ROTARY OPP HOT MELT LABELLING MACHINE

TO BE THE BEST, ONE STOP PACKAGING AND

FILLING SUPPLIER

Operation Manual

© Emec Packaging Solutions Sdn Bhd

No 4, Jalan Gangsa , Kawasan Perusahaan Telok Panglima Garang
42500 Kuala Langat
Phone +603 5033 5804 • Fax 603 3168 090

PACKAGING, FILLING, WEIGHING

Table of Contents
1. Acknowledgement ........................................................ 1
2. General Information ...................................................... 2
i) Check the Shipment ............................................................. 2
ii) Instruction Manual ................................................................ 2
iii) Safety procedures, Precaution and Safety Symbols ............ 2
3. Product Warranty .......................................................... 3
4. Health & Safety Procedures ......................................... 4
i) Safety Precaution Sign & Symbols ....................................... 4
5. Technical Specification ................................................ 6
6. Machine Layout and Drawing ..................................... 10
8. Operation ..................................................................... 10
9. Maintenance ................................................................ 22
10. Troubleshooting .......................................................... 44
11. Spare Part List ............................................................. 45
i) Electrical and Mechanical ................................................... 45
12. Rotary OPP Hot Melt Labelling Diagram ....................... 46
i) Control Panel Layout .......................................................... 46
ii) Schematic Diagram ............................................................ 46

PACKAGING, FILLING, WEIGHING

1. Acknowledgement

T
hank you for choosing Rotary OPP Hot Melt Labelling Machine . Our machines and equipments
are manufactured with latest technology and tested prior delivery. Full testing will be done at site
during commissioning.

We use high quality and reliable components such as PLC, Indicators and Load Cells. We also use standard
pneumatic cylinders, solenoid valves and fittings that are easy available. In addition, our machine and
equipments comes with 1 (One) year warranty on electronic parts and manufacturing defects.

Like any other machine, proper use of the machine with regular preventive maintenance and service will
increase the machine and equipment lifespan and potentially avoid unnecessary breakdown and costly
downtime.

If in doubt, please do not hesitate to contact our Sales or our engineers for more information. All information
and specification in this manual are correct at the time of printing.

Inline with our corporate mission to provide "Quality Products With Affordable Price", we reserve the right to
make changes in engineering design, materials specification, and component brand and automation system at
any time without giving prior notice.

Manufactured and supplied by :

EMEC PACKAGING SOLUTIONS
No 4, Jalan Gangsa, Kawasan Perusahaan
Teluk Panglima Garang,42500,
Kuala Langat,Selangor Darul Ehsan,
Malaysia.
Tel: +603 5033 5804
Fax: 603 3168 0900
Website : www.emec-corp.com
Email :info@emec-corp.com

1
2. General Information
i) Check the Shipment

The first thing to do when received your machine/s and equipments is to check it and ensure that the
contents conform to the shipment list/advise/documents. EMEC inspects all equipment prior shipment, but
it cannot guarantee that the merchandise reaches the user intact. Therefore, the machine, equipments and any
other items when received should be checked and in the event the item / s question did not conform to the
specification and / or is missing, contact the transportation company, shipping agent and the manufacturer
immediately.

ii) Instruction Manual

Generally, Instruction Manual should include in the shipment unless notified. We reserved the right to modify
the design and / or manufacturing specification of our products as required, devoid of any obligation on our
part to adapt any product supplied prior to such alteration and without giving any prior notice. Read the
Instruction Manual thoroughly before installation, operation, repair or service and it should be made available
easily for the technical, machine maintenance and operators to access when needed.

iii) Safety procedures, Precaution and Safety Symbols

Read and remember to observe all the SAFETY PROCEDURES, PRECAUTIONS and descriptions
mentioned for general safety of the operators, service technician and foreman.

CAUTION WARNING

DANGER PROHIBITION

REMARKS IMPORTANT

2
3. Product Warranty
Warranty right varies from country to country, but it is the general intention of our corporation, EMEC
PACKAGING SOLUTIONS SDN BHD, to offer customers a (1) one-year warranty on this product from
the day of installation and commissioning.

In some countries, consumer protection legislation state that your dealer or agent is responsible for offering a
warranty and as such, please refer to your local dealer.

The product (if defective) should be notified immediately in formal for verification and to be checked by EMEC
Packaging Solutions Sdn. Bhd. technical team.

This warranty only applies to product failures due to defective materials and or workmanship. It will be rendered
invalid if, upon inspection is found that the product was:

• Wrong application against specification and machine design

• Mishandled or damaged due to carelessness / accident by operator

• Unauthorized modification or repair

• Poor or No maintenance
If the machine or equipment is still under warranty, then EMEC will take the responsibility to repair or replace
at the discretion of EMEC and then returned to the customer at no extra cost.

3
4. Health & Safety Procedures
Read this Instruction Manual thoroughly to understand the operation procedures, safety and preventive
maintenance. Allow qualified and trained technician to do inspection, maintenance or repair work. Fail to
do so with result shock circuit, damaged electronic instruments, serious or fatal injury.

i) Safety Precaution Sign & Symbols

CAUTION
Always remember to SWITCH OFF the MAIN POWER and AIR
SUPPLY before doing any maintenance or repair work.

