supply��4

1�2�3 Weight ��4

1�2�4 Noise Level ��4

1�2�5 Speed��4

1�2�6 Maximum Film Size ��4

1�2�7 Max Min Package Length��4

1�2�8 Dimensions��4

1�2�9 Machine name plate ��5

1�3 General Description �� 6

1�3�1 Standard Features��6

1�3�2 Optional Features��6

1�4 Installation�� 7

1�4�1 Place the Equipment ��7

1�4�2 Connect the Air ��8

1�4�3 Connect the Electricity��8

1�5 Disassembly, Storage & Conservation�� 8

Notes �� 9

Pack201 | Preface | Section 1 EN | 3

1 Preface

1.1 General Information

To all personnel who will be operating, servicing or

adjusting this equipment: DO NOT attempt any of

these operations until you have read and understood

the instruction manual and all other information

supplied with this equipment� Although the design

of this equipment incorporates safeguards to protect

operating and maintenance personnel, use extreme

care when operating, adjusting and or servicing the

equipment�

This document is intended for operating personnel,

maintenance technicians, service technicians from

Bosch Packaging Services, and service engineers from

Bosch�

The manuals and other documentation contain

information and drawings that may not be copied,

distributed, discussed with third parties, or used for

competitive purposes without written permission by

BOSCH Packaging Technology, Inc�

1.1.1 Technical Assistance

For customer convenience, technical assistance is

available from the Bosch Packaging Services help line

(715-243-2555) between the hours of 7:00 AM to 5:00

PM Central Standard Time, Monday through Friday�

1.1.2 Instructions For Ordering Parts

Always include the model and serial number of your

machine along with the part name and stock number

with every parts order�

Address orders to:

Bosch Packaging Services

869 South Knowles Ave�

New Richmond, WI� 54017 U�S�A�

Phone: 715-246-6511

Fax: 715-243-2513

1.1.3 Disclaimer

Bosch, in good faith, is providing information of a

technical nature, and details of the product and its

use� However, we acknowledged that there might

be errors or omissions in this manual� Operate at

all times with only Bosch-approved parts� Bosch

or its authorized distributors must carry out any

maintenance and service that is not identied in this

manual�

This manual was carefully written in order to assist the

reader in using the product� However, Bosch shall not

be liable for any loss or damage arising from use of any

information herein, errors or omissions in the manual,

or any incorrect use of the product whatsoever�

Pack201 | Preface | Section 1 EN | 4

1.2 Machine Specications

1.2.1 Electrical

The standard wrapper’s electrical requirements are as

follows:

• 230 VAC ±10%, 3 phase, 50/60 cycle

• Dedicated line from service entry

• Green wire tied directly to earth ground at service

entry

• No other equipment may use the ground wire

There are several ways that the machine can be

connected to the power source. Consult a qualied

electrician to make this decision�

1.2.2 Air Supply

The wrapper requires 6 bar, 80PSI minimum�

1.2.3 Weight

The weight of the machine, including its standard

features, is approximately 4000 pounds without the

infeed�

1.2.4 Noise Level

The noise generated by the machine when it is running

is less than 80 decibels�

1.2.5 Speed

The speed at which the wrapper can wrap product

depends in part on the type and diameter of the

crimper�

• Maximum 1-up (1 crimper per shaft) capacity is

150 packages per minute�

• Maximum 2-up (2 crimpers per shaft) capacity is

250 packages per minute�

1.2.6 Maximum Film Size

The maximum reel diameter is 400 mm; the maximum

reel weight is 35 kgs, and the maximum lm width is

650 mm�

1.2.7 Max Min Package Length

Crimper Dia� Length Max

# Crimpers Range Height

100mm 1 up 140-310mm 45mm

(3�9”) (5�5”-12�2”) (1�75”)

100mm 2 up 85-155mm 45mm

(3�9”) (3�35”-6�1”) (1�75”)

120mm 1 up 170-375mm 65mm

(4�7”) (6�7”-14�75”) (2�5”)

120mm 2up 90-185mm 65mm

(4�7”) (3�5”-7�25”) (2�5”)

150mm 1up 200-470mm 95mm

(5�9”) (8�25”-18�5”) (3�75”)

150mm 2up 110-235mm 95mm

(5�9”) (4�3”-9�25”) (3�75”)

180mm 1up 250-565mm 115mm

(7�0”) (9�8”-22�25”) (4�5”)

180mm 2up 130-280mm 115mm

(7�0”) (5�1”-11�1”) (4�5”)

1.2.8 Dimensions

Dimensions given are approximate� Machine options

and associated equipment will vary�

Machine length: Approximately 1500 mm (excluding

the infeed

Machine width: Approximately 550 mm

Machine height: Approximately 1500 mm

Pack201 | Preface | Section 1 EN | 5

1

2

3

4

5

7

8

FIG 1

6

1.2.9 Machine name plate

The machine name plate (Fig� 1) is located on the side of the electrical cabinet and contains the following informa-

tion:

