Loveshaw Little David CF25 User manual

LOVESHAW
Little David™ Case Sealer
CF25
Case Erector
Version: P – Valid from October, 2019 P/N: CF25-OM
Operator’s Manual

i
Little David™ CASE ERECTOR
CF25 Operation
Copyright Loveshaw
Loveshaw, Inc.
2206 Easton Turnpike, PO. Box 83
South Canaan, PA 18459
Tel: [phone] • 570-937-4921
Fax: [phone]
www.loveshaw.com
Loveshaw Europe
Unit 1 Newton Park
West Portway Industrial Estate
Andover, Hampshire SP10 3SH
ENGLAND
Tel: [phone]
Fax: [phone]

ii
The information contained in this manual is correct and accurate at the time of its
publication. LOVESHAW reserves the right to change or alter any information or
technical specifications at any time and without notice.
©2016 LOVESHAW. All rights reserved Printed in the United States of
America

iii
TABLE OF CONTENTS
Introduction
Operating Safety
Instructions
Warnings
Cautions
Safety Devices Functional Testing
Overview
Case Sealer Sections
Machine Specifications
Installation
Section 1: Placing the Machine
Section 2: Important Considerations
Theory of Operation
Theory of Operation for Chain Drive Machines
Theory of Operation for Belt Drive Machines
Operating Procedures
Set Up Procedure
Loading the Hopper
Start-Up Procedure
Sequence of Operation
Shut-Down Procedure
Maintenance
Chain and Lug Drive Maintenance
Side Belt Drive Maintenance
CF25 Preventative Maintenance Schedule
Spare Parts
Troubleshooting
Preliminary Checks
Using Test Mode to Troubleshoot Machine

iv
Checking Solenoid Valves
Checking PLC Inputs and Outputs
Tape Cartridge and Taping Issues
Troubleshooting Table
Warranty
Mechanical Drawings and Schematics
Standard Universal Mechanical Drawings
Standard Chain Drive Mechanical Drawings
Standard Belt Drive Mechanical Drawings
Special Options Mechanical Drawings
Pneumatic Drawings and Schematics
Standard Chain Drive Pneumatic Drawings
Standard Belt Drive Pneumatic Drawings
Electrical Drawings and Schematics
Standard Universal Electrical Drawings
120 Volt, 60 Hz, Standard Chain Drive Electrical Drawings
120 Volt, 60 Hz, Standard Belt Drive Electrical Drawings
240 Volt, 60 Hz, Non CE Compliant, Standard Chain Drive Electrical
Drawings
240 Volt, 60 Hz, Non CE Compliant, Standard Belt Drive Electrical Drawings
240 Volt, 50 Hz, CE Compliant, Standard Chain Drive Electrical Drawings
240 Volt, 50 Hz, CE Compliant, Standard Belt Drive Electrical Drawings
230 Volt, 3 Phase, 60 Hz, Standard Chain Drive Electrical Drawings
230 Volt, 3 Phase, 60 Hz, Standard Belt Drive Electrical Drawings
460 Volt, 3 Phase, 60 Hz, Standard Belt Drive Electrical Drawings
460 Volt, 3 Phase, 60 Hz, Standard Belt Drive Electrical Drawings
Appendices
Appendix A: Available Special Options
Appendix B: B-LOC Instructions
Appendix C: Recommended Spare Parts List

v
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INTRODUCTION
hank you for purchasing the Little David™ case erector, the CF25. The CF25 is an automatic
case erector and bottom sealer. The CF25 is a robust built 24/7 case erector constructed of
quality materials, bearings, pneumatic and electrical components. All employees who will be
required to operate and maintain the case erector must read this manual to ensure safe
operation as well as proper set-up and maintenance throughout the life of the machine. After reading this
manual, you will know how to perform the following functions:
How to install the machine.
How to operate the machine safely.
Troubleshooting and replacing of worn or defective parts.
Throughout this manual there are several illustrations designed to help you perform the variety
of tasks described.
Chapter
1
T
1

OPERATING SAFETY
his manual contains operator information for Little David Application Equipment. It is
directed toward the person who operates and maintains the machine. Read through the
manual completely before operating the machine. Thereafter, refer to it as necessary.
Take special note of all warnings, cautions, and maintenance instructions. Like any other piece of
equipment, the Little David Case Erector functions best when maintained and used correctly.
Observe the warnings and cautions below when using the Little David CF25 case sealer. Within this
manual, on page 5, all safety labels are depicted with location and part numbers. If a safety, label is
missing or not legible it must be replaced immediately. Failure to follow safety labels can lead to
injury or damage to the machine.
Instructions
Instructions are requirements to system operations.
Instruction: An electrical receptacle must be located near the machine. The
line cord connection to the receptacle is the disconnect means for
the machine. The receptacle must be located in an area that is
easily accessible to all personnel.
Chapter
2
T
2

