Pro Mach Wexxar BEL Series Installation and operating instructions

OPERATION & SERVICE MANUAL 65-11-7
BEL 505 / BEL 505S
SEMI-AUTOMATIC CASE FORMER
AND PACKING STATION
Wexxar Packaging Inc.
E-mail: [email protected]
Phone [phone] • Fax [phone]
65-11-07 2/5/2007

BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 2
S
SA AF FE ET TY Y C CA AU UT TI IO ON N
Although the BEL 505 & 505 ‘S’ packing stations can be used in conjunction with competitive case
taper/sealers, BELCOR cannot assume responsibility for safety issues resulting from these applications.
We specifically do not recommend using these packing stations in close proximity with
conventional back flap “kickers” and three-flap folders.
Be sure that:
• the main on/off valve at the air connection is shut off and that the red emergency stop button is
pushed down before connecting an air supply to the machine.
• the machine is disconnected from the air source before undertaking any maintenance or service
procedures. This is to avoid inadvertent machine actuation that could result in personal injury.
Never leave the machine unattended with the air switch on.
Only qualified personnel must operate the machine!
65-11-07 2/5/2007

BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 3
BEL 505
SEMI-AUTOMATIC CASE FORMER AND PACKING STATION
Standard Case Size Range:
Length Width Height
Minimum 8” (203mm) 6” (152mm) 3.5” (89mm)
Maximum 26.5” (673mm) 16” (406) Unlimited
Machine Size 37.5 (953mm) 25 (635mm) 18.5” (470mm) [min]
Case Infeed/Outfeed Height:
• UHMW Pads: 21.5” (546mm) [min] 28.5” (724mm) [max]
• Castors: 25” (635mm) [min] 32” (813mm) [max]
Power Requirements (standard):
• Compressed Air: 80-90 PSI ; 0.1 CF/Cycle
BEL 505 ‘S’
SEMI-AUTOMATIC CASE FORMER AND PACKING STATION
Standard Case Size Range
Length Width Height
Minimum 8” (203mm) 5” (127mm) 3.5” (89mm)
Maximum 16” (406mm) 15” (381mm) Unlimited
Machine Size 27.5” (700mm) 25” (635mm) 22 (560)
Case Infeed/Outfeed Height:
• UHMW Pads: 21.5” (546mm) 28.5” (724mm)
• Castors: 25” (635mm) 32” (813mm)
Power Requirements (standard):
• Compressed Air: 80-90 PSI ; 0.1 CF/Cycle
65-11-7 2/5/2007

BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 4
TABLE OF CONTENTS
INTRODUCTION.......................................................................................................... 5
ABOUT THIS MANUAL ............................................................................................................................................. 5
INSTALLATION PROCEDURES ................................................................................. 6
INSTALLING THE BEL 505 & 505 ‘S’ ........................................................................................................................6
LEVELLING THE MACHINE ..................................................................................................................................... 6
AIR CONNECTION ................................................................................................................................................... 7
OPERATION & ADJUSTMENT PROCEDURES.......................................................... 8
MACHINE SET-UP ADJUSTMENTS...............................................................................................................................8
CASE WIDTH ........................................................................................................................................................... 8
CASE LENGTH ......................................................................................................................................................... 9
MAJOR FLAP FOLDER ROLLER PLATES .............................................................................................................. 10
MACHINE OPERATION ..............................................................................................................................................11
STARTING THE MACHINE ..................................................................................................................................... 11
ERECTING A CASE................................................................................................................................................. 11
MACHINE OPERATING CYCLE ............................................................................................................................. 12
TROUBLESHOOTING GUIDE ............................................................................................. 14
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BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 5
INTRODUCTION
The BEL 505 & 505 ‘S’ are designed for semi-automatic folding of new corrugated cases. The machines
combine the following functions:
1. A bottom major and minor flap folder mechanism assist in erecting flat cartons ready for packing.
2. A packing station position to fill the case with product.
The machine does not require a high level of technical knowledge to operate.
ABOUT THIS MANUAL
The Installation section in the beginning of the manual is intended for those who will be installing and
maintaining the machine.
The Machine Set-up and Machine Operation instructions should provide a new operator with the
knowledge needed to run the machine safely and effectively. No one should operate the machine without
first reading this manual.
Following the operating instructions is a Troubleshooting section to provide solutions to common problems that
may occur with the quality of corrugated cartons used and effectiveness of the case folding process.
A separate “Technical Reference” manual or manual section provides details on parts kits, parts identification
and machine construction for those who will service and repair the machine.
PLEASE NOTE:
Best performance with BEL machines will occur when adjusted, operated and maintained in accordance
with the instructions in this manual. We cannot be responsible for unauthorized changes to the machine
or methods of its operation.
The following information is a reference guide for our standard machines. We strive to provide up-to-date
manuals with machines but we are continually improving our products and the details in the manual
provided might not exactly match the machine at the time it is shipped. Many machines are modified in
response to customer requests or as required by the case samples supplied at the time the machine is built
and the manual may not provide a complete reference to the changes or modifications. If there are any
questions about your machine not covered by the manual, please contact us and we will do our best to
provide the additional information you need.
65-11-7 2/5/2007

BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 6
INSTALLATION PROCEDURES
INSTALLING THE BEL 505 & 505 ‘S’
Unpack the machine and remove any packing material from the interior or supports from underneath used
to protect components during shipping.
Install the legs at each of the three positions on the machine frame with one nut and washer for each leg
underneath the frame and another nut and washer on the inside. If the 505 or 505S is to be mounted on
[and supported from] the case sealer with mounting options 70-378 or 70-395, refer to the instructions
included with them.
LEVELLING THE MACHINE
If standing directly on the floor, the base of the frame should be made level to ensure personnel safety,
provide optimum performance and avoid frame stress.
Please note that the standard BEL 505 & 505 ‘S’ are intended to operate in a horizontal position.
Attempting to tilt the 505 or 505 ‘S’ toward the operator will cause excessive wear in the case width
adjustment mechanism and may case it to bind or damage the width adjustment screw. A width
adjustment equalizer option 70-380 is on BEL 505’s that are used with side-tilt mounted systems.
[Another possibility for a side-tilt system is the BEL Model 507 Tilt Packing Station. It is designed to tilt
towards the operator for case erecting and loading and then back to the horizontal position for feeding
into a sealer or onto a conveyor.]
ALIGNING THE MACHINE
The machine should be securely mounted to adjoining equipment to prevent the machine moving as it
operates. If being directly connected to a BEL case sealer, it is important that the centers of both
machines be in line for ease of case transfer between machines. When a BEL 505 is provided together
with a BEL sealer a jig is provided to further assist aligning the machines. The BEL 505 should be level
with, or slightly higher than, the case sealer conveyor.
Alignment Jig
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BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 7
AIR CONNECTION
S
SA AF FE ET TY Y C CA AU UT TI IO ON N
Make sure that the red emergency stop button is pushed down (off)
before connecting an air supply to the machine.
The air may come from either a separate source or by tapping off the supply of an adjoining case sealer.
The supply must be clean factory air and must be lubricated by the unit on the machine.
Air pressure should be set to 80 psi. for most applications with a minimum setting of 65 psi. and
maximum of 100 psi.
65-11-7 2/5/2007

BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 8
OPERATION & ADJUSTMENT PROCEDURES
S
SA AF FE ET TY Y C CA AU UT TI IO ON N
3. Open a case from the flat blank and insert it into the m
4. Crank in the width adjustment until the red case
hold-down rollers are lightly gripping the sides
of the case. It should be easy to insert and
remove the case without forcing but it must
maintain contact on the white “body “ switch
roller until the case leaves the machine.
5. Re-tighten the hand knobs.
Switch off or disconnect the air supply to the machine before making any changes or
adjustments.
MACHINE SET-UP ADJUSTMENTS
Setting up the BEL 505 & 505 ‘S’ to fold a particular box size is accomplished with two main
adjustments for case width and length. There is a third adjustment to reposition the major flap folder
plates that, after initial setup, will need to be changed only where there is a large difference between cases
widths.
CASE WIDTH
1. Loosen the hand
knobs at the end
of the BEL 505
or 505 ‘S’.
2. Attach the hand
crank supplied
with the machine
on the square
shaft that extends
from either side
of the frame.
Adjust the frame
to be wider than
the case.
achine.
Case hold-
down roller
“Body”
switch roller
65-11-7 2/5/2007

BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 9
CASE LENGTH
1. Remove the case and loosen the clamp at the base of the front minor flap folding “tower “
2. Reinsert the case into the machine and position it ½” back from the minor flap folder at the exit end
of the machine. Push the tower forwards until it just contacts the back of the case. Remove the case
and tighten the tower clamp
“Body”
switch roller
Case hold-
down roller
Minor flap
folding “tower”
65-11-7 2/5/2007

BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 10
“Floor” switch
valve arm
MAJOR FLAP FOLDER ROLLER PLATES
The major flap folding plates and wheels may need to be extended to provide additional support for wide
heavy cases or retracted for narrow ones.
Important Note Regarding Major Folder Plates Adjustment: Sliding the plates in towards the
machine centre increases the case bottom support but limits the minimum width adjustment when the
major flap folder wheels hit the minor folder tower. Also, extended folder plates in the down position will
wedge against the bottom control valve / flap opener bracket as the machine is adjusted for minimum
width. If forced, either of these conditions can damage machine components.
There are two major folder plates on each side of the machine, one small and one large that are adjusted
independently.
1. Loosen the four socket-head cap screws on each side that hold the folder rollers in place. Slide the
front [large] folder to the desired position and retighten the screws.
2. Adjust the rear [small] major folder
plate. Make sure that the plate will
not contact the “floor” switch valve
arm as it moves through its arc. For
wide cases, the small folder plate will
not be able to be extended as far as
the large plate and has a separate
adjustment for this reason.
Front [large] major
flap folder plate
Rear [small]
major folder
plate
Plate adjustment
clamp screws
65-11-7 2/5/2007

BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 11
Additional Note: For wide cases on 18” & 20” maximum width 505 versions, optional roller wheels are
mounted on extensions from the folding plates to place them closer to the centre of the box for better folding
performance and product support. Extensions may need to be removed for narrow cases run on the same
machine to avoid interference with other machine components. If your application requires these extensions and
they are not provided with your machine, contact BELCOR for information and parts.
MACHINE OPERATION
S
SA AF FE ET TY Y C CA AU UT TI IO ON N
Make sure that the main on/off valve at the air connection is shut off and that the
red emergency stop button is pushed down before connecting an air supply to the machine.
STARTING THE MACHINE
Prior to starting, hand swing all moving parts to check adjustment and for any mechanical
interference. Turn on main supply valve, keeping hands clear of moving parts.
ERECTING A CASE
1. Open a case so that it is fairly square.
2. Place the open bottom into the BEL
505 or 505 ‘S’, pushing the case all
the way down to the floor switches
3. The machine will first fold the front
and rear end minor flaps, then the two
side major flaps. The case is held in
place and is ready to fill, if desired
4. When filled, or if the case is just
erected for filling downstream, push
it out of the packing station to the
next operation.
5. As the end of the case breaks contact
with the “body” switch, the 505 will
automatically reset ready for the next
case.
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BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 12
MACHINE OPERATING CYCLE
1. The bottom edges of the major flaps depress the actuators of the two “floor” switch valves and
the side of the case depresses the wheeled “body” switch valve. All three switches must be
actuated for the machine cycle to start.
2. The two small levers of the major (side) flap openers momentarily open the bottom major flaps
wider to clear the minor (end) flaps.
“Body” switch
“Floor”
switches
Bottom major flap
opener
65-11-7 2/5/2007

BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 13
3. The minor flap folders fold up both end flaps of the box bottom and retract.
Front [tower] Minor Flap
Folder
Front Minor Flap Folder
Rear Minor Flap Folder
[Machine out-feed end]
Rear Minor Flap Folder
4. The major flap folders then fold up both side flaps of the bottom and stay in position to support
the box for packing.
5. Pushing the box out of the machine breaks contact with the body switch inside the packing
station. The machine then resets, ready for the next case.
Major folder [RH
h
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BEL 505/505S SEMI-AUTOMATIC CASE FORMER & PACK STATION 14
65-11-7 2/5/2007
TROUBLESHOOTING GUIDE
Problem: Case releases, all flaps drop, during folding or packing cycle.
• Check that width adjustment is correct. If it is too wide, the wheeled “body switch” that
contacts the side of the case will reset and cause the machine to return to the start position.
• Shaking the box to level the contents can cause the body switch to reset.
• Check that the body switch is correctly adjusted and secured in the frame for proper box
contact and that the contact wheel is firmly attached.
Problem: Minor flaps fail to fold fully and return to home position, then may try to fold again.
• Check that the actuator arms attached to the floor switches (mounted on floor plates) are not
out of position or loose. Both of them should be in a position to be pushed down fully by the
bottom flaps of the open box.
Problem: Major flaps have difficulty folding and cause inner edges of minor flaps to be folded
over.
• Check that the air pressure is adequate and that the air pressure does not drop during the
cycle.
• Check that the flow controls on the small major flap opening cylinders are set so that they
will momentarily open the major flaps wider and allow the minor flaps to clear the inside of
the major flaps before releasing.
Problem: Back or front case collapses inward during minor flap folding.
• Be sure that the case width setting does not hold the box too tightly.
• Check the air pressure and volume.
• Check that the scoring on the box is adequate and promotes folding.
• Check that the flow controls on the minor flap folding cylinders are set for a fast enough
speed of the minor flap folders. Excessive speed, however, can cause damage of the folder
arms.
Problem: Packed case fails to transfer smoothly from packing station into case sealer.
• Check the height of the rollers at the outfeed end of the packing station and that the box
clears the machine frame.
• Check that the machines are aligned accurately, i.e. that the belt surfaces line up with the
insides of the packing station when in the vertical position. Use a long straight-edge to check
the alignment.

66-05-11 5/16/2007
Operation & Service Manual 65-06-11 Effective May 17, 2007
Replaces 65-06-10, March 2, 2007
BEL 252 V.02
Fully Automatic Top and Bottom Uniform Case Tape Sealer
Wexxar Packaging Inc.
Phone [phone] • Fax [phone]
E-mail: [email protected]

BEL 252 Fully Automatic Uniform Case Tape Sealer 2
66-05-11 5/16/2007
SAFETY CAUTION
WHEN THE MACHINE IS FIRST SWITCHED ON, THE CASE TOP FLAP FOLDING
SNAP FOLDERS WILL CYCLE ONCE AUTOMATICALLY. KEEP HANDS CLEAR
OF THE MACHINE.
Make sure machine is disconnected from power sources, air and electric, before
undertaking any maintenance or service procedures.
Qualified personnel only must operate the machine.
2
2
5
DEKKA
Standard Specifications:
Length Width Height
Case Size Range Minimum 8” / 203mm 6” / 153mm 4.5” / 114mm
Maximum 22” / 559mm 15” / 381mm 16” / 406mm
Machine Dimensions 58” / 1473mm 33” / 838mm 53.3" / 1353mm
In/Outfeed Height Frame 22” / 559mm
With adjustable leg extensions
[foot pad]
Minimum
Maximum
23.5” / 597mm
32” / 813mm
Speed Up to 25 cases / min.
Shipping Weight Approx. 650 Lbs.
/ 295 kg.
For further detail, see Layout Drawing 75-058

BEL 252 Fully Automatic Uniform Case Tape Sealer 3
65-06-11 5/18/2007
TABLE OF CONTENTS
Installing The BEL 252 ________________________________________________________5
LEVELING THE MACHINE_____________________________________________________5
POWER CONNECTIONS _______________________________________________________5
ELECTRIC ________________________________________________________________5
COMPRESSED AIR _________________________________________________________5
Machine Adjustments _________________________________________________________6
1. Case Height Adjustment __________________________________________________7
2. Snap Folder width adjustment _____________________________________________8
3. Conveyor case width adjustment ___________________________________________8
4. Center (Top) Ski Adjustment ______________________________________________9
5. Snap Folder Manual / Automatic Modes ____________________________________10
Operating the Machine _______________________________________________________11
Machine Sequence of Operations ____________________________________________11
Compressed Air___________________________________________________________11
Electrical Switching _______________________________________________________11
Feeding Cases ____________________________________________________________11
Automatic Stop Gate (Option)_______________________________________________11
Service and Maintenance Procedures____________________________________________12
Uni-Drive Side Belt Drive System ____________________________________________12
Chain Drive_____________________________________________________________13
Gear Reducer ___________________________________________________________13
Side Drive Belts _________________________________________________________13
Belt Replacement ________________________________________________________13
Snap Folder Adjustments And Servicing ______________________________________14
Manual / Automatic Override Control.________________________________________14
Arch Cross Member Vertical Slide Adjustment ________________________________15
Procedure to Adjust Vertical Slider Bearing Clearance ___________________________17
Preventative Maintenance Guide BEL 250/ 252 ________________________________18
For detailed Technical Reference Information, Please see publication 66-06 _________18

