Lead MKH-6 User manual

MKH-6
(KC22)
END LOAD CARTONING
MACHINE
Model: MKH-6
Prog: KC21-23
SERIAL NUMBER
0 2 2 7 1 7 K C 2 2

CUSTOMER: LANGDON / PPN

TABLE OF CONTENTS
1. COVER PAGE
2. TABLE OF CONTENTS
3. SAFETY INSTRUCTION
4. MACHINE DESCRIPTION
5. SPECIFICATIONS
6. OPERATION INSTRUCTION
7. SERVICE
8. MANUAL OPERATION
9. PROGRAM
10. PARAMETERS
11. PARAMETER LIST
12. SETUP
13. PRODUCT SETUP SHEET
14. FAULTS
15. MECHANICAL SETUP
16. SERVICE & MAINTENANCE
a. MAINTENANCE TIMETABLE
17. PARTS LIST
18. PLC DATA & CONNECTION LIST
19. ELECTRIC & PNEUMATIC DIAGRAMS
20. INVERTER PARAMETERS
21. PRODUCT SETUP SHEETS

SAFETY INSTRUCTIONS
This machine is designed and manufactured in accordance to current safety legislation.
However to ensure the correct and safe handling of this equipment, operators and
technician must follow some safety instructions to avoid damages or injuries.
WARNING
DO NOT ATTEMPT TO INSTALL, ADJUST OR OPERATE THE MACHINE WITHOUT
FIRST READING THE CONTENTS OF THIS MANUAL. ALTHOUGH THIS MACHINE IS
EQUIPPED WITH SAFETY GUARDS TO PROTECT OPERATORS, CARE MUST BE
TAKEN WHEN OPERATING, ADJUSTING AND SERVICING IT.
THE MACHINE SHOULD BE INSPECTED CAREFULLY AFTER IT HAS BEEN
UNPACKED TO CHECK IF IT HAS BEEN DAMAGED DURING TRANSPORT. IF THE
MACHINE HAS BEEN DAMAGED INFORM THE MANUFACTURER IN ORDER TO
EXAMINE THE DAMAGE AND TO GIVE HIS APPROBATION FOR OPERATING THE
MACHINE.
The requisite safety features have been incorporated into the design of the machine in order to
eliminate the risk of accidents. Current safety regulations have been observed in designing and
constructing this machine. A number of different hazard are referred to in this document. It is
strongly recommended that the warnings given in this document are read carefully.
THE FOLLOWING RECOMMENDATIONS MUST BE STRICTLY OBSERVED TO
ENSURE THAT THE MACHINE IS INSTALLED, OPERATED AND SERVICED SAFELY
Do not attempt to start or operate the machine until all the safety notices, installation
instructions, operating guide and service procedures have been read, fully understood and
implemented.
Only qualified service personnel can carry out checks, repairs and servicing. In doing so they
must follow the instructions contained in this manual.
Do not put any tools, parts or other objects on top of or inside the machine.
Always switch off the machine at the mains before cleaning or servicing it.
Always keep the machine clean, lubricated, greased and in good working condition.
Do not climb onto the machine and do not enter from underneath the machine even if the
machine is stopped.
General information:
•
The machine must be installed by qualified workers on a solid floor. A
sufficient space must be allowed around the machine to ensure easy access to
all equipment
•The operators and technician must wear clothing's that are close fitting to
avoid them catching by mobile components. Workers must wear protective
gloves when conducting maintenance operation.
•Ensure a daily cleaning of the machine and around it.
•The equipment must be use only for its original function. Modifications are
not allowed without acceptance of the manufacturer of the equipment.
•Operator must pay attention to the signs apposed on the machine in order to
avoid injuries

