Pregis SHARP MAX 1143 User manual

Rev. 11 Original Printed In English
Copyright © 2021
THE MAX™
Operator Manual
Models 1143 & 1145
Parts: [phone] ext. 1571
[email protected]
Service: [phone] ext. 1572
[e-mail]

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MAX™ Operator Manual©Original Printed In English
SECTION 1 –INTRODUCTION
Prefix
Introduction
About This Manual 1-1
General Information
Important Safety Information 1-2
EZ-Bags® and Film Materials 1-4
Specifications
Packaging Specifications 1-5
Machine Specifications 1-5
Machine Dimensions 1-6
Theory of Operation
Manual Mode 1-9
Filler Mode 1-9
Auto Mode 1-10
Auto Filler Mode 1-10
Parts Counter Mode 1-11
Batch Counter 1-12
Event Log 1-14
Permissive & Special Conditions 1-15
Security 1-16
SECTION 2 –SETUP & ADJUSTMENTS
Machine Placement
Electrical 2-1
Air Supply 2-2
Loading Bag Film - Standard Unwind 2-3
Loading Bag Film - Box Power Unwind 2-4
Machine Adjustments
Height 2-7
Head Rotation 2-8
Load Plate 2-9
Load Shelf 2-9
Brake Strap 2-9
Dancer Weight 2-9
Air Pressure - Box Power Unwind 2-9
Pinch Roller Closing - Box Power Unwind 2-10
SECTION 3 –CONTROLS
Touchscreen
Left Menu Bar 3-1
Fault Banner 3-2
Cycle Start 3-2
Help Screen 3-3
SECTION 4 –HMI SCREENS
Main Menu
Home Screen 4-1
Bagger Settings Screen 4-2
I/O Screen 4-3
Job Setup Screen 4-4
Job Detail Screen 4-5
Admin Screen 4-7
Communication Screen 4-8
Security Screen 4-9
Dashboard Setup Screen 4-10
Dashboard Screen 4-11
Directories Screen 4-12
Event Log Screen 4-13
Option Screens
Options Screen 4-14
Printer Screen 4-16
Package Eject Screen 4-17
Filler Screen 4-18
Exit Conveyor Screen 4-19
Bag Open Assist Screen 4-20
Seal Flattener Screen 4-21
Funnel Screen 4-22
Verification Screen 4-23
Package Condenser Screen 4-24
Trim Seal Screen 4-25
Service Screen
Main 4-26
Slot 1 4-27
Slot 3 4-28
Slot 5 4-29
TABLE OF CONTENTS

MAX™ Operator Manual©Original Printed In English
Printer Display
Display Layout 4-30
Soft Keys 4-31
System Menu 4-32
Printer Icons 4-33
User Settings 4-34
SECTION 5 –MACHINE OPERATION
Operation
Machine Operation 5-1
Creating a Job 5-2
Editing a Job 5-3
Deleting a Job 5-4
Loading Print Job 5-5
Cleaning Machine 5-5
Machine Maintenance 5-6
SECTION 6 –FAULT & ALERT MANAGEMENT
Fault Management
Faults 6-1
Alert Management
Alerts 6-6
SECTION 7 –APPENDIX A
Warranty 7-1
Airborne Noise Emissions 7-2
CE Declaration 7-3
SECTION 8 - APPENDIX B
CE Power Up 8-1
CE Power Down Procedure 8-2
CE Machine Placement 8-3
TABLE OF CONTENTS

MAX™ Operator Manual©Original Printed In English
COMPLETE POWER-UP PROCEDURE*
1. Connect Power Cord to the 120V Power Entry
Module.
2. Turn switch to the ON position. The HMI will au-
tomatically start up when Power Entry Module
Switch is turned ON.
3. Release the E-Stop Button and press the Green
Power Button. The green light should illuminate
and energize the MCR.
Note: If the bagger has the Stack Light option,
the horn will sound until the HMI program has
finished loading. To prevent horn blowing, do
not press the Green Power Button until HMI pro-
gram is loaded. The horn then can be silenced
by pressing the reset button.
* CE models, see Page 8-1.
QUICK START-UP GUIDE*
Read and understand the en-
tire Operator Manual before
attempting any procedures on
this machine. Failure to follow
these instruction can result in
serious injury.