BEL 252 Fully Automatic Uniform Case Tape Sealer 4
65-06-11 5/18/2007
Trouble Shooting Guide ______________________________________________________19
Section 1 - Corrugated Case Quality & Specifications ___________________________19
Section 2 - Case Drive Belt System ___________________________________________20
Section 3 - Top Flap Folding ________________________________________________21
Section 4 - General Taping Conditions ________________________________________24
Section 5 - Case Infeed and Indexing _________________________________________26
Optional Equipment _______________________________________________________27

BEL 252 Fully Automatic Uniform Case Tape Sealer 5
65-06-11 5/18/2007
Installing the BEL 252
Remove the through bolts that secure the machine to the base. Use wood dunnage blocks under the frame
when using a forklift to lift the machine off its shipping base and to position it.
Note: If the machine will be moved frequently, optional casters are available.
Leveling the Machine
The machine should be level to avoid frame stress and ensure optimum performance. An adjustable height
footpad kit is included as standard equipment and can be used to level the machine on an uneven floor.
The machine should be anchored to adjoining equipment or the floor to prevent any movement of the
machine by reactive forces that may occur as sealed cases are being driven through the machine outfeed.
Power Connections
Electric
The standard BEL 252 requires 120 VAC / 8A. single-phase electrical supply. The electrics are to
NEMA 12 specifications and a 1/2 horsepower TEFC motor powers the conveyor drive. A minimum
AWG 14 gauge power extension cord with standard three pin connection must be used to connect the
machine to the power source.
A dedicated electrical circuit is recommended for this machine. If any electrical connections are needed
to install the machine an electrician qualified in your jurisdiction should provide them.
Compressed Air
The BEL 252 requires an air supply that must be clean and dry, not less than 65 P.S.I. to a maximum of
120 P.S.I. with an optimal pressure of 80 P.S.I. The volume of air required for the BEL 252 is rated at
0.1 C.F./cycle at 80 P.S.I. (6 Bar). As well, the incoming air supply line must be of sufficient diameter to
provide an adequate amount of air without pressure drops when the machine is cycling, a 1/2” air line size
is recommended.
One of the most common causes of inconsistent machine performance is inadequate air supply therefore
the foregoing requirements must be carefully observed to assure satisfactory operation.
The BEL 252 is equipped with a manual compressed air on-off/dump valve, unless otherwise specified,
and a filter/regulator/lubricator, which should be checked daily to ensure the lubricator reservoir is filled,
air pressure regulated to the proper setting, and any water drained from the filter.

BEL 252 Fully Automatic Uniform Case Tape Sealer 6
65-06-11 5/18/2007
Machine Adjustments
Safety: Disconnect machine electrics and compressed air before making any machine
adjustments.
There are three main adjustments required in setting up the BEL 252 to run a particular case size:
1. Case height ‘E’ - made with top hand wheel to move the machine head assembly up and down to the
height of the box.
2. Snap Folder case width adjustment ‘D’- made by loosening the locking handles above each folder
unit and pulling or pushing a folder from the side of the machine. A self-centering mechanism moves
both folders together.
3. Conveyor case width adjustment ‘D’- made with side hand crank to move side belt conveyors in
and out to fit the width of the box.
D
120-093
D
E
Snap Folders
[TOP FLAP
FOLDERS]
Bottom Tape Head
Top Tape Head
UNI-Drive side belt
Conveyor
CONVEYOR CASE
WIDTH ADJUSTMENT
DIMENSION ‘D’
CASE HEIGHT ADJUSTMENT
DIMENSION ‘E’
On/Off Switch
Snap Folder WIDTH
ADJUSTMENT
DIMENSION ‘D’
Compressed air supply [LH rear
corner
]