Tetra Pak Tetra Cardboard Packer 70 User manual

GH100374.eps
Tetra Cardboard Packer 70
Multi infeed
Doc No OM-585572-1
OM
Operation Manual

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This document is valid for:
Series No/ Machine No Sign.
Table of content:
Doc No OM-585572-1
OM
Operation Manual
Tetra Cardboard
Packer 70
670272-060V
Equipment included:
Multi infeed
670292-0405
Wrap around unit
670375-040V
Central lubrication kit
CK-1287000-010V
Note!
This Operation Manual is only
valid for a custom built version
of Tetra Cardboard Packer 70
/ Multi infeed 670272-060V.
Introduction . . . . . . . . . . . . . . . . . . . .1
Safety precautions. . . . . . . . . . . . . . .3
General description . . . . . . . . . . . . .11
Alarms /Troubleshooting . . . . . . . . .15
Preparations . . . . . . . . . . . . . . . . . .23
Start . . . . . . . . . . . . . . . . . . . . . . . . .27
Production . . . . . . . . . . . . . . . . . . . .29
Emptying . . . . . . . . . . . . . . . . . . . . .33
Stop . . . . . . . . . . . . . . . . . . . . . . . . .35
Storing of material . . . . . . . . . . . . . .39
Cleaning. . . . . . . . . . . . . . . . . . . . . .41
Technical data . . . . . . . . . . . . . . . . .43
Lubricants . . . . . . . . . . . . . . . . . . . .45
Issue 9704
Tetra Pak Distribution AB

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1
Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Introduction
This section contains basic information
about the described Tetra Pak equipment
and this document.
WARNING!
To ensure maximum safety for the operator,
always read the section “Safety
precautions” before doing any work on the
machine or making any adjustments.
The purpose usage of this Tetra Pak
equipment
To place Tetra Brik packages or other
packages approved by Tetra Pak Distribution
AB into units made of corrugated cardboard.
Service
In case of problems when operating the
machine, contact the nearest Tetra Pak
service station.
Manufacturer
This Tetra Pak equipment is produced by:
Tetra Pak Distribution AB
Ruben Rausings gata
221 86 Lund
Sweden
Machine identification
The machine plate at the left is the type of
machine plate attached to the machine
frame. The plate carries data needed when
contacting Tetra Pak concerning this specific
machine.
The plate is marked with a CE sign. It means
that this machine complies with the basic
health and safety regulations of the
European Economic Area (EEA).
Machine Type
Drawing Spec.
Machine No.
Manufacturer
Year of manufacture
Tetra Pak
GH300005
Example of machine plate

Introduction
2Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Purpose of Operation Manual (OM)
The purpose of the Operation Manual is to
provide the operator with information on
how to handle and operate the machine
before, during, and after the production. For
instructions on maintenance in connection
with production, see the Maintenance
Manual (MM).
Design modifications
The directives in this document are in
accordance with the design and construction
of the machine at the time it was delivered
from Tetra Pak machine production facility.
Document producer:
The document has been produced by:
Tetra Pak Distribution AB
Ruben Rausings gata
221 86 Lund
Sweden
Further copies
Additional copies can be ordered from
nearest Tetra Pak service station.
When ordering technical publications,
always quote the document number printed
on the front cover of the document
concerned.
Number of pages
This document contains totally 48 pages.
Copyright © 1997
Tetra Pak Distribution AB
All rights reserved. No parts of this
document may be reproduced or copied in
any form or by any means without written
permission from Tetra Pak Distribution AB.
Example of manual
Document number

