Wexxar WF30T Operation manual

WF30T Case Former
WEXXAR WF30T CASE FORMER
Operation and Service Manual
10101 Nordel Court, Delta, B.C. V4G 1J8 Canada
Telephone [phone], Fax [phone]
WF30T; Rev. 1.15

WF30T Case Former

WF30T Case Former Table of Contents
i
Table of Contents
LIST OF TABLES ..................................................................................................................................IV
TABLE OF FIGURES ............................................................................................................................VI
PREFACE ..............................................................................................................................................IX
About this manual ...........................................................................................................................x
How to use this manual.................................................................................................................. xi
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 COMPLIANCE .........................................................................................................1-3
1.5 COMPRESSED AIR ..................................................................................................................1-3
1.6 ELECTRICAL POWER...............................................................................................................1-3
1.7 CONVEYOR DRIVEBELTS .........................................................................................................1-3
1.8 GUARD DOORS ......................................................................................................................1-3
1.9 SAFETY INTERLOCKS ..............................................................................................................1-4
1.10 CAUTIONARY LABELS..............................................................................................................1-4
1.11 TOUCHSCREEN CAUTIONARY ALERTS ......................................................................................1-4
1.12 LUBRICANTS,ETC...................................................................................................................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 MECHANICAL ASSEMBLY .........................................................................................................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....................................................................................................2-8
2.6 SERVICE CONNECTIONS .........................................................................................................2-8
2.6.1 Compressed Air...........................................................................................................2-8
2.6.2 Electrical Power...........................................................................................................2-9
3COMPONENT IDENTIFICATION..............................................................................................3-10
3.1 MAJOR COMPONENTS (ALPHABETIZED) .................................................................................3-12
3.2 PIN AND DOME TECHNOLOGY................................................................................................3-16
4THEORY OF OPERATION........................................................................................................4-17
4.1 SEQUENCE OF OPERATIONS..................................................................................................4-17
4.2 SENSORS ............................................................................................................................4-19
4.2.1 Optical Proximity Sensors .........................................................................................4-19
4.2.2 Inductive Sensors......................................................................................................4-19
4.2.3 Sensor Cables...........................................................................................................4-19
4.2.4 Remote Demand Sensor...........................................................................................4-20
4.2.5 Magazine Management.............................................................................................4-20
4.3 INTERLOCK SWITCHES ..........................................................................................................4-20
4.4 TAPE MANAGEMENT SYSTEM ................................................................................................4-21
4.5 SENSOR LOCATIONS.............................................................................................................4-22
4.6 PNEUMATIC VALVE OPERATION .............................................................................................4-24
4.6.1 Solenoid Valves.........................................................................................................4-24
4.6.2 Servo Valves.............................................................................................................4-24
4.6.3 Factors Influencing Pneumatic Speeds.....................................................................4-25
4.6.4 Non-Lube Pneumatic System....................................................................................4-25
4.6.5 Low Pressure Switch.................................................................................................4-26
5CONTROLS...............................................................................................................................5-27
5.1 CONTROLS OVERVIEW..........................................................................................................5-27