Electrical hazard
•
Connection to the electric power must be done by a qualified electrician.
•Follow the electric diagram to connect the electric power.
•Use suitable wires for the electrical power needs.
•Ensure that the machine is earthed.
•Install a Circuit breaker with earth leakage detection (500 mA) at the head of
the electric supply cable.
•Modification of the electrical circuit is not allowed.
•Always disconnect the electric supply when conducting maintenance
operation.
•Check periodically that wires or cables are not damaged and replace it by a
qualified electrician if necessary.
Mechanical hazard
•
Doors and protective panel must be in place when operating the machine.
•By-passing the door switches is strongly prohibited.
•When conducting maintenance operation or machine setup, switch off the
electric power and disconnect the air supply.
Burn hazard
•
The machine includes a Holt-melt device to close the boxes. The tank, the
pump, the heated hoses and the guns are heated to a temperature above 150C
during working time.
•The operator and technician must not touch these elements without adequate
protective wearing. Take care that a long time is necessary to cool this
elements after switched off.
•Read the manual book of the Holt-melt device before conducting any
operation.
VERY IMPORTANT! The following checking should be done every week:
The main electric switch is working properly. (Electric power is interrupted when the main
switch is in the OFF position)
The emergency-stop push-buttons are working properly. (The machine stops immediately when
the emergency-stop is pressed)
The hinged guard safety switch is working properly. (The machine stops immediately when the
hinged guard is open
The fixed guards are in place and properly fixed to the machine and are not damaged.
The main electrical control box and the auxiliary connection boxes are properly closed.
The electric cables and the air pipes are not damaged. (Must be replaced by a qualified
technician).
WARNING: If any fault is detected during these checking procedures, the machine must
be disabled. The electrical must be taken out from the wall and the air must be
disconnected until the failure is repaired. In the event of an accident the machine
manufacturer shall not be deemed liable if the checking procedures listed above have not
been complied with.

SAFETY WARNING
1. General warnings.
DO NOT ATTEMPT TO INSTALL, ADJUST OR OPERATE THE MACHINE WITHOUT FIRST
READING THE CONTENTS OF THIS MANUAL. ALTHOUGH THIS MACHINE IS EQUIPPED
WITH SAFETY GUARDS TO PROTECT OPERATORS, CARE MUST BE TAKEN WHEN
OPERATING, ADJUSTING AND SERVICING IT.
THE MACHINE SHOULD BE INSPECTED CAREFULLY AFTER IT HAS BEEN UNPACKED TO
CHECK IF IT HAS BEEN DAMAGED DURING TRANSPORT. IF THE MACHINE HAS BEEN
DAMAGED INFORM THE MANUFACTURER IN ORDER TO EXAMINE THE DAMAGE AND TO
GIVE HIS APPROBATION FOR OPERATING THE MACHINE.
The requisite safety features have been incorporated into the design of the machine in order to eliminate
the risk of accidents. Safety regulations have been observed in designing and constructing this machine.
THE FOLLOWING RECOMMENDATIONS MUST BE STRICTLY OBSERVED TO ENSURE THAT
THE MACHINE IS INSTALLED, OPERATED AND SERVICED SAFELY
Do not attempt to start or operate the machine until all the safety notices, installation instructions,
operating guide and service procedures have been read, fully understood and implemented.
Only qualified service personnel can carry out checks, repairs and servicing. In doing so they must
follow the instructions contained in this manual.
Machine operators must never put their hands or any cloths, etc. inside the machine while it is operating.
Do not put any tools, parts or other objects on top of or inside the machine.
Always switch off the machine at the mains before cleaning or servicing it.
Always keep the machine clean, lubricated, greased and in good working condition.
Do not climb onto the machine and do not enter from underneath the machine even if the machine is
stopped.
VERY IMPORTANT!
The following checking should be done every week:
The main electric switch is working properly. (Electric power is interrupted when the main switch is in
the OFF position)
The emergency-stop push-buttons are working properly. (The machine stops immediately when the
emergency-stop is pressed)
The hinged guard safety switch is working properly. (The machine stops immediately when the hinged
guard is open
The fixed guards are in place and properly fixed to the machine and are not damaged.
The main electrical control box and the auxiliary connection boxes are properly closed.
The electric cables and the air pipes are not damaged. (Must be replaced by a qualified technician).
WARNING: If any fault is detected during these checking procedures, the machine must be disabled.
The electrical must be taken out from the wall and the air must be disconnected until the failure is
repaired. In the event of an accident the machine manufacturer shall not be deemed liable if the checking
procedures listed above have not been complied with.
1.1. Foreseen application.
The machine model MKH can pack solid, regular product into cardboard boxes from pre-cut cardboard
blank.
The equipment must be use only for its original function. Modifications are not allowed without
acceptance of the manufacturer of the equipment
1.2. General safety laws.
The employer has the obligation to accurately inform all the operator s and authorized personnel of the
hazards, consequences from the noise, importance of safety devices and general safety regulations
recommended by the international and national standards and regulations of the importing country.
Before an operator work s on the machine he/she must be fully aware of how the machine functions, and
must have carefully read and understood the technical contents of the instruction manual.
It is forbidden to tamper or substitute parts on the machine unless expressly authorized by the
manufacturer