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MAX™ Operator Manual©Original Printed In English
COMPLETE POWER DOWN SEQUENCE
The bagger must be properly Power down in the
correct sequence.
1. From the Main Menu Screen, press and hold
the “Shutdown HMI” button for 3 seconds. The
HMI program will start shut down.
2. IMPORTANT! ALLOW THE HMI/PC TO POW-
ER DOWN COMPLETELY BEFORE CONTINU-
ING TO NEXT STEP.
- The Windows software must shut down
properly.
- Do not remove power during this process.
Corruption of Windows files could occur.
3. WHEN SCREEN IS BLACK, switch Power Entry
Module Switch to OFF. The machine is now
electrically shut down.
* CE models, see Page 8-2.
BAGGER SHUT DOWN PROCEDURE*

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MAX™ Operator Manual©Original Printed In English
Thank you for purchasing the Sharp MAX™ bagger. The Sharp MAX™ is the low cost solution for manually
bagging product, dramatically reducing packaging costs and improving package quality. The Sharp MAX™ has
an optional integrated high-performance, low-cost ribbon printer for printing barcodes, text, or graphics on the
packaging material.
Both models of the Sharp MAX™ can be upgraded to a version that meets the EU safety, health, and envi-
ronmental requirements.
The Sharp MAX™ bagger can be upgraded from a manual, hand-loaded operation, to a fully automated pack-
aging system. A variety of options, including weighers, counters, and conveyors are easily connected via option-
al interfaces.
Your Sharp MAX™ is a product of extensive research and field testing with the following features:
• State of the art Step Logic Programming technique that logically controls each machine
action (step) in sequence and verifies that the correct action occurred with sensor feed-
back.
• Simplified layout of digital outputs in PLC program for ease of troubleshooting.
• Improved fault handling that can display multiple fault conditions simultaneously.
• Simplified operator set-up.
• Displays all PLC I/O status, including Expansion I/O.
• Manual motion pushbuttons on Options Screen that provide both text and color cues as to
the state of the device.
• Help Screens show setting range and default values.
• Speed settings in inches/second instead of raw numbers.
The materials used were selected for maximum durability and optimum performance. Every unit is thoroughly
inspected and tested prior to shipment.
ABOUT THIS MANUAL
This manual has been prepared for your use in operating the Sharp MAX™ Modular System. Included in the
manual are helpful facts on operating and basic troubleshooting information.
It is important that you familiarize yourself with the product as much as possible before operating or trouble-
shooting.
Make sure you read through the IMPORTANT SAFETY INFORMATION and INTRODUCTION sections of this
manual before operating this machine.
PREFIX

MAX™ Operator Manual©Original Printed In English
SECTION 1 - INTRODUCTION
GENERAL INFORMATION
1-1
READ ALL INSTRUCTIONS BEFORE OPERATION
• Upon receipt, unpack and inspect the unit for damages that may have occurred during shipment. Sharp
Packaging is not in any way responsible for any damages that occur during transport. If you receive dam-
aged equipment, it is your responsibility to make a claim with the transporter.
• Read instructions carefully. Be familiar with the controls and proper use of the unit. Do not operate the ma-
chine when tired, ill, or under the influence of alcohol, drugs or medication.
• The instructions and data in this manual are vital to the proper installation and operation of this equipment.
In order to avoid delays due to faulty installation and operation of the machine, please see that these in-
structions are read by the persons who will install or operate or maintain the machine.
• The WARNING instructions issued on this manual are not meant to cover all possible conditions and situa-
tions that may occur. It must be understood that common sense, caution and carefulness are factors that
cannot be built into all machines. These factors must be supplied by the persons installing, maintaining, or
operating the machine. Failure to install, maintain, and/or operate the equipment according to the manufac-
turer’s instructions may result in conditions which can produce bodily injury and/or property damage. Con-
tact Sharp Packaging about any problems or conditions you do not fully understand.
EQUIPMENT SAFETY FEATURES
The safety information presented in this manual are guidelines that should be followed by all personnel. Anyone
operating or maintaining the equipment should read and follow all safety information in this manual, without ex-
ception.
DO NOT DISABLE OR REMOVE SAFETY DEVICES DESIGNED INTO THIS MACHINE.
All Operators should be familiar with their own Labor Protection Guidelines. Hands, arms, hair and clothing
should not be near any moving or heating parts of the machine. Do not turn the machine ON if any of the ma-
chine’s components have been removed or modified.
Emergency Stop (E-Stop) Button
An Emergency Stop (Red) Button is located on the lower left corner of the Display Panel, which immediately
stops the machine when pressed bye de-energizing power to the PLC outputs, motors, and motor drives.
FIRE PREVENTION
Keep a fire extinguisher near the machine. Keep machine away from any sparks, flames and flammable materi-
als. Unplug the machine before maintaining or cleaning. All electrical components must be in good condition and
clean.
Electrical fires can occur if any wires are scratched, corroded, color-faded, lost their insulation or have damaged
wire ends. These should be changed immediately.
Any exposed electrical components should never come into contact with the ground-connector and any other
electrically conductive objects such as tools.
ELECTRICAL PRECAUTIONS
Ensure no liquids are near the machine to eliminate the possibility of spilling onto any electrical components and
creating a short circuit.
Should a liquid spill onto the machine, turn off the power immediately and once having cleaned the liquid, test all
the electrical components to ensure they are functioning properly. To avoid short-circuiting, keep all wires and