WF30T Case Former Table of Contents
ii
5.2 CONTROLS DESCRIPTION......................................................................................................5-27
HIGH SPEED SERVO SETTINGS ............................................................................................5-45
LOW SPEED SERVO SETTINGS.............................................................................................5-45
6OPERATING PROCEDURES ...................................................................................................6-46
6.1 SAFETY ...............................................................................................................................6-46
6.2 START-UP............................................................................................................................6-47
6.2.1 Preliminary Checks ...................................................................................................6-47
6.2.2 Start-up Procedures..................................................................................................6-48
6.2.3 ‘CYCLE’ Operation....................................................................................................6-50
6.2.4 ‘JOG’ Operation.........................................................................................................6-50
6.3 MONITORING........................................................................................................................6-50
6.3.1 Monitoring Machine Operation..................................................................................6-50
6.3.2 Loading the Magazine...............................................................................................6-51
6.4 CLEARING A CASE JAM .........................................................................................................6-52
6.5 SHUTDOWN..........................................................................................................................6-54
7CASE SIZE ADJUSTMENTS....................................................................................................7-55
7.1 SAFETY ...............................................................................................................................7-55
7.2 FLAT CASE HEIGHT (DIMENSION ‘B’)......................................................................................7-58
7.3 FORMED CASE HEIGHT (DIMENSION ‘E’) ................................................................................7-60
7.4 CASE WIDTH (DIMENSION ‘D’)...............................................................................................7-62
7.5 CASE LENGTH (DIMENSION ‘C’) ............................................................................................. 7-64
7.6 FLAT CASE WIDTH (DIMENSION ‘A’).......................................................................................7-66
7.7 FEEDBELT HORIZONTAL ADJUSTMENTS (DIMENSION ‘H’).........................................................7-67
7.8 CASE SEPARATOR HORIZONTAL ADJUSTMENT (DIMENSION ‘G’)...............................................7-68
7.9 CORRUGATE THICKNESS ADJUSTMENT (DIMENSION 'F') ..........................................................7-68
7.9.1 Jawplate ‘F’ Adjustment ............................................................................................7-69
7.9.2 Caliper ‘F’ Adjustment...............................................................................................7-70
8OTHER MACHINE ADJUSTMENTS.........................................................................................8-72
8.1 SAFETY ...............................................................................................................................8-72
8.2 STABILIZER BARS AND PINBLOCKS.........................................................................................8-73
8.3 MAGAZINE PUSHER ..............................................................................................................8-74
8.4 SENSOR LS-7 ADJUSTMENT .................................................................................................8-75
8.5 MINOR FLAP FOLDERS..........................................................................................................8-75
8.6 TESTING THE SIZE ADJUSTMENTS..........................................................................................8-75
8.7 QUICK SIZE CHANGE GUIDE..................................................................................................8-77
9MACHINE MAINTENANCE.......................................................................................................9-79
9.1 SAFETY ...............................................................................................................................9-79
9.2 MAINTENANCE .....................................................................................................................9-80
9.2.1 Inspections................................................................................................................9-80
9.2.2 Cleaning....................................................................................................................9-81
9.3 PREVENTATIVE MAINTENANCE SCHEDULE..............................................................................9-82
9.4 TYPICAL MAINTENANCE ADJUSTMENTS ..................................................................................9-83
9.4.1 Machine Output Rate ................................................................................................9-83
9.4.2 Mechanism Speeds...................................................................................................9-83
9.4.3 Magazine Pusher ......................................................................................................9-84
9.4.4 Magazine Feedbelts..................................................................................................9-84
9.4.5 Injector Assembly......................................................................................................9-85
9.4.6 Mast Assembly..........................................................................................................9-85
9.4.7 Forming Head............................................................................................................9-86
9.4.8 Discharge Pusher......................................................................................................9-86
9.4.9 Shock Absorbers.......................................................................................................9-86
9.4.10 Conveyor Belt Tension & Tracking............................................................................9-87
9.4.11 Discharge Conveyor Assemblies ..............................................................................9-88
9.4.12 Machine Management System..................................................................................9-88
9.4.13 Tape Head Adjustments............................................................................................9-88
9.4.14 Proximity Sensors .....................................................................................................9-89
9.4.15 Flap Folder Assemblies.............................................................................................9-89

