Wexxar Wf-10t Operation manual

WF-10T Case Former

WEXXAR WF-10T CASE FORMER

Operation and Service Manual

10101 Nordel Court, Delta, B.C. V4G 1J8 Canada

Telephone (604) 930-9300, Fax (604) 930-9368

WF-10T; Rev. 1.13

WF-10T Case Former

 WF-10T Case Former Table of Contents 
 
i
Table of Contents 
 
LIST OF TABLES............................................................................................................................V
TABLE OF FIGURES.....................................................................................................................VI 
PREFACE.....................................................................................................................................VIII 
About this manual....................................................................................................................ix 
How to use this manual............................................................................................................x
1SAFETY................................................................................................................................1-1 
1 SAFETY CONSIDERATIONS ............................................................................................... 1-2 
2 SAFETY STANDARDS ....................................................................................................... 1-2 
3 GENERAL PRECAUTIONS ................................................................................................. 1-2 
4 LOCK-OUT PROVISION ..................................................................................................... 1-3 
5 COMPRESSED AIR........................................................................................................... 1-3 
6 ELECTRICAL POWER ....................................................................................................... 1-3 
7 CONVEYOR DRIVEBELTS ................................................................................................. 1-3 
8 GUARD DOORS AND SAFETY PLATING.............................................................................. 1-3 
9 SAFETY INTERLOCKS........................................................................................................ 1-4 
10 CAUTIONARY LABELS ...................................................................................................... 1-4 
11 LUBRICANTS,ETC............................................................................................................ 1-4 
12 SAFETY ORIENTED DESIGN ............................................................................................. 1-4 
2INSTALLATION ...................................................................................................................2-5 
1 PREREQUISITES .............................................................................................................. 2-5 
2 SITE ENVIRONMENT CONSIDERATION ............................................................................... 2-5 
3 REMOVAL FROM CRATE................................................................................................... 2-6 
4 INSTALLING THE WF-10T ................................................................................................ 2-6 
5 LOCATION,LEVELING AND CONVEYORS............................................................................ 2-7 
5.1 Location ................................................................................................................2-7 
5.2 Leveling ................................................................................................................2-7 
5.3 Discharge Conveyor.............................................................................................2-7 
6 SERVICE CONNECTIONS .................................................................................................. 2-8 
6.1 Compressed Air....................................................................................................2-8 
6.2 Electrical Power....................................................................................................2-9 
6.3 Installing the Tape Heads.....................................................................................2-9 
3COMPONENT IDENTIFICATION ......................................................................................3-10 
1 MAJOR COMPONENTS ................................................................................................... 3-14 
2 PIN AND DOME TECHNOLOGY ........................................................................................ 3-17 
4THEORY OF OPERATION................................................................................................4-18 
1 SEQUENCE OF OPERATIONS .......................................................................................... 4-18 
2 SENSORS &CABLES ..................................................................................................... 4-21 
2.1 Inductive Sensors...............................................................................................4-21 
2.2 Optical Sensors ..................................................................................................4-21 
2.3 Interlock Switches...............................................................................................4-22 
2.4 Sensor Cables....................................................................................................4-22 
3 PNEUMATIC VALVE BANK............................................................................................... 4-22 
 
 
 