MAX™ Operator Manual©Original Printed In English
connections clean and keep your body, hand-held tools and any other electrically conductive objects away from
any exposed electrical components.
Ensure the electrical cabinet is always closed, unless needed for maintenance. Always ensure that the ground
wire is firmly connected with the ground before starting the machine. Use double grounding for added protec-
tions. After installation, check all electrical connections and test all electrical circuits before starting the machine.
GROUNDING INSTRUCTIONS
Improper connection of the equipment grounding conductor can result in a risk of electrical shock. Check with a
qualified electrician or service person if you are in doubt as to whether your machine outlets are properly ground-
ed.
This machine must be grounded. In the event of malfunction or breakdown, grounding will reduce the risk of
electrical shock by providing a path of least resistance for electrical current. This machine is equipped with a
cord having an equipment-grounding conductor for a 3 prong grounding plug. The plug must be connected into
an outlet that is properly installed and grounded in the accordance with all local codes and ordinances. Do not
modify the plug provided with the machine.
If your electrical supply does not meet the above specifications, or if you are unsure your building has an effec-
tive ground, have a qualified electrician or your local electrical utility company check the ground and correct any
problems.
The safety information presented is a guideline that should be followed by all personnel. Anyone operating or
maintaining the equipment should read and follow all the information in this manual, without exception.
STORAGE
If the machine will not be used for a considerable amount of time, it should be stored in the original shipping
crate to protect it from damage.
SECTION 1 - INTRODUCTION
GENERAL INFORMATION
1-2
DEFINITION OF TERMS
Throughout this manual, you will find the follow-
ing safety notices with this accompanying sym-
bol.
This symbol signifies important safety issues regard-
ing the operation and maintenance of the Sharp
MAX™.
SAFETY RULES AND PROCEDURES
The machine requires regular, periodic maintenance
to ensure reliable service. No maintenance should be
performed unless the safety precautions for mainte-
nance are thoroughly understood.
• Follow all instructions in this manual for safe oper-
ation.
• Follow all company and industry standard safety
policies regarding this kind of machinery that may
exceed those listed in this manual.
• Keep all safety features, guards, interlocks and
sensors in good working order.
• Always ensure that all mechanical motion has
stopped and allow any heated components to cool
down before removing any machine parts.
• Keep the area surrounding the machine free from
debris. Spent film/bags should not be allowed to
accumulate around bagger.

