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