 WF-10T Case Former Table of Contents 
 
ii 
5CONTROLS........................................................................................................................5-23 
1 CONTROLS OVERVIEW .................................................................................................. 5-23 
2 CONTROLS DESCRIPTION .............................................................................................. 5-23 
3 AUTOMATIC CYCLE MODE........................................................................................ 5-26 
4 JOG MODE .................................................................................................................. 5-28 
5 DRY CYCLE MODE ..................................................................................................... 5-29 
6 BOX CALL MODE ........................................................................................................ 5-31 
7 CASE ORIENTATION CHANGES....................................................................................... 5-32 
7.1 Case Orientation Change-over Procedure.........................................................5-34 
6OPERATING PROCEDURES............................................................................................6-40 
1 SAFETY ........................................................................................................................ 6-40 
2 START-UP..................................................................................................................... 6-41 
2.1 Preliminary Checks.............................................................................................6-41 
2.2 Start-up Procedures............................................................................................6-42 
3 MONITORING................................................................................................................. 6-44 
3.1 Monitoring Machine Operation ...........................................................................6-44 
3.2 Loading the Magazine ........................................................................................6-44 
3.3 Magazine Pushers..............................................................................................6-45 
4 CLEARING A CASE JAM.................................................................................................. 6-47 
5 SHUTDOWN .................................................................................................................. 6-48 
7CASE SIZE ADJUSTMENTS.............................................................................................7-49 
1 SAFETY ........................................................................................................................ 7-49 
2 MACHINE ADJUSTMENTS ............................................................................................... 7-50 
3 CASE SIZE ADJUSTMENT INSTRUCTION LABELS .............................................................. 7-51 
4 CASE DIMENSION MEASUREMENTS ................................................................................ 7-52 
5 CASE SIZE RANGE ........................................................................................................ 7-53 
6 CASE BLANK LENGTH DIMENSION ‘A’ ADJUSTMENT ........................................................ 7-54 
7 BOTTOM FLAP HEIGHT DIMENSION ‘M’ ADJUSTMENT ...................................................... 7-55 
8 CASE BLANK HEIGHT DIMENSION ‘B’ ADJUSTMENT ......................................................... 7-56 
9 JAWPLATE CASE WIDTH DIMENSION ‘D1’ ADJUSTMENT................................................... 7-57 
9.1 Horizontal Pinblock Adjustments........................................................................7-60 
9.2 Pinblock Mounting Orientation............................................................................7-62 
9.3 Bottom Carriage Jawplate Pin & Dome Position Adjustments...........................7-63 
10 CENTER SKI CASE WIDTH DIMENSION ‘D2’ ADJUSTMENT................................................ 7-64 
11 CONVEYOR CASE WIDTH DIMENSION ‘D3’ ADJUSTMENT ................................................. 7-65 
12 CARRIAGE CASE LENGTH DIMENSION CADJUSTMENT .................................................... 7-66 
13 TESTING THE SIZE ADJUSTMENTS .................................................................................. 7-67 
14 QUICK SIZE CHANGE GUIDE .......................................................................................... 7-69 
8MACHINE MAINTENANCE ............................................................................................... 8-70 
1 SAFETY ........................................................................................................................ 8-70 
2 SERVICE AND MAINTENANCE PROCEDURES.................................................................... 8-71 
2.1 Uni-Drive Side-Belt Drive System.......................................................................8-71 
2.2 Chain Drive.........................................................................................................8-71 
2.3 Conveyor Side-Belt Replacement ......................................................................8-72 
2.4 Gear Reducer.....................................................................................................8-72 
2.5....................................................................................................................................8-73 
3 MAINTENANCE .............................................................................................................. 8-73 
3.1 Non-Lube Pneumatic System Maintenance.......................................................8-73 
3.2 Inspections..........................................................................................................8-73 
3.3 Routine Operator Maintenance ..........................................................................8-74 
3.4 Cleaning..............................................................................................................8-74 
 