WF30T Case Former Table of Contents
iii
9.5 PNEUMATIC SYSTEM MAINTENANCE ......................................................................................9-90
9.5.1 Pneumatic Supply Adjustments.................................................................................9-90
9.5.2 Valve Bank................................................................................................................9-90
9.5.3 Filter-Regulator..........................................................................................................9-90
9.5.4 General Pneumatics..................................................................................................9-91
9.6 ELECTRICAL SYSTEM MAINTENANCE......................................................................................9-91
9.6.1 Safety Circuit.............................................................................................................9-91
9.6.2 Electrical Enclosure...................................................................................................9-91
9.7 MECHANICAL MAINTENANCE .................................................................................................9-92
9.7.1 Vertical Alignment Procedures..................................................................................9-92
9.8 MAINTENANCE PARTS LIST ...................................................................................................9-93
9.8.1 Wear Parts ................................................................................................................9-93
9.9 LUBRICATION .......................................................................................................................9-93
9.9.1 Moving Components .................................................................................................9-93
9.9.2 Ball Bearings.............................................................................................................9-93
9.9.3 Sealed Guide Wheels................................................................................................9-93
10 TROUBLESHOOTING & REPAIRS....................................................................................10-95
10.1 SAFETY .............................................................................................................................10-95
10.2 GENERAL TROUBLESHOOTING .............................................................................................10-96
10.3 MACHINE SEQUENCE TROUBLESHOOTING ............................................................................10-99
10.4 ELECTRICAL TROUBLESHOOTING .......................................................................................10-101
10.5 TAPE APPLICATOR TROUBLESHOOTING..............................................................................10-103
10.6 PNEUMATIC TROUBLESHOOTING........................................................................................10-103
10.6.1 Other Typical Pneumatic Issues............................................................................10-106
10.7 LED STATUS TABLES .......................................................................................................10-107
10.8 REPAIR PROCEDURES ......................................................................................................10-109
10.8.1 Pneumatic Cylinder Repairs..................................................................................10-109
10.8.2 Magazine Repairs .................................................................................................10-110
10.8.3 Forming Head Bearing Repairs.............................................................................10-110
10.8.4 Major Flap Folder Repairs.....................................................................................10-110
10.8.5 Solenoid Valve Repairs.........................................................................................10-111
10.8.6 Conveyor Drivebelt Repairs ..................................................................................10-111
10.8.7 Drivebelt Bearings Repairs....................................................................................10-111
10.8.8 Gearmotor Repairs................................................................................................10-111
11 ENGINEERING SPECIFICATIONS...................................................................................11-112
11.1 OPERATING PARAMETERS.................................................................................................11-112
11.2 MACHINERY DRAWINGS ....................................................................................................11-112
11.3 PROGRAM CODE ..............................................................................................................11-112
12 TRAINING GUIDE.............................................................................................................12-113
12.1 INSTRUCTOR DATA SHEET ................................................................................................12-113
12.2 TRAINING OUTLINES .........................................................................................................12-114
12.3 PERFORMANCE CHECKLISTS .............................................................................................12-116
13 SERVICE & WARRANTY..................................................................................................13-118
14 OPTIONS...........................................................................................................................14-119
14.1 MACHINE MANAGEMENT SYSTEM ......................................................................................14-119
14.1.1 Tape Monitoring ....................................................................................................14-119
14.1.2 Magazine Monitoring.............................................................................................14-119
14.1.3 Normal Operation..................................................................................................14-120
INDEX .................................................................................................................................................121
APPENDIX A ......................................................................................................................................124
Material Safety Data Sheets: Fuchs Lubricants – Geralyn FMG 387 .........................................124
APPENDIX B ......................................................................................................................................132
Material Safety Data Sheets: Keystone Lubricants – Nevastane HT-2 ......................................132

