Sharp MAX-PRO 1182 User manual
INTENTIONAL BLANK PAGE
MAX-PRO Operator Manual Original Printed in English
Prefix I
General Information II
Definition Of Terms II
SECTION 1 - INTRODUCTION
Safety Rules & Procedures
Emergency Stop Button 1-1
Fire Prevention 1-1
Equipment Safety Features
Machine Guards 1-2
Safety Labels 1-3
Specifications
Packaging Specifications 1-5
Machine Specifications 1-5
Service Information 1-5
Machine Dimensions
Front View 1-6
Top View 1-7
Side View 1-8
Sharp EZ-Bags©1-9
SECTION 2 - CONTROLS
Security 2-1
Home Screen 2-2
Operator Dashboard Screen 2-3
Job Setup Screen 2-5
Bag Dimension And Feed Speed 2-6
Bag Opening 2-7
Package Eject 2-8
Pressure Bar And Seal Bar 2-9
Auxiliary Inputs/Outputs 2-10
Printer 2-12
Applications Screen 2-13
Service Screen 2-14
Bagger Head 2-15
Bag 2-15
Bag Open Fingers 2-16
Integrated Exit Conveyor 2-17
Load Plate 2-18
Low And High Pressure Air 2-19
Pass-Thru 2-20
Pressure Bar 2-21
Printer 2-22
Seal Bar 2-23
Seal Flatteners 2-24
Vacuum 2-25
Support Screen 2-26
SECTION 3 - SET-UP & OPERATION
Machine Placement
Electrical Precautions 3-1
Grounding Instructions 3-1
Storage 3-1
Power Supply 3-2
Air Supply 3-3
Machine Adjustments
Height Adjustment 3-3
Head Rotation 3-3
Load Plate 3-4
Loading Bag Film 3-5
Loading Ribbon 3-7
Operation
Machine Operation 3-8
Cleaning & Maintenance
Cleaning Guidelines 3-9
Cleaning / Maintenance Intervals 3-10
Cleaning Bag Edge Present Sensor 3-11
Cleaning Printhead 3-11
Cleaning Rollers 3-12
Cleaning Seal Bar 3-13
Cleaning Unwind Rollers 3-14
SECTION 4 - FAULTS & ALERTS
HMI Fault Management 4-1
HMI Alert Management 4-3
Printer Fault Management 4-4
Printer Troubleshooting 4-5
APPENDIX
Sharp Warranty 5-1
CE Declaration of Conformity 5-2
UK Declaration of Conformity 5-3
TABLE OF CONTENTS
MAX-PRO Operator Manual Original Printed in English
The MAX-PRO Continuous Bagging System, redesigned from the ground up for increased productivity and easi-
er operation. The MAX-PRO is an effective solution for manually bagging product, dramatically reducing packag-
ing costs and improving package quality. The MAX-PRO platform features an integrated ZT610 Zebra pivoting
printhead.
Print Method Thermal Transfer, directly onto surface of bag
Print Speeds 14 ips at 203 dpi
12 ips at 300 dpi
Print Resolution 203, 300 dpi
Print Width (max.) 4.09” (104 mm)
Your Sharp MAX-PRO is the result of extensive research and field testing with the following features:
• Advanced diagnostics monitor individual machine components, notifying technicians of any potential prob-
lems and allowing replacement parts to be ordered before a failure occurs.
• Networkable HMI responds like a smartphone: faster and more intuitive, with easy to understand icons.
• Pass-through size now adjustable via the HMI, with not tools required.
• Simplified bag threading system allows even novice operators to load new bags easily.
• Sharp MAX-PRO accommodates 24” wide bags with an 12” pass-through depth.
• Save job settings and label designs in HMI for easy access.
• Incorporating Zebra thermal printers permits direct printing onto the package for bar codes, graphics, and
alphanumeric fonts.
• Movable printing head sets to precise positions, eliminating queuing and reducing material cost and scrap.
• Decrease thermal ribbon usage as much ad 90% with reduced spacing between impressions, printing with
alternative registrations, and adjusting impression placement to maximize ribbon usage.