 WF-10T Case Former Table of Contents 
 
iii 
 
4 PREVENTATIVE MAINTENANCE SCHEDULE ...................................................................... 8-75 
5 MAINTENANCE ADJUSTMENTS........................................................................................ 8-77 
5.1 Mechanism Speeds............................................................................................8-77 
5.2 Shock Absorbers ................................................................................................8-77 
5.3 Conveyor Belt Tension & Tracking.....................................................................8-77 
5.4 Tape Head Adjustments.....................................................................................8-78 
5.5 Pneumatic Supply Adjustments..........................................................................8-78 
5.6 Proximity Sensors...............................................................................................8-78 
5.7 Mechanical Maintenance....................................................................................8-79 
6 LUBRICATION ................................................................................................................ 8-79 
6.1 Moving Components...........................................................................................8-79 
6.2 Ball Bearings.......................................................................................................8-79 
6.3 Tape Head..........................................................................................................8-79 
9TROUBLESHOOTING & REPAIRS ..................................................................................9-80 
1 SAFETY ........................................................................................................................ 9-80 
2 GENERAL TROUBLESHOOTING ....................................................................................... 9-81 
3 MACHINE SEQUENCE TROUBLESHOOTING ...................................................................... 9-83 
4 ELECTRICAL TROUBLESHOOTING ................................................................................... 9-85 
5 PNEUMATIC TROUBLESHOOTING .................................................................................... 9-86 
6 CORRUGATED CASE QUALITY TROUBLESHOOTING ......................................................... 9-87 
7 CASE DRIVEBELT SYSTEM TROUBLESHOOTING............................................................... 9-88 
7.1 Case Not Sealing Squarely ................................................................................9-88 
7.2 Crushed Band on Bottom of Case’s Side Panels...............................................9-88 
7.3 Belt Sheds Rubber ‘Dust’....................................................................................9-88 
7.4 Conveyor Drive Rattles Audibly..........................................................................9-88 
7.5 Cases Jam Frequently Between Belts................................................................9-89 
7.6 Frequent Belt Breakage......................................................................................9-89 
8 BOTTOM FLAP FOLDING TROUBLESHOOTING .................................................................. 9-90 
8.1 Rear Minor Flap Does Not Fold..........................................................................9-90 
8.2 Rear Flap Folds, Releases, and Turns Backwards............................................9-90 
8.3 Bottom Major Flaps Bind On Center Ski.............................................................9-90 
8.4 Major Flaps Overlap in Center of Case..............................................................9-90 
8.5 Bottom Major Flaps Have a Gap in Center.........................................................9-90 
8.6 Major Flap Leading Edges Wrinkle After Taping................................................9-90 
8.7 Major Flaps Have a Tapered Gap or Gap / Overlap Combination.....................9-91 
8.8 Major Flaps Fold, but Leading Edge Lifted by Tape and Folded Back ..............9-91 
9 GENERAL TAPE APPLICATOR TROUBLESHOOTING........................................................... 9-92 
9.1 Tape Does Not Stick To Case Surface...............................................................9-92 
9.2 Tape is not Cut Uniformly...................................................................................9-93 
9.3 Tape Tail does not Stick Down Properly ............................................................9-93 
9.4 Tape is Off-center...............................................................................................9-94 
9.5 Tape Falls Forward on Tape Head.....................................................................9-94 
10 REPAIR PROCEDURES ................................................................................................... 9-94 
10.1 Solenoid Valve Repairs ......................................................................................9-94 
10.2 Conveyor Drivebelt Repairs................................................................................9-95 
10.3 Drivebelt Bearings Repairs.................................................................................9-95 
10.4 Gearmotor Repairs.............................................................................................9-95 
 
 
 
 

WF-10T Case Former Table of Contents

10 ENGINEERING SPECIFICATIONS.............................................................................10-96

10.1 OPERATING PARAMETERS ........................................................................................... 10-96

11 TRAINING GUIDE........................................................................................................11-97

11.1 PERFORMANCE CHECKLISTS ....................................................................................... 11-97

11.2 INSTRUCTIONS FOR ASSESSING PERFORMANCE ........................................................... 11-98

12 SERVICE & WARRANTY ............................................................................................12-99

13 OPTIONS....................................................................................................................13-100

13.1 TAPE MONITORING SYSTEM ...................................................................................... 13-100

14 INDEX.........................................................................................................................14-101

APPENDIX A............................................................................................................................... 104

Material Safety Data Sheets: Fuchs Lubricants – Geralyn FMG 387 ................................. 104

APPENDIX B............................................................................................................................... 112

Material Safety Data Sheets: Keystone Lubricants – Nevastane HT-2............................... 112

WF-10T Case Former List of Tables

List of Tables

Table 1: Inductive Sensors ........................................................................................................ 4-21

Table 2: Photosensors............................................................................................................... 4-21

Table 3: Interlock Switches........................................................................................................ 4-22

Table 4: Sensor Cables ............................................................................................................. 4-22

Table 5: Preliminary Start-up Checklist ..................................................................................... 6-42

Table 6: Mechanism HOME Positions and Valve Numbers...................................................... 6-42

Table 7: Machine Start-up Procedures...................................................................................... 6-43

Table 8: Machine Loading Checklist ......................................................................................... 6-46

Table 9: Clearing Jams.............................................................................................................. 6-47

