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 [phone], Fax [phone]
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
1.1 SAFETY CONSIDERATIONS ............................................................................................... 1-2
1.2 SAFETY STANDARDS ....................................................................................................... 1-2
1.3 GENERAL PRECAUTIONS ................................................................................................. 1-2
1.4 LOCK-OUT PROVISION ..................................................................................................... 1-3
1.5 COMPRESSED AIR........................................................................................................... 1-3
1.6 ELECTRICAL POWER ....................................................................................................... 1-3
1.7 CONVEYOR DRIVEBELTS ................................................................................................. 1-3
1.8 GUARD DOORS AND SAFETY PLATING.............................................................................. 1-3
1.9 SAFETY INTERLOCKS........................................................................................................ 1-4
1.10 CAUTIONARY LABELS ...................................................................................................... 1-4
1.11 LUBRICANTS,ETC............................................................................................................ 1-4
1.12 SAFETY ORIENTED DESIGN ............................................................................................. 1-4
2INSTALLATION ...................................................................................................................2-5
2.1 PREREQUISITES .............................................................................................................. 2-5
2.2 SITE ENVIRONMENT CONSIDERATION ............................................................................... 2-5
2.3 REMOVAL FROM CRATE................................................................................................... 2-6
2.4 INSTALLING THE WF-10T ................................................................................................ 2-6
2.5 LOCATION,LEVELING AND CONVEYORS............................................................................ 2-7
2.5.1 Location ................................................................................................................2-7
2.5.2 Leveling ................................................................................................................2-7
2.5.3 Discharge Conveyor.............................................................................................2-7
2.6 SERVICE CONNECTIONS .................................................................................................. 2-8
2.6.1 Compressed Air....................................................................................................2-8
2.6.2 Electrical Power....................................................................................................2-9
2.6.3 Installing the Tape Heads.....................................................................................2-9
3COMPONENT IDENTIFICATION ......................................................................................3-10
3.1 MAJOR COMPONENTS ................................................................................................... 3-14
3.2 PIN AND DOME TECHNOLOGY ........................................................................................ 3-17
4THEORY OF OPERATION................................................................................................4-18
4.1 SEQUENCE OF OPERATIONS .......................................................................................... 4-18
4.2 SENSORS &CABLES ..................................................................................................... 4-21
4.2.1 Inductive Sensors...............................................................................................4-21
4.2.2 Optical Sensors ..................................................................................................4-21
4.2.3 Interlock Switches...............................................................................................4-22
4.2.4 Sensor Cables....................................................................................................4-22
4.3 PNEUMATIC VALVE BANK............................................................................................... 4-22