The use of accessories and spare parts different from those recommended by the manufacturer or those
shown in this manual can be a hazard to the operator and/or cause damage to the machine.
Any modifications or maintenance work carried out without the permission from LEAD Technology
excludes LEAD Technology from any civil or penal responsibility.
It is strictly forbidden to remove the safety devices or safety warnings on the machine
All ordinary or extra-ordinary maintenance carried out on the machine must be done with the machine
switched-off, emergency button pressed, the electrical plug removed from the main wall socket and the
air supply disconnected.
Do not introduce your hands or tools such as screw-drivers, spanners etc. into the moving parts.
The working space of the operator must be kept in order, clean and free of any object that can obstructs
the operator from moving freely.
The operator must avoid insecure operations in inconvenient positions that can compromise his balance.
The operator must pay attention to the risks of entanglement of his clothes or hair in the moving parts. We
recommend the use of a cap in order to keep the hair out of the way. The use of chains, bracelets and
rings can be a hazard to the operator.
The working area must be adequately lightened for the foreseen operations. An insufficient or excessive
lighting can be a hazard.
1.3 Noise
The machine model MKH has been designed and constructed to cause the least possible noise.
The sound level measured in the operators working area, one meter from the machine should be less than
80 dBA. Operator must wear noise protection devices. The noise has been measured with the machine in
operation for 10 seconds according to the standard ISO 3744.
If the machine is used in an area where the operator is exposed to a noise level higher than 80 dBA, the
employer must-see that all the safety measures are applied and observed in order to ensure the operators
health. In particular the operator when necessary must use the individual accessories in order to protect
himself from the noise.
1.4 Layout
Work definition:
Operator of the machine: The person starting the machine will load the cardboard sheets into the
magazine conveyor and stop the machine by pressing the stop button or in case of emergency the
emergency stop button.
Maintenance personnel: Intended for personnel with a specific technical training, qualification and
experience in the unloading, transporting, installation, operation and maintenance of machinery. It is also
essential that the personnel responsible for the maintenance of the machine will be trained by an
authorized technician.
1.4.1 Area reserved for the machine operation.
The operator job is limited to the loading of the cardboard sheet into the magazine and the basic
functions of starting and stopping the machine. The operator cannot carry out any maintenance or operate
in any other area. The finished products that come out on the discharge conveyor must be conveyed to
another machine or dropped into a container. The machine must be positioned in such a way that there is
easy access to all of its parts. On the left and right sides of the machine, at least 1meter of free space will
be provided. In the back part of the machine, a space of 1meter is necessary so that the cardboard can be
easily manipulated and loaded in the magazine. The front part of the machine must be free of obstacles in
order to allow the output of the finished products.
1.4.2 Areas with safety devices.
In order to ensure the operators safety the machine model MKH is equipped with a series of fixed and
hinged safety guards in order to prevent the operator from having access to hazardous moving parts.
Fixed guards on the bottom of the machine to prevent access to the moving parts.
Hinged guard in polycarbonate in the front and in the back of the machine, covering the boxes
forming/closing stations. The opening and closing of the guard is assisted by gas springs. The guard is
monitored by safety switch sensors which immediately stops the machine if the guard is open.

