Wexxar BEL 180 User manual

Operator Manual 65-34-5 Effective APRIL 21, 2010
BEL 180
SEMI-AUTOMATICRANDOM/SELF-ADJUSTING
UNIFORMTOPANDBOTTOMCASETAPESEALER
©Belcor Division of Wexxar Industries Inc.
Phone [phone] • Fax [phone]
E-mail: [email protected]

BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 2
Introduction
The BEL 180 is capable of applying pressure-sensitive tape to both the top and bottom of various
size cases presented to the machine at random or without manual adjustment between sizes. In
addition, the machine features the ability to use the random function to automatically adjust to a
uniform case size and lock itself in position for longer runs of a single case size.
The features of the BEL 180 are:
 DEKKA CADET - 2” high performance tape heads
 A special sensor system that activates the dynamic case height adjustment while eliminating a
potential pinch point. Moving parts are concealed by design and by guarding to a high
standard of safety
 A stainless steel controls enclosure with logic controller and a second conveniently placed
start/stop switch at the front of the top tapehead holder. There is a solenoid valve as well as a
manual valve for compressed air supply.
 Roller infeed section for easier case entry
 A robust vertical actuator system for moving the top drive and tape head. It uses air cylinders
with pneumatic rod locks to secure the random case size adjustments, lock the machine in
position for uniform case sizes in ‘Lock’ mode and for safety to prevent unexpected
movement in the case of a sudden electrical or pneumatic power failure.
 A tilt-up bottom tapehead holder for easier access to replace the tape roll or remove the
bottom tapehead from the machine.
 Heavy duty stainless steel frame.
 Interlocked enclosure guard doors.
Standard Specifications:
Length Width Height
Case Size Range Minimum 6” / 152mm 6” / 152mm 6” / 152mm
Maximum 72” / 1829mm* 17” / 432mm 19” / 483mm
*can be made longer
Machine Dimensions 46” / 1175mm 36” / 889mm 54” / 1372mm
In/Outfeed Height Frame 23.5” / 597mm
With adjustable leg extensions
[foot pad] Minimum
Maximum
23.5" / 597mm
30” / 762mm
Speed Up to 10 cases / min.
Shipping Weight Approx. 500 lbs. / 227 kg.
For further detail, see Layout Drawing 75-678
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 3
Table of Contents
BEL 180 Main Controls & Function Reference................................................................. 4
Connecting Power............................................................................................................... 5
Electric........................................................................................................................ 5
Compressed Air .......................................................................................................... 5
Installing & Removing the Tape Heads.............................................................................. 6
Bottom Tape Head.......................................................................................................... 6
Top Tape Head................................................................................................................ 8
Top Tapehead Downward Force [Pressure Regulator] Adjustment................................... 9
Conveyor Side Force [Pressure Regulator] Adjustment................................................... 10
Feeding Cases to the Machine .......................................................................................... 11
Automatic Random Case Size Operation ..................................................................... 11
Self-Adjusting Uniform Case Size Operation – ‘Lock’ Mode ..................................... 12
Troubleshooting Guide ..................................................................................................... 14
Section 1 - Corrugated Case Quality and Specifications.............................................. 14
General Taping Conditions........................................................................................... 15
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 4
BEL 180 Main Controls & Function Reference
Machine Status Light
• Steady Green – Ready
• Flashing Green – Bottom tape
head raised and ready to access
• Quick-Flashing Green – Machine
or cycle fault
Control Station
• E-stop
• Reset
• Self-Adjustment
lock function
Front Guard doors
with key interlock
switch
Bottom tape head tilt-up lever
Main Air Supply
• Manual and solenoid air
shut-off valves
• Air filters
Main Controls Enclosure
• Main Electrical Power
Shut-off
• Top tape head lift
switch
• Conveyor drive test
Side belt conveyor
and top tapehead
pressure (force)
adjustment
Bottom tape head
Top tape head
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 5
Connecting Power
Electric
The BEL 180 is single-phase 110-120 VAC. The conveyor drive system is powered by
dual gear-motors that together draw 5.5 amps.If required, a minimum 14 gauge (AWG)
power extension cord with standard three pin connection must be used to connect the
machine to the power source.