WF-10T Case Former Table of Contents
ii
5CONTROLS........................................................................................................................5-23
5.1 CONTROLS OVERVIEW .................................................................................................. 5-23
5.2 CONTROLS DESCRIPTION .............................................................................................. 5-23
5.3 AUTOMATIC CYCLE MODE........................................................................................ 5-26
5.4 JOG MODE .................................................................................................................. 5-28
5.5 DRY CYCLE MODE ..................................................................................................... 5-29
5.6 BOX CALL MODE ........................................................................................................ 5-31
5.7 CASE ORIENTATION CHANGES....................................................................................... 5-32
5.7.1 Case Orientation Change-over Procedure.........................................................5-34
6OPERATING PROCEDURES............................................................................................6-40
6.1 SAFETY ........................................................................................................................ 6-40
6.2 START-UP..................................................................................................................... 6-41
6.2.1 Preliminary Checks.............................................................................................6-41
6.2.2 Start-up Procedures............................................................................................6-42
6.3 MONITORING................................................................................................................. 6-44
6.3.1 Monitoring Machine Operation ...........................................................................6-44
6.3.2 Loading the Magazine ........................................................................................6-44
6.3.3 Magazine Pushers..............................................................................................6-45
6.4 CLEARING A CASE JAM.................................................................................................. 6-47
6.5 SHUTDOWN .................................................................................................................. 6-48
7CASE SIZE ADJUSTMENTS.............................................................................................7-49
7.1 SAFETY ........................................................................................................................ 7-49
7.2 MACHINE ADJUSTMENTS ............................................................................................... 7-50
7.3 CASE SIZE ADJUSTMENT INSTRUCTION LABELS .............................................................. 7-51
7.4 CASE DIMENSION MEASUREMENTS ................................................................................ 7-52
7.5 CASE SIZE RANGE ........................................................................................................ 7-53
7.6 CASE BLANK LENGTH DIMENSION ‘A’ ADJUSTMENT ........................................................ 7-54
7.7 BOTTOM FLAP HEIGHT DIMENSION ‘M’ ADJUSTMENT ...................................................... 7-55
7.8 CASE BLANK HEIGHT DIMENSION ‘B’ ADJUSTMENT ......................................................... 7-56
7.9 JAWPLATE CASE WIDTH DIMENSION ‘D1’ ADJUSTMENT................................................... 7-57
7.9.1 Horizontal Pinblock Adjustments........................................................................7-60
7.9.2 Pinblock Mounting Orientation............................................................................7-62
7.9.3 Bottom Carriage Jawplate Pin & Dome Position Adjustments...........................7-63
7.10 CENTER SKI CASE WIDTH DIMENSION ‘D2’ ADJUSTMENT................................................ 7-64
7.11 CONVEYOR CASE WIDTH DIMENSION ‘D3’ ADJUSTMENT ................................................. 7-65
7.12 CARRIAGE CASE LENGTH DIMENSION CADJUSTMENT .................................................... 7-66
7.13 TESTING THE SIZE ADJUSTMENTS .................................................................................. 7-67
7.14 QUICK SIZE CHANGE GUIDE .......................................................................................... 7-69
8MACHINE MAINTENANCE ............................................................................................... 8-70
8.1 SAFETY ........................................................................................................................ 8-70
8.2 SERVICE AND MAINTENANCE PROCEDURES.................................................................... 8-71
8.2.1 Uni-Drive Side-Belt Drive System.......................................................................8-71
8.2.2 Chain Drive.........................................................................................................8-71
8.2.3 Conveyor Side-Belt Replacement ......................................................................8-72
8.2.4 Gear Reducer.....................................................................................................8-72
8.2.5....................................................................................................................................8-73
8.3 MAINTENANCE .............................................................................................................. 8-73
8.3.1 Non-Lube Pneumatic System Maintenance.......................................................8-73
8.3.2 Inspections..........................................................................................................8-73
8.3.3 Routine Operator Maintenance ..........................................................................8-74
8.3.4 Cleaning..............................................................................................................8-74

WF-10T Case Former Table of Contents
iii
8.4 PREVENTATIVE MAINTENANCE SCHEDULE ...................................................................... 8-75
8.5 MAINTENANCE ADJUSTMENTS........................................................................................ 8-77
8.5.1 Mechanism Speeds............................................................................................8-77
8.5.2 Shock Absorbers ................................................................................................8-77
8.5.3 Conveyor Belt Tension & Tracking.....................................................................8-77
8.5.4 Tape Head Adjustments.....................................................................................8-78
8.5.5 Pneumatic Supply Adjustments..........................................................................8-78
8.5.6 Proximity Sensors...............................................................................................8-78
8.5.7 Mechanical Maintenance....................................................................................8-79
8.6 LUBRICATION ................................................................................................................ 8-79
8.6.1 Moving Components...........................................................................................8-79
8.6.2 Ball Bearings.......................................................................................................8-79
8.6.3 Tape Head..........................................................................................................8-79
9TROUBLESHOOTING & REPAIRS ..................................................................................9-80
9.1 SAFETY ........................................................................................................................ 9-80
9.2 GENERAL TROUBLESHOOTING ....................................................................................... 9-81
9.3 MACHINE SEQUENCE TROUBLESHOOTING ...................................................................... 9-83
9.4 ELECTRICAL TROUBLESHOOTING ................................................................................... 9-85
9.5 PNEUMATIC TROUBLESHOOTING .................................................................................... 9-86
9.6 CORRUGATED CASE QUALITY TROUBLESHOOTING ......................................................... 9-87
9.7 CASE DRIVEBELT SYSTEM TROUBLESHOOTING............................................................... 9-88
9.7.1 Case Not Sealing Squarely ................................................................................9-88
9.7.2 Crushed Band on Bottom of Case’s Side Panels...............................................9-88
9.7.3 Belt Sheds Rubber ‘Dust’....................................................................................9-88
9.7.4 Conveyor Drive Rattles Audibly..........................................................................9-88
9.7.5 Cases Jam Frequently Between Belts................................................................9-89
9.7.6 Frequent Belt Breakage......................................................................................9-89
9.8 BOTTOM FLAP FOLDING TROUBLESHOOTING .................................................................. 9-90
9.8.1 Rear Minor Flap Does Not Fold..........................................................................9-90
9.8.2 Rear Flap Folds, Releases, and Turns Backwards............................................9-90
9.8.3 Bottom Major Flaps Bind On Center Ski.............................................................9-90
9.8.4 Major Flaps Overlap in Center of Case..............................................................9-90
9.8.5 Bottom Major Flaps Have a Gap in Center.........................................................9-90
9.8.6 Major Flap Leading Edges Wrinkle After Taping................................................9-90
9.8.7 Major Flaps Have a Tapered Gap or Gap / Overlap Combination.....................9-91
9.8.8 Major Flaps Fold, but Leading Edge Lifted by Tape and Folded Back ..............9-91
9.9 GENERAL TAPE APPLICATOR TROUBLESHOOTING........................................................... 9-92
9.9.1 Tape Does Not Stick To Case Surface...............................................................9-92
9.9.2 Tape is not Cut Uniformly...................................................................................9-93
9.9.3 Tape Tail does not Stick Down Properly ............................................................9-93
9.9.4 Tape is Off-center...............................................................................................9-94
9.9.5 Tape Falls Forward on Tape Head.....................................................................9-94
9.10 REPAIR PROCEDURES ................................................................................................... 9-94
9.10.1 Solenoid Valve Repairs ......................................................................................9-94
9.10.2 Conveyor Drivebelt Repairs................................................................................9-95
9.10.3 Drivebelt Bearings Repairs.................................................................................9-95
9.10.4 Gearmotor Repairs.............................................................................................9-95