1 Model: This is the machine model�

2 Machine serial number: This is the number under which the machine data are stored at Bosch�

3 Wiring Diagram: The electrical schematic for the machine�

4 Largest Motor Amps�: This is the maximum amount of amps the drive motor will draw�

5 Short Circuit Interrupt Amps: This is the maximum amps the main circuit breaker can handle�

6 Volts/Hertz/Phase: This is the voltage, frequency and phase required for the machine�

7 Fla/Watt: This is the full load amps or watts the machine can draw��

8 Short Circuit Current Rating: This is the lowest component short circuit rating on the panel�

Pack201 | Preface | Section 1 EN | 6

1.3 General Description

The Pack201 is a servo-driven wrapper intended to

lm-wrap a large variety of mid-size products such as

soft bakery items, trays, candy, biscuit stacks, and

non-food items� It may be hand-fed or used with simple

feeders�

1.3.1 Standard Features

• Compact, cantilevered design�

• 3 sets of longitudinal sealing nwheels in separate

hygienic housings�

• One reel holder with quick-clamp mechanism for

70 and 76 mm reel�

• Broken lm detection.

• Balance arm (torsion-spring loaded with break)�

• Film roller adjustable from the front�

• Quick-exchange former/folding box�

1.3.2 Optional Features

• Second reel holder with manual splice table�

• Brackets for coder mount�

• End of lm and lm breakage detection.

• Automatic pneumatic lm splicer.

• Power feed roll with pinch roller, which can be

manually lifted�

• First nwheel can be canted during production to

control package tightness�

• Air evacuation device for tight packages�

• Gusseting device�

• Delta hole punch�

• No product - no package�

• No gap - no seal�

• Air reject of incorrect packages (out of registration

lm splice, uncut packages).

• Adjustable former/folding box�

• Available in stainless steel�

Pack201 | Preface | Section 1 EN | 7

1.4 Installation

DANGER

Although the design of this equipment

incorporates safeguards to protect

operating and maintenance personnel,

care must always be used when

operating, adjusting, and/or servicing� If

extreme care is not taken, a very serious

or fatal injury may result�

Remove the wrapper from the shipping crate and

check it carefully for any damage� If damaged, notify

the carrier immediately to le a claim. Contact Bosch

for further instructions if the damage is extensive�

Make sure all items that are listed on the packing slip

are received� Remove all packing material, chips, nails

etc� from the equipment�

1.4.1 Place the Equipment

The wrapper is shipped with crossbars for moving and

positioning� To lift the machine off of the pallet using

a fork lift, bolt the crossbars under the main section of

the frame� Position the forks under the crossbars, not

directly under the machine frame�

Check all access ways, from the shipping and receiving

dock to the installation location to ensure that they are

wide enough for the machine to pass through�

Move the wrapper and all related equipment to the

production area�

DANGER

When lifting, be sure to use a lifting de-

vice rated to handle the machine’s weight

(approximately 4,000 pounds without the

infeed)�

Align the machine with the upstream and downstream

equipment and place the wrapper� Level the wrapper

by using a wrench on the ats of the adjusting legs to

turn the legs� If equipped with optional casters, make

sure that the casters are not touching the oor; the

wrapper must rest only on the adjusting legs� Remove

the crossbars�

If the Infeed conveyor was detached for shipping or

there is an automatic feeder, position and attach to

the wrapper’s receiving conveyor plate� After attach-

ing, level the infeed conveyor with the adjusting legs

as with those on the wrapper�

Pack201 | Preface | Section 1 EN | 8

1.4.2 Connect the Air

Connect the air supply to the pneumatic assembly�

The main regulator is located behind the backstand�

The regulator is factory-set to 60 PSI and should not

have to be adjusted�

1.4.3 Connect the Electricity

Refer to the electrical schematics in the Parts Manual�

All work must be performed only by a qualied

electrician�

1� Make sure all the switches are OFF�

2� Locate the electrical connections inside the

enclosure to terminals L1, L2, L3 and GND�

3� Determine the best location for the plant’s

electricity supply to enter the wrapper’s electrical

enclosure� Drill an access hole�

4� Connect the green lead to GND�

5� Connect the black lead to L1�

6� Connect the white lead to L2�

7� Connect the red lead to L3�

8�

DANGER

To avoid a very serious or fatal shock

hazard, the line cord and the wrapper

must be attached to the building elec-

trical safety ground before making the

electrical connections� Connections must

be made by a qualied electrician and

in compliance with all national and local

codes�

1.5 Disassembly, Storage & Conservation

The machine should only be disassembled by trained

personnel� To disassemble the machine, follow the

instructions below�

1� Disconnect machine from all external power

supplies�

2� Switch off compressed air and remove the main

air hose�

3� Release all sprung parts and remove all torsion

springs�

4� Dispose of the material in accordance with local

regulations�

To keep the machine in working order if it is not in use

for an extended period, ensure the following:

