DURAVANT Hamer 540 User manual

Rev.4
MODEL 540
OPERATION MANUAL
14650 28
th
Avenue North
Plymouth, MN 55447-4821 USA
TELEPHONE # [phone] [phone]
FAX # [phone]
WEBSITE: www.hamerinc.com
MADE
IN THE ***
USA

Rev.4
IMPORTANT
Some Machine Assembly drawings are labeled with a range of reference
Serial Numbers. Refer to the Serial Number Plate on your machine to relate to
the correct Machine Assembly drawing.
Those Machine Assembly drawings without reference Serial Numbers should
be current to your machine.
NOTE: All photographs and illustrations may not necessarily
depict actualmodels or equipment, but are intended for
reference only and arebased on the latest product
information available at the time ofpublication.
All product specifications are subject to change.
WARNING
PERSONAL INJURY MAY RESULT FROM DISREGARDING
THE FOLLOWING SAFETY PRECAUTIONS:
MACHINE IS TO BE PROPERLY CONNECTED TO YOUR BUILDING SAFETY GROUND.
READ OPERATION MANUAL THOROUGHLY BEFORE OPERATING THIS MACHINE.
DISCONNECT ELECTRICAL AND AIR POWER BEFORE PERFORMING MAINTENANCE
OR REPAIR WORK.
DO NOT OPERATE MACHINE WITH SAFETY GUARDS REMOVED.
MACHINE IS TO BE USED ONLY IN A MANNER OUTLINED IN THE OPERATION
MANUAL AND ONLY FOR THE PURPOSE FOR WHICH THE MACHINE WAS DESIGNED.
MODEL# __________________________________________________________
SERIAL# __________________________________________________________

TABLE OF CONTENTS
SECTION ONE
Model 540 Form, Fill & Seal Machine
•Machine Specifications..............................................................................................1
•Film & Bag Specifications........................................................................................1
•Film Roll Belt Path (Standard & High Speed Wind).................................................2
•Machine Layout.........................................................................................................3
•Operator Controls (Electrical Control Panel..............................................................4
Touchscreen Display – Operator Control Station............................................................ 6
•Operator Interface......................................................................................................6
•Main Menu.................................................................................................................6
•Setup Menu................................................................................................................7
•Dump Selector Menu.................................................................................................7
•Volumetric Filler Speed Control Menu.....................................................................8
•Top Sealer Speed Control Menu................................................................................8
•Side Sealer Setup Menu.............................................................................................9
•Side Sealer “ON” Delay Timer Menu........................................................................9
•Side Sealer “OFF” Delay Timer Menu......................................................................10
•Low Ice Delay Timer Menu.......................................................................................10
•Lubricator Timer Menu (Optional)............................................................................11
•Seal Wash Timer Menu (Optional)............................................................................11
•Bag Counter Menu.....................................................................................................12
•Bag per Minute Rate Counter Menu..........................................................................12
•Input / Output Monitor Menu.....................................................................................13
•Input Monitor Menu...................................................................................................13
•Output Monitor Menu.................................................................................................14
•Combined Input / Output Monitor Menu...................................................................14
•Machine Status Monitor Menu...................................................................................15
•Alarm Status Monitor Menu.......................................................................................15
•Low Roll Alarm Menu...............................................................................................16
•Double Dump Alarm Menu........................................................................................16
Programmable Logic Controllers.......................................................................................17
Horner
•Inputs..........................................................................................................................17
•Outputs.......................................................................................................................19
Allen Bradley
•Inputs...........................................................................................................................17
•Outputs........................................................................................................................19

