ROVEMA VPK Series User manual

VPK Operations Manual

About this Manual
This manual is a reference tool for the Rovema VPK series bagmakers: models
VPK-260 and VPK-360. It should be used in conjunction with instructor lead training.
The following information is include in this manual:
nIntroduction
nSafety Instructions
nParts and Functions
nTheory of Operations
nOperator Controls
nMachine Setup Procedures
nOperation Procedures
nWorking with Components
nChangeover Procedures
nMaintenance Procedures
nTroubleshooting Procedures
nAppendix (Setup of Auxiliary Equipment)
How to Use this Manual
There are several ways to find information in this manual:
nThe Table of Contents lists the chapters and sections of the manual
and their corresponding page numbers.
nThe header at the top of every page indicates the name of the chapter.
nThe bottom of every page contains the page number, the manual
number, and the revision date.

Table of Contents
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 I
Table of Contents
Introduction ..................................................................................................... 1-1
Safety Instructions .......................................................................................... 2-1
Safety Devices ....................................................................................................... 2-2
Guard Doors ............................................................................................................... 2-2
EMERGENCY STOP Push-Button ............................................................................ 2-3
Safety Labels.............................................................................................................. 2-4
Component Safety ................................................................................................. 2-5
Operator Safety ...................................................................................................... 2-6
Operator Safety Guidelines ...................................................................................... 2-6
Lockout Procedures .............................................................................................. 2-7
Air Supply Lockout .................................................................................................... 2-7
Power Lockout Procedure ........................................................................................ 2-8
Parts and Functions ........................................................................................ 3-1
Film Carriage .......................................................................................................... 3-2
Film Spindle ................................................................................................................ 3-3
Dancer Assembly ....................................................................................................... 3-4
Film Unwind Brake ..................................................................................................... 3-5
Film Tracking Assembly............................................................................................. 3-6
Touchscreen Controls .......................................................................................................... 3-7
Out of Film Sensor Assembly ................................................................................... 3-8
Guide Rollers.............................................................................................................. 3-9
Film Feeding Device ............................................................................................ 3-10
Belts Assemblies ....................................................................................................... 3-11
Drive System ............................................................................................................ 3-12
Engage/Retract Device ............................................................................................ 3-13
Touchscreen Controls ........................................................................................................ 3-14
Forming Set.......................................................................................................... 3-15

Table of Contents
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 II
Table of Contents (continued)
Vertical Sealing Device ........................................................................................ 3-16
Seal Band Unit .......................................................................................................... 3-17
Heating Bar........................................................................................................................ 3-18
Sealing Band, Band Sensor, and Band Release Lever ...................................................... 3-19
Drive System ..................................................................................................................... 3-20
Engage/Retract Device ............................................................................................ 3-21
Touchscreen Controls ........................................................................................................ 3-22
Seal Band Support ................................................................................................... 3-23
Horizontal Sealing Device ................................................................................... 3-24
Jaw Assemblies ........................................................................................................ 3-25
Jaw Body ........................................................................................................................... 3-26
C-Frames, Jaw Carriers and Jaw Springs .......................................................................... 3-27
Seal Pressure ........................................................................................................... 3-28
Drive System ............................................................................................................ 3-29
Touchscreen Controls ........................................................................................................ 3-30
Knife Assembly ........................................................................................................ 3-31
Touchscreen Controls ........................................................................................................ 3-32
Temperature Controllers ......................................................................................... 3-33
Registration Sensor ............................................................................................. 3-34
Touchscreen Controls ............................................................................................. 3-35
Pneumatics System ............................................................................................. 3-36
Primary Manifold ...................................................................................................... 3-37
Pressure Switch ....................................................................................................... 3-38
Horizontal and Vertical Cooling Devices ................................................................ 3-39
Vacuum System ....................................................................................................... 3-40
Solenoid Bank .......................................................................................................... 3-41
Optional Equipment ............................................................................................. 3-42
Bevel Plates .............................................................................................................. 3-43
Bag Grippers ............................................................................................................ 3-43
Foam Deflators ......................................................................................................... 3-43
Splice Table .............................................................................................................. 3-44
Automatic Film Tracking Sensors ........................................................................... 3-45
Touchscreen Controls ........................................................................................................ 3-46