WF30T Case Former List of Tables
iv
List of Tables
Table 1: Optical Proximity Sensors ........................................................................................... 4-19
Table 2: Inductive Sensors ........................................................................................................ 4-19
Table 3: Sensor Cables ............................................................................................................. 4-19
Table 4: Remote Demand Sensor ............................................................................................. 4-20
Table 5: Magazine Management Sensors................................................................................. 4-20
Table 6: Interlock Switches........................................................................................................ 4-20
Table 7: Tape Management System Sensors ........................................................................... 4-21
Table 8: Case Measurement Dimensions ................................................................................. 5-31
Table 9: High Speed Servo Settings ......................................................................................... 5-45
Table 10: Low Speed Servo Settings ........................................................................................ 5-45
Table 11: Preliminary Start-up Checklist ................................................................................... 6-48
Table 12: Mechanism HOME Positions and Valve Numbers.................................................... 6-48
Table 13: Machine Start-up Procedures.................................................................................... 6-49
Table 14: Machine Loading Checklist ....................................................................................... 6-52
Table 15: Clearing Jams............................................................................................................ 6-53
Table 16: Machine Shutdown .................................................................................................... 6-54
Table 17: Case Size Range....................................................................................................... 7-56
Table 18: Dimension ‘B’ Adjustments........................................................................................ 7-59
Table 19: Dimension 'E' Adjustments........................................................................................ 7-61
Table 20: Dimension 'D' Adjustments........................................................................................ 7-63
Table 21: Dimension 'C' Adjustments........................................................................................ 7-65
Table 22: Dimension 'A' Adjustments........................................................................................ 7-66
Table 23: Dimension 'H' Adjustments........................................................................................ 7-67
Table 24: Dimension ‘G’ Adjustment ......................................................................................... 7-68
Table 25: Dimension 'F' Adjustments ........................................................................................ 7-71
Table 26: Magazine Pusher Adjustment ................................................................................... 8-74
Table 27: Mechanism HOME Positions..................................................................................... 8-76
Table 28: Full Cycle Sequence..................................................................................................8-76
Table 29: Sensor Adjustment References................................................................................. 8-77
Table 30: Dimension Adjustment Reference............................................................................. 8-78
Table 31: Machine Inspection.................................................................................................... 9-80
Table 32: Cleaning the Machine................................................................................................ 9-81
Table 33: Magazine Pusher Maintenance................................................................................. 9-84
Table 34: Feedbelt Maintenance............................................................................................... 9-84
Table 35: Injector Maintenance .................................................................................................9-85
Table 36: Mast Maintenance .....................................................................................................9-85
Table 37: Forming Head Maintenance ...................................................................................... 9-86
Table 38: Discharge Pusher Maintenance ................................................................................ 9-86
Table 39: Discharge Conveyor Maintenance ............................................................................ 9-88
Table 40: Machine Management ............................................................................................... 9-88
Table 41: Flap Folder Maintenance........................................................................................... 9-89
Table 42: Valve Bank Maintenance........................................................................................... 9-90
Table 43: Filter-Regulator Maintenance .................................................................................... 9-90
Table 44: General Pneumatic Maintenance .............................................................................. 9-91
Table 45: Safety Circuit ............................................................................................................. 9-91
Table 46: Electrical Enclosure Maintenance ............................................................................. 9-91
Table 47: Lubricants .................................................................................................................. 9-94
Table 48: General Troubleshooting Reference ....................................................................... 10-97
Table 49: Machine Sequence Troubleshooting....................................................................... 10-99
Table 50: Error Codes ........................................................................................................... 10-100
Table 51: General Pneumatic Troubleshooting..................................................................... 10-103
Table 52: Forming head too slow; jaw speed normal............................................................ 10-103

WF30T Case Former List of Tables
v
Table 53: Both forming head and jaw too slow ..................................................................... 10-104
Table 54: Jaw too slow; forming head speed normal ............................................................ 10-105
Table 55: Forming head not moving...................................................................................... 10-105
Table 56: Jaw not moving...................................................................................................... 10-106
Table 57: PLC Input LED Status Table for Jog Step Sequence ........................................... 10-107
Table 58: PLC Output LED Status Table for Jog Step Sequence......................................... 10-108
Table 59: Operating Parameters ........................................................................................... 11-112
Table 60: Training Outlines ................................................................................................... 12-114
Table 61: Performance Checklists......................................................................................... 12-116