Table 10: Machine Shutdown .................................................................................................... 6-48

Table 11: Case Size Range....................................................................................................... 7-53

Table 12: Dimension ‘A’ Adjustments........................................................................................ 7-54

Table 13: Dimension ‘M’ Adjustments ....................................................................................... 7-55

Table 14: Dimension ‘B’ Adjustments........................................................................................ 7-56

Table 15: Dimension ‘D1’ Adjustments ..................................................................................... 7-59

Table 16: Horizontal Pinblock Adjustments............................................................................... 7-61

Table 17: Pinblock Mounting Orientation .................................................................................. 7-62

Table 18: Dimension ‘D2’ Adjustments ..................................................................................... 7-64

Table 19: Dimension ‘D3’ Adjustments ..................................................................................... 7-65

Table 20: Dimension ‘C’ Adjustments ....................................................................................... 7-67

Table 21: Full Cycle Sequence..................................................................................................7-68

Table 22: Dimension Adjustment Reference............................................................................. 7-69

Table 23: Machine Inspection.................................................................................................... 8-73

Table 24: Routine Operator Maintenance ................................................................................. 8-74

Table 25: Cleaning the Machine................................................................................................ 8-75

Table 26: General Troubleshooting Reference ......................................................................... 9-82

Table 27: Machine Sequence Troubleshooting......................................................................... 9-83

Table 28: General Pneumatic Troubleshooting Reference ....................................................... 9-86

Table 29: Cylinders too slow ..................................................................................................... 9-86

Table 30: Cylinders not moving .................................................................................................9-87

Table 31: Operating Parameters ............................................................................................. 10-96

Table 32: Performance Checklists........................................................................................... 11-97

WF-10T Case Former Table of Figures

Table of Figures

Figure 1-1: Locked Out Electrical Disconnect and Filter-Regulator Assembly ........................... 1-3

Figure 1-2: Example of Safety Interlock ...................................................................................... 1-4

Figure 1-3: Sample Cautionary Label.......................................................................................... 1-4

Figure 2-1: Filter-Regulator Assembly......................................................................................... 2-8

Figure 3-1: Case Former Operator’s Side View ........................................................................ 3-10

Figure 3-2: Carriage Return Shocks Absorbers and Sensor..................................................... 3-11

Figure 3-3: Flap Folding Section Components.......................................................................... 3-11

Figure 3-4: Injector, Caliper, and Sensors................................................................................. 3-12

Figure 3-5: Walk-In Magazine Assembly................................................................................... 3-12

Figure 3-6: Carriage and Jawplate Assemblies......................................................................... 3-13

Figure 4-1: Injector Down; Pins Penetrating Corrugate Flutes.................................................. 4-19

Figure 4-2: Rear Flap Folder Kicker Arm Actuated ................................................................... 4-19

Figure 4-3: Solenoid Valve Bank ............................................................................................... 4-22

Figure 5-1: Main Disconnect Switch.......................................................................................... 5-23

Figure 5-2: ‘RESET’ Button ....................................................................................................... 5-23

Figure 5-3: ‘EMERGENCY STOP’ Buttons ............................................................................... 5-23

Figure 5-4: 'Service' Screen ...................................................................................................... 5-24

Figure 5-5: 'Main Control' Screen ..............................................................................................5-24

Figure 5-6: 'Main Control' Button ............................................................................................... 5-25

Figure 5-7: Machine in AUTOMATIC CYCLE Mode .................................................................. 5-25

Figure 5-8: ‘START’ Button ....................................................................................................... 5-25

Figure 5-9: ‘STOP’ Button ......................................................................................................... 5-25

Figure 5-10: 'LARGE BOX / SMALL BOX’ Button..................................................................... 5-26

Figure 5-11: 'Box Setup' Screen................................................................................................5-26

Figure 5-12: Box Size Selection Button..................................................................................... 5-26

Figure 5-13: Changing the Box Size.......................................................................................... 5-27

Figure 5-14: SMALL BOX Selected........................................................................................... 5-27

Figure 5-15: 'Box Setup Jogging On' Button ............................................................................. 5-27

Figure 5-16: 'Previous' Button ................................................................................................... 5-27