WF-10T Case Former Table of Contents
iv
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
v
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
vi
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.

WF20H Case Former Preface
ix
About this manual
Although this manual is not a series of regulations, it contains guidance that will make the use of
the WF-10 Series machines simple and safe. The manual has 13 chapters, as well as 2
appendices, listed below:
Chapter 1 describes the safety guidelines required for machine operation, maintenance and
servicing.
Chapter 2 provides recommended installation procedures, including unpacking and inspection,
site environment consideration, location, spacing requirements, assembly instructions, and
electrical connections.
Chapter 3 provides an explanation of the major pneumatic, mechanical and electrical
components.
Chapter 4 explains the machine’s theory of operation, including electronic, pneumatic, and
mechanical functions.
Chapter 5 explains all major equipment operation functions and procedures, including preliminary
checks, start-up procedures, shutdown procedures and instructions for clearing jams.
Chapter 6 provides a detailed explanation of the Human-Machine Interface (HMI) LCD
touchscreen control system, which controls all electronic and pneumatic machine functions with
the exception of manual override buttons and safety interlocks.
Chapter 7 deals with machine calibration and case size adjustments, as well as testing and
troubleshooting.
Chapter 8 is for users who maintain equipment or systems. It provides the safety guidelines, a
maintenance schedule, the procedures for maintenance and lubrication, and a list of maintenance
parts.
Chapter 9 is for qualified repair technicians, and provides them with safety guidelines to follow
when undertaking any repairs. It explains the warranty and services that accompany Model WF-
10T machines. It also describes advanced troubleshooting and repair procedures, and lists the
repair parts. It is written for users who design and modify equipment. Please note that
modifications to the equipment may void your warranty.
Chapter 10 provides detailed specifications required for machine set-up, maintenance and repair,
and troubleshooting.
Chapter 11 is intended for users who train others how to operate and maintain the WF-10 Series
machines. It includes references to instructor data sheets throughout the manual, and provides
performance checklists.
Chapter 12 explains WEXXAR/BEL product support policies and practices, as well as important
warranty information.
Chapter 13 provides a comprehensive index of terms commonly used in this manual.
Appendices A and B provide comprehensive Material Safety Data Sheets for the machine’s
various recommended lubricants and adhesive solutions for your protection.

WF20H Case Former Preface
x
How to use this manual
Please note that some of the images in this manual may differ slightly from your machine.
You will also be alerted that you must stop and read the instructions carefully using the following
symbol.
Throughout this manual, you will find three safety symbols: The names of all buttons, keys,
sensors, switches, and status indicators are capitalized, boldfaced, and placed in single
quotes.
For example, “Press the ‘START’ button.”
All machine component status terms, operations, functions, displays, and features are
capitalized and boldfaced.
For example, “The case separator returns to the UP position.”
When referring to sections in this manual, we italicize the link and use single quotes.
For example, See Section 6: ‘Operating Procedures’.
Please note that some of the some of the pictures in this manual may differ slightly from your
machine.
This symbol alerts you to a risk of personal injury due
to mechanical or pneumatic operation.
This symbol indicates that an electrical hazard may be
present. It may be used in lieu of the wording ‘caution,
risk of electric shock’ for any cautionary marking.
This symbol alerts you to general risks not associated
with electrical, pneumatic or mechanical operations, or
indicates that an action could cause equipment damage
or affect the quality of the product.
This symbol is used to alert you of an important step in
operational sequence, to note exceptions to normal
machine operation, or when special circumstances must
be taken into consideration by the machine operator.