CAUTION
Earth wire must be properly connected to prevent electrical shock.
Earth wire - Green or Yellow Green color wire.

CAUTION
DO NOT use any sharp object or metal to press push buttons switch
or setting Indicators, Touch screen or any electrical instruments.

WARNING
Some products are HOT and under HIGH working PRESSURE.
DO NOT open any hose, pipelines or valve when in RUNNING MODE.

DANGER
DO NOT open any SAFETY GUARD, DOOR OR MOTOR
CHAIN COVER while machine is in RUNNING MODE.

4
 WARNING
Wear SAFETY apparatus like protective eyewear, safety helmet
and safety shoes to prevent injury.

WARNING
Use HAIR CAP for SAFETY and Hygiene purpose.
Long and WITHOUT hair CAP is Hazardous in production areas.

CAUTION
Use ORIGINAL PARTS.
DO NOT modified or use NON-ORIGINAL PARTS without consents.

WARNING
DO NOT tamper, cutoff or bridged "Safety Device or Circuit" connection.
Breached or fail to do so may cause short circuit, injury or loss of live.

CAUTION
"Do Not Assume" all instruments using same power supply.
It can be 380V AC 3 Phase or 230V AC Single Phase and 24V DC
currents.

CAUTION
NO WELDING should be perform on the machine.
Welding can damage the Electronic Instruments or components.

5
 Safety Regulations
1). Do not wipe the vacuum drum while the machine is running. It must
be wiped during shutdown.
2). Do not use a flammable solvent to wipe the cleaning vacuum drum, which
will corrode the rubber. Jiangsu Ian recommends that you use special glue
provided by hot melt adhesive manufacturers. (chemical solvents to avoid
inhalation)
3). The storage area of the hot melt machine must be covered at any time,
and there will be a pungent odor when heated. (Chemical solvent to avoid
inhalation)
4). The equipment has a heating area and is marked with a safety mark to
avoid burns. 5). The device is labeled with a safety mark (for reference only).
Pay attention to safe operation.
6). When the machine is shut down for maintenance, the power supply is cut off
on the panel to prevent the machine from accidentally pre-rotating.

Second; device security protection settings

1). The equipment has a safety protection device. When the main engine runs
and encounters the inverted bottle, the bottle will be bottled when the size of
the star wheel passes. At this time, the device will automatically stop running.

2) When the cutter mechanism is stuck, the main motor torque limiter
will automatically bounce and trigger the alarm to stop the main
engine.

3). An emergency stop button is provided before and after the machine.
(Emergency stop using emergency)
4). The device is equipped with a security alarm door, and the device
automatically stops running when it is turned on.

Kindly reminds you to read the instruction manual before operating the equipment. (Non-
operators must not operate this equipment)

6
5. Technical Specification

MACHINE TYPE : Rotating OPP Hot Melt Labelling Machine

MACHINE DIMENSION : 3650mm x 1700mm x 2010mm

METHOD OF SPEED
ADJUSTMENT : Uninterrupted – Adjust Rate

LABEL TYPE : BOPP, Paper-Plastic Composite Film, Paper Label

LABELLING STATION : 12 per cycle

LABELLING SPEED : 10000 – 12000 BPH

LABELLING ACCURACY : ±3mm

MAX LABEL WIDTH : 200mm (standard width, can be adjusted)

MAX OUTER DIA. OF

LABEL : 600mm

PAPER CORE
HOT MELT : 152mm

LABELLING GLUE : Glue at both ends of each label with hot melt

GLUING TEMP. : 120 ~ 160 C

PRODUCT TYPE : Round or square container made of plastic, metal &

glass

AIR SUPPLY : 5-6 bar / 72-88 psi

POWER SUPPLY : 380V/60Hz/5000W, 3 phase

7
Introduction to mechanical specifications:

1. Physical Dimension: 2700 x 1900 x 2100 cm.

2. Applicable Specifications

1. Number of rotating heads; 8 heads

2. Bottle type requirements; round, square, rectangular

3. Into the bottle direction; left into the right

4. Production Speed; 30-200 Bottles / Minute (According To The Bottle Type)

5. Voltage requirements; 380v, three-phase five-wire

6. Host power; 10kw

7. Label height; 5-190mm (up to the bottom of

the bottle)

8. Cans diameter; 40-110mm

9. Label material; OPP, Composite Film, Pearl Film, Laser Film Anti-Counterfeiting Film.

8
7. Mechanical power distribution

1. main motor power 2.2KW

2. fan power 1.5KW

3. delivery standard servo motor power 0.75KW

4. glue pump motor 90W

5. rack motor 180W (single rack)

8. Heating power distribution

1. Hot Melt Machine: 1.2KW

2. Spray Strip:100W

3. Rubber Roller 500W

9
6.Machine Layout and Drawing
1. Overall layout

Label

Cutter
Motor for
Star Wheel

Infeed Outfeed

Bottle Screw

10
 1. Enter the label method:

Cutter
mechanism

Marking Station Correction

system Tray 1

Note: The label has a diameter of 500mm, the inner diameter of the paper

11
 Replace the following changes according to different bottle types;

Replacement order :
1. Bottle Screw
2. Bottle Straight Plate (can be shared when the bottle position is close)
3. Star Wheel Guide Guard
4. Bottle Star Wheel
5. Out Of The Bottle Star Wheel
6. Bottles Of Drag
7. Stop Bottle Small Star Wheel
8. Labeling Vacuum Drum (multiple use according to the bottle type)
9. Labeling Brush
10. Gland Head (caps diameter, different shape, need to be replaced) replacement order

12
1. Introduction to compressed air use

10
 2. Introduction to compressed air use

Cutter adjustment method;

Position 1; fixed blade

Position 2; static knife adjustment screw

Position 3; disc-shaped shrapnel pressure is fast (locked)

Position 4; static knife integral stroke adjustment screw

No. 5 position; cutter roller negative pressure regulating valve

1). The first step is to tighten the fixing screw of the No. 1 position to a semi-elastic
state, and then use the three adjustment screws of the stationary knife No. 2 position to
push the pusher out. Note that the blade cannot touch the cutter roll and observe the
11
 upper and lower gaps. It is about 1-2mm (the upper and lower gaps are basically the
same). Finally, push the three adjustment screws back about 5mm.
2). In the second step, click the jog button on the operation panel and turn it slowly to
make the rotary blade hit the stationary blade. At this time, the stationary knife will
retreat as a whole, and after the rotating knife collides, the operation will stop. Then,
tighten the No. 1 position platen screw.
3). The third step is to enter the control interface, click the Open

button to keep the device running. Then fine-tune

the stationary knife stroke control screw counterclockwise.
Listen to the knife collision sound. If there is a collision sound, click the

Open button to feed the label into the cutter roll to see
if the label can be cut.

The Problem that will appear when trying to cut the label is:

A If the label has a uniform cutter mark but there is no cut, then the counter-clockwise
fine adjustment of the No. 4 position stationary knife stroke control screw. Then divide the
middle and lower sections to test the label, and observe that the label can be cut off.

B If there is a knife mark above the label, there is no underneath. Then loosen the platen
screw to a semi-tight state and finely adjust the bottom of the stationary knife. Conversely, if
there is a knife mark under the label and there is no upper part, fine-tune the top of the stationary
knife. Lock the blade screw and repeat the test until the label is cut.

Note: Use the auxiliary blow pipe to blow the front end of the label attached to the cutter
roll when the cutter roll is running at a certain position. (Blowing size can be adjusted according
to usage)

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2. Rubber roller mechanism adjustment

1. As shown above; loosen the fixing screw at position 5 of the spray strip, adjust the
vertical adhesion of the strip and the applicator roller, and then tighten the screw.
2. As shown above; the No. 2 position resistive U-shaped groove can control the
amount of glue.
3. As shown above; the No. 1 position rubber strip prevents the glue from going up.
4. As shown above; the heating tube and the temperature sensing rod at position 3.
5. As shown above; the position of the 4th position scrapes the brass fast.

13
1. As shown above; the rubberizing amount of the adjustment screw, adjust the fit of the
spray strip and the rubberized roller to control the amount of glue on the surface of the
rubberized roller.
2. Open the opening and closing handle to disengage the spray strip from the applicator
roll. If it is turned into the label, it can be opened for cleaning.
3. Glue stroke adjustment cylinder is to adjust the distance between the rubber roller
and the suction drum, and apply glue to the front and rear ends of the label.

14
6. Labeling suction drum adjustment

1. In the first step, loosen the 6 M6 screws of the 2nd position tensioner, and the second part
loosens the 2 positioning screws at the 1st position. At this time, the labeling drum can be rotated
back and forth. In the third step, the labeling drum rear projection is moved to a position of
about 1 mm behind the rotary blade as shown in the figure above, and the position 2 screw is
fixed. The fourth step is to observe whether the labeling position of the labeling drum is suitable.
When the labeling is performed, the label is basically flush with the front boss, and the rear end
covers the tail end by about 1.5 mm.

15
7. Indenter and bottle drag adjustment

1 As shown above; the head is adjusted perpendicularly to the center of the bottle. The
first step is to prepare 1-2 two bottles.

In the second step, loosen the 6 fixing screws above the rotating head.

The third step is to rotate the head by hand to find the approximate position.

The fourth step is to put the bottle into the bottle, the pressure head is lowered to press the
bottle cap, and then fine-tuned.

16
8. Into the bottle star wheel and bottle drag adjustment

1 Remove the 3 adjustment screws and remove the screws in the first step.
The second step is to rotate the star wheel so that the center of the star wheel is aligned
with the center of the bottle, and the screws are pre-tensioned. It can be put into the bottle
and watch the bottle smoothly and completely into the bottle.

nine.

1 .screw and bottle star wheel adjustment.

1.1 When the bottle is replaced, the diameter changes. When adjusting the screw
clamp bottle tightness, loosen the screw parallel adjustment screw, and rotate the
stroke to open and close the handle to slightly clamp the bottle. (Note that the screw