Compressed Air
The BEL 180 requires an air supply that must be clean and dry and at an optimal pressure
of 80 PSI. The volume of air required is 0.02 CF/cycle at 80 PSI (6 Bar). The air supply
line must be of sufficient diameter to provide an adequate amount of air without pressure
drops when the machine is cycling. A ½” air line size is recommended.
One of the most common causes of inconsistent machine performance is inadequate air
supply. Therefore, meeting machine air requirements is important to assure satisfactory
operation.
The BEL 180 is equipped with both solenoid and manual compressed air shut-off / dump
valves and a filter/regulator which should be checked daily to ensure that the air pressure
is adjusted to the proper setting, and any water drained from the filters. The BEL 180
does not use lubrication in the compressed air supply.
Pneumatic Controls
Compressed air
connection
Filter Water Drains
Solenoid Control
Valves
Manual Shut-off
/ Lockout Valve
Main Machine
Pressure
Regulator
Main Air Supply
Solenoid Valve
Pressure Regulators for
Side Belt Conveyor
Gripping Force and Top
Tapehead Downward
Force [see pages 9 & 10]
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 6
Installing & Removing the Tape Heads
Tape dispensing heads are mounted with pins on their sides that fit into corresponding slots in the
upper and lower tape head mounting positions.
Bottom Tape Head
The bottom tapehead is installed and removed by using the manual lever to rotate it up and out of
the bottom conveyor rollers. It is first necessary to raise the top tapehead holder to be out of the
way using a switch on the main controls enclosure.
1. With the machine power turned on and all the guard doors closed, turn the TAPE
HOLDER selector switch on the main control panel to ‘UP’. The top tape head holder
will raise it to its maximum height and lock in position, making the bottom tape head
accessible. The green light on top of the machine will flash quickly indicating that the
machine guard door can be opened to reach the bottom tape head.
2. Pull the bottom tapehead holder lever towards you to rotate the bottom head up and out of
the bottom machine frame. The lever has a latching pin to secure it in the up position.
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 7
3. On the right side of the holder at the top in the raised position, there is a latch that locks
the tape head into the holder. It must be released to remove the head from the holder.
4. To lower the bottom head back down into the machine frame, use the lever to take the
weight of the head and pull the latch pin out to release the lever arm.
5. Once the tape has been changed or the tapehead has been remounted in the bottom holder
and the guard doors closed, turn the TAPE HOLDER selector switch to DOWN and push
the RESET button to lower the holder back down into the bottom frame.
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 8
Top Tape Head
1. Lower the bottom tape head holder, if raised, pushing the RESET button so that the top
holder will move its lowest position. Turn off the power or open a guard door to shut off the
machine. The top tape roll can be changed in this position.
2. On the top tape head, both the front and rear pins head engage in key-shaped slots. Drop the
head in and then push it back in its holder to engage in retainer clips.
Please consult the tape head manual for instructions on the mounting of tape rolls and the proper
threading of tape through the applicator head.
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 9
Top Tapehead Downward Force [Pressure Regulator] Adjustment
The top tapehead downward force can be adjusted to provide adequate clamping of the top flaps
and proper taping performance. Too much downward force can cause crushing of the top of the
case or create taping problems. The regulators for the top tape head and conveyor grip are on the
left-hand side of the machine next to the pneumatic air supply and solenoid control valves.
The right hand regulator controls
the top tape head downward force.
To adjust the downward force of the top tapehead, have the machine in ‘Ready’ mode and
use a screwdriver to manually actuate the right-hand end valve on the manifold so that the
pressure indicates on the regulator gauge. Turn the regulator knob to adjust the pressure, it
should be set in the range of 15 psi for average conditions.
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 10
Conveyor Side Force [Pressure Regulator] Adjustment
The force required to center and grip incoming case in the conveyor drive belts may vary
according to the weight of the product. The amount of force exerted by the conveyor belts can be
adjusted by regulating the air pressure in the conveyor case width adjustment mechanism. The
regulator for the width adjustment is on the left-hand side of the machine behind the main control
enclosure at the outfeed end.