Table of Contents
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 III
Table of Contents (continued)
Bag Shaping Devices ............................................................................................... 3-47
Gusset Device ................................................................................................................... 3-48
Touchscreen Controls .................................................................................................. 3-49
STABILO SEAL® Sealing System ...................................................................................... 3-50
Touchscreen Controls .................................................................................................. 3-51
Theory of Operations ...................................................................................... 4-1
Forming Cycle ........................................................................................................ 4-2
Timing Chart .......................................................................................................... 4-3
Heat Sealing ........................................................................................................... 4-4
Vertical Sealing Cycle ............................................................................................ 4-5
Horizontal Sealing Cycle........................................................................................ 4-6
Film Registration .................................................................................................... 4-7
Operator Controls ........................................................................................... 5-1
Operator Interface .................................................................................................. 5-2
Touchscreen Display and Function Keys ................................................................ 5-3
Numeric Keypad and Arrow Keys ............................................................................. 5-4
Operations Screen ................................................................................................. 5-6
MOVE FILM Switch .................................................................................................... 5-7
JOGGING SELECT Switch ........................................................................................ 5-7
BELTS Switch ............................................................................................................. 5-8
HEAT Switch ............................................................................................................... 5-8
FEEDER Switch .......................................................................................................... 5-8
LENGTH Switch ......................................................................................................... 5-9
SPEED Switch ............................................................................................................ 5-9
SETTINGS Switch ...................................................................................................... 5-9
ACT POSITION Display .............................................................................................. 5-9

Table of Contents
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 IV
Table of Contents (continued)
Settings Screen........................................................................................................ 5-10
Cam Settings ......................................................................................................................5-11
Horiz. Cooling Settings ................................................................................................. 5-12
Vertical Cooling Settings (if equipped) ......................................................................... 5-12
Knife Settings............................................................................................................... 5-13
Film Tracking Settings.................................................................................................. 5-13
Vibrator ........................................................................................................................ 5-14
Bag Folder ................................................................................................................... 5-14
Jaw Seal Settings Screen .................................................................................................. 5-15
AUTO/MAN SELECT Switch........................................................................................ 5-15
SET SEAL TIME Switch ............................................................................................... 5-15
Film Bulge Factor Setting ............................................................................................. 5-16
Actual Seal Time Display ............................................................................................. 5-16
JAW PROFILE Switch .................................................................................................. 5-16
Jaw Profile Settings Screen ............................................................................................... 5-17
AUTO/MAN Switch ...................................................................................................... 5-17
Postseal Angle and Postseal Time Settings ................................................................. 5-17
Preseal Time Setting .................................................................................................... 5-17
Feeder Screen ................................................................................................................... 5-18
Printer Screen .................................................................................................................... 5-20
Vertical Seal Screen........................................................................................................... 5-21
Photoeye Screen ............................................................................................................... 5-22
Stabilo Seal Screen ........................................................................................................... 5-23
Recipe Management Screen .............................................................................................. 5-24
Recipe Load Selection Screen ..................................................................................... 5-25
Recipe Save Selection Screen..................................................................................... 5-26
Alarms Screen ................................................................................................................... 5-27
Temperature Controllers ..................................................................................... 5-28
MAIN DISCONNECT Switch ............................................................................... 5-29
AIR DISCONNECT Lever .................................................................................... 5-30
Push-Buttons and Selector Switch .................................................................... 5-31
SYSTEM READY Push-Button ................................................................................ 5-31
JOG/AUTO Selector Switch .................................................................................... 5-31
JOG/RUN Push-Button ............................................................................................ 5-32
STOP Push-Button .................................................................................................. 5-32
EMERGENCY STOP Push-Button .......................................................................... 5-33