Figure 5-17: 'JOG CONTROL' Button ....................................................................................... 5-27

Figure 5-18: ‘Jog Control’ Screen..............................................................................................5-28

Figure 5-19: JOG CONTROL Status Indicator Illuminated........................................................ 5-28

Figure 5-20: Sensor Status Indicator......................................................................................... 5-28

Figure 5-21: 'MACHINE CYCLE JOG' Button ........................................................................... 5-28

Figure 5-22: 'SETUP' Button ..................................................................................................... 5-28

Figure 5-23: 'Setup' Screen ....................................................................................................... 5-29

Figure 5-24: DRY CYCLE OFF/ON Toggle Switch ................................................................... 5-29

Figure 5-25: DRY CYCLE ACTIVE Indicator............................................................................. 5-29

Figure 5-26: DRY CYCLE Function........................................................................................... 5-29

Figure 5-27: 'REMOTE DEMAND OFF/ON’ Toggle Switch ...................................................... 5-30

Figure 5-28: REMOTE DEMAND Indicator ............................................................................... 5-30

Figure 5-29: REMOTE DEMAND Function ............................................................................... 5-30

Figure 5-30: Remote Demand Sensor ...................................................................................... 5-30

Figure 5-31: 'BOX CALL’ Button................................................................................................ 5-31

Figure 5-32: 'REMOTE DEMAND OFF/ON’ Toggle Switch ...................................................... 5-31

Figure 5-33: REMOTE DEMAND Indicator ............................................................................... 5-31

Figure 5-34: BOX CALL Function.............................................................................................. 5-31

Figure 5-35: Right-handed Case Orientation ............................................................................ 5-33

Figure 5-36: 'Case Orientation’ Toggle Switch.......................................................................... 5-34

Figure 5-37: Case Orientation Toggle Switch ........................................................................... 5-35

Figure 5-38: Case Orientation 'Handing' Change-over ............................................................. 5-35

Figure 5-39: 'ALARM HISTORY' Button.................................................................................... 5-36

WF-10T Case Former Table of Figures

vii

Figure 5-40: 'Alarm History' Screen........................................................................................... 5-36

Figure 5-41: 'CLEAR' Button ..................................................................................................... 5-36

Figure 5-42: ‘Password’ Window ............................................................................................... 5-36

Figure 5-43: 'Alphanumeric Keypad’ Window............................................................................ 5-36

Figure 5-44: ‘PREVIOUS’ Button............................................................................................... 5-36

Figure 5-45: 'Service' Button ..................................................................................................... 5-37

Figure 5-46: 'TROUBLESHOOTING’ Button ............................................................................. 5-37

Figure 5-47: 'Troubleshooting' Screen ...................................................................................... 5-37

Figure 5-48: 'PLC INPUTS’ Button ............................................................................................ 5-37

Figure 5-49: 'PLC Inputs’ Screen .............................................................................................. 5-38

Figure 5-50: 'PLC Inputs’ Status Indicator................................................................................. 5-38

Figure 5-51: PLC Input Status Indicator Illuminated.................................................................. 5-38

Figure 5-52: 'PLC OUTPUTS’ Button ........................................................................................ 5-38

Figure 5-53: 'PLC Outputs' Screen............................................................................................ 5-39

Figure 5-54: 'PLC Outputs’ Status Indicator .............................................................................. 5-39

Figure 5-55: PLC Output Function Indicator Illuminated ........................................................... 5-39

Figure 6-1: Walk-In Magazine ...................................................................................................6-44

Figure 6-2: Magazine Pusher ....................................................................................................6-45

Figure 6-3: Magazine Pusher in Locked Position...................................................................... 6-45

Figure 6-4: Discharge Pusher Before and After Adjustment ..................................................... 6-45

Figure 6-5: Discharge Pusher Adjustment Wingnuts ................................................................ 6-45

Figure 7-1: Case Size Adjustment and Jawplate Adjustment Instruction Labels...................... 7-51

Figure 7-2: Case Dimension Measurements............................................................................. 7-52

Figure 7-3: Case Size Range Dimensional Diagram................................................................. 7-53