• HMI, printer, and PLC can be networked, so they can be accessed at any time from almost anywhere.
• Use remote label printing, production reporting, and SCADA (supervisory control and data acquisition) con-
trol.
• New design utilizes fewer components, decreasing downtime and increasing ease of maintenance.
• Improved error reporting pinpoints problems for hassle free troubleshooting.
• The color touchscreen display provides troubleshooting guidance with exploded view drawings, manufac-
turer and part numbers, and .html help files with hyper links to explain any term.
• Off-the-shelf, nonproprietary parts can be purchased at most MRO stores.
The materials used were selected for maximum durability and optimum performance. Every unit is thoroughly
inspected and tested prior to shipment.
PREFIX
I
MAX-PRO Operator Manual Original Printed in English
GENERAL INFORMATION
II
ABOUT THIS MANUAL
This manual has been prepared for your use in operating model 1174-02 of the Sharp MAX-PRO Continuous
Bagging System. Images and instructions may differ slightly for older models, but basic function is the same.
Included in the manual are helpful facts on operating and basic troubleshooting information.
It is important that you familiarize yourself with the product as much as possible before operating or trouble-
shooting.
Make sure you read through the EQUIPMENT SAFETY FEATURES and INTRODUCTION sections of this man-
ual before operating this machine.
• Upon receipt, unpack and inspect the unit for damages that may have occurred during shipment. Sharp
Packaging is not in any way responsible for any damages that occur during transport. If you receive dam-
aged equipment, it is your responsibility to make a claim with the transporter.
• Read instructions carefully. Be familiar with the controls and proper use of the unit. Do not operate the ma-
chine when tired, ill, or under the influence of alcohol, drugs or medication.
• The instructions and data in this manual are vital to the proper installation and operation of this equipment.
In order to avoid delays due to faulty installation and operation of the machine, please see that these in-
structions are read by the persons who will install or operate or maintain the machine.
• The WARNING instructions issued on this manual are not meant to cover all possible conditions and situa-
tions that may occur. It must be understood that common sense, caution and carefulness are factors that
cannot be built into all machines. These factors must be supplied by the persons installing, maintaining, or
operating the machine. Failure to install, maintain, and/or operate the equipment according to the manufac-
turer’s instructions may result in conditions which can produce bodily injury and/or property damage. Con-
tact Sharp Packaging about any problems or conditions you do not fully understand.
DEFINITION OF TERMS
Throughout this manual, you will find the following safety notices with this accompanying symbol.
This symbol signifies important safety issues regarding the operation and maintenance of the Sharp MAX PRO.
SECTION 1 - INTRODUCTION
MAX-PRO Operator Manual Original Printed in English
SECTION 1 - INTRODUCTION
SAFETY RULES & PROCEDURES
1-1
The machine requires regular, periodic maintenance to ensure reliable service. No maintenance should be per-
formed unless the safety precautions for maintenance are thoroughly understood.
• Follow all instructions in this manual for safe operation.
• Follow all company and industry standard safety policies regarding this kind of machinery that may exceed
those listed in this manual.
• Keep all safety features, guards, interlocks and sensors in good working order.
• Always ensure that all mechanical motion has stopped and allow any heated components to cool
down before removing any machine parts.
• Keep the area surrounding the machine free from debris. Spent film/bags should not be allowed to accumu-
late around bagger.
• Follow all company and industry standards with the use and wearing of Personal Protective Equipment.
“PPE”
The safety information presented in this manual are guidelines that should be followed by all personnel. Anyone
operating or maintaining the equipment should read and follow all safety information in this manual, without ex-
ception.
All Operators should be familiar with their own Labor Protection Guidelines. Hands, arms, hair and clothing
should not be near any moving or heating parts of the machine. Do not turn the machine ON if any of the ma-
chine’s components have been removed or modified.
It is illegal to operate the equipment in an EU member state if the manual(s) is not written in that State’s lan-
guage. Contact your company if a translation is needed.