WF-10T Case Former Safety
1-1
1 SAFETY
MUST BE READ PRIOR TO OPERATING
The WF-10T has safety features to prevent you from injury while the machine is operating.
Guard doors equipped with interlock switches prevent you from entering the work cell while the
case formation is in progress; the machine will not run if these doors are open. The electrical
enclosure access door must also be closed in order for the machine to operate.
The perimeter guarding system surrounds the area known as the restrictive envelope and covers
the entire range of possible machine motion. For your safety, you should never try to bypass the
perimeter guarding system or enter the restrictive envelope while the machine is in operation.
There are three ‘EMERGENCY STOP’ buttons that immediately halt all machine operations by
cutting off air supply and electrical power. These buttons should be pushed IN to stop the
machine in case of an emergency.
WARNING!
The instructions in this manual are not intended to cover
all of the details or variations in equipment, or to provide
for every possible contingency to be met in connection
with installation, operation, or maintenance. Should
further information be desired, or should particular
problems arise which are not covered sufficiently for the
purchaser’s purposes, the matter should be referred
directly to WEXXAR/BEL.
WARNING!
Any electrical or mechanical modifications to this
equipment without the prior consent of WEXXAR/BEL may
void your warranty. Unauthorized modifications can also
result in personal injury, death, or destruction of the
equipment.

WF-10T Case Former Component Identification
1-2
1.1 Safety Considerations
WEXXAR/BEL is proud to employ every conceivable precaution in the research and development
of our case formers. Our commitment to workplace safety has made us a world-class leader in
the packaging industry due to our adoption of the following best practices:
•Fully automatic functionality, requiring minimal operator interaction
•Advanced safety guarding with keyed electronic safety interlock switches
•Lock-out provision on electrical and pneumatic main shut-offs
•Intuitive cautionary labeling demonstrating electrical and mechanical risks
•E-STOP shutdown, with two auxiliary ‘E-STOP’ buttons
•PLC operated sequence and timing control
1.2 Safety Standards
WEXXAR/BEL observes the following safety standards:
•ANSI B151.1-2000 Safety Standards for Mechanical Power Transmission Apparatus
•CSA C22.2.1-02; 0-M91 Canadian Electrical Code Part I and Part II
•NFPA 79 Electrical Standards for Industrial Machines
•CSA C22.2 No. 14-95 Industrial Control Equipment
•ANSI Z535.4-2002 Product Safety Signs & Labels
•ANSI B155.1-2000 for Packaging Machinery
•NEMA 12 UL listed standard electrical control
1.3 General Precautions
Your WEXXAR packaging machine is a rugged piece of industrial machinery. It is equipped with
various guards and other safety features, but it must be treated with respect at all times to avoid
the possibility of personal injury. The following points are particularly important:
•Do not operate the machine until it is completely set up and installed properly, and you
are familiar with its operation.
•Do not operate machine without guards and safety mechanisms in place and functioning.
•Do not attempt to enter the machine for any reason while the air pressure is still on.
•Do not wear neckties, jewelry, loose clothing, or other items that can get caught in
moving parts or mechanisms near the machine.
•Do not operate, troubleshoot, or maintain the machine while under the influence of any
type of drug or alcohol.
•Always observe all safety warnings and notices on the machine and in this manual.
•Do not use solvents when cleaning or maintaining the machine.
•All installation wiring must comply with applicable local codes.