3
Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Safety precautions
Before any measures are taken, this section
must be read.
Avoid personnel injuries and machine
damages by following the instructions
given.
Tetra Pak will not accept any responsibility
in case of injuries and damages caused by
incorrect use of the machine.
Definitions
Skilled personnel
Service technicians: maintenance staff,
specialists etc.
Electrical: an individual with technical
knowledge or sufficient experience to
enable that individual to avoid hazards
which electricity can create.
Operator: an individual that has required
sufficient knowledge about operating the
machine by reading the Operation Manual,
OM.
General
Only skilled personnel is allowed to
operate the machine.
The machine may only be used in the
manner described in the Operation Manual,
OM.
Always use hearing protectors when the
machine is in operation.
GH200053
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Safety precautions
4Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Emergency stop
When there is risk of injury or machine
damage, the machine must be stopped
immediately by pushing one of the four
Emergency Stop buttons.
See section General description for
location of Emergency stop buttons.
Signs
The sign to the left indicates that water
must not be flushed towards the area with
the sign.
DANGER!
Failure to observe may result in danger to
your life.
The sign to the left indicates that there is a
hot surface. The temperature may exceed
60° C.
WARNING!
Failure to observe may result in injuries
caused by burning.
The sign to the left indicates that there is
entrapped heat in the area where the sign is
placed. The temperature may exceed
60° C.
WARNING!
Failure to observe may result in injuries
caused by burning.
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Safety precautions
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Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Signs (cont’d)
The sign to left indicates that there is
entrapped compressed air in the area where
the sign is placed.
WARNING!
Failure to observe may result in injuries
caused by moving parts.
The sign to left indicates that there is a risk
of electrical shock that may cause injury or
death in the area where the sign is placed.
DANGER!
Failure to observe may result in danger to
your life.
Doors
WARNING!
All doors leading to risk areas are fitted
with safety switches. These switches are
part of the security system and must under
no circumstances be by passed, bridged,
or in any other way put out of working
order.
If any one of the doors on the machine are
opened, it will immediately stop.
Covers
WARNING!
All covers screwed on to the machine must
be securely attached, before starting
the machine.
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Safety precautions
6Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Electrical cabinet
DANGER!
The voltage is 400V inside the electrical
cabinet. Can cause electrical shock or
serious injury. In case of accident,
immediately call for medical attention.
Work inside the electrical cabinet must be
performed by skilled persons only.
WARNING!
Risk of impaired hearing. Use hearing
protection to minimize the risk of impaired
hearing.
Always wear hearing protection while the
machine is running.
Note!
Always keep the ear protectors clean.
Infeed conveyor
WARNING!
If a safety cover is opened, the infeed
conveyor will still be in motion. Risk of
injuries.
The conveyor only stops when an
Emergency stop button is pushed or
when the machine is completely turned
OFF.
GH200053
GAD00051
GH200053

Safety precautions
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Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Hot melt equipment
DANGER!
There is high voltage inside the hot melt
unit. Risk of electrical shock that may
cause injury or death.
Always wear safety glasses, protective
gloves, and other protective clothing to
avoid injuries caused by splashing hot melt
material.
Never remove any part or component until
air and electric power have been
disconnected and the pressure of the hot
melt in the system has been relieved.
Failure to relieve any remaining air or liquid
(adhesive) pressure may cause serious
injuries through burning.
All service work on the hot melt unit must
be carried out by skilled personnel.
Hot melt unit
WARNING!
Risk of burning! During heating and
production the unit gets hot.
Do not touch the unit!
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Safety precautions
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Doc No OM-585572-1
Hot melt unit
DANGER!
Never flush water towards the hot melt unit
when cleaning the machine.
Hot melt
WARNING!
The hot melt tank contains heated hot melt
which can cause serious injuries. Do not
touch the hot melt!
GH200019
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Safety precautions
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Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Infeed brake
WARNING!
The infeed brake contains entrapped
compressed air which can cause serious
injuries.
Wrap around unit
WARNING!
The wrap around squeezer cylinder
contains entrapped compressed air which
can cause serious injuries.
Note!
This warning only applies for machines
equipped with a wrap around unit.
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Safety precautions
10 Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Production mode changes
All changes concerning packing pattern
and infeed alternatives must be carried out
by skilled personnel.
WARNING!
Do not reach into the machine neither from
above or below, risk of injuries caused by
crushing.
Discharge unit
The machine fulfils the safety demands
only when a discharge unit with covers
Tetra Pak no. C-1074350, C-1074388 is
mounted or similar equipment which fulfils
Machinery directive 89/392/EEC and
subdirectives.
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Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
This section gives the operator
information on where on the machine the
parts that the operator needs to be in
contact with are located and what the
different regulators control.
General description
Machine overview
1 Blanks magazine
2 Warning lamp
3 Hot melt unit
4 Emergency stop
5 Pneumatic cabinet
6 Emergency stop
7 Electrical cabinet
8 Main switch
9 Emergency stop
10 Control panel
11 Emergency stop
12 Grouping section
13 Pusher section
123
5
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4
6
7
8
9
10
11
12
13
7
9
4
12
11
13
86
Z-infeed
U-infeed 10