Use just enough pressure to center and drive the case effectively. On soft-sided cases, it will
prevent the case and product from being squeezed unnecessarily. The recommended pressure
range is about 40 PSI.
The left hand regulator controls the side
belt conveyor case centering and gripping
force. It should be set in the range of 40
psi for average conditions
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 11
Feeding Cases to the Machine
Automatic Random Case Size Operation
1. Fold down the top flaps of the case and, holding them down at the rear of the case; push it
against the ‘nose’ roller of the top tapehead holder. The top tapehead holder will rise until
the roller no longer contacts the case and allow it to be pusher further into the sealer.
There is a pin that rises through the bottom sensor plate that limits how far the case can
be pushed into the machine.
Top tapehead holder
‘nose’ roller Case infeed position limit pin
2. The top tapehead will drop down until it senses the top of the case and the conveyor side
belts will come in against the sides of it, driving the case through the sealer.
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 12
Self-Adjusting Uniform Case Size Operation – ‘Lock’ Mode
In addition to random case size mode, the BEL 180 can be set to measure the first of a series of
same size cases and then lock its adjustments to run them without having to sense and adjust to
each case individually. This allows both faster operation and saves wear on the machine
adjustment mechanisms when running several cases of uniform size.
1. As shown on the on-machine instructions, push the MODE button on the machine control
so that it is illuminated.
2. Run the first case through as you would in Random Mode as described above. The
machine will go through the same self-adjusting procedure but once it has adjusted to the
case size it will lock itself in that position. Run the rest of the cases of the same size
through the sealer without having to wait for the machine to adjust to the case size.
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3. To unlock the machine adjustments and return to Random Mode, or to measure a new
uniform case size, push the MODE button so that its light is off. The machine
adjustments will return to their home positions in Random Mode.
4. To repeat the measurement process for a new uniform case, push the MODE button again
so that it is lit and present the next case as in step 2.
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 14
Troubleshooting Guide
Section 1 - Corrugated Case Quality & Specifications
Corrugated case quality is a major factor in smooth running and quality sealing. The following
points will help determine if you have a case size or quality problem:
1. Case dimensions: Ensure that the products fill the case efficiently and do not bulge, over-
fill, or under-fill the case. Re-sizing of cases can often result in cost savings by using the
correct case size and material weight. Consult your corrugated case supplier, for help to
achieve this. A correctly filled case will help the automatic process by supporting the case
body during flap folding and the top flap sealing.
2. Score (fold) Lines: Ensure that the scores in the cases are as well defined as possible to help
with the automatic folding process. Your corrugated case supplier can help with this by
making sure that correct scoring pressure is used for your case specification. This is one of
the most common causes of poor case- closing performance
3. Corrugated case weakness: The case manufacturing process can damage the fluted
construction of corrugated board. Points to watch for:
a. Crushed corrugate: Ensure that the flutes have not been crushed overall, causing
the case to have a soft and limp feeling. This causes poor case rigidity during
machining and also does not give your product the protection it deserves.
b. Bands of crushed corrugate flutes: Selective bands of crushing, usually parallel to
the case flutes, can cause failure lines down the case and result in poor machine-
handling performance.
c. Case storage: Flat cases should be stored in dry conditions and on a flat surface. Be
careful not to stack excessive weight on to the cases, as crushing can result.
4. Case squareness: The glue joint where the manufacturer glues the flat case together often
can present a quality problem if they are misaligned. This causes the case to be wider at one
end than the other or to be twisted from end to end. Both conditions can cause case jams and
poor sealing quality.
5. Flap corner slots: If the corner slots are wide, cases can be automatically folded with a
minimum of interference between major and minor flaps.
6. Overlapped or gapped case flaps: These conditions can be caused by incorrect flap lengths.
Fold the case by hand to see that flaps meet neatly in the case center.
Use your corrugated case supplier’s expertise to help you achieve the correct specifications for
your automatic sealing line.
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 15
General Taping Conditions
Problem: Tape Does Not Stick To Case Surface.