WF30T 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: Safety Guard Doors .................................................................................................. 1-3
Figure 1-3: Examples of Safety Interlocks................................................................................... 1-4
Figure 2-1: Main Disconnect Switch............................................................................................ 2-9
Figure 3-1: Component Overview.............................................................................................. 3-10
Figure 3-2: Operator's Side View .............................................................................................. 3-11
Figure 3-3: Left Hand (Infeed) View .......................................................................................... 3-11
Figure 4-1: Sensor Locations, Part 1......................................................................................... 4-22
Figure 4-2: Sensor Locations, Part 2......................................................................................... 4-23
Figure 4-1: Solenoid Valve Bank ............................................................................................... 4-24
Figure 4-2: Mast and Jawplate Servo Valve Locations ............................................................. 4-24
Figure 4-3: Low Pressure Switch............................................................................................... 4-26
Figure 5-1: ‘MAIN DISCONNECT’ Switch ................................................................................. 5-27
Figure 5-2: ‘RESET’ Button ....................................................................................................... 5-27
Figure 5-3: 'EMERGENCY STOP' Button ................................................................................. 5-27
Figure 5-4: 'Main Control' Screen – machine stopped .............................................................. 5-28
Figure 5-5: ‘Service’ Screen ...................................................................................................... 5-28
Figure 5-6: 'MAIN CONTROL' Button........................................................................................ 5-28
Figure 5-7: 'Main Control' Screen ..............................................................................................5-29
Figure 5-8: ‘START’ Button ....................................................................................................... 5-29
Figure 5-9: ‘STOP’ Button ......................................................................................................... 5-29
Figure 5-10: ‘Touch-sensitive Displays ..................................................................................... 5-30
Figure 5-11: ‘Case Dimension’ Buttons..................................................................................... 5-30
Figure 5-12: ‘Box Settings’ Screen........................................................................................ 5-30
Figure 5-13: ‘Box Dimension’ Selection Keypad ....................................................................... 5-31
Figure 5-14: ‘SELECTED CPM AND CPM RANGE’ Status Indicators ..................................... 5-31
Figure 5-15: 'JOG CONTROL' Button ....................................................................................... 5-31
Figure 5-16: 'Jog Control' Screen.......................................................................................... 5-32
Figure 5-17: Blinking Sensor ‘LS6’ ............................................................................................ 5-32
Figure 5-18: Error Identification Screen .................................................................................... 5-32
Figure 5-19: 'MACHINE CYCLE JOG' Button ........................................................................... 5-33
Figure 5-20: 'SETUP' Button ..................................................................................................... 5-33
Figure 5-21: 'Setup' Screen ....................................................................................................... 5-33
Figure 5-22: 'DRY CYCLE ON' Toggle Switch .......................................................................... 5-34
Figure 5-23: 'DRY CYCLE ACTIVE' Indicator ........................................................................... 5-34
Figure 5-24: ‘Remote Demand’ Switch ON ............................................................................... 5-34
Figure 5-25: ‘Dry Cycle’ Switch ON ........................................................................................... 5-34
Figure 5-26: 'REMOTE DEMAND ON' Toggle Switch............................................................... 5-34
Figure 5-27: 'REMOTE DEMAND ON' Indicator ....................................................................... 5-34
Figure 5-28: 'ALARM HISTORY' Button.................................................................................... 5-35
Figure 5-29: 'Alarm History' Screen........................................................................................... 5-35
Figure 5-30: 'CLEAR' Button ..................................................................................................... 5-35
Figure 5-31: 'MACHINE FEEDBACK' Button ............................................................................ 5-35
Figure 5-32: ‘Machine Feedback’ Screen.................................................................................. 5-35
Figure 5-33: 'TROUBLESHOOTING’ ........................................................................................ 5-36
Figure 5-34: 'Troubleshooting’ Screen ...................................................................................... 5-36
Figure 5-35: 'PLC INPUTS’ Button ............................................................................................ 5-36
Figure 5-36: PLC Inputs Screen ................................................................................................ 5-37
Figure 5-37: Illuminated 'PLC INPUTS’ Status Indicator........................................................... 5-37
Figure 5-38: Sample Alarm Diagnostic Detail Screen............................................................... 5-37
Figure 5-39: 'PLC OUTPUTS’ Button ........................................................................................ 5-38