Warnings
Warnings help prevent potential bodily injury.
Warning: This machine is equipped with moving parts. Do not place hands in the
machine when parts are moving. Always use a roller-type exit conveyor,
and always remove boxes after they clear the exit end of the machine.
Warning: Always disconnect all sources of energy to the machine before performing
maintenance. Sources of energy include but are not limited to electrical and
pneumatic. Refer to your company’s lock out tag out procedures.
Warning: Never bypass or remove safety guards from the machine or tape cartridge.
Warning: Never override safety devices such as Emergency Stop switches.
Warning: Never adjust the machine or tape cartridges when the machine is operating.
Warning: Never place hands or body inside confines of the machine unless all power
sources are locked out.
Warning: Never wear jewelry, loose clothing, such as ties, scarves etc. and long hair
must be pulled back when operating this machine.
Warning: Never pull a jammed box out of the machine while it is in operation.
Warning: Use caution when near cartridge knife or when threading tape. The knife is
very sharp, automatically operated and linked to the wipe-down rollers.
Warning: Do not attempt to open or work on the electrical box, junction boxes, or
other electrical components without first disconnecting power to the
machine. Shock hazard exists if the power is not disconnected.
Cautions
Cautions help prevent potential machine damage.
Caution: Provide and use proper electrical power.
Caution: Do not operate, maintain, or otherwise use this machine, except as
described in this manual.
3

Safety Devices Functional Testing
It is necessary to test the functionality of the safety devices at regular time intervals. The safety
emergency stop function must be tested daily before each and every shift of operation. The
procedure for testing the emergency stop function is as follows:
1. Connect the machine to the main electrical power source.
2. De-press the emergency stop pushbutton on the main electrical enclosure.
3. Press the start pushbutton on the main enclosure. If the machine does not start proceed to
the next step. If the machine does start unplug it from the main electrical power source and
report it to your supervisor. This machine cannot be used until a qualified technician
corrects the issue.
4. Reset the estop pushbutton to its extended state. Push the start pushbutton the machine
should start. With the machine running de-press the emergency stop pushbutton, the
machine should now stop. This confirms that the emergency stop function is working
correctly.
5. Test all E-Stops on the machine separately.
The overload motor relay must be tested every three months to confirm its operation. This test can
only be performed by a qualify technician since it requires the enclosure door to be opened.
1. Connect the machine to the main electrical power source.
2. Insure that the emergency stop pushbutton is fully extended.
3. De-press the machine start pushbutton. The machine drive motor should start at this time.
4. Open the main electrical enclosure. Use extreme caution not to contact any live conductors.
5. Locate the overload relay and de-press the red test button on the front of the unit. The
machine should stop. If the machine does not stop the overloads relay is defective and needs
to be changed out. If the machine stops the overload relay passes the functionality test.
6. Install the main enclosure cover and secure all (4) screws.
Never operate a machine that does not pass the safety functional testing! Report it to management
and have the machine taken out of service until the deficiency is corrected.
4

1 1
2 2
3 3
4 4
A A
B B
C C D D
TITLE
DWG NO SCALE
DRAWN
CHECKED
APPROVED
LOVESHAW
2206 EASTON TPK., SOUTH CANAAN, PA.
MATERIAL
TOLERANCES UNLESS OTHERWISE NOTED:
INCH
METRIC
.X
.XX .XXX
= .050
= .015
= .005
+
-+
+
--
-
.X .XX
.XXX
= 1.0mm
= .3mm
= .1mm
+
+
+
-
-
-
FRACTIONS 1/64
+
-
ANGLES 1/2
+
-
-
MACH. FINISH 125
CAD FILE PLOT DATE
DRAWN DATE
DO NOT SCALE PRINT
MAT'L
ST. ST.
STD
PART #
STAINLESS : NO FINISH
THIS DRAWING AND SUBJECT MATTER THEREON IS THE EXCLUSIVE PROPERTY OF LOVESHAW AND IS TO BE TREATED BY YOU AS CONFIDENTIAL PRPRIETARY INFORMATION. THIS DRAWING OR SUBJECT MATTER THEROF SHALL NOT BE REPRODUCED OTHER THAN FOR YOUR OWN USE OR TO BE DISCLOSED TO OTHER WITHOUT THE EXPRESSED WRITTEN CONSENT OF LOVESHAW AND WILL BE RETURNED TO LOVESHAW UPON REQUEST.
1/18/2017
1:13
N/A
1/20/2017
N/A
.CF25T
CF20-T FOOT PRINT
SAFETY LABEL ASSY, CF25.idw
N/A
thaner
REVISION HISTORY
REV DESCRIPTION DATE BY
A RELEASED 1/20/2016 RTR
SL-0006
SL-0004
SL-0003
SL-0006
SL-0001
SL-0021
SL-0002
SL-0070
SL-0004
SL-0004
SL-0070
SL-0004
SL-0002
SL-0002 SL-0001 SL-0003
SL-0004 SL-0006 SL-0021
SL-0070
PM862