Table of Contents
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 V
Table of Contents (continued)
Machine Setup Procedures ............................................................................ 6-1
Powering the Bagmaker ....................................................................................... 6-2
Loading a Product Recipe..................................................................................... 6-3
Setting the Machine Speed and Bag Length ....................................................... 6-4
Installing the Forming Set...................................................................................... 6-5
Loading a Film Roll ................................................................................................ 6-6
Threading a Film Roll............................................................................................. 6-7
Vertical Seal Setup................................................................................................. 6-8
Pneumatic Pressure Settings ............................................................................. 6-10
Setting the Film Tension...................................................................................... 6-11
Setting the Film Tracking Position ..................................................................... 6-12
Positioning the Automatic Film Tracking Sensors ............................................ 6-13
Registration Sensor Setup .................................................................................. 6-14
Sensor Setup for Non-Registered Film .................................................................. 6-15
Sensor Setup for Registered Film .......................................................................... 6-16
Window In and Offset In Settings ....................................................................................... 6-17
Determining the Window In Value ............................................................................... 6-18
Determining the Offset In Value .................................................................................... 6-19
Operating Procedures ..................................................................................... 7-1
Start-Up .................................................................................................................. 7-2
Preparing the Bagmaker ....................................................................................... 7-3
Making Empty Bags ............................................................................................... 7-4
Making Filled Bags ................................................................................................. 7-6
Checking Filled Bags ............................................................................................. 7-7
Starting a Production Run..................................................................................... 7-8
Shut Down the Bagmaker ......................................................................................... 7-9
Emergency Stop......................................................................................................... 7-9
Normal Stop ............................................................................................................... 7-9
Extended Shutdown ................................................................................................... 7-9
Restart the Bagmaker After an E-Stop .............................................................. 7-10
Jog the Bagmaker ............................................................................................... 7-11
Film Feed Jogging .................................................................................................... 7-11
Jaw Jogging .............................................................................................................. 7-11

Table of Contents
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 VI
Table of Contents (continued)
Working with Components............................................................................ 8-1
Replacing Heater Cartridges and Temp. Probes .................................................... 8-2
Horizontal sealing Jaws .............................................................................................8-2
Vertical Sealing Device ...............................................................................................8-5
Replacing the Film Feed Belts ................................................................................ 8-7
Replacing the Cutting Knife .................................................................................... 8-8
Aligning the Forming Set ........................................................................................ 8-9
Aligning the Belt Assemblies ................................................................................ 8-10
Changeover Procedure ................................................................................... 9-1
Maintenance Procedures.............................................................................. 10-1
Daily Cleaning ...................................................................................................... 10-2
Daily Maintenance ................................................................................................ 10-3
Weekly Maintenance ............................................................................................ 10-4
Troubleshooting Guide................................................................................. 11-1

Introduction
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 1-1
Introduction
The Rovema VPK is a continuous motion form-fill-seal vertical
bagmaker that packs a variety of products into bags. It forms, fills,
and seals bags by forming flat packaging material into a tube, sealing
the edges and bottom of the tube, filling the tube with product, cutting
the tube to length, and sealing the top of the tube.
The bagmaker can be equipped with a number of options that can
change a bags shape or print information on a bag.
Figure 1.1
Shows the standard VPK-260 bagmaker.

Safety Instructions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 2-1
Safety Instructions
This section contains information on machine safety issues. These
issues include:
nBagmaker Safety Devices
nComponent Safety
nOperator Safety
nMachine Lockout Procedure

Safety Instructions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 2-2
Safety Devices
The VPK safety devices include guard doors, an EMERGENCY STOP
push-button, and safety labels.
Guard Doors
The guard doors isolate the operator from the forming and sealing
area. The doors are also equipped with a switch that causes the
machine to stop when they are opened.
Figure 1.2
Shows the front guard door switch. If your machine is equipped with a side
guard door, there will be a similar switch attached to it.
Door Switch

Safety Instructions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 2-3
Safety Devices
EMERGENCY STOP Push-Button
The EMERGENCY STOP push-button causes the bagmaker to
immediately stop operating if pushed. This push-button should be
used when there is perceived or actual damage occurring to the
bagmaker or to an operator.
Figure 2.3
Shows the EMERGENCY STOP push-button.
EMERGENCY STOP
Push-Button

Safety Instructions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 2-4
Safety Devices
Safety Labels
Safety labels alert an operator to a particular hazard. These labels
appear at various places on the machine. Look for these labels, read
them, and follow their instructions.
Figure 2.4
The two top labels indicate areas of the bagmaker that could burn you if
touched. The two bottom labels indicate areas of the bagmaker that could
break a limb.
DANGER
PINCH POINTS
WATCH YOUR HANDS
CAUTION
HOT SURFACE
DO NOT TOUCH

Safety Instructions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 2-5
Component Safety
Rovema does not allow any electrical or mechanical modifications to
the VPK bagmaker without explicit authorization.
Only original Rovema spare parts and accessories should be used
on the bagmaker; This ensures that the machine will perform safely
and as designed.
The user must confirm that the wrapping material (film) will not produce
harmful gases during sealing. The film supplier should provide such
assurances.