WF30T Case Former Table of Figures
vii
Figure 5-40: 'PLC Outputs’ Screen............................................................................................ 5-38
Figure 5-41: Illuminated ‘PLC OUTPUT STATUS’ Indicator ..................................................... 5-39
Figure 5-42: 'SETUP GUIDE’ Button......................................................................................... 5-39
Figure 5-43: 'SETUP GUIDE/HELP’ Screen ............................................................................. 5-39
Figure 5-44: Setup Guide Detail Screen Button ........................................................................ 5-40
Figure 5-45: Sample Setup Guide Detail Screen ...................................................................... 5-40
Figure 5-46: ‘BACK’ and 'FORWARD’ Buttons ......................................................................... 5-40
Figure 5-47: 'PARAMETERS’ Button ........................................................................................ 5-40
Figure 5-48: 'PARAMETERS’ Screen ....................................................................................... 5-41
Figure 5-49: ‘Servo High and Low Speed Settings’ Screens .................................................... 5-42
Figure 5-50: ‘HOMING VALUE’ Button ..................................................................................... 5-42
Figure 5-51: ‘Current Value’ Display.......................................................................................... 5-42
Figure 5-52: ‘INITIAL SPEED’ Button........................................................................................ 5-42
Figure 5-53: 'RAMP RATE' Button ............................................................................................ 5-43
Figure 5-54: ‘HOMING VALUE’ Button ..................................................................................... 5-43
Figure 5-55: ‘Current Value’ Display.......................................................................................... 5-43
Figure 5-56: ‘INITIAL SPEED’ Button........................................................................................ 5-43
Figure 5-57: ‘RAMP RATE’ Button ............................................................................................ 5-44
Figure 5-58: ‘ACTUAL CPM’ Button.......................................................................................... 5-44
Figure 5-59: 'CYCLE MODE' Button.......................................................................................... 5-44
Figure 5-60: 'JOG MODE' Button .............................................................................................. 5-44
Figure 5-61: 'START' Button...................................................................................................... 5-44
Figure 5-62: 'STOP' Button........................................................................................................ 5-44
Figure 5-63: 'DRY CYCLE OFF' Button..................................................................................... 5-44
Figure 5-64: 'DRY CYCLE ON' Button ...................................................................................... 5-45
Figure 5-65: 'PREVIOUS' Button............................................................................................... 5-45
Figure 7-1: Dimensions on Left and Right Hand Cases ............................................................ 7-56
Figure 7-2: Case Measuring Scale........................................................................................ 7-56
Figure 7-3: Mast Assembly Components .................................................................................. 7-57
Figure 7-4: Dimension ‘B’ .......................................................................................................... 7-58
Figure 7-5: Dimension ‘B’ Adjustments ..................................................................................... 7-58
Figure 7-6: Adjusting the Collar Assembly ................................................................................ 7-59
Figure 7-7: Dimension ‘E’ .......................................................................................................... 7-60
Figure 7-8: Head-up Latch......................................................................................................... 7-60
Figure 7-9: Dimension ‘E’ Adjustments ..................................................................................... 7-60
Figure 7-10: Forming Head – OPEN and DOWN...................................................................... 7-61
Figure 7-11: Dimension ‘D’ ........................................................................................................ 7-62
Figure 7-12: Dimension ‘D’ Adjustments ................................................................................... 7-62
Figure 7-13: ‘D1’ Adjustments ................................................................................................... 7-63
Figure 7-14: ‘D2’ Adjustments ................................................................................................... 7-63
Figure 7-15: Dimension ‘C’ ........................................................................................................ 7-64
Figure 7-16: Main Magazine Assembly Components................................................................ 7-64
Figure 7-17: Dimension ‘C’ Adjustments ................................................................................... 7-65
Figure 7-18: Case in the Forming Area ..................................................................................... 7-65
Figure 7-19: Dimension ‘A’ ........................................................................................................ 7-66
Figure 7-20: Dimension ‘A’ Locking Handles ............................................................................ 7-66
Figure 7-21: Red Clamp Handles .............................................................................................. 7-67
Figure 7-22: Feedbelt Positions................................................................................................. 7-67
Figure 7-23: Case Separator Adjustment Handles..................................................................... 7-68
Figure 7-24: Case Separator Adjustment Handles.................................................................... 7-68
Figure 7-25: Minor Jawplate Mounting Bracket......................................................................... 7-69
Figure 7-26: Dimension ‘F’ Adjustments ................................................................................... 7-69
Figure 7-27: Caliper Adjustment................................................................................................7-70
Figure 8-1: Pinblock Orientation ................................................................................................ 8-73
Figure 8-2: Jawplate Assembly ................................................................................................. 8-73
Figure 8-3: Magazine Pusher ....................................................................................................8-74