The tape is not bonding to the corrugated board of the flaps or ends of the case to provide a secure
seal. Look for the following conditions:
• Under-filled Case. Ensure that the product provides support under the top flaps so that they
are not simply pushed down or away from the tape head rather than having the tape rolled
onto the surface.
• Overlapping flaps. If the outside (major) flaps are allowed to overlap, the ‘step’ created
results in an uneven taping surface, causing poor tape adhesion that can release during
shipping and handling. See comments on flaps (Troubleshooting Section 1, Corrugated Case
Quality & Specifications)
• Tape-head roller contact. Ensure that the tape-head contact or wipe-down rollers are
making good contact with the case and that the roller spring tension is correct.
• Dust or dirt. Large amounts of dust or dirt gathering on the cases or in the air will impair
adhesive effectiveness.
• Temperature. Extremely hot or cold temperature may require tapes with appropriate
adhesive formulations for good initial bond and permanent sealing performance.
• Tape adhesive. Ensure the presence and quality of tape adhesive. We recommend the ‘hot
melt’ type of adhesive over Acrylic adhesive.
Problem: Tape is not cut uniformly.
The tape is not cut properly every time. In the worst situations several cases may be taped
together.
SAFETY CAUTION –Tape Head knife is very sharp
Ensure the following conditions:
• Tape head position. If the top tape head is set too high [in manual machine operation] the
cut-off knife will not be fully activated, resulting in poor cut off. The tape head side plates
should be within 1/16 to 1/8” of the case. Ensure also that cases ride fully down between the
conveyor belts to provide proper contact with the bottom head cut-off knife.
• Knife extension. Ensure that the knife extends enough to fully contact the tape during the
cutting stroke.
• Tape tension. The unroll tension should be smooth and not too tight, as a ‘snap back’
caused by stretched tape can cause a jagged cut-off and tape pieces to stick to the blade.
• Clean knife. Clean the blade, and apply a little silicon or oil to avoid adhesive build up on
the sharp points.
• Knife blade wear or damage. Blades must be very sharp to work well. The points are
easily damaged if contacted by any hard material. Replace the blade if it seems dull.
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BEL 180 SEMI-AUTOMATIC RANDOM TAPE SEALER 16
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• Cut-off spring tension. Ensure that the spring that provides power to cut-off arm has
enough tension to cut through the tape. Replace the spring if it is too weak.
Problem: Tape tail does not stick down properly.
The end of the tape on the back side of the case as it leaves the machine has not adhered well to
the case. Check these conditions:
• Tape tension. Tension should be is smooth and not too tight. Tape tension ‘snap back’ will
cause tape tail to recoil and not stick well on the back of the case.
• Tape head roller contact. Ensure that the wipe-down roller is actively pushing the tape
down and that the spring is in good condition and set to the right tension.
Problem: Tape is off-center.
The line of tape is not centered over the gap between flaps on the top or bottom of the
case. Look for the following conditions:
• Tape roll position. Ensure that the tape roll is fully pushed on to the spool.
• Tape head straightness. Ensure that the tape head sits straight in its bracket and is not
tilted to one side.
• Obstructions. Look for obstructions that could be pushing the tape off center.
Problem: Tape Falls Forward on Bottom Tape Head.
The beginning end of the tape must stand vertically in front of the tape head front roller
in order to contact the leading end of the next case. A bow made across the tape by the
tape head guides helps to stiffen it, and a static electric charge on the tape head rollers
attracts the tape and helps to keep it in place. If the bottom tape will not stand vertically,
look for the following conditions:
• Contamination. The tape may be wound around the roller, or there may be dirt on the roller.
• No static charge. Dust roller surfaces with talcum powder to the increase static charge on
the roller.
• Incorrect tape head guide settings. Ensure that the tape holder or finger is set correctly.
See the Dekka tape head manual.
• Inappropriate environment. A strong breeze in the vicinity of the tape sealer can cause the
tape to blow down. High temperature or humidity may affect the tape characteristics.
• Inappropriate tape. Some brands and types of tape have more ‘body’ than others, so a
change of tape may be needed, particularly in difficult ambient conditions. We recommend
that the tape have minimum thickness of at least 1.7 mil.