Safety Instructions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 2-6
Operator Safety
Only properly trained personnel can operate the bagmaker. 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 bagmaker.
1. Do not operate the bagmaker 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 bagmaker.
3. Secure long hair under a hair net or bump cap while operating the
bagmaker.
4. Follow the lockout procedure before performing any cleaning,
maintenance, or repairs on the bagmaker.
5. Never use the MAIN DISCONNECT switch to stop the bagmaker.
6. Do not remove the guards or open doors except during necessary
adjustments or repairs. Be sure to lockout the bagmaker before
removing any guards or doors.
7. Lockout the bagmaker before clearing jaw jams. Never use your
fingers to remove jammed material; Use a tool or a rod.
8. Always wear safety glasses when servicing the bagmaker.

Safety Instructions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 2-7
Lockout Procedures
The bagmaker must be properly locked out before any repair or
maintenance tasks can be performed on it. This section describes
procedures that should be used to lockout the air and power supplies.
Air Supply Lockout
Use the following procedure to lockout the air supply:
1. Raise the AIR DISCONNECT lever to its horizontal position to
disable the air supply to the machine.
2. Remove the lever from the inlet valve.
Figure 2.7
Shows how to disable the bagmakers air supply and how to remove the AIR
DISCONNECT lever.

Safety Instructions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 2-8
Lockout Procedures
Power Lockout Procedure
Use the following procedure to lockout the electrical power supply:
1. Press the STOP push-button to halt the machine.
2. Turn the MAIN DISCONNECT switch to the OFF position to disable
electrical power to the machine
3. Pull out the lockout handle on the MAIN DISCONNECT switch.
4. Place a lockout tag through the hole in the lockout handle.
5. Place a pad lock through one of the holes in the lockout tag.
6. Attempt to start the bagmaker by turning the MAIN DISCONNECT
switch to the ON position.
If the MAIN DISCONNECT switch will not turn to the ON position
then the lockout procedure was successful. If the switch will turn
to the ON position then the lockout procedure was not successful
and must be performed again.
Pad Lock
MAIN DISCONNECT Switch
LockoutTag
Lockout Handle
Figure 2.8
Shows how to lockout the electrical supply to the bagmaker.

Parts and Functions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 3-1
Parts and Functions
This section describes the major parts and functions of the VPK vertical
bagmaker. These parts include the:
nFilm Carriage
nFilm Feeding Device
nForming Set
nVertical Sealing Device
nHorizontal Sealing Device
nRegistration Sensor
nPneumatics System
nOptional Equipment

Parts and Functions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 3-2
Film Carriage
The film carriage controls the supply of packaging material that the
bagmaker uses to form bags. It includes a:
nFilm Spindle
nDancer Assembly
nFilm Unwind Brake
nFilm Tracking Assembly
nOut of Film Sensor Assembly
nGuide Rollers
Figure 3.1
Shows the components of the film carriage.
Dancer
Assembly
Guide Roller
Film Spindle
Out of Film
Sensor Assembly
Film Unwind
Brake Assembly
FilmTracking
Assembly

Parts and Functions
Rovema VPK Operators Manual
3/2000 VPK REV(B) PANELVIEW 600 3-3
Film Carriage
Film Spindle
The film spindle supports the packaging material on the film carriage.
It consists of an air bladder that is partially enclosed within a metal
housing. The housing has slots that allow sections of the air bladder
to protrude through it. When the bladder is inflated, it protrudes through
the slots and presses against the inside of the film core; holding the
film on the spindle. The bladder is inflated and deflated through the
air valve located in the end of the spindle.
Figure 3.2
Shows the film spindle.
AirValve
Air Bladder