WF30T Case Former Table of Figures
viii
Figure 8-4: Flap Folders ............................................................................................................ 8-75
Figure 8-5: Minor Flap Folder Top Plates.................................................................................. 8-78
Figure 9-1: Conveyor Belt Tensioning....................................................................................... 9-87
Figure 9-2: Inductive Sensor Adjustment Range....................................................................... 9-89
Figure 9-3: Mast Assembly Showing Guide Wheels ................................................................. 9-93
Figure 9-4: Discharge Pusher Sealed Guide Wheels................................................................ 9-94
Figure 9-5: Mast Assembly Sealed Guide Wheels.................................................................... 9-94
Figure 14-1: Beacon Lamp Status Indicators ........................................................................ 14-120

WF30T Case Former Preface
ix
PREFACE
WEXXAR Model WF30T 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 this manual be kept 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.
The WF30T 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 WF30T 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 written permission of
WEXXAR.

WF30T Case Former Preface
x
About this manual
Although this manual is not a series of regulations, it contains guidance that will make the use of
the WF30 Series machines simple and safe. The manual has 15 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 case size adjustments, as well as testing and troubleshooting.
Chapter 8 describes machine calibration procedures not dealt with in Chapter 7.
Chapter 9 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 10 is for qualified repair technicians, and provides them with safety guidelines to follow
when undertaking any repairs. 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 11 provides detailed specifications required for machine set-up, maintenance and repair,
and troubleshooting.
Chapter 12 is intended for users who train others how to operate and maintain the WF30 Series
machines. It includes a training outline, instructor data sheets, and performance checklists.
Chapter 13 explains the WEXXAR product support policies and practices, as well as important
warranty information.
Chapter 14 lists the various options available with your WEXXAR WF30 Series Case Former.
Chapter 15 provides a comprehensive index of terms commonly used in this manual.
Appendices A and B provide comprehensive Material Safety Data Sheets for lubricating moving
machine parts for your protection.

WF30T Case Former Preface
xi
How to use this manual
Please note that some of the pictures in this manual may differ slightly from your machine.
You will also be alerted to 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.

WF30T Case Former Safety
1-1
1 SAFETY
MUST BE READ PRIOR TO OPERATING
The WF30T has safety features to prevent you from injury while the machine is operating. Sliding
and bi-folding 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.
An ‘EMERGENCY STOP’ button immediately halts all machine operations by cutting off air
supply and electrical power. This button 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.
WARNING!
Any electrical or mechanical modifications to this
equipment without the prior written consent of WEXXAR
may void your warranty. Unauthorized modifications can
also result in personal injury, death, or destruction of the
equipment.