General description
2Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Status indicators
1 Step 1: Preheating
2 Step 2: Air pressure on
3 Step 3: Production
13 Indication, cardboard unit type
14 Indication, Single / Multi pack
15 Indication, packing pattern length
16 Indication, packing pattern width
Push buttons
4 Emergency stop
5Alarmreset
6 Manual emptying
7 Programme up
8 Programme down
9 Selector, cardboard unit type
10 Selector, Single / Multi pack
11 Selector, packing pattern length
12 Selector, packing pattern width
Status indicators and push buttons
7
13
14
15
16
9
10
11 12 8
5
6
4
1
2
3
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General description
3
Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
1 Main air valve
2 Pressure regulator, working pressure
3 Pressure regulator, vacuum, suction cups
4 Pressure regulator, hot melt gun, left
5 Pressure regulator, hot melt gun, right
6 Pressure regulator, hot melt unit
7 Pressure regulator, folding station
See section Techni cal dat a for settings.
Pressure regulators
12
3
4
5
6
7
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General description
4Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
1 Temperature regulator, hot melt tank
2 Temperature regulator, hot melt gun, left
3 Temperature regulator, hot melt hose, left
4 Temperature regulator, hot melt gun, right
5 Temperature regulator, hot melt hose, right
6 Temperature regulator, hot melt gun, wrap around,
right
7 Temperature regulator, hot melt hose, wrap around,
right
8 Temperature regulator, hot melt gun, wrap around,
left
9 Temperature regulator, hot melt hose, wrap around,
left
See section Technical data for settings.
Temperature regulators, hot melt unit
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OFF
100
150
200
C
OFF
100
150
200
C
OFF
100
150
200
C
OFF
100
150
200
C
OFF
100
150
200
C
OFF
100
150
200
C
OFF
100
150
200
C
OFF
100
150
200
C
OFF
100
150
200
C
SYSTEM FAULT
TEMP WARNING
CONTROL ON
SYSTEM READY
REMOTE SHUTDOWN
OVER TEMPERATUREOPEN SENSOR
SHORTED SENSOR
MICROSE
T
MULTISCAN
1
3
2
5
4
7
6
9
8

1
Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Alarms /Troubleshooting
This section describes all the alarms that
can appear and the actions that the
operator should take to correct them.
Warning lamp
When one of the three colours of the
warning lamp flashes, an alarm has been
triggered.
Depending on what kind of alarm that has
been triggered, the result is as follows:
• If the red colour, at the top, is flashing,
this indicates a dangerous status such as
a fault in the supervision circuit of the
doors. This requires an immediate
action from the operator.
• If the yellow colour, in the middle, is
flashing, this indicates an abnormal
status such as low air pressure during
production. This requires an immediate
action from the operator.
• If the blue colour, at the bottom, is
flashing, this indicates an alarm that
requires some action from the operator,
such as loading new blanks into the
magazine.
Note!
When several alarms are triggered at the
same time, only the alarm with the highest
alarm status is giving a signal to the
warning lamp.
When an alarm has been acknowledged but
the alarm still remains, the warning lamp is
steadily alight.
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Alarms /Troubleshooting
2Tetra Cardboard Packer 70 Multi infeed
Doc No OM-585572-1
Control panel
1
6
7
8
91011
12
2345
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Tetra Cardboard Packer 70 Tetra Pak