ROVEMA CMK User manual

ROVEMA Packaging Machines L.P.
650 Hurricane Shoals Road, NW
Lawrenceville, GA 30045
Phone: [phone]
Fax: [phone]
http://www.rovema.com
CMK
Continuous Motion Cartoner
Operator’s Manual
Customer:
Machine: 200246
Order No.: 39077

Rovema CMK Operator’s Manual
Table of Contents
200246 CMK Operators Manual (02/06/2006) i
Table of Contents
Section 1: Introduction....................................................1-1
About this Manual...................................................................................1-2
Symbol Descriptions...................................................................................1-2
Introduction to the CMK........................................................................1-3
Main Areas..................................................................................................1-3
Section 2: Safety Instructions.........................................2-1
Operator Safety........................................................................................2-2
Operator Safety Guidelines.........................................................................2-2
Sound Level................................................................................................2-3
In Case of Danger.......................................................................................2-3
Component Safety ..................................................................................2-4
Electrical and Control System.....................................................................2-4
Spare Parts.................................................................................................2-4
Maintenance...............................................................................................2-4
Safety Devices..........................................................................................2-5
Machine View .............................................................................................2-6
Dangerous Areas........................................................................................2-7
Guard Doors...............................................................................................2-7
Changes and Modifications.........................................................................2-7
EMERGENCY STOP Push-Button.............................................................2-8
Safety Labels..............................................................................................2-9
Lockout Procedures.............................................................................2-10
Air Supply Lockout....................................................................................2-10
Electrical Power Supply Lockout...............................................................2-11
Section 3: Functional Descriptions................................3-1
Functional Descriptions........................................................................3-2
Variable and Fixed Side..............................................................................3-2
Carton Production.......................................................................................3-3
Case Production.........................................................................................3-3
Carton Material...........................................................................................3-3
Carton Designations...................................................................................3-4
Gluing .........................................................................................................3-4

Rovema CMK Operator’s Manual
Table of Contents
200246 CMK Operators Manual (02/06/2006) ii
Transporting and Shipping..................................................................3-5
Transporting Cartons..................................................................................3-5
Shipping Cartons........................................................................................3-5
Storage........................................................................................................3-6
Storage Conditions.....................................................................................3-6
Carton Considerations..........................................................................3-7
Dimensional Deviations ..............................................................................3-7
Glue Placement..........................................................................................3-7
Folds...........................................................................................................3-8
Fiber Direction ............................................................................................3-8
Grooving.....................................................................................................3-8
Scoring .......................................................................................................3-8
Bent or Curved Cartons..............................................................................3-9
Gluing Considerations ........................................................................3-10
Processing Data .......................................................................................3-10
Glue Vapors..............................................................................................3-11
Cleaning the Glue Applicator....................................................................3-11
Properties .................................................................................................3-12
Processing Temperature ..........................................................................3-12
Open Time................................................................................................3-12
Relationship Between Temperature and Viscosity....................................3-12
Contact Pressure......................................................................................3-13
Heating Time ............................................................................................3-13
Section 4: Parts and Functions ......................................4-1
Areas of the Machine.............................................................................4-2
Sequence of Operations.............................................................................4-2
Carton Supply...........................................................................................4-3
Carton Supply Setup...................................................................................4-4
Carton Magazine......................................................................................4-5
Separation of Cartons.................................................................................4-6
Front and Rear Pushers .............................................................................4-7
Hold Down Device...................................................................................4-8
Carton Erector..........................................................................................4-9
Flap Raiser ...............................................................................................4-10
Side Guides and Air Nozzle......................................................................4-11
Carton Conveyor ...................................................................................4-12
Carton Chain.............................................................................................4-13
Front Flap Closers....................................................................................4-14
Rear Flap Closers.....................................................................................4-15
Bucket Conveyor...................................................................................4-16