If the machine or parts of the machine have to be permanently put out of service, laws and Directives
in force at the time of the dismantling have to be strictly observed and complied with. In any case,
check which materials can be recycled. These must be sent to an appropriate waste collecting com-
pany.
The sound pressure level measured at the operator station does not exceeds 70 dB(A).
EMERGENCY STOP (E-STOP) BUTTON
An Emergency Stop (Red) Button is part of HMI/PC Box. The E-Stop immediately stops the machine when
pressed bye de-energizing power to the PLC outputs, motors, and motor drives.
FIRE PREVENTION
Keep a fire extinguisher near the machine. Keep machine away from any sparks, flames and flammable materi-
als. Unplug the machine before maintaining or cleaning. All electrical components must be in good condition
and clean.
Electrical fires can occur if any wires are scratched, corroded, color-faded, lost their insulation or have damaged
wire ends. These should be changed immediately.
Any exposed electrical components should never come into contact with the ground-connector and any other
electrically conductive objects such as tools.
It is extremely important to follow all of the safety guidelines and warning detailed inside the Sharp Op-
erator Manual before removing any guards or servicing the machine.
MAX-PRO Operator Manual Original Printed in English
MACHINE GUARDS
The Sharp MAX-PRO is equipped with guards cover-
ing the heated sealing area and the underside of the
Head Assembly. DO NOT operate the MAX-PRO with
these or any other guards removed.
The Top Lexan® Guard sits on top of the Jaw Guard.
The shape allows for loading of product into the bags.
Sharp Packaging recommends the MAX-PRO be
equipped with the optional Dual Palm Buttons to start
the cycle to ensure the operator’s hands are clear of
the Sealing and Pressure Bars when the machine is
cycled.
DO NOT operate the unit with this feature removed.
An Emergency-Stop Button is located on the Control
Panel, which immediately stops the machine when
pressed by de-energizing power to the Master Control
Relay, PLC outputs, motor, motor drive and air valves.
OBSTRUCTION SENSING JAW
The Sealing Assembly is equipped with Obstruction
Sensing Sensors, which can detect an obstruction in
the Sealing Area. If the Jaw Sensors detect and object
preventing the Jaw from closing, the Sensors de-
energize and place the machine into a fault condition.
A message appears in the display informing the Oper-
ator of the Jaw Fault, allowing the Operator to clear
the Sealing Area and reset the bagging cycle.
EQUIPMENT SAFETY FEATURES
1-2
The Sharp MAX-PRO is equipped with Jaw Ob-
struction Detection Sensors. The sensors are
not designed, nor intended, to be safety sen-
sors.
WARNING!
SECTION 1 - INTRODUCTION
MAX-PRO Operator Manual Original Printed in English
SAFETY LABELS
General Danger Label
This label is located on the Sharp MAX-PRO wherev-
er a removable shield or panel guards electrical com-
ponents to warn of potential danger behind shield or
panel. Always disconnect electrical power from ma-
chine prior to removing any guards and/or panels with
this label.
Electric Shock/Electrocution Label
This label is located on the Sharp MAX-PRO wherev-
er a removable shield or panel guards electrical com-
ponents to warn of potential danger behind shield or
panel. Always disconnect electrical power from ma-
chine prior to removing any guards and/or panels with
this label.
Side Crush
This label is placed onto removable shields, panels, or
guards near the Sealing Jaw of the Sharp MAX-PRO
to warn of potential crush danger. Always disconnect
electrical power from the machine prior to removing
any guards and/or panels.
Burn Hazard Label
This label is placed onto removable shields, panels, or
guards near the Heated Sealing Area of the Sharp
MAX-PRO to warn of potential burn danger. Always
disconnect electrical power from the machine prior to
removing any guards and/or panels.
Entanglement Hazard, Rotating Parts
This label is placed where there is the potential of your
hands, long hair, jewelry, etc., becoming entangled
between two rotating parts. Be sure to secure loose
items before approaching and operating the machine.