OVERVIEW
Case Sealer Sections
This manual covers several parts of the machine. The following diagram identifies the some key sections
of the machine.
Chapter
3
V
ertical Feed
Assembly
Box Opening
Assembly
Hopper Assembl
y
Flap Folder
Assembly
Sled
A
ssembl
y
Main Drive
Assembly
Machine Guard
Assembly
Cartridge

Machine Specifications
Machine dimensions:
Height: 75.75”
Length : 75.13”
Width: 43.25”
Standard Discharge Height: 23”
Weight: 1100 lb. uncrated
Electrical Requirements:
Standard Voltage: 120/1/60 with 15 amp dedicated service.
Operating speed:
Cases per Minute: 10 for standard machines (up to 15 c.p.m. options available)
Air Requirement:
14 SCFM @ 85 psi –Maximum throughput based on maximum box range.
Machine box capacity:
Length: 6” to 16”
Width: 6” to 14” (3.5” minimum for side-belt machines)
Height: 4” to 12”
NOTE: Actual maximum dimensions are a function of each other and may be larger.
7

Machine Options:
Spare Parts Kit
Special Electronics
Custom Color
Casters
Low Tape Alarm
Low Hopper Alarm
Box Jam Alarm
Leg Extensions
High Speed (12, 14, & 15)
8

INSTALLATION
lways check for any signs that the machine may have been damaged before fully removing it
from the shipping skid. If machine arrives damaged contact Loveshaw immediately to help in
filing a claim with the shipping company.
Exercise care when handling this machine, a sudden jolt or jar may cause serious damage.
Do not remove the shipping skid until machine has been moved to a point of installation. The skid is
designed for easy and safe handling of your machine.
Section 1: Placing the Machine
The case former is fully assembled and ready for operation.
Step One: Carefully remove the machine from the shipping skid. Remove all fasteners and
brackets holding the machine to the skid.
Step Two: Transfer the machine from the shipping skid to the factory floor by lifting it with
a fork lift. Approach the machine from the side and carefully position the forks
under the frame. Locate the forks in the center on the machine, so that they lift
on the main frame flanges. Take care that the forks do not lift on any sub-
assemblies as they may be damaged by the force. Take care removing the machine from
the skid as it weighs 1,100 pounds!
Step Three: Use jack screws (1/2-13unc x 3” lg) in each leg to level the machine.
Step Four: Connect compressed air and electricity to the machine. Connect air supply to
an air source with a minimum line pressure of 85 psi.
Chapter
4
A
9

Step Five: Before starting the machine, load a new roll of tape on the cartridge and
thread the tape according to the arrows on the unit.
Step Six:For proper start-up procedure, see the start-up procedure section of this
manual.
Section 2: Important Considerations
• A great deal of trouble may be caused if the current is supplied by lines which are not
heavy enough. If this occurs, the controls cannot operate at their full capacity and
overheating may result. A similar condition will exist if poor electrical connections are
made. It is, therefore, worthwhile to make sure that everything is electrically correct.
• Electrical polarity must be supplied to the machine exactly as shown on the electrical
diagram. Power must be supplied to the L1 side of the circuit, and the L2 side will be
neutral.
• The compressed air supplied to the machine should be clean and dry, as the filter is only
meant to remove minor particles or slight amounts of moisture in the air line. Dirt or
moisture can cause erratic operation or failure of control valves.
(This space is intentionally blank. Continue to next page.)
10