Rovema CMK Operator’s Manual
Table of Contents
200246 CMK Operators Manual (02/06/2006) iii
Product Insertion – Barrel Loader...................................................4-17
Gluing Station.........................................................................................4-19
Closing Flaps..........................................................................................4-20
Flap Guides.............................................................................................4-21
Carton Guides ........................................................................................4-22
Drying Zone.............................................................................................4-23
Carton Removal Chain ........................................................................4-25
Product Reject Conveyor...................................................................4-26
Bag Transfer Stations..........................................................................4-27
Section 5: Operator Controls..........................................5-1
HMI (Human-Machine-Interface).........................................................5-2
Menu Tree ..................................................................................................5-3
Parameters and Submenus .................................................................5-4
Parameters and Submenus........................................................................5-4
Main Parameters Screens ..........................................................................5-5
Main Parameters Descriptions................................................................5-6
Carton Magazine Parameters Screens.......................................................5-8
Carton Magazine Parameters Descriptions.............................................5-9
PLS Timing Channels Screens.................................................................5-10
Cartoner PLS Parameters Descriptions ................................................5-13
Bag Transfers Screens.............................................................................5-15
Bag Transfer Parameters Descriptions .................................................5-18
Bagger Sync Screens...............................................................................5-21
Bagger Sync Parameters Descriptions .................................................5-23
Cartoner Glue Setup Screen.....................................................................5-26
Checkweigher Feedback Screen..............................................................5-27
Checkweigher Feedback Parameters Descriptions...............................5-28
Additional Screens ...............................................................................5-29
Adjustments Screen..................................................................................5-29
Servo Menu Screens................................................................................5-30
Batch Control Menu..................................................................................5-31
Batch Control Menu – Continued..............................................................5-32
Downstream Setup Menu .........................................................................5-33
Cartoner Setup Screen.............................................................................5-34
Cartoner Setup Screen - Continued..........................................................5-35
Bag Transfer Setup Menus.......................................................................5-36
Configuration Screen................................................................................5-37
Panelview Config Mode............................................................................5-37
Copy Current Parameters to All Recipies .................................................5-37
Main Drive Servo......................................................................................5-37

Rovema CMK Operator’s Manual
Table of Contents
200246 CMK Operators Manual (02/06/2006) iv
PLS (Programmable Limit Switch) Config.................................................5-38
PLS (Programmable Limit Switch) Compensation Parameters.................5-39
Shift Register Setup..................................................................................5-40
Recipe Management Screen..............................................................5-41
Recipe Management Screen ....................................................................5-41
Indication of Edited Recipe.......................................................................5-42
Save To Current Recipe Screen...............................................................5-42
Save To Selected Recipe Screen.............................................................5-43
Load Recipe Screen.................................................................................5-44
Rename Recipe Screen............................................................................5-45
View Recipe List Screen...........................................................................5-46
View Data Screen.....................................................................................5-47
View I/O Screens......................................................................................5-48
PanelView Configuration Screen..............................................................5-49
Buttons and Switches..........................................................................5-50
MAIN DISCONNECT Switch.....................................................................5-51
MACHINE READY Push-Button...............................................................5-51
JOG/RUN Push-Button.............................................................................5-52
STOP Push-Button...................................................................................5-52
EMERGENCY STOP Push-Button...........................................................5-53
Air Disconnect Handle ..............................................................................5-54
Section 6: Operating Procedures...................................6-1
Startup.........................................................................................................6-2
Preparatory Actions...............................................................................6-2
Activate the Machine..............................................................................6-3
Jogging the Machine...................................................................................6-4
Routine Operations.................................................................................6-5
Routine Operations - Continued........................................................6-6
Shut Down the Machine........................................................................6-7
Emergency Stop......................................................................................6-8
Product Rejection ...................................................................................6-9
Section 7: Working with Components ...........................7-1
Adjusting Dimensions on Dials and Scales.................................................7-3
Carton Dimensions.................................................................................7-4
Set Up and Adjustments.....................................................................7-10
Carton Supply.........................................................................................7-12
Adjusting the Carton Guide.......................................................................7-12
Supply Conveyor Tension.........................................................................7-13