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1.4 Lock-out Provision
The WF-10T is lock-out / tag-out compliant on both
the electrical and pneumatic main shut-offs. Both
the main electrical disconnect and the filter-
regulator assembly can be locked out on our
WEXXAR Case Formers. Ensure that you lock out
the machine and adhere strictly to the safety
precautions listed in Section 6.2.1: ‘Preliminary
Checks’ prior to performing any repairs or
maintenance.
1.5 Compressed Air
Compressed air is used to power the movement of many machine motions. You must be sure
that the machine's main air solenoid valve is shut off before attempting to clear jams or make
minor adjustments which require you to get close to the moving parts of the machine. This air
valve shuts off when the guard doors are opened, or when the main power is switched off.
To safely carry out service or repair work on the machine, a lockable shutoff valve is located on
all WEXXAR machines upstream of the filter-regulator unit. Padlock this valve in the OFF
position for absolute safety during service work. Always follow local lock-out/tag-out regulations.
Always exercise caution when switching the compressed air back ON. Stay well clear of all
moving parts, as they may move quickly when the pressure is reapplied. Make sure that no other
people are in a dangerous position when switching the compressed air on.
1.6 Electrical Power
The main supply voltage for the WF-10T is 120V 60Hz single-phase. Switch off the main power
disconnect switch located on the control panel, and lock it out before attempting service work
outside of the electrical enclosure. Before performing service work inside of the electrical
enclosure, disconnect all electrical power to the machine (customer supplied disconnect).
1.7 Conveyor Drivebelts
Where used, the optional outfeed conveyor drivebelt systems used on WEXXAR packaging
machines operate at moderate speeds. Be sure to keep fingers well clear of all moving parts, as
the gearmotor develops substantial torque, and does not stop easily. Do not wear loose clothing,
jewelry, or accessories (e.g., neckties) when operating WEXXAR packaging machines.
1.8 Guard Doors and Safety Plating
WEXXAR/BEL takes your safety seriously, offering the added benefit of safety guarding on all of
our WF Series units, which prevent operators from reaching into the machine during routine
operation and maintenance.
Figure 1-1: Locked Out Electrical
Disconnect and Filter-Regulator
Assembly

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1.9 Safety Interlocks
WEXXAR/BEL is an industry leader in the
incorporation of advanced integrated safety guarding
with key-activated interlock switches on all of our
WEXXAR Case Formers. Opening any of the guard
doors on the WF-10T instantly disables all machine
functions, as described in Section 6.5: ‘Shutdown’.
1.10 Cautionary Labels
WEXXAR/BEL provides ANSI Z535 compliant cautionary labels for every conceivable workplace
hazard, including electrical, pneumatic and mechanical hazards. Please pay particular attention
to the cautionary labels found on the machine. Examples of cautionary labels are shown below.
Figure 1-3: Sample Cautionary Label
1.11 Lubricants, etc.
Read the attached Material Safety Data Sheets (Appendices A and B), which fully describe the
specifications of all of the chemicals used with the WEXXAR Model WF-10T.
1.12 Safety Oriented Design
All machine motions in the case erecting area are engineered to be performed low to the ground
in order to make the machine safer. All other machine motions are performed along the
machine’s centerline behind the machine’s guarding as far away as possible from the machine
operator.
Figure 1-2: Example of Safety Interlock

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2 INSTALLATION
2.1 Prerequisites
To install the WEXXAR WF-10T Case Former you will require:
•A forklift truck to remove the machine from the skid.
•A spirit level to level the machine.
•Compressed air and electrical power supplies.
2.2 Site Environment Consideration
Before receiving the machine, consider the physical environment that the machine will operate in.
Consider the following factors before transporting, unpacking, installing, or setting up the
machine.
•The machine operator is required to guarantee that the temperature and humidity values
of the site into which the machine will be installed meet the required and published
manufacturer specifications. The machine should be installed within the range allowed
by these specifications.
•This machine is intended for use in a controlled indoor environment free of conductive
contaminants.
•Do not let the any areas of the unit adjacent to electrical components come in contact
with water.
•Do not stand beverage containers on the electrical panel, or on any surface adjacent to
electrical components.
•This system is not intended for external use unless it has been specifically modified for
that purpose.
•This unit is rated in accordance with national and local electrical codes. Make sure that
the wall outlet is also wired to these specifications.
•The power supply for this unit:
1. Must be rated in accordance with the equipment data plate.
2. Must be suitably grounded.
•Do not place the machine near any heat source or machinery which may produce
metallic particles, dust or powder. Do not place the machine near equipment that will
produce corrosive substances or vapor.
•Walls, ceilings, floors, or anything near to the machine should be constructed of
noncombustible materials. A portable fire extinguisher should be accessible nearby.

