Hamer 525WT User manual

Rev.7
MODEL 525WT
FORM FILL AND SEAL
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.7
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 actual models or equipment, but are intended for
reference only and are based on the latest product
information available at the time of publication.
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# __________________________________________________________

Rev.72
TABLE OF CONTENTS
SECTION ONE
The Model 525 Wire Tie
•Machine Operation...............................................................................................1
•Machine Specifications........................................................................................2
•Machine Layout ..................................................................................................2
•Film & Bag Specifications...................................................................................3
•Electrical Control Panel.......................................................................................4
•Operation Controls...............................................................................................5
•Programmable Controller.....................................................................................5
Programmable Logic Controller
•Inputs................................................................................................................... 7
•Outputs.................................................................................................................8
Setting up the Model 525 Wire Tie Machine
•Installing a Roll of Polyethylene Film.................................................................8
•Loading Film into the Film Feed Belts................................................................10
•Positioning the Vertical Heat Seal.......................................................................11
•Positioning the Photo Eye Assembly...................................................................12
•Positioning the Perforator Assembly...................................................................12
Adjustments
•Air Pressure Regulator/Filter...............................................................................13
•Roll Holder.......................................................................................................... 13
•Photo Eye Detector Placement.............................................................................13
•Perforator Blade Adjustment or Replacement.....................................................13
•Heat Seal Temperature Controller.......................................................................13
•Teflon Cloth.........................................................................................................14
•Flow Controls...................................................................................................... 14
•Film Feed Belts ; Removal & Replacement........................................................ 15
•Film Roll Brake Cam...........................................................................................17
•Film Feed Chain Tension.....................................................................................18
•Tear Off System...................................................................................................18
•Tear Off Belt Tension Adjustment...................................................................... 18
•Tear Off Belt Pressure Adjustment......................................................................19
•Conveyor Adjustments.........................................................................................20
•Production Rate....................................................................................................20
•Proximity Switch Activating Cam (Volumetric).................................................20
•Product Slapper and Wiggler...............................................................................23
•Low Level Product Detector Sensitivity Setting................................................. 23
•Bag Closer Mounting...........................................................................................24

Rev.73
TABLE OF CONTENTS (CONTINUED)
Maintenance Instructions and Schedules.................................................................... 25
Troubleshooting Guide..................................................................................................26
Parts Ordering............................................................................................................... 30
SECTION TWO
Model 525 Wire Tie Machine Assembly Drawings
•Roll Holder Assembly
•Dancer Assembly
•Perforator Assembly
•Photo Eye Assembly
•Vertical Heat Seal Assembly
•Belt Path Assembly
•Volumetric Assembly
•Conveyor Lift Assembly
•Conveyor Assembly
•Tearoff Assembly
•Control Panel Mounting Assembly
•125 Wire Tie Mounting Assembly
•Electrical/Pneumatic Assembly
Warranty

Rev.71
SECTION ONE
MODEL 525WIRE TIE
MACHINE OPERATION
The Hamer Model 525 Wire Tie is designed to Form, Fill, and Seal bag sizes of 9” to 16” wide by 16” to 35”
long.
To activate this machine, product must enter the Volumetric Filler. Product is detected by a sensor in the filler
which activates a cam that strikes the prox switch on the filler drum. The prox switch sends an electrical signal
telling the film feed clutch to engage; thus releasing the clutch brake and driving the film feed belts, which
advances the film. This puts pressure on the dancer arm, activating the brake air valve and allowing the film
roll to index with the machine.
The indexing is controlled by the photo eye which reads the eye mark on the film, located according to the bag
width you have selected. The photo eye then sends a signal to the programmable controller inside the electrical
box. This advances the film to the next station, where the film is perforated at the top for separation. The film
advances and the sides are formed by the vertical heat sealer and separated by the hot knife. While this
operation is taking place, the bag in front is allowed time to cool so the side seals can create a solid bond before
being filled with product.
The bag then advances to the fill station, where it is filled with product to the prescribed weight and supported
by the conveyor to the end of the machine.
The bagged product then moves into the tear off and through the bag closer completing the process and
presented for your product handling system.
•Note: If the Low Level Product Detector inside the Filler sees no product, the machine will shut down.