• The storage area must be dry and clean�

• The machine should not be exposed to extreme

heat or cold�

• Place the machine on a at surface to prevent

torsion stress�

• Cover the machine to protect it from dust or dirt�

Pack201 | Preface | Section 1 EN | 9

Notes

Any information concerning this section or operation

of this equipment can be recorded on this page�

____________________________________________________________________________________________________________________________

Pack201 | Section 2 | Safety

EN | 1

2

Contents

2 Safety ��1

2�1 Safety Precautions ��1

2�2 Safety Symbols��2

2�3 Safety Equipment ��3

2�3�1 Emergency Stop Button ��3

2�3�2 Safety Interlocks��3

2�3�3 Main Disconnect and Lockout ��4

2�3�4 Maintenance Doors and Covers ��4

Notes ��5

Pack201 | Section 2 | Safety

EN | 1

2 Safety

2.1 Safety Precautions

DANGER

Failure to observe the dangers can result

in possible death or a very serious injury.

WARNING

Failure to observe the warnings can result

in a very serious injury.

CAUTION

Failure to observe the cautions can result

in damage to the equipment.

INFORMATION

Refers to a potentially harmful situation

which if not heeded might lead to damage

to the machine or its environment.

Familiarize yourself with the location and meaning of

the safety warning labels afxed to the machine.

Illustrations in this manual may show the equipment

without guards. This is for informational purposes

only. Guards must be in place before operating the

equipment.

NOTE: The use of any type of mechanical or

electrical spare actuator to bypass or disable the

safety interlocks on any guard door can result in a

very serious injury!

Do not operate the controls or wrapper until the

operating instructions have been thoroughly read and

understood.

Wrapper main power must be connected to the build-

ing electrical safety ground.

Do not operate the wrapper with guards removed or

with safety switches bypassed.

Main power must be disconnected and LOCKED OUT

before performing any maintenance, cleaning, or

adjusting.

Do not touch heated surfaces without wearing proper

protection.

Keep hands, hair and all loose tting clothing away

from moving parts.

Never activate any controls while other persons are

performing maintenance on the equipment.

Do not start the wrapper until all other personnel

in the area have been warned of start-up and have

moved outside the operating area.

Read and follow all warning labels on the wrapper

and all DANGERS, WARNINGS and CAUTIONS in the

instruction manual.

Pack201 | Section 2 | Safety

EN | 2

2.2 Safety Symbols

These symbols are afxed to the equipment where

potential danger to life and limb is indicated.

Particular attention must be paid in these areas and

personnel are to exercise extreme caution at all times.

All personnel must be fully informed of operational

safety instructions.

Symbol Signicance Symbol Signicance

Safety Alert Danger

Hot Surface

Danger

Electric

Voltage/Cur-

rent

Danger

Suspended

Load

Danger

Crushing

Hands

Danger

Explosive

Atmosphere

Danger

Irritating

Substances

Danger

Fire

Danger

Moving

Parts

Danger

Explosive

Substance

Danger

Corrosive

Substance

Lock out

Tag out

Pack201 | Section 2 | Safety

EN | 3

2.3 Safety Equipment

2.3.1 Emergency Stop Button

If an emergency stop button is pushed, the wrapper

will stop immediately without regard for the machine

position and timing. When the button is pushed, it

will remain in. The button must be either turned or

pulled out again before the wrapper can be started.

This button should be pushed in and the power source

disconnected and locked out before performing

any cleaning, maintenance or mechanical setup

procedures.

This button should not be used for normal stop

situations. Its may cause the wrapper to lose

synchronization.

2.3.2 Safety Interlocks

To prevent accidents, the wrapper is tted with safety

interlocks on the guards that must be kept closed dur-

ing operation.

Unauthorized opening of any interlocked guard leads

to an immediate stoppage of the wrapper. Do not use

these guards for a regular cycle stop.

Pack201 | Section 2 | Safety

EN | 4

2.3.3 Main Disconnect and Lockout

This main disconnect/lockout is on the endseal guard

on the back side of the wrap-

per and is used to disconnect

all power to the wrapper

circuits. If the wrapper con-

trols overload and the main

circuit breaker trips, move

this switch to the O (OFF)

position , open the electri-

cal enclosure door, reset the

breaker, then close the door

and turn back to 1 (ON).