Moving Parts Can Crush And Cut (Pinch Point)
EQUIPMENT SAFETY FEATURES
1-3
SECTION 1 - INTRODUCTION
MAX-PRO Operator Manual Original Printed in English
This label on the Sharp MAX-PRO is placed where
there is potential of injury due to pinch points or mov-
ing parts. Make certain electrical power is disconnect-
ed before removing any guards and/or panels.
Risk Of Fire - Correct Fuse Replacement
The following labels are located in the proximity of a
fused circuit. Be certain to replace blown fuses ONLY
with fuses with the same electrical rating. Always dis-
connect electrical power before removing any guards
and/or panels and servicing the Sharp MAX PRO.
Fork Lift Use Label
These labels are placed next to the lifting points for
the Sharp MAX-PRO bagger. Only lift this bagger with
a Fork Lift at these points.
LIFTING PROCEDURE
The only approved lifting of this bagger is with a Fork-
lift through the Base of Frame Assembly. Forklift Use
Labels are on sides of Base to indicate the lift points.
EQUIPMENT SAFETY FEATURES
1-4
SECTION 1 - INTRODUCTION
MAX-PRO Operator Manual Original Printed in English
PACKAGING SPECIFICATIONS
MACHINE SPECIFICATIONS
1Material, gauge and size of package, along with weight and
size of product will cause rate to vary.
TECHNICAL ASSISTANCE
Assistance with your Sharp MAX-PRO can be ob-
tained by contacting Sharp Packaging Systems Tech-
nical Service Hotline by phone or e-mail. To help
serve you better, Sharp Packaging requests that you
provide the serial number of bagger and a brief de-
scription of the problem.
Phone: +1 (262) 246-8815 (ext. 1572)
E-mail: sharpservice@pregis.com
SERIAL IDENIFCATION DECAL
The serial number of the can be found on the Serial
Identification Decal located on the rear of the bagger
or inside of Electrical Box.
In the above example:
MAX-PRO 24 - Type of Sharp Bagger.
21B - The year and month bagger was built.
1182-02 - Model Number of bagger.
XXXX - The number of bagger.
SPECIFICATIONS
1-5
BAG WIDTH BAG LENGTH FILM GAUGE
MINIMUM 10” (25.4 cm) 10” (25.4 cm) 1 mil (25 microns)
MAXIMUM 24” (60.96 cm) 36” (91.44 cm) 4 mil (100 microns)
WIDTH HEIGHT DEPTH WEIGHT POWER OPERATING
TEMP HUMIDITY
RANGE
42.0”
(106.68 cm)
41.52-48.02”
(105.45-
121.97 cm)
85.71”
(217.7 cm) 955 lbs.^
(433.18 kg) 120VAC,
15A 32° - 140° F
10% - 90%RH,
Non-
Condensing
SECTION 1 - INTRODUCTION
MAX-PRO Operator Manual Original Printed in English
The Sharp MAX-PRO is designed to use a wide varie-
ty of bag sized and materials. Sharp EZ-Bags© are
recommended for optimum operating performance,
efficiency and safety. System performance specifica-
tions are base on utilizing consistent, high quality, pre-
opened bags. Any bag used must meet Sharp Pack-
aging Systems’ manufacturing tolerances. The follow-
ing list shows so me of the Sharp EZ-Bags© films
available through Sharp Packaging Systems, Inc.:
E-Z Bags©
• General Purpose
• Xtreme Poly (XP)
• Ultra
• HD Mailer
• Sharp Packaging High Density (SPHD)
• Polypropylene
• Sharp’s Military Specification Film
• Gamma Patient
• Sharp’s Metalized Barrier Film
• Electric Static Discharge (ESD)
• Modified Atmospheric Packaging (MAP)
• Sharp’s Non-Scratch Film
• E-Z Stat™ (Anti-Static)
• Vapor Corrosive Inhibitor (VCI)
Contact Sharp Customer Service at +1 (262) 246-
8815 to order Sharp EZ-Bags© and for information
regarding film and bag specifications.
THERMAL TRANSFER RIBBON
The Sharp MAX-PRO uses thermal transfer ribbon to
print various information onto the bags as they pass
through the machine. The following is a list of ribbon
that is available through Sharp Packaging Systems.:
• Standard Direct Wax Ribbon
• Premium Was Resin Ribbon.