Setting Up & Adjusting the Model 540 FFS.......................................................................21
•Installing Roll of Polyethylene Film...........................................................................21
•Loading Film into the Film Feed Belts.......................................................................22
•Positioning the Vertical Heat Seal..............................................................................22
•Positioning the Photo Eye Assembly..........................................................................23
•Positioning the Single Hole Punch.............................................................................23
•Positioning the Perforator Assembly..........................................................................23
•Air Pressure Regulator / Filter....................................................................................24
•Roll Holder.................................................................................................................24
•Photo Eye Detector Placement...................................................................................24
•Perforator Blade Adjustment & Replacement............................................................24
•Teflon Cloth................................................................................................................25
•Flow Controls.............................................................................................................25
•Film Feed Belts; Removal & Replacement................................................................26
•Film Roll Brake Cam..................................................................................................27
•Film Clamp................................................................................................................ 28
•Film Feed Chain Tension...........................................................................................28
•Jaw Air Cylinder Adjustment & Replacement...........................................................29
•Jaw Liner Alignment..................................................................................................29
•Jaw Liner Installation Instructions.............................................................................30
•Conveyor Adjustment................................................................................................30
•Prox Switch Activating Cam.....................................................................................30
•Product Slapper & Wiggler........................................................................................32
•Low Level Product Detector Sensitivity Setting........................................................31
Setting Up & Adjusting The Hot Air Sealer......................................................................33
•Setting Up the Hot Air Sealer....................................................................................33
•Shutting Down the Hot Air Sealer.............................................................................33
•Film Feed System.......................................................................................................34
•Film Feed Belt Tension..............................................................................................35
•Knurling Belts............................................................................................................35
•Machine Speed...........................................................................................................36
•Temperature Controller..............................................................................................36
•Air Pressure Regulator/Filter.....................................................................................36
Maintenance Instructions and Schedules...........................................................................37
Troubleshooting Guide........................................................................................................38
Parts Ordering......................................................................................................................44
SECTION TWO
Model 540 Machine Assembly Drawings
Warranty

Rev.4
SECTION ONE
MODEL 540
FORM, FILL AND SEAL MACHINE

Rev.4 1
MACHINE SPECIFICATIONS Also see machine layout for Power, Air and Water locations.
Power (Standard Requires one electrical drop of 230V, 60Hz, single phase
Requirements (SEE ELECTRICAL SCHEMATICS FOR FLA)
(Optional Requires one electrical drop of 220V, 50Hz, single phase
(SEE ELECTRICAL SCHEMATICS FOR FLA)
Air Requires one air drop: One 1/2” tubing (minimum with 3/4” NPT fitting,
Requirements 30 CFM at 80 PSI to the Form Fill & Seal Machine (total 30 CFM Dry Air.
Water Water supply with minimal pressure, ¼” tubing (maximum with 1/8” NPT fitting to
Requirements the Form, Fill, & Seal Machine. Recommended sediment filter and shut-off valve.
(Optional)
FILM & BAG SPECIFICATIONS
NOTES:
1. EYE MARK WILL BE 1/2" IN FROM SEAL - TOWARDS THE ROLL - REGARDLESS OF WHICH WAY THE ROLL IS WOUND.
2. EYE MARK TO BE DARK COLOR (BLACK PREFERRED).
. TO INSURE THAT YOU HAVE THE PROPER LEVEL OF CONTRAST BETWEEN THE BACKGROUND AND THE EYE MARK,
A TEST MUST BE CONDUCTED. IF YOU HAVE ANY DOUBT ABOUT HAVING ENOUGH CONTRAST, SEND SAMPLES TO HAMER LLC.
4. TINTED FILM MUST HAVE CONSISTENT TINT LEVEL - VARIATION CAUSES MISFIRE.
5. THE FILM MUST BE ABLE TO UNWIND FROM THE ROLL WITH A FORCE OF NO MORE THAN 8 POUNDS.
6. NO PRINT ALLOWED WITHIN SPECIFIED DIMENSIONS.
7. NO COATINGS, TREATMENTS, OR FINISHES, ETC. PERMITTED IN "NO PRINT AREAS" ON BOTH SIDES OF THE BAG.
(SEALABLE SURFACE REQUIRED FOR BONDING OF HANDLE FILM)
8. SEE PATCH FILM SPECS IN YOUR MANUAL(S) FOR ADDITOINAL REQUIREMENTS FOR THE HANDLE(S).
9. SEE BAG SPECS FOR THE BAG LENGTH / WIDTH DIMENSIONS.
10. WHEN ADDING ZIPPERS AN ADDITIONAL 1-1/4" OF FILM IS REQUIRED FROM THE STANDARD BAG SIZE.
11. ZIPPER MODULES ADD 40" TO THE LENGTH OF THE STANDARD 540 / 5 5 FFS MACHINES.
12. SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
FLAT BAG
WIDTH
14"- 5" MAX.
*
1
1
2
" MIN.
*
1" MIN. BETWEEN PRINT
FLAT BAG
LENGTH
*
4" MIN.
Ø 20" MAXIMUM
*
EYE MARK
DETAIL
**
Machine with 6” Flex Fill Opening
Bag Width: Minimum: 10-3/4”
Maximum: 18”
Bag Length: Minimum: 14”
Maximum: 35”
Poly Thickness: Minimum: 1.75 mil. Center Fold Film
Maximum: 4 mil. Center Fold Film
1.75 mil (minimum Center Fold Film.
4 mil (maximum Center Fold Film