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2.3 Removal from Crate
Before transporting the machine to its final
destination, check for sufficient floor and elevator
loading capacity. Then move the machine in an
upright position, in its original packaging, to its final
destination. This machine is packaged on a pallet,
and is suitable for handling with a forklift or lifting
belts with spreader bars.
Pay strict attention to the center of gravity. The
machine must be moved in an upright position. Do
not tilt machines more than +/- 10° during handling.
Do not stack any other packages on top of the
machine.
When the machine is in its final destination, inspect the machine thoroughly for shipping damage,
and ensure that all mechanisms move freely. Report any shipping damage immediately to your
Carrier.
Check spare parts kits, change parts, and any other loose items against the packing slip, and
report any errors or omissions to your WEXXAR/BEL agent for corrective action.
The crate should be dismantled and all packing materials and shipping ties should be removed.
Do not disassemble the unit.
2.4 Installing the WF-10T
To safely install the machine:
1. Remove the lagbolts that secure the machine to the base.
2. If possible, use a forklift to move machine from its base, with wooden dunnage blocks between
the forks and the frame.
3. While machine is elevated, install the footpad extensions or caster extensions to the bottom of
each leg and adjust for the appropriate outfeed height.
4. Position the machine where it is to be used.
CAUTION!
Be careful to avoid damaging the lower mechanisms in the
central part of the machine which are not capable of
supporting the weight of the machine.

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2.5 Location, Leveling and Conveyors
2.5.1 Location
When selecting the machine location, carefully consider the following points:
•Adequate access around the machine for correct operation and service.
•Sufficient room to open the guards and access doors (including control enclosure).
•A minimum 3-foot clearance in front of the main electrical enclosure.
•Easy lift-truck access.
•Good access for magazine loading and nearby space for pallet loads of flat cases.
2.5.2 Leveling
•Use at least a two-foot carpenter level, marked on one end so that you always work to
the same bubble line and with the concave side down (if there is one).
•Open the guard doors, and position the spirit level along the length of the main frame to
level one side of the machine.
•Adjust the machine leveling feet on this side of the machine as appropriate to centralize
the bubble between the parallel lines.
•Position the spirit level on the main frame along the width of the machine at the discharge
end.
•Adjust the machine leveling feet under the magazine and discharge ends on the opposite
side in order to centralize the bubble between the parallels.
•Tighten the level adjuster lock nuts.
•Anchor the machine to the floor.
The machine should be kept level in order to avoid frame stress and ensure optimum
performance. An adjustable height footpad kit is included as standard equipment, and can be
used to level the machine on an uneven floor.
The machine should be anchored to adjoining equipment or to the floor in order to prevent any
movement of the machine by reactive forces that may occur as sealed cases are being driven
through the machine outfeed.
2.5.3 Discharge Conveyor
The discharge conveyor is customer supplied and may be a gravity-fed or powered type. If the
discharge conveyor is powered, a smooth top surface is preferred. It is important to note that the
case discharge mechanism is designed to discharge the case against zero restraint. It is not
intended to overcome the friction of a long conveyor filled with cases, or push cases up an
inclined slope. Excessive discharge friction will cause improper machine operation.
CAUTION!
The machine should NOT be operated on casters.

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2.6 Service Connections
2.6.1 Compressed Air
The WF-10T requires an air supply that must be clean and dry, and must not drop below 75 PSI
to a maximum of 90 PSI. The air supply should be clean and dry, and the air-line should have a
minimum inside diameter of 1/2”. The incoming air supply line must be of sufficient diameter to
provide an adequate amount of air without the pressure dropping when the machine is cycling.
One of the most common causes of inconsistent machine performance is inadequate air supply.
Therefore, the foregoing requirements must be carefully observed in order to assure satisfactory
operation.
The WF-10T is equipped with a manual compressed air ON-OFF/dump valve, unless otherwise
specified, and a filter-regulator that regulates the air pressure to the proper setting, and ensures
that any water is drained from the filter.
With the electrical power OFF, open the manual shutoff valve and check that the regulator is set
to a pressure of 90 PSI. After connecting the electrical power (see Section 2.6.2), switch the
electrical power ON; all cylinders should revert to their HOME positions, and there should be no
evidence of air leaks. See Section 6.2: ‘Start-up’. To check that the pneumatic components of
each mechanism are functioning properly, the solenoid valves may be operated mechanically.
Figure 2-1: Filter-Regulator Assembly
SAFETY NOTICE!
Service connections (electrical and pneumatic) should ONLY
be undertaken by qualified personnel. Observe proper lock-
out procedures and recommended sequence to avoid
personal injury or damage to the machine.