MAX™ Operator Manual©Original Printed In English
EQUIPMENT SAFETY FEATURES
The Sharp MAX™ is equipped with guards covering
the heated sealing area and the underside of the
Head Assembly. DO NOT operate the MAX™ with
these or any other guards removed.
The Top Lexan® Guard sits on top of the Jaw Guard.
The shape allows for loading of product into the bags.
Sharp Packaging recommends the MAX™ be
equipped with the optional Dual Palm Buttons to start
the cycle to ensure the operator’s hands are clear of
the sealing and pressure bars when the machine is
cycled.
An Emergency-Stop Button is located on the Control
Panel, which immediately stops the machine when
pressed by de-energizing power to the Master Control
Relay, PLC outputs, motor, motor drive and air valves.
Figure 1-3A.
SAFETY LABELS
Figure 1-3B shows a label that is placed on the Sharp
MAX™ wherever a removable guard or panel is at-
tached. Always disconnect electrical power from the
machine prior to removing any guards and/or panels.
OBSTRUCTION SENSING JAW
The Sealing Assembly is equipped with an Obstruc-
tion Sensing Jaw, which can detect an obstruction in
the sealing area. If the jaw sensors detect an object
preventing the jaw from closing, the jaw solenoid will
de-energize and place the machine into a fault condi-
tion.
A message appears in the display window informing
the operator of the jaw fault, allowing the operator to
clear the seal area and reset the bagging cycle.
SECTION 1 - INTRODUCTION
IMPORTANT SAFETY INFORMATION
1-3
Emergency Stop Pushbutton Jaw Guard
Figure 1-3A. Safety Features

MAX™ Operator Manual©Original Printed In English
SHARP EZ-BAGS® and FILM MATERIALS
Call Sharp Customer Service ([phone]) to
order Sharp EZ-Bags® and for information regarding
film and bag specifications.
The Sharp MAX™ is designed to use a wide variety
of bag sizes and materials. Sharp EZ-Bags® are rec-
ommended for optimum operating performance, effi-
ciency and safety. System performance specifications
are based on utilizing consistent, high quality, pre-
opened bags. Any bag used must meet Sharp Pack-
aging Systems’ manufacturing tolerances. The follow-
ing list shows some of the Sharp EZ-Bags® films
available through Sharp Packaging Systems.
• Low Density Polyethylene (LDPE)
• Linear Low Density Polyethylene (LLDPE)
• High Molecular Weight, High Density
• Polyethylene (HMWHDPE)
• Laminated Oriented Polypropylene
(Laminate/OPP)
• Polypropylene
• Metallic Films (including conductive films)
• Co-Extended Films (combination films)
• Other Laminates (any other laminates lami-
nated with polyethylene)
• Anti-static and Turbo
• Electric films
• VCI corrosion inhibiting films
• Opaque films
THERMAL TRANSFER RIBBONS
Sharp thermal transfer ribbons are selected specifical-
ly for use with our printer. Use of ribbons other than
those supplied by Sharp, may result in a poor quality
printing, especially barcodes and their ability to be
successfully scanned.
• Recommended Sharp ribbons are:
•Black ink, scratch and smudge resistant
•2000’ (609.6 meters), 3.5 to 4.5 microns thick.
•1” core, no notch required
•Ink side in
•Back coated ribbons only
Special purpose thermal transfer ribbons, sizes other
than those listed above, such as colored ribbons, or
low temperature release ribbons are also available.
SECTION 1 - INTRODUCTION
SHARP EZ-BAGS & FILM MATERIALS
1-4

MAX™ Operator Manual©Original Printed In English
PACKAGING SPECIFICATIONS
Table 1-5A. 1143 Packaging Specifications.
Table 1-5B. 1145 Packaging Specifications.
MACHINE SPECIFICATIONS
Table 1-5B. Machine Specifications
** Power source for CE versions only.
^ Weight depends on installed options and model of bagger.
* Sealing options, size of package, along with weight and size of product will cause rate to vary.
SECTION 1 - INTRODUCTION
SPECIFICATIONS
1-5
BAG WIDTH BAG LENGTH FILM GAUGE
MINIMUM 2” (5.1 cm) 3.5” (8.9 cm) .001” (1 mil) 25 Microns
MAXIMUM 12” (30.5 cm) 32” (101.6 cm) .004” (4 mil) 100 Microns
POWER
(SOURCE) WEIGHT AIR REQUIREMENT SPEED OPERATING TEMP HUMIDITY RANGE
115VAC 50/60 Hz,
10 Amps
**230VAC 1Phase,
5 Amp, 50-60 Hz
Est. 500
lbs.^
(227 kg)
80 PSI (5 SCFM)
(5.5 Bar)
50 Bags per
Minute*
32° - 140° F
0° – 40° C
10% - 90% RH Non-
Condensing
BAG WIDTH BAG LENGTH FILM GAUGE
MINIMUM 2” (5.1 cm) 4.5” (11.4 cm) .001” (1 mil) 25 Microns
MAXIMUM 20” (50.8 cm) 32” (101.6 cm) .004” (4 mil) 100 Microns