Sign indicating danger if hands or other foreign objects are introduced into the body of the machine.
Sticker to indicate very hot temperature in area of the glue guns.
Safety switches for hinged guards.
Emergency stop button.
Main power switch. The main power switch disconnects the machine from the electric power supply.
Sticker to indicate high voltage.
1.4.3 Unprotected Hazard areas
In certain areas of the machine it has not been possible to assemble safety guards due to the particular
function that the machine has to carry out. Each operator and maintenance personnel are to be aware
of these areas in order to prevent and avoid accidents.
Parts in movement can catch onto loose clothing and injure hands and arms.
Input and output conveyor on the optional stacker unit
Belt of the output conveyors
Electrical cabinet presents danger of electrical shock. The main power supply plug must be
disconnected from the wall before opening the door of the electric box. Only authorized electricians
must open the electric box.
Running belt of the discharge conveyor can catch onto loose clothing or injure hands.
Glue guns and hoses can cause serious bums and injure hands and arms. The operator must not
touch the body of the hot-melt unit and he is only allowed to load glue pellets into the glue tank.
Refer to the instruction manual of the hot-melt unit for specific safety instruction.
2. Installation
The personnel responsible for the installation and start up of the machine must be qualified and have
received adequate technical training and experience in order to carry out the different operations with
competence.
2.1. Transport
Generally the machine is transported completely assembled and covered with transparent wrapping.
The machine must be lifted and transported to the desired installation area by the use of an adequate fork
lift. The fork lift must lift a weight of 1500 kg without any risk. The forks must be introduced between the
4 feet of the machine. Once the forks are inserted they must be opened so that they touch the two sets of
feet.
The forks must be inserted opposite to the control panel side.
During the lifting of the machine with the fork lift attention must be paid that the machine is balanced.
Counter weights in steel are to be used if necessary. Place the machine in the desired working place,
adjust the machine level by turning the adjustable feet in the desired direction . Then you can proceed to
assemble the output conveyor and the optional stacker unit. It is essential that the maximum attention is
paid during all the phases of lifting, unloading, transporting and positioning of the machine.
2.2. Environment
The machine must be installed in a closed tempered local (indoor). The ambient temperature must be
between 5 °C and 40 °C. Relative humidity must be less than 80% at 20 °C. Altitude must be less than
1000 meters above sea level. In case of flood, explosion, landslide, …etc, the machine must not be turn
on without the advice and acceptance of the manufacturer.
2.3. Electrical connection
Make sure that the electricians respect the safety features foreseen by the local regulation. The electrical
supply must be sufficient for the maximum possible load of the machine model MKH which is equal to 4
KW.
Make sure that the main supply is compatible with the electrical supply required by the machine and that
shown on the tag attached to the machine.
The standard machine is supplied with a 5 poles electrical cable (Live-neutral--earth). When connecting
the wires, make sure that the neutral and the earth are fixed in the correct position on the main electrical
plug. An incorrect connection of the neutral or earth can seriously damage the electrical parts of the
machine.