Contact Sharp Customer Service at +1 (262) 246-
8815 to order ribbon.
SHARP EZ-BAGS© & RIBBON
1-9
SECTION 1 - INTRODUCTION
MAX-PRO Operator Manual Original Printed in English
The ‘Technician’, ‘Field Service’, and ‘Manufacturing’ icons are password protected. Pressing any of these icons
will prompt user to type in a password.
The ‘Operator’ and ‘Support’ icons are not password protected.
NOTE: See Supervisor or Manager for correct password for each icon.
SECURITY
SECTION 2 - CONTROLS
2-1
MAX-PRO Operator Manual Original Printed in English
OPERATOR BUTTON
Pressing the Operator Button from the Home Screen opens the Operator Dashboard Screen. This screen al-
lows Operator to monitor bagger function. Access to this screen is not password protected.
JOB DETAILS
Pressing the Job Detail button opens a pop-up window with bag dimensions and bag feed speed.
SEARCH JOBS
Opens a window that lists all jobs saved in bagger. Green light indicates which job is currently loaded.
LABEL PRINTER
Status: Reported status from Zebra Label Printer. Pressing About button shows details of the printer.
Control: Pause button pauses printer. Only works if you are Service/Factory User.
Darkness: Allows user to change darkness of print. Only works if you are a Service/Factory User.
Reset: Resets internal printer faults (e.g. Printhead errors)
Labels in Queue: Clear button clears out all labels from printer.
Send Test: Sends 1 test label to printer.
BAG
Photo-eye Covered: When Lit bag is over Photo-eye.
SCREEN NAVIGATION
SECTION 2 - CONTROLS
2-3
MAX-PRO Operator Manual Original Printed in English
SCREEN NAVIGATION
SECTION 2 - CONTROLS
2-4
Reverse and Forward: Buttons jog film.
OPERATOR DASHBOARD - CONTINUED
PERFORMANCE
Last Cycle Time: Displays the actual time of last completed cycle, in seconds.
Average Cycle Time: The average cycle time all cycles, in seconds.
Reset Average Cycle Time: Reset or clears the average cycle time.
SEAL BAR TEMPERATURE
Current: The current temperature of Seal Bar.
Required: The temperature of Seal Bar per settings in loaded job.
MACHINE COUNTERS
Informational display of counters and cycles of bagger.
OPERATOR BAGS
Operator Resettable bag counter.
FILLER
Toggles Filler ON or OFF.
BAGGER HEAD
Press the UP or DOWN Arrow to raise or lower head.
MAX-PRO Operator Manual Original Printed in English
TECHNICIAN BUTTON
Pressing the Technician Button from the Home Screen opens the Job Setup Screen. This screen allows a Us-
er to configure Bag Dimensions and Feed Speed, Bag Opening, Package Eject, Pressure Bar and Seal Bar,
Auxiliary Input/output and Printer. Access to this screen is password protected.
SCREEN NAVIGATION
SECTION 2 - CONTROLS
2-5
MAX-PRO Operator Manual Original Printed in English
SCREEN NAVIGATION
SECTION 2 - CONTROLS
JOB SETUP SCREEN - BAG DIMENSIONS AND FEED SPEED
Any changes made to this screen requires operator to press ‘Load Job’ button.
BAG DIMENSIONS
Length: This refers to the usable area inside the bag. This is measured from the bottom of the bag
to the seal. The typical setting is .5 to 1.5 inches less than the measured overall bag length.
Skirt Length: The distance from the bottom of the bag to the start of the seal.
Width: The width of the loaded bag.
Thickness: The thickness of bag material.
BAG FEED SPEED
Forward: Adjusts the forward web speed in inches per second.
Reverse: Adjusts the reverse web speed in inches per second.
LOW-PRESSURE AIR
LPA During Bag Feed: Toggle switch to have LPA ON or OFF while bag feeding out. This helps open
the bag.
2-6
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