MAX™ Operator Manual©Original Printed In English
SECTION 1 - INTRODUCTION
MACHINE DIMENSIONS
FRONT VIEW
Bagger dimensions viewed from front.*
Measurements are in inches.
Table 1-6. 1145 Front View.
* The 1143 model adjusts to the same height.
1-6

MAX™ Operator Manual©Original Printed In English
SECTION 1 - INTRODUCTION
MACHINE DIMENSIONS
SIDE VIEW
Bagger dimensions viewed from side.*
Measurements are in inches.
Table 1-7. 1145 Side View
* 1143 model has same height adjustments.
1-7

MAX™ Operator Manual©Original Printed In English
SECTION 1 - INTRODUCTION
MACHINE DIMENSIONS
TOP VIEW
Bagger dimensions viewed from top.*
Measurements are in inches.
Table 1-8. 1145 Top View
* The 1143 model is 45.32” wide and 39.81” deep.
** Center of Gravity for 1143 Model is 26.90” wide and 23.32” deep.
1-8

MAX™ Operator Manual©Original Printed In English
1-9
SECTION 1 - INTRODUCTION
THEORY OF OPERATION
The MAX™ machine have four distinct operating modes: Manual, Auto, Filler, and Auto Filler. Manual and Auto
modes are built into the machine and require no optional equipment or changes to the Factory Configuration.
Filler and Auto Filler are optional and must be setup in the Factory Configuration screen.
To better define these terms, a Filler is a machine such as a weigh scale, vibratory bowl, or in-feed conveyor
that will fill the open bag with product, prior to sealing the bag. A Filler requires the use of Handshaking I/O be-
tween the bagger PLC and the Filler, so that the Filler will know when to deliver product to the bagger and the
bagger will know when to cycle.
The term Auto refers to how the bagger cycles. If the machine cycles bags continuously without the operator
manually initiating each cycle start, not including the first bag out, then the machine is cycling automatically
(Auto). If each bagger cycle requires the operator to manually press a cycle start button, foot switch, etc., then
the machine is said to be cycling in Manual Mode.
MANUAL MODE
The Bagger Mode viewed from Dashboard Screen.
Filler = OFF
Auto = OFF
Both the Filler and Auto buttons are OFF at the HMI. In manual mode the operator hand loads or fills each
opened bag and then cycles the bagger. The operator initiates a cycle by one of these methods:
1. Stepping on the Foot switch.
2. Pressing the Cycle pushbutton on the HMI.
3. Pressing the optional Optical Touch buttons (anti-tie down).
In manual mode, the machine cycles one bag at a time. Cycle rates in this mode are largely dependent upon the
loading speed of the operator.
FILLER MODE
Filler = ON
Auto = OFF
With Filler ON and Auto OFF, the bagger will run in “Filler Mode”. This mode cycles a single bag out each time
and requires the operator to initiate a Cycle Start for each bag. In this mode, a filler device or machine does the
actual loading or filling of the open bag.
The Filler uses handshake signals to synchronize with the bagger for product delivery. A bagger output, signals
the Filler to deliver product and a bagger input, signals when the Filler is done. For example, Filler Mode could
be used when an operator is hand loading literature after the in-feed conveyor delivered its separate part or
component.