Once the connection correctly completed make sure that the output conveyor runs in the appropriate
direction (from the machine to the output). Make sure that the earth is connected correctly according
standards. The earthing of the machine is to be carried out by the customer. Install a residual current
breaker with earth leakage detection (300 or 500 mA) at the head of the electric supply cable.
3. Cleaning and maintenance
IMPORTANT
DAILY CLEANING OF THE MACHINE AND CORRECT MAINTENANCE INSURE GOOD
WORKING, LONG LIFE AND HELP IN COMPLYING WITH CURRENT HEALTH AND SAFETY
REGULATIONS. FOLLOW THE INSTRUCTIONS SET OUT IN THIS SECTION.
3.1 Cleaning procedure
Follow the instructions below:
Stop the machine.
Switch off the main power switch and lock it in the OFF position.
Wait at least 1 hours that the hot-melt equipment cool down
Use an industrial vacuum cleaner with a sufficient long hose in order to access all the parts of the
machine without removing any fixed guards or entering into the machine.
Aspirate all the cardboard dust and scraps inside the machine and around the machine.
If necessary use a wet cloth for cleaning the outside surface of the machine.
It is advisable to keep the area around the machine clean and it is also important to clean the area below
the machine daily.
3.2 Maintenance and lubrication
Follow the instructions below:
Stop the machine.
Switch off the main power switch and lock it in the OFF position.
Disconnect the air supply.
Wait at least 1 hours that the hot-melt equipment cool down
For the detail of the maintenance operation and they frequency,refer to the SERVICE/MAINTENANCE
chapter in this manual.

MACHINE DESCRIPTION
High speed end load cartoning machine model MKH-6.
•Simple and economic.
•Construction full stainless steel 304l
•Automatically forms and glues boxes from cardboard sheets.
•Products are loaded on an infeed conveyor.
•Feeds products into cardboard box.
•Magazine carton with a capacity of 1000 cartons
(depend on the thickness).
•Controlled by a Multi-axis motion controller.
•Heavy Duty cables and connectors for the motor and encoder.
•Safety doors around the machine.
•Human machine interface for changing parameters and alarm
display.
•Continuous motion – High speed.
•Sealing type: by glue (Hot-melt).
•Quick adjustable parts by mechanical tachometers accuracy
0.1mm

SPECIFICATION
Capacity: Up to 100 boxes/minute depending on the products size.
Box size: 250 mm x 300 mm (between flaps) x 90 mm High
Carton style: 4 side flap glue system.
Other option as required
Air consumption: At Max. Speed 150 NL/min at 6 Bar.
Electric power: 6.6 KW 3x400VAC+Neutral
or 3x220VAC 50/60Hz
Control box low voltage 24V DC
Machine motor: 5 kW
Vacuum unit: Static vacuum pump (venturi).
Sealing type: glue jet system
Carton design: As required
Machine dimension: 4500 (L) 2350(W) 1750(H)
Weight: 1300 KG
Recommend
Glue: hot melt granulate temp’ 150°C-170°C cool time 1 sec,
Open time 1 Sec,
Air compressor unit: 250 L tank 5.5HP.

OPERATION INSTRUCTION
•Turn on the main switch on the main electric box.
•LEAD logo and program no will show on the main screen.
Touch the screen in the center area and the main screen will be displayed.
Machine Speed Shows the current speed of the machine while running, calculated every cycle.
SERVICE Displays the service screen : counter, manual operation, input monitor
ALARMS When an alarm appears ALARM switch will blink, press on it to display the alarm
screen.
PARAMETERS Change the parameters of the machine function.
PROGRAM Can switch between programs for example: sizes of product, speed, each
program will save those parameters for easy set up.
MAIN MOTOR
POSITION Displays the current position of the main motor (box conveyor).
INFEED Allows to feed the products into the machine
SHIFT OFFSET Opens the menu for shifting the offsets of the motors for synchronization.