Rovema CMK Operator’s Manual
Table of Contents
200246 CMK Operators Manual (02/06/2006) v
Carton Magazine....................................................................................7-14
Adjusting the Retaining Roller...................................................................7-14
Front and Rear Pusher Adjustment Instructions.......................................7-15
Main Drive Chain ...................................................................................7-16
Main Drive Chain Base Setting.................................................................7-16
Chain Tension Drive Chain.......................................................................7-17
Tension Drive Chain Drive Belt.................................................................7-18
Carton Chain...........................................................................................7-20
Chain Drivers Adjustments .......................................................................7-20
Carton Chain Base Setting Adjustment ....................................................7-22
Tensioning the Carton Chain....................................................................7-23
Position Drivers Vertically.........................................................................7-24
Replacing Chain Segments ......................................................................7-25
Tensioning Carton Chain Drive Belts........................................................7-26
Tension Drive Chain: Main Shaft-Carton Chain.......................................7-27
Barrel Loader..........................................................................................7-28
Upper Conveyor Height ............................................................................7-28
Insertion Slides Cover Guide....................................................................7-29
Tensioning Upper Conveyor (Barrel Loader) Chains................................7-31
Flap Closers............................................................................................7-32
Flap Closer Base Settings ........................................................................7-32
Flap Closer Drive Belts Tension ...............................................................7-33
Glue Device.............................................................................................7-34
Glue Heads Height Adjustment.................................................................7-34
Distance from Carton................................................................................7-34
Glue Station Controls................................................................................7-34
Drying Zone.............................................................................................7-35
Drying Zone Adjustments .........................................................................7-35
Guides.......................................................................................................7-36
Flap Guide Adjustments ...........................................................................7-36
Bucket Conveyor...................................................................................7-37
Adjust Bucket Conveyor ...........................................................................7-37
Adjust Bucket Conveyor - Continued........................................................7-38
Product Supply Conveyor Base Setting....................................................7-39
Bucket Conveyor Base Setting.................................................................7-40
Conveyor Adjustments:.............................................................................7-41
Filling Height Monitoring...........................................................................7-42
Adjusting Fill Height Monitoring: ...............................................................7-42
Tensioning the Bucket Conveyor Chains..................................................7-43
Tensioning the Main Drive Belt.................................................................7-44

Rovema CMK Operator’s Manual
Table of Contents
200246 CMK Operators Manual (02/06/2006) vi
Carton Removal Chain ........................................................................7-45
Carton Removal Chain Base Setting........................................................7-45
Tensioning the Chain Removal Drive Belts...............................................7-46
Tensioning the Removal Conveyors.........................................................7-47
Section 8: Maintenance...................................................8-1
General..........................................................................................................8-1
Cleaning Intervals ........................................................................................8-2
Protection doors...........................................................................................8-2
Housing.........................................................................................................8-2
Display ..........................................................................................................8-2
Daily Maintenance........................................................................................8-3
Before starting..............................................................................................8-3
After stopping...............................................................................................8-4
Weekly Maintenance ....................................................................................8-6
Preparatory Actions.....................................................................................8-6
Checks ..........................................................................................................8-6
Monthly Maintenance...................................................................................8-8
Checks ..........................................................................................................8-8
Other Maintenance Procedures ................................................................8-10
Lubrication..................................................................................................8-14
Section 9: Troubleshooting.............................................9-1
Alarm Banner..............................................................................................9-1
Alarm Screen..............................................................................................9-2
Alarm History Screen..................................................................................9-3
Alarms and Warnings ............................................................................9-4
Alarm Messages.........................................................................................9-4
Warning Messages...................................................................................9-13

Rovema CMK Operator’s Manual
Section 1: Introduction
200246 CMK Operators Manual (02/06/2006) 1-1
Section 1: Introduction
This manual has been prepared for the machine number indicated on the front
cover.
This manual is a reference tool for the Rovema CMK – Continuous Motion
Cartoner. It should be used in conjunction with instructor lead training.
ROVEMA machines have been designed in accordance with the customer's
requirements. For each machine a special manual will be provided based on a
standard machine. Therefore, this manual is only applicableforone machine,or for
machineswith thesame features. In casethatyour machineisnot equippedwith all
features available, then these features will not appear in the manual.
The following information will be included in this manual:
! Safety Instructions
! Functional Descriptions
! Parts and Functions
! Operator Controls
! Operating Procedures
! Working with Components
! Maintenance Procedures
! Troubleshooting