Figure 7-4: Dimension ‘A’ Hand Crank...................................................................................... 7-54

Figure 7-5: Dimension ‘A’ Pointer..............................................................................................7-54

Figure 7-6: Magazine Width ...................................................................................................... 7-54

Figure 7-7: Vertical Adjustment Chain Lock .............................................................................. 7-55

Figure 7-8: Dimension ‘M’ Hand Crank ..................................................................................... 7-55

Figure 7-9: Dimension ‘M’ Pointer ............................................................................................. 7-55

Figure 7-10: Dimension ‘B’ Vertical Adjustment Chain Lock..................................................... 7-56

Figure 7-11: Dimension ‘B’ Pointer on Injector Backplate ......................................................... 7-56

Figure 7-12: Dimension ‘B’ Hand Crank.................................................................................... 7-56

Figure 7-13: Dimension ‘D1’ Hand Crank.................................................................................. 7-57

Figure 7-14: Dimension ‘D1’ Pointer.......................................................................................... 7-57

Figure 7-15: Measuring Parallel Jawplate Width....................................................................... 7-57

Figure 7-16: Jawplate Formed Case Width 'D1' Adjusts ........................................................... 7-58

Figure 7-17: Improperly Adjusted Synchronizer Bar ................................................................. 7-58

Figure 7-18: Properly Adjusted Synchronizer Bar ..................................................................... 7-58

Figure 7-19: Divergent Jawplates.............................................................................................. 7-58

Figure 7-20: Parallel Jawplates ................................................................................................. 7-58

Figure 7-21: Jawplate and Carriage Assemblies....................................................................... 7-60

Figure 7-22: Ringpins and Horizontal Pinblock Adjustment Wingnuts ...................................... 7-60

Figure 7-23: Outer (left) and Inner (right) Pins Engaged........................................................... 7-62

Figure 7-24: Pin & Dome Position Adjustments ........................................................................ 7-63

Figure 7-25: Clearance Between Rear Flap and Center Ski..................................................... 7-64

Figure 7-26: Bottom Center Ski .................................................................................................7-64

Figure 7-27: Dimension ‘D3’ Case Width Adjust ....................................................................... 7-65

Figure 7-28: Case Width Verification......................................................................................... 7-65

Figure 7-29: Dimension ‘C’ Formed Case Length Adjust.......................................................... 7-66

Figure 7-30: Jawplate and Carriage Assemblies....................................................................... 7-66

Figure 8-1: Serpentine Chain Drive........................................................................................... 8-71

Figure 8-2: Conveyor Belt Tensioning....................................................................................... 8-77

Figure 8-3: Inductive Sensor Adjustment Range....................................................................... 8-78

Figure 9-1: Lowering the Tape Head Bracket ........................................................................... 9-89

Figure 9-2: Elevating the Tape Head Bracket ........................................................................... 9-91

WF20H Case Former Preface

viii

PREFACE

WEXXAR Model WF-10T Case Formers are versatile and industry-proven machines with unique

mechanical case forming and bottom-flap folding technology. These machines offer maximum

flexibility and performance within a broad range of case styles and sizes, and have available a

choice of options to meet your own specific requirements.

Please read this Operation & Service Manual carefully, as it contains the necessary information

required to extend the service life of this machine to its fullest. Furthermore, this manual will

inform you regarding the correct and safe usage of this machine.

We recommend that you keep this manual with the case former for future reference. If any

problems are encountered with the procedures contained in this manual, please contact our

Service Center before proceeding.

While every effort has been made to ensure the completeness and accuracy of this manual,

WEXXAR assumes no responsibility or liability for any losses or damages resulting from the use

of the information contained in this document.

Due to technical advances and improvements, some of the information contained in this manual

may be changed or modified without prior notice from WEXXAR/BEL.

The WF-10T Case Former Operation and Service Manual was written to assist you in installing,

operating, troubleshooting, maintaining, repairing, and training others to operate the machines

properly. This manual describes the standard features that are present in WF-10T machines,

along with a few of the most common optional features. For information specific to your machine,

please refer to the custom-made Supplementary Manual and material that accompanies this

guide.

This document may not be copied or reproduced without the explicit permission of

WEXXAR/BEL.

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