THEORY OF OPERATION
Theory of Operation for Chain Drive Machines
he Machine E-Stop circuit is reset and the machine is started. All the cylinders go to their
home position and the machine is ready to operate.
Selector switch, SS1, is set to Automatic mode which will allow the machine to operate
continuously.
With boxes loaded in the hopper and limit switches LS1 (Vertical blank trolley home) and LS4
(Blanks in hopper ready) the vacuum cups cylinder will extend into the hopper to contact a blank.
Solenoid valve, SV5 will be energized.
The vacuum generator connected to the vertical trolley vacuum cups will be enabled. This allows
the vacuum cups to attach to the side wall of the box to be erected. Solenoid valve SV9 is
energized.
SV5 will be de-energized pulling the blank out of the hopper.
Solenoid SV6 is energized and the vertical trolley will travel downwards towards the box opening
area of the machine until finally reaching cylinder proximity switch Prox1. As the trolley is moving
downward it will first trigger cylinder proximity switch Prox4. This will signal the vacuum cylinder
to extend again to get the blank into positon to be opened. Solenoid valve SV5 will be energized.
With the vertical trolley in position at Prox1, the box opening arm is rotated into positon, contacting
the opposite side of the blank with a vacuum cup. Solenoid valve SV2 is energized and cylinder
proximity switch Prox6 is triggered.
Chapter
5
T
11

When Prox6 is triggered vacuum is applied to the cup on the box opening arm. Solenoid SV8 is
energized.
With the blank being held on both sides with vacuum cups, the opening arm is rotated back to its
home position making cylinder proximity switch Prox5. Solenoid valve SV2 is de-energized.
With the box open the minor flap folders rotate upwards closing he flaps. Solenoid SV4 is
energized.
With the minor flaps folded, both of the vacuum generators are turned off. The open box is only
being supported by the minor flap folders. Solenoid valves SV8 and SV9 are de-energized.
The vacuum trolley moves up back to the hopper to get the next blank to be opened. At the same
time the box pusher is waiting for a signal from photoelectric sensor PE2. When PE2 is triggered, it
verifies the lugs are in position to receive the erected box. Solenoid valve SV7 is energized. Then
the box pusher cylinder extended proximity switch is made, SV7 is de-energized, and the pusher
goes back to its home position.
The open box is transferred by lugs that push the box by its rear panel. The major flaps are plowed
upwards and tape is applied to the bottom of the box as it exits the machine.
The cycle repeats.
12

Theory of Operation for Belt Drive Machines
o start the machine, all guard doors must be closed, with the E-Stop reset. All cylinders will
travel to their home position. The downstream photo eye, PE1, must be clear for machine
to run.
With blanks properly loaded in the hopper, proximity switch, Prox7, will be made, allowing the
operation sequence to continue.
With the selector switch on the control box set to “Auto”, press the “Start” button. The machine
will process boxes continuously.
Solenoid valve, SV5, will be activated, extending the cylinder on the vacuum trolley to extend the
vacuum cups towards the blanks. After a timed delay, SV9 is activated, supplying vacuum to the
vacuum trolley vacuum cups. SV5 is deactivated, retracting the cylinder carrying the vacuum cups
and carrying the blank.
After a timed delay, SV6 is actuated, retracting the vertical cylinder, lowering the vacuum trolley
carrying the blank into the case forming section of the machine.
When the vertical trolley cylinder is lowered into position, Prox3 is made, activating SV2, rotating
the box opening arm towards the blank. When the box opening arm reaches the blank, Prox6 is
made, activating SV8, supplying vacuum to the box opening vacuum cups.
After a timed delay, SV2 deactivates, allowing the opening arm to rotate outward, opening the case.
When the case is opened, Prox5 is made, activating SV4, which extends the minor flap folder
cylinders, folding the minor flaps.
After a timed delay, both SV8 and SV9 are deactivated, shutting off the vacuum from all cups.
SV7 is actuated, retracting the box pusher cylinder, pushing the box into the belt drive. SV6 is
activated, extending the vertical trolley cylinder up to its home position.
The box enters the belt drive and PE3 is made, deactivating SV7 and SV10. SV7 extends the box
pusher cylinder to its home position. SV10 retracts the box squaring cylinders, relieving the squaring
paddles from the box. Once the box clears PE3, SV10 is deactivated, extending the box squaring
cylinders, resetting the squaring paddles.
When the pusher cylinder extends back to its home position, PROX1 is made, SV4 actuates,
retracting the minor flap folder cylinders, lowering the flap folder.
The cycle repeats.
T
13

OPERATING PROCEDURES
Set Up Procedure
Determine the length, width and height (with flaps up) of box in inches (see diagram).
Important: Use scales and yellow pointers. Due to changes in design for continual improvement,
the set-ups depicted in the steps below might not be exact, but similarities should exist.
Chapter
6
14