Rovema CMK Operator’s Manual
Section 1: Introduction
200246 CMK Operators Manual (02/06/2006) 1-2
About this Manual
There are several ways to find information in this manual:
The Table of Contents lists the sections ofthemanual andtheircorresponding page
numbers.
The header at the top of every page indicates the name of the section.
The bottom of every page contains the page number, the manual number, and the
revision date.
Symbol Descriptions
Throughout this manual, you will find these symbols.These symbolsareintended to
show you at a glance the content of the respective text.
Safety Instructions - Warning
Text near this symbol must be observed in any
case.
Information
This symbol indicates a description of functions.
Important Note
Denotes a particular function to be observed during
operation.
Manual Operations
Symbol indicates work to be performed manually,
e.g. changing the format parts, etc.

Rovema CMK Operator’s Manual
Section 1: Introduction
200246 CMK Operators Manual (02/06/2006) 1-3
Introduction to the CMK
The CMK continuous motion cartoner is designed to meet a wide variety of bag-in-
box applications as well as other side load applications. The CMK is a horizontal
carton loading machine used to erect, fill and close cartons.
Main Areas
Figure 1.1
Shows the front view of the CMK machine.
HMI Touchscreen
Carton Infeed
Emergency Stop
Button
Operator
Buttons
Glue Applicator
Barrel
Loader
Remote Jog
Button

Rovema CMK Operator’s Manual
Section 1: Introduction
200246 CMK Operators Manual (02/06/2006) 1-4
Introduction to the CMK
Main Areas
Figure 1.2
Shows the back view of the CMK machine.
Product
Tamper
Infeed
Bucket
Conveyor
Infeed Tunnel
Guard
Lubrication
Reservoir Air
Supply
Emergency
Stop Button
Emergency
Stop Button
Electrical
Cabinet
HMI
Touchscreen

Rovema CMK Operator’s Manual
Section 1: Introduction
200246 CMK Operators Manual (02/06/2006) 1-5
Introduction to the CMK
The CMK takes carton blanks and erects them(Areas1-5). Bags,filled withproduct,
are transported to the CMK and the CMK inserts the bags intothe cartons(Area 6).
The CMK closes and seals the cartons (Areas 7-11) and transfers them to
downstream equipment for further processing (Area 12).
Figure 1.3
Shows the typical sequence of operations for the CMK.
General Process
Areas 1-5: Carton blanks feed in and are erected.
Area 6: Prepackaged products are pushed into the cartons.
Areas 7-11: The cartons are closed and sealed.
Area 12: The cartons are transferred to downstream equipment.
Note: Machines may vary due to individual design requirements. Specific machine
design and may be different from the figure shown above.

Rovema CMK Operator’s Manual
Section 1: Introduction
200246 CMK Operators Manual (02/06/2006) 1-6
Introduction to the CMK
Figure 1.4
Overview of CMK- Continuous Motion Cartoner. (Side and Top views.)
See next page for corresponding number descriptions.
Side View
Top View

Rovema CMK Operator’s Manual
Section 1: Introduction
200246 CMK Operators Manual (02/06/2006) 1-7
Introduction to the CMK
The below legend corresponds to the previous figure.
Legend
1- HMI Display
2- Drive (Not in view)
3- Carton Supply
4- Carton Magazine
5- Carton Erector
6- Carton Drive Chain
7- First Flap Inserter
8- Barrel Loader
9- Printer/Coder
10- Second Flap Inserter
11- Gluing Station
12- Carton Discharge
13- Central Lubrication
14- Connection Monitoring
15- Bucket Conveyor
16- Height Adjustment
17- Length Adjustment
18- Angle Encoder
19- Carton/Bag Reject Conveyor
20- Electrical Cabinet

Rovema ULF Operator’s Manual
Section 2: Safety Instructions
200246 CMK Operators Manual (02/06/2006) 2-1
Section 2: Safety Instructions
This section contains information on machine safety issues. These issues include:
! Operator Safety
! Component Safety
! Safety Devices
! Machine Lockout Procedures