Rev.42
FILM ROLL BELT PATH (STANDARD & HIGH SPEED)
HIGH SPEED
FILM ROLL BELT PATH
STANDARD
FILM ROLL BELT PATH

Rev.43
MACHINE LAYOUT
PRODUCT IN-FEED
2'-11"
2'-7"
CONTROL PANEL
230VAC, 1-PHASE
60HZ, 46FLA
(OPTIONAL: 50HZ, 46FLA)
SEE NOTE 5
AIR IN
30 CFM @ 80 PSI
1
2
" LINE MINIMUM
EXAUST VENT
3'-7"
3'-2"
FEED DIRECTION
4'-6" REF.
9" MIN
30" MAX
SEE NOTE 1
7'-6"
NOTES:
1) ALL DIMENSIONS ARE IN INCHES.
2) THESE DIMENSIONS CHANGE ACCORDING TO BAG SIZE, AND
SOME ADJUSTMENTS MAY BE REQUIRED.
3) THE MACHINE SHOULD BE LOCATED WITH A MINIMUM OF 3 FT.
CLEARANCE ON ALL FOUR SIDES
4) ALL AIR INPUTS REQUIRE CLEAN DRY AIR.
5) DO NOT DRILL HOLES IN THE TOP OR ANY SIDE OF CONTROL PANEL.
ALL WIRES MUST GO IN THROUGH THE BOTTOM OF THE CONTROL
PANEL. ANY MODIFICATIONS TO THE CONTROL PANEL
WILL VOID MANUFACTURES WARRANTY!
6) OPTIONAL REMOTE INSTALLATION OF ELECTRICAL PANEL AVAILIBLE.
7) SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.
*
AIR DROPS
ELECTRICAL DROPS
*
0" MIN.
2" MAX
SEE NOTE 1
0" MIN.
9" MAX.
*
*
*
1'-2"
FACTORY SET LEGS TO 3"
7'-9"
1'-2"
9'-8"
7'-0"
14'-5" 12'-10"

Rev.44
OPERATOR CONTROLS (Electrical Control Panel)
(Refer to the “Electrical Parts List for Schematic” when odering replacement parts for your control panel)
FIGURE ONE

Rev.45
OPERATOR CONTROLS (CONTINUED)
1. Low Level Indicator Light - when the light is “on” indicates that the level of product in the Volumetric
Hopper is below that of the Detector.
2. Side Seal Temperature Controller - controls the amount of heat required for the Vertical Heat Sealer to seal
the sides of a bag (See Figure Two). Proper setting will depend on bag rate (production rate), film thickness,
and type of film. Testing the bags at various temperature settings will yield the best results. 500°F is a good
starting temperature.
3. Top Seal Temperature Controller - controls the temperature level of the Heat Elements according to the
type of film used (See Figure Two).
4. Touchscreen Display - Operator Control Station allows the machine operator to access and change set up
parameters (ie. Timers, Alarms & Bag Counters).
5. Main Disconnect - shuts the machine down when the Control Panel door is open. Panel must be closed
and the disconnect turned to the “on” position before the machine will operate.
6. Top Sealer ON / OFF - switches off / on the Heat Elements and the Film Feed Motor that drives the Film
Feed Belts and Knurled Wheels (See Hot Air Sealer Set Up & Shut Down procedures).
7. Start Button -- one button on the Control Panel and one on the Remote -- with the Mode Selector Switch in
the Auto mode, depress the Start Button, this will activate the automatic operation of the machine. The Start
Button must be used to restart the machine whenever it has been stopped.
8. Hand / Auto Mode Selector Switch - one button on the Control Panel and one on the Remote – select the
Hand mode at one Selector Switch location for operation of the machine during film change. Switch both
Control Panel and Remote to the Auto mode for the machine to operate in automatic.
9. Jog Button - one button on the Control Panel and one on the Remote, another on the Rear Switch Box --
during the film change when the Selector Switch is in the Hand mode, the Jog Button is used to advance the
film through the machine.
10. Stop Button - one button on the Control Panel and one on the Remote, another on the Rear Switch Box --
when one of these buttons is depressed the machine will shut down after one complete machine cycle. All
buttons must be pulled out for the machine to operate.
11. Emergency Stop Button - when this button is depressed the machine will stop immediately. The button
must be pulled out to reset the machine to operate.
FIGURE TWO

Rev.46
TOUCHSCREEN DISPLAY – OPERATOR CONTROL STATION:
The following guide will help you understand the Touchscreen Display and assist you in setting up and
troubleshooting your machine.
When the main power is turned on to the machine, Touchscreen Display activates.
OPERATOR INTERFACE
This screen appears when the machine is powered up.
Press the BOTTOM RECTANGULAR Button or F1 to return to the Main Menu Screen regardless of what
screen is being viewed.
MAIN MENU
Press the RECTANGULAR Buttons to access the desired menu.

Rev.47
SETUP MENU
This screen accesses the Machine Set-up Functions and Timers.
Press the RECTANGULAR Buttons to access the desired menu.
DUMP SELECTOR MENU
This menu allows the Machine Operator to select the number of times the Volumetric will dump before the
bag will advance.
The average bags per minute rate that the machine is running is displayed in the Bottom Rectangular Box.
Press A NUMBER to select the number of dumps.
Press the RETURN Button to go back to the Setup Menu.

Rev.48
VOLUMETRIC FILLER SPEED CONTROL MENU
The Rotation Speed of the Volumetric Filler is controlled by this screen.
The speed can be changed by Pressing the RECTANGULAR BOX above the graph and entering the motor
speed (Hz) on the numeric key pad or by Pressing the SLOWER and FASTER Buttons to adjust the speed.
The average bags per minute is displayed in the Bottom Rectangular Box.
Press the RETURN Button to go back to the Setup Menu.
TOP SEALER SPEED CONTROL MENU
The belt speed of the Top Sealer is controlled by this screen.
The speed can be changed by Pressing the RECTANGULAR BOX above the graph and entering the motor
speed on the numeric key pad or by Pressing the SLOWER or FASTER Buttons to adjust the speed.
Press the RETURN Button to go back to the Setup Menu.

Rev.49
SIDE SEALER SETUP MENU
This screen accesses the Side Sealer Setup Timers.
Press the RECTANGULAR BUTTONS to access the desired Timer.
SIDE SEALER “ON” DELAY TIMER MENU
The Side Sealer “ON” Delay Timer is controlled by this screen. This timer controls the Time Delay before
the Side Sealer Solenoid turns on. The timer starts timing when the bag stops advancing and the Fill Opening
has opened.
The time can be adjusted by Pressing the TOP RECTANGULAR BOX and entering the time on the numeric
key pad or by Pressing the UP / DOWN ARROWS.
•Note: The time range is 0.20 seconds to 0.40 seconds.
The average bags per minute is displayed in the Bottom Rectangular Box.
Press the RETURN Button to go back to the Setup Menu.

Rev.410
SIDE SEALER “OFF DELAY TIMER MENU
The Side Sealer “OFF” Delay Timer is controlled by this screen. This timer controls the length of time that
the Side Sealer Solenoid stays on.
The time can be adjusted by Pressing the TOP RECTANGULAR BOX and entering the time on the numeric
key pad or by Pressing the UP / DOWN ARROWS.
•Note: The time range is 0.10 seconds to 1.50 seconds.
The average bags per minute are displayed in the Bottom Rectangular Box.
Press the RETURN Button to go back to the Setup Menu.
LOW ICE DELAY TIMER MENU
The Low Ice Delay Timer is controlled by this screen. This timer controls the length of time that the
Volumetric will continue to run after a low ice condition is detected.
The time can be adjusted by Pressing the TOP RECTANGULAR BOX and entering the time on the numeric
key pad or by Pressing the UP / DOWN ARROWS.
•Note: The time range is 1.00 second to 5.00 seconds.
The average bags per minute are displayed in the Bottom Rectangular Box.
Press the RETURN Button to go back to the Setup Menu.

Rev.411
LUBRICATOR TIMER MENU (OPTIONAL)
The (Optional) Water Lubricator time is controlled by this screen.
The time can be adjusted by Pressing the RECTANGULAR BOX and entering the time on the numeric key
pad or by Pressing the UP / DOWN ARROWS.
•Note: Timer range is 0.00 seconds to 1.00 seconds.
The average bags per minute are displayed in the Bottom Rectangular Box.
Press the RETURN Button to go back to the Setup Menu.
SEAL WASH TIMER MENU (OPTIONAL)
The (Optional) Seal Wash Timer is controlled by this screen. This timer controls the length of time that the
(optional) Seal Wash Solenoid stays on. The Seal Wash Solenoid starts when the bag begins to advance.
The time can be adjusted by Pressing the TOP RECTANGULAR BOX and entering the time on the numeric
key pad or by Pressing the UP\DOWN ARROWS.
•Note: The time range is 0.00 to 3.00 seconds.
The average bags per minute are displayed in the Bottom Rectangular Box.
Press the RETURN Button to go back to the Setup Menu.