Whenever performing maintenance on the

equipment, lockout power so that the equipment

cannot be cycled. Lockout the power according to

OSHA Standard 1910.147 by placing the switch in

the O (OFF) position and putting a lock through the

hole in the switch as shown.

The Main Electronic Enclosure has a Disconnect/

Lockout located on the Main Power switch and on

each door. If the machine overloads and the main

circuit breaker trips, move the switch to the OFF

position and lock it out before opening the electrical

enclosure door to reset the breaker.

2.3.4 Maintenance Doors and Covers

Doors that require a tool to open are for qualied

maintenance personnel only and for maintenance

purposes only. Do not open a door requiring a tool,

except for qualied personnel entrusted with the ac-

cess tool.

Lock

For example, the access tool is needed to open the

electronic enclosure door.

Pack201 | Section 2 | Safety

EN | 5

Notes

Any information concerning this section or operation

of this equipment can be recorded on this page.

____________________________________________________________________________________________________________________________

Pack201 | Operator Instructions | Section 3 EN | 1

3

Contents

3 Operator Instructions �� 2

3�1 Start of Production�� 2

3�2 Checks During Production�� 4

3�3 End of Production�� 5

3�4 Troubleshooting �� 6

3�5 Changeover�� 11

Notes �� 15

Pack201 | Operator Instructions | Section 3 EN | 2

3 Operator Instructions

3.1 Start of Production

Preparation

1� Check that there is enough sealing material and

double-sided tape (for the splicer option) on hand

for the day’s production�

2� Have scissors on hand to prepare the sealing

material�

3. Check that all protective covers are in place.

Close all moving covers and doors.

4. Put all guides in place and adjust them to suit the

packaging format.

5. Follow the settings list to set the correct format/

change parts, such as former, side guides, crimp-

er unit and so on, for the product being packaged.

6. Switch on the compressed air.

7. Release the emergency stop(s).

Install Sealing Material

1� Turn ON the main disconnect to apply power to

the control circuits�

2� Push the Emergency Stop button�

3� Remove the outside chuck from the lm spindle.

4� Place a roll of lm on the spindle and replace the

outside chuck� Turn to secure the chuck against

the lm roll.

5� Adjust the centering cone on the lm spindle as

needed�

6� Use the centering knob to nd tune the lm roll

position�

7� If necessary, reposition the inclination arm and/or

roller for proper lm ow.

WARNING

The rolls of sealing material can be heavy

and awkward to handle� Use some type of

lifting device to prevent a possible injury�

8� Move the balance arm until it locks in the down

position�

9� Thread the lm through the backstand rollers as

shown on the threading diagram�

10� Pull out the release rod to release the balance

arm�

11� Pull the lm through the former/folding box; bring

the two bottom edges together and draw them

through the rst set of nwheels.

12� Use the Finwheel Open/Close switch to close the

nwheels with the material between them.

Chuck

Centering Knob

Balance Arm

Pack201 | Operator Instructions | Section 3 EN | 3

13� Close the power feed roll (optional)�

14� Release the Emergency Stop button� There is

a two-second delay before the wrapper can be

started�

15� Jog the wrapper until the sealing material is

through the endseal�

Set Up Production

1� Select the desired recipe for the production run�

See Section 4 Operator Interface for a detailed

description�

2� Select the desired functions/parameters for the

production run�

3� Push the START button and run the wrapper for a

series of packages, then push STOP�

4� Examine the packages to make sure the lm is

centered and sealing properly�

5� Make adjustments to nseal and/or the endseal

components as needed�

6� Once everything is sealing properly, push START

and begin production�

Pack201 | Operator Instructions | Section 3 EN | 4

3.2 During Production

During production, periodically examing the following

items�

Examine both the endseals of the packages. If the seal

is not correct:

• Check the crimper temperature setting�

• Check for dirty crimpers

• Check the crimper clearance�

• Check the crimper pressure�

Examine the longitudinal seal on the package. If the

seal is not correct:

• Check the nwheel temperature setting.

• Check for dirty nwheels.

• If package is too loose, adjust the cant on the rst

nwheel assembly.

• If the lm edges are not even, turn the centering

knob to adjust�

Examine the lm ow into and out of the former/fold-

ing box. If lm is not owing properly:

• Check to make sure the material is centered and

remains mated properly in the former�

• Check the position of the inclination arm and

roller on the backstand�

• Check position and alignment of the former wings�

Prepare Second Film Roll

1� Mount the second lm roll on the backstand, if

equipped�

2� Unroll some lm until two registration marks can

be seen�

3� Cut the lm halfway between the two marks.

4� Apply double-sided tape 25 mm from the cut end

of the lm.

5� Trim off the corners of the lm.

6� Attach the new lm to the end of the old lm so

that the registration marks align�

Bosch Pack201HS User manual

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