Rovema ULF Operator’s Manual
Section 2: Safety Instructions
200246 CMK Operators Manual (02/06/2006) 2-2
Operator Safety
Only properly trained personnel must operate the machine.
ROVEMA is prepared to train your operators. The operator is
responsible for following the operator safety guidelines
presented in this section as well as any employer safety
guidelines.
Operator Safety Guidelines
Use the following safety guidelines for safe operation of the
machine.
1. Do not operate the machine until you have read and
understood it’s operating instructions and have become
thoroughly familiar with them.
2. Do not wear rings, loose jewelry, or loose clothing while
operating the machine.
3. Secure long hair under a hair net or bump cap while
operating the machine.
4. Follow the lockout procedure before performing any
cleaning, maintenance, or repairs on the machine.
5. Never use the MAIN DISCONNECT switch to stop the
machine.
6. Do not remove the guards or open doors except during
necessary adjustments or repairs. Be sure to lockout
the machine before removing any guards or doors.
7. Lockout the machine before clearing jams. Never use
your fingers to remove jammed material; Use a tool or a
rod.
8. Always wear safety glasses when servicing the
machine.

Rovema ULF Operator’s Manual
Section 2: Safety Instructions
200246 CMK Operators Manual (02/06/2006) 2-3
Operator Safety
Only one (1) person is allowed to operate the machine at a time.
Onlyone (1) person is allowedto performwork at the machinewith themain switch
in the ON position. No other person is allowed to stay in the danger area of the
machine.
Before starting the machine, the operator (or any person
charged to operate the machine) must read and completely
understand the operating instructions, especially the safety
instructions and safety regulations.
Sound Level
Depending on the product, cycle number and the ambience conditions of the room,
sound levels may arise deviating from the determined values.
According to DIN 45 635, the average sound pressure level is < 80 dbA.
Before Starting
The machine must only be used for its intended work, under
the strict observance of the operating instructions.
Before starting the machine, the operator must be sure that no other persons are in
the danger area of the machine.
Before starting the production, the operator must be sure that no other person is in
the danger area of the machine.
In Case of Danger
Immediately press an EMERGENCY STOP button!
Daily before starting the production, make sure the EMERGENCY STOP buttons
are functioning properly!

Rovema ULF Operator’s Manual
Section 2: Safety Instructions
200246 CMK Operators Manual (02/06/2006) 2-4
Component Safety
Electrical and Control System
No modifications or changes in the electrical and control system are allowed.
All retrofits and modifications must be performed only by ROVEMA.
Spare Parts
Only originalROVEMA sparepartsand accessoriesshouldbe
used.
ROVEMA is not liable for any damage caused due to the use
of foreign products.
Maintenance
Before starting any cleaning, maintenance and repair procedures, be sure that the
main switch is turned OFF, and make sure that it cannot be turned ON again.
Use only cleansing agents that wouldnot cause damage to mechanicalor electrical
equipment. (For details concerning cleansing agents, refer to Section 6:
Maintenance.)
Machinesused forpackaging foodstuffsshouldbe treatedwith
special cleansers or disinfectants in accordance with the
existing hygienic prescriptions of the country in which the
machine is installed. For more detailed information, please
contact the appropriate authorities of your country.

Rovema ULF Operator’s Manual
Section 2: Safety Instructions
200246 CMK Operators Manual (02/06/2006) 2-5
Safety Devices
Properly trained and instructed specialists must test all
technical devices, especially safety devices:
• Before commissioning
• After alterations or modifications
• After repairs
The machine must only be allowed to operate if all safety
devices (guards, locks switches etc.) are in place and fully
operational.
Safety devices must not be bypassed or otherwise made
ineffective.
Only properly trained specialists must perform maintenance
and repair work on safety devices and electrical equipment.
Any defective technical devices, especially safety devices
must be replaced immediately.
Before starting the production, the operator must perform a
daily check to ensure that all safety devices are functioning
correctly.
The user must ensure that all safety devices are examined by
a qualified specialist (e.g. by the safety inspector) at regular
intervals.Under nocircumstances shallsuchintervals exceed
one year!

Rovema ULF Operator’s Manual
Section 2: Safety Instructions
200246 CMK Operators Manual (02/06/2006) 2-6
Safety Devices
Machine View
Figure 2.1
Shows the Safety Devices
Emergency Stop
Button
Door Switch
Locations
Protective Doors