SERVICE
Opens the Operation Manual
Allows access to the system
(not available in operator mode)
Allows switching between: operator, technician and supervisor modes.
Note: not all parameters available in every mode.
Perform a machine homing process when pressing this key
OVER VIEW 1
Display an overall view of the machine state
MANUAL OPERATION
Allows manual control of the machine
IN/OUT MONITOR
Displays the state of the controller inputs & outputs.
MAINTENANCE
Display the maintenance menu
COUNTER
Displays available counters
SERVOMOTORS MONITOR
Display the servomotors status
SERVICE PARAMETERS
Allows control of the service parameters

MACHINE OVERVIEW
INPUTS / OUTPUTS MONITOR
Pressing this key will display the following screens which will allow a technician to check the
state of the controller inputs & outputs.
At any time pressing on the "HOME" key
in the upper right corner will back to the
main screen

.
COUNTER
Counts packed products and machine working hours.
Batch counter - Counts produced boxes since the last reset. Press the reset key to reset to 0.
Working hours - Displays the number of working hours. The value cannot be reset.
Total counter - Displays the total number of cycles. The value cannot be reset.
MAINTENANCE
Reminder of the periodic maintenance that must be conduct in order to insure a good
operation of the machine. When the maintenance procedure is completed the corresponding
key "DONE" must be pressed. If the "DONE" key is not pressed, a red warning is displayed on
the main screen.

SERVOMOTORS MONITOR
Monitors state of the servomotors and the actual position of each axis.
LOGIN - LOGOUT
The operation of this machine has 3 levels of access:
Operator - Basic access. Basic machine operation.
Technician – Full access including parameter and program changes, manual operation etc….
Supervisor – Full access like technician + access to system and Teamviewer button
In order to switch between users, press LOGIN key. Select desired level of access and enter a password.
The operator level doesn't require password and is the selected level at power up. The technician or
supervisor login is enabled for a maximum period of 2 hours, after this delay, the operator level will be
enabled.

MANUAL OPERATION
Pressing on the [MANUAL OPERATION] switch will display this screen
This menu allows operating some functions while the machine is stopped.
Vacuum rotor
position Display the actual position of the pulling rotor (help to determine the end
vacuum position)
VACUUM Operate the vacuum valves in the jog mode. The valves are activated in
regards with the start and stop vacuum parameters.
VAC #1 Force start vacuum valve #1 without regards to the position of the rotor.
Press once again to release the vacuum.
VAC #2 Force start vacuum valve #2 without regards to the position of the rotor.
Press once again to release the vacuum..
VAC #3 Force start vacuum valve #3 without regards to the position of the rotor.
Press once again to release the vacuum.
Cascade Manual
(A or B) Run the cascade unit once each time the key is pressed (the level 1,2,3
will light in accordance)
Simulation Run the cascade unit continuously at a speed of 100 bags/minute.

Input belts
Manual Operate the cascade input conveyors (when the machine is stopped).
Magazine Conv.
M9 Operate the magazine conveyor (without relation with the cardboard
sensor).
Right (B) side-
folder Operate manually the right-folding unit
Left (A) side-
folder Operate manually the left-folding unit

PROGRAM
A program is a set of related parameters that the operator can load to operate the
machine for a related product.
To load a program from the memory, press the "PROG" key on the main screen.
The following screen is displayed.
Load the program you required
Choose the program number you want to load (on the left side)
To edit program name, press on the field to the right of the program number
and a keyboard will appear. Enter the desired name and press OK.
To the main screen

PARAMETERS
To change the parameters – press PARARAMETERS on the main screen.
The screen below will appear.
Change the parameters
Press on the value you would like to change.
A numeric keypad will be displayed; change the value and press ENTER. Notice that the new
value is automatically saved in the program number displayed on the top of the screen.
PARAMETER
DESCRIPTION
1 Machine Speed Set the machine speed
(in boxes per minute for continuous
motion)
2 Glue Start Position Set the start position of the glue line (in regard with the
main
motor position displayed at the bottom in the yellow case).
3 Glue End Position Set the end position of the glue line (in regard with the
main
motor).
5 Vacuum Start
Position Set the start position of the
vacuum valve related with the rotor
position.
6 Vacuum Distance
Set the end position of the vacuum valve related with the rotor
position.
Next screen
Home Key
Present active
program