MAX™ Operator Manual©Original Printed In English
1-10
SECTION 1 - INTRODUCTION
THEORY OF OPERATION
Ready for Filler (O:3/00) - The bagger PLC (Programmable Logic Controller) turns on this output as follows:
1. The machine has successfully completed a cycle and presented a new bag.
2. If the bagger is equipped with a positive entry funnel.
• The funnel is opened
3. If the bagger is equipped with a positive entry funnel AND “Bag Opened” Sensor (s):
• The funnel is opened
• The sensor detects that the bag is positively opened.
Once the above condition (s) is (are) met the PLC program turns on O:3/00, essentially telling the Filler device
that a bag is present and ready to be filled. The filling device releases its product into the open bag.
Filler Done (I:2/00) - The Filler device will turn on the bagger PLC input I:2/00
This signals the bagger that the filler has completed delivery of the product. The filler machine must include a dry
contact isolation relay for its signaling device to ensure electrical isolation between the Filler and the Bagger
PLC.
The filler function has a separate detailed specification, “Sharp Packaging Filler Handshaking”. The specification
covers all Sharp Baggers and includes signature sign-off lines so that Filling machine vendors are in 100% com-
pliance with this specification. This also ensures proper operation of a complete system.
AUTO MODE
Filler = OFF
Auto = ON
With Filler OFF and Auto ON, the bagger will run in “Auto Mode”. In Auto Mode the machine operator manually
fills the opened bag, while the machine cycles automatically. The cycle is started by means of a time delay
called the “Auto Dwell Timer”. This allows the bagger machine to be self paced, when production rates are criti-
cal. The Auto Dwell timer allows the operator time to manually drop product into the open bag. When the time
delay is ended the bag is sealed and the next bag is fed out. The Load Dwell time is adjustable at the HMI.
The operator initiates the first bag out and Auto Mode is immediately activated. When the bag is opened, the
operator loads the bag (Load Dwell Timer is timing). When the timer finishes, the bagger automatically starts the
bagger sealing cycle and feeds out the next bag. To cancel Auto Mode, the operator can press the Stop Button
on the HMI.
AUTO FILLER MODE
Filler = ON
Auto = ON

MAX™ Operator Manual©Original Printed In English
1-11
SECTION 1 - INTRODUCTION
THEORY OF OPERATION
With Filler and Auto both ON the bagger will run in “Auto Filler Mode”. In this mode a Filler device is used to both
fill and automatically initiate the next cycle. This is accomplished by means of hand-shaking I/O provided in the
bagger's standard control interface. The Filler device must comply with the “Sharp Packaging Filler Handshaking
Specification”.
Ready for Filler - This output turns ON only if the following conditions have been met:
1. The machine has successfully completed a cycle and presented a new bag, ready to be filled.
2. IF the bagger is equipped with a positive entry funnel AND “Bag Opened” sensor (s):
• The sensor detects that the bag was positively opened.
Once the above condition (s) is (are) met the PLC program turns on O:3/00, essentially telling the Filler device
that a bag is present and ready to be filled. The filling device releases its product into the open bag. The Filler
device will turn on the PLC input I:2/00 Filler Done, signaling the bagger that it has completed filling the bag.
When the PLC reads I:2/00 as ON, it resets handshake output O:3/00 to OFF. This also causes a Filler Drop
Timer to start in the PLC. This time delay can be adjusted by the user. The next bagger cycle will automatically
start upon completion of the time delay. The bag is sealed and the next bag is fed out, opened, and made ready
for the filler. O:3/00 is again turned ON when the bagger cycle is completed without fault.
Auto Filler Mode makes full use of the handshaking I/O signals for the Filler, while automatically cycling the ma-
chine on a continuous basis. Auto Filler Mode can be easily cancelled by pressing the Stop Button on the HMI.
PARTS COUNTING
The Batch Counter is turned on from the Bagger Settings Screen and is viewed from Dashboard Screen.
The bagger has a setting for counting parts. Parts Counting mode is used in conjunction with the Filler mode.
When the parts counter is turned on, the bagger counts each part as it is being loaded into the opened bag.
When the terminal count is reached, the Filler Trigger signal is turned on to start the Filler Drop Timer.
Filler = ON
Auto = ON/OFF
Parts Counter = ON
Actual Count – The number below “Parts Counter” displays how many parts have been counted. This number
resets to 0 once the bagger cycle is initiated or if Part Counter is turned off. The Target is determined in the Job
that has been loaded from Job Setting Screen.
Parts can be loaded and counted in the following ways:
1. Filling Machine
• An automatic filling Machine that can deliver one part at a time and signal the bagger using the “FILLER
DONE” input I:2/00. The bagger will count each rising edge of I:2/00 as a single part. When the parts
counted equals the target value, the filling cycling is completed and the bagger will automatically cycle af-
ter the drop timer has expired.
• When the Parts Counting is done by a filler, it must only deliver parts or attempt to count when the O:3/00