WF30T Case Former Safety
1-2
1.1 Safety Considerations
WEXXAR 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 interlock switches
•Lock-out provision on electrical and pneumatic main shut-offs
•Integrated 24-volt DC power supply for safe, low voltage operating controls
•Intuitive cautionary labeling demonstrating electrical and mechanical risks
•E-STOP shutdown, with optional extra ‘E-STOP’ buttons
•PLC operated sequence and timing control
1.2 Safety Standards
WEXXAR 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.

WF30T Case Former Safety
1-3
1.4 Lock-out Compliance
The WF30T 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
All WEXXAR machines use electrical power. Switch off the main power disconnect switch 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).
The main supply voltage is typically 230V 60Hz 3-phase, but may range from 110V to 600V
depending on your specific requirement. Where possible, control voltages are 24V DC from a
built-in power supply.
1.7 Conveyor Drivebelts
Where used, the 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
gearmotors develop substantial torque, and do not stop easily. Do not wear loose clothing or
accessories (e.g., neckties) when operating WEXXAR packaging machines.
1.8 Guard Doors
WEXXAR 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
Figure 1-2: Safety Guard Doors

WF30T Case Former Safety
1-4
1.9 Safety Interlocks
WEXXAR is an industry leader in the
incorporation of advanced integrated safety
guarding with key-activated interlock
switches on our WEXXAR Case Formers.
Opening any of the guard doors on the
WF30T instantly disables all machine
functions, as described in Section 6.5:
‘Shutdown’.
1.10 Cautionary Labels
WEXXAR 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.
1.11 Touchscreen Cautionary Alerts
The WF30T also features cautionary alerts on the Human-Machine Interface (HMI) touchscreen.
1.12 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 WF30T.
Figure 1-3: Examples of Safety Interlocks

WF30T Case Former Installation
2-5
2 INSTALLATION
2.1 Prerequisites
To install the WEXXAR WF30T Case Former you will require:
•A forklift truck and four (4”x4”) wooden blocks to remove the machine from the skid.
•A spirit level to level the machine.
•Compressed air and electrical power supplies.
The preferred method to remove the machine from the base is by means of a forklift. Use
appropriate wood blocking (i.e.: 4 pieces of 4” x 4” x 12” timber) to block protruding parts.
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 in Section 11.1. 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 power connection 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.
•Do not place the machine below the shower of a fire extinguishing system.
•Do not locate in an area where unauthorized personnel may have access to the unit.
•Install the unit in a well-ventilated area away from flammable liquids, gases, and
explosives.

WF30T Case Former Installation
2-6
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 agent for corrective action.
The crate should be dismantled and all packing materials and shipping ties should be removed.
Do not disassemble the unit.
Removal of the machine from the shipping base must be done carefully. The lifting equipment
that is used must be sufficiently strong to support the weight of the machine (≈1,300 lbs./590 kg).
2.4 Mechanical Assembly
The Model WF30T Case Former is shipped in a fully assembled ‘ready-to-run’ condition.
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.

WF30T Case Former Installation
2-7
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 bi-fold and access doors (including control enclosure).
•A minimum 3-foot clearance in front of the main electrical enclosure.
•Sufficient clearance for magazine width increases that occur when the machine is set
up for large cases.
•Easy lift-truck access.
•Good access for magazine loading and nearby space for pallet loads of flat cases.
2.5.2 Leveling
•Set the machine for maximum Dimension ‘C’ (with the magazine in the maximum
rearward position).
•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 bi-fold 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.
CAUTION!
Note that the bi-fold doors jut out further when the ‘C’
adjustment is shortened for shorter cases. To adjust
Dimension ‘C’, refer to Section 7.5: ‘Case Length’. This
increase in machine width should be taken into
consideration while ensuring easy access for magazine
loading.