Rev.72
MACHINE SPECIFICATIONS
Power 240/120 VAC (3 pole, 4 wire) single phase, 60 Hz 30 Amp (240 VAC – line to line)
Requirements (120 VAC = each line to neutral)
Air Requires one air drop: One 1/2” tubing (minimum) with ¼” NPT fitting,
Requirements 20 CFM at 80 PSI to the Form Fill & Seal Machine (total 20 CFM).
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.
Machine Size 11’5” maximum length by 3’6” maximum width by 6’8” to 7’9” maximum height.
MACHINE LAYOUT
6" MINIMUM DISTANCE TO TOP
OF CUSTOMER CONVEYOR
79.5" MIN
93" MAX
60"
SEE NOTE 2
115"
81" REF.
21"
REF.
35"
FEED DIRECTION
AIR IN 20 CFM @ 80 PSI
1/2" TUBE MINIMUM
WATER (CLEAN) IN
1/2" TUBE MINIMUM
CONTROL PANEL (ONE DROP INCLUDES)
120 / 240 VAC 1-PHASE 60HZ 30 AMP
(4 WIRE WITH NEUTRAL)
(120 VAC = EACH LINE TO NEUTRAL)
(240 VAC = LINE TO LINE)
SEE NOTE 5
PRODUCT INFEED
FACTORY SET LEGS TO 3"
128" - 137" REF.
MODEL 125
BAG CLOSER
NOTES:
1) ALL DIMENSIONS ARE IN INCHES.
2) 60" NEEDED FOR 21" BAGS. DIMENSIONS CHANGE
ACCORDING TO BAG SIZE, AND SOME ADJUSTMENTS MAY
BE REQUIRED. (THIS DIMENSION INCREASES 1" FOR EACH
ADDITIONAL 1" OF BAG LENGTH)
3) MACHINE SHOULD BE LOCATED WITH A MINIMUM OF 2 FT.
CLEARANCE ON ALL FOUR SIDES
4) ALL AIR INPUTS REQUIRE CLEAN DRY AIR.
ALL WIRES MUST GO IN THROUGH THE BOTTOM OF THE CONTROL
PANEL. ANY MODIFICATIONS TO THE CONTROL PANEL
MAY VOID MANUFACTURES WARRANTY!
6) SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.
*
AIR DROPS
ELECTRICAL DROPS
*

Rev.73
FILM AND BAG SPECIFICATIONS
FLAT
BAG WIDTH
9" - 16"
FLAT
BAG LENGTH
16" - 35"
1" MIN. BETWEEN PRINT
*
5" MIN.
EYE MARK
DETAIL
Ø 14-1/2" MAXIMUM
Bag Width: Minimum: 9”
Maximum: 16”
Bag Length: Minimum: 16”
Maximum: 35”
Poly Thickness: Minimum: 1.50 mil. Center Fold Film
Maximum: 4 mil. Center Fold Film
Film Roll: Maximum: 14-1/2” Diameter
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).
3. 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. SEE BAG SPECS FOR THE BAG LENGTH / WIDTH DIMENSIONS.
8. SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE .
*

Rev.74
ELECTRICAL CONTROL PANEL
FIGURE 1

Rev.75
OPERATION CONTROLS (Electrical Control Panel) (See Figure 1, pg 9)
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. Main Disconnect - shuts the machine down when the Control Panel is open. The Panel must be closed
and the disconnect turned to the “on” position before the machine will operate.
3. Emergency Stop Button - when this E-Stop button is depressed, the machine will stop immediately. The
button must be pulled out for the machine to operate.
4. Temperature Controller (Side Seal) - - controls the amount of heat required for the Vertical Heat Sealer to
seal the sides of a bag (See Figure 2). Proper setting will depend on bag rate (which is production rate), film
thickness, and type of film. Testing the bags at various temperature settings will yield the best results. 575° F
is a good starting temperature. Set the Temperature Controller as described in the “Adjustments” section.
5. Bag Totalizer - the Totalizer located on the Control Panel maintains the bag count and can be reset
anytime during machine operation. A second Bag Totalizer located on the subpanel inside is constant and non-
resetable.
6. Start Button - when the Selector Switch is in the Auto mode and product filling is ready to begin, the Start
Button activates the automatic mode of the machine. The Start Button must be used to restart the machine
whenever it has been stopped.
7. Hand/Auto Mode Selector Switch - select the Hand Mode for operation of the machine during film change
and Auto mode for automatic product filling operation.
8. Dump Select Button (Optional) – allows the Machine Operator to select the number of times the
Volumetric will dump before the bag will advance.
9. Stop Button - one button on the Control Panel, another on the Rear Switch Box, when one of these buttons
is depressed, the machine will shut down after one complete machine cycle.
10. Jog Button - one button on the Control Panel, another on the Jog Stop 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.
FIGURE 2

Rev.76
THE PROGRAMMABLE CONTROLLER (Viewed through the window on the Electrical Control Panel)
The following guide lists the functions for the Programmable Controller as labeled. This will help you
understand the Controller and assist you in troubleshooting your machine.
Mitsubishi FX1S-30MR-ES/UL PLC
When the main power is turned on to the machine, lights on the Controller labeled Power, Ok and Run should
be lit.

Rev.77
INPUTS
Light # Function of Light Comments
X0
Start Lights when the Start Button is depressed. If the input indicator is on at any other time, the Start Button is faulty.
X1
Stop Lights when all Stop Buttons are pulled out indicating that the
machine is ready for operation.
Always use one of the Stop Buttons to stop the machine
operation. The Stop Button will prevent the machine from
stopping in the middle of a cycle. The E-Stop button will
stop the machine at the time the button is pushed.
X2
Photo Eye Lights as the Eye Mark passes the Photo Eye Detector. The input indicator light on the PLC should be on when the LED located on the Photo Eye is on.
X3
125 Wire Tie
Limit Switch
Lights when a bag is passing
through the Bag Closer and
activates the Bag Closer Limit
Switch.
The Bag Closer is jammed if the input indicator light
remains on.
The machine will shut down after 1.7 seconds and will be
prevented from restarting until the problem is resolved.
X4
Volumetric
Position
Detector
Lights only when the
Volumetric Position Detector is
activated with the rotation of
the drum.
When in the Auto Mode and the Volumetric Position
Detector has been activated, the film will advance.
X5
Vertical Seal
Limit Switch
Lights when the Vertical Heat
Sealer mechanism is in the
operating position.
The Film Feed Belts will not index the film unless this input
is on.
X6
Jog Lights when the Jog Button is depressed to index the film. The Jog Button will index the film when the Mode Selector is set to the Hand Position.
X7
Hopper Product
Detector
Lights when the Detector senses
product in the Hopper. The input indicator light is “On” when the hopper product level is detected by the sensor. The input must be on for the
machine to operate when in Auto Mode. The sensitivity of
the Detector can be adjusted using a small screwdriver and
turning the base counterclockwise to decrease sensitivity.
X10
Hand/Auto
Switch
Lights when the Mode Selector
Switch is in the Hand Mode and
“Off” when in the Auto Mode.
When in Auto Mode and depressing the Start Button, the
entire machine will run. When in Hand Mode and using the
Jog Button, the entire machine will run through one cycle.
X11/X12
Dump Selector
Switch
Lights on/off Inputs The Dump Selector Switch offers four selections. Each
selection represents one additional cavity of product from the
Volumetric Drum, as shown below.
Switch
Selection INPUTS-Key: Lights on = X Lights off = O
X11 X12
#1 O O
#2 X O
#3 O X
#4 X X
#1 = One Dump
#2 = Two Dumps
#3 = Three Dumps
#4 = Four Dumps
X13
125 Wire Tie
Motor
Lights when the 125 Power
Switch is “On” The machine will not operate in Auto Mode if the 125 Power Switch is in the “Off” position. The input must be on for the
machine to operate when in the Auto Mode.
X14
Air Pressure
Switch
Lights when the air pressure is
maintained at 80 PSI. When the main air pressure is maintained at 76 PSI or above, the input indicator light will be on continuously. If the
pressure falls below 76 PSI, the input indicator light will turn
off, and the machine will complete one full cycle before
stopping.

Rev.78
INPUTS (CONTINUED)
Light # Function of Light Comments
X15
Temperature
Control Alarm
Side Seal
Light is “ON” when the Side
Seal Temperature is outside of
it’s operating range.
If the Side Seal Temperature is more than 50ºF above or
below the setpoint, the Input will be “ON”. The machine
will not operate in Auto Mode when this Input is on.
X16 Spare Input
OUTPUTS
Light # Function of Light Comments
Y0
Film Feed
Motor Starter
Lights when the Film Feed
Motor is running. The Film Feed Motor is running when the machine is operating in either the Auto Mode or Hand Mode selection.
Y1
Vertical Seal &
Perforator
Solenoid
Lights when the Vertical Heat
Sealer is sealing the bag and the
top of the bag is perforated for
separation.
The light is “On” during the time that the sides of the bag are
being sealed and the top of the bag is being perforated. Then
“Off” when the Heat Seal Knife starts to withdraw from the
film.
Y2
Film Feed
Clutch Relay
Lights when the film is
advancing. The light is “On” only when the Film Feed Motor engages the Clutch and advancing the film.
Y3
Low Product
Detector
Lights when product is at a low
level in the Hopper. The output indicator light is on when the product level in the Hopper is below that of the Detector.
Y4
Water Injector
Solenoid
Lights when the film is
advancing. The Injector sprays a mist of water between the sheets of film for lubrication while traveling around the Fill Opening. The
Injector is activated by the Solenoid when the film is
advancing.
Y5
Volumetric
Motor Starter
Lights when the machine is
operating in the Auto Mode. The Volumetric will operate continuously while the machine is running in the Auto Mode and the Hopper is maintained with a
sufficient supply of product. The Motor Starter will not
energize while in the Hand Mode. Note: The Volumetric can
be emptied of product by cycling the machine in the Auto
Mode while depressing the Start Button for each cycle.
Y6
125 Wire Tie
Clutch Relay
Light flashes once with each
cycle of the 125 Wire Tie. This output signals the 125 Wire Tie to operate, completing one cycle.
Y7
Vertical Seal
Swing Out
Lights when the Vertical Heat
Sealer has pivoted to a non-
operational position.
The light is “On” when the Vertical Heat Seal has swung out
to a non-operational position after the machine has sat idle for
more than 60 seconds.
Y10
Bag Totalizer Light flashes when counting a bag. The light will flash after the bag has received the prescribed amount of product selected on the Dump Switch.
Y11
Tear Off Relay Lights when the Tear Off is operating. The Tear Off operates continuously in the Auto Mode and in the Hand Mode after pushing the Jog Button and allowing the
machine to cycle.
Y12 Spare Output
Y13 Spare Output
Y14 Spare Output
Y15 Spare Output

Rev.79
SETTING UP THE MODEL 525 WIRE TIE MACHINE
FIGURE 3
INSTALLING A ROLL OF POLYETHYLENE FILM
1. Release the Lock Knob and pull up on the core shaft, removing the core holder from the cardboard tube of
the previous roll of film.
2. Lift up on the pivot bar so you clear the lock pin, then swing the pivot bar out to the side of the machine
and allow the bar to lock at that position.
3. Install the new roll of polyethylene film on the hub of the roll holder.
4. Return the pivot bar to the original position over the center of the film roll and lower the core holder into
the cardboard tube maintaining a loose fit in the tube, then tighten the lock knob onto the core shaft.
•Note: See “Adjustments” for raising or lowering the roll holder.

Rev.710
LOADING FILM INTO THE FILM FEED BELTS (See Figure 5)
1. Set the Selector Switch (See Figure 1) to the Hand Position.
2. Feed the film through the Film Feed Rollers.
3. Pass the Film between the Static Eliminator brushes, the Photo Eye Detector and the Perforator Unit.
4. Separate the Film into two halves and pass one half to each side of the Film Opening Rod.
5. Continue manually feeding the Film until it reaches the Film Feed Belts.
6. CAREFULLY hold the Film up to the Film Feed Belts with one hand and press the Jog Button with the
other hand. Let go of the Film as the Film Feed Belts pull it forward.
7. Continue pressing the Jog Button, moving the Film to the Vertical Heat Sealer and guiding the Film to the
Fixed Fill Opening.
8. Using the Jog Button, pass the Film around the Fixed Fill Opening (See Figure 5). If the Film bunches up,
pull just that bag away, try again and help the Film along by pulling on the Film near the top of the bag in the
same direction of the belt path.
CAUTION: AVOID PUTTING YOUR HANDS IN THE BELT PATH.
9. Continue pressing the Jog Button. You will notice the Film Feed System will stop whenever the Photo
Eye Detector “reads” a Timing Mark along the top edge of the Film as shown in (Figure 4), jog the Film until a
Bag is centered with the Fixed Fill Opening (See Figure 5).
10. On the Photo Eye Detector and the Perforator unit, loosen the Lock Knobs and center the Perforator on
the edge of a bag (See figure 4). Slide the Photo Eye Detector up next to the Perforator (approx. ½” of space
between the two mounting bars) and retighten the Lock Knobs.
11. When the Photo Eye Detector “reads” a timing mark, a perforation is made there. The Vertical Heat Seal
Unit should be positioned to locate a perforation in the middle of the Seal Pad (See Figure 4) when the Film has
stopped. To accomplish this, loosen the Lock Knobs, roll the Vertical Heat Seal Carriage into the proper
position and retighten the Lock Knobs.
12. Set the Vertical Heat Seal Temperature Controller (See Figure 2) as described in the “ADJUSTMENTS”
section.
13. Now the Film is properly loaded. Check to make sure the Photo Eye Detector, the Perforator, and the
Vertical Heat Seal Carriage are all LOCKED firmly into place.
14. Set the Selector Switch (See Figure 1) to the Auto position.

Rev.711
FIGURE 4
POSITIONING THE VERTICAL HEAT SEAL
The centering of the Bag with the Fixed Fill Opening is determined by the position of the Vertical Heat Sealer.
•Note: Do not be concerned with location of the label on the bag during this procedure.
1. Loosen the two Lock Knobs on the Carriage Locks, which secures the Vertical Heat Sealer Carriage.
2. With the Mode Selector Switch in the Hand position, using the Jog Button, cycle the machine to be sure
there is a complete bag around the Fixed Fill Opening.
3. Compare the center of the Bag with the center of the Fixed Fill Opening. Measure the distance from the
center of the Bag to the center of the Fixed Fill Opening. Move the Vertical Heat Sealer that same distance in
either direction to center the Bag with the Fixed Fill Opening.
4. Using the Jog Button cycle the machine several times to be sure the Bag is centered, if not repeat Step #3
as many times needed.
5. Tighten the Lock Knobs to secure the Vertical Heat Sealer in that position.

Rev.712
POSITIONING THE PHOTO EYE ASSEMBLY
The centering of the Label with the Bag is determined by the position of the Photo Eye.
1. Pull back on the Cam Lock to release the Photo Eye Assembly.
2. Compare the center of the Label with the center of the Bag. Measure the distance from the center of the
Label to the center of the bag. Slide the Photo Eye Assembly that same distance in either direction.
3. Secure the Photo Eye Assembly in that position by pushing down on the Cam Lock.
4. With the Mode Selector Switch in the Hand position, using the Jog Button cycle the machine several
times to see that the Label is centered with the Bag, if not repeat Steps #1 thru #3 as many times needed.
•(Refer to "Adjustment" section, Photo Eye Detector).
POSITIONING THE PERFORATOR ASSEMBLY
1. Pull back on the Cam Lock to release the Perforator Assembly.
2. Slide the Perforator Assembly over to the Eye Mark that is closest to the Photo Eye Assembly. Position
the Blade of the Perforator approx. 1/2" from the leading edge of the Eye Mark as shown in (Figure 4).
3. Secure the Perforator Assembly in that position by pushing down on the Cam Lock.
•(Refer to "Adjustments" section for Perforator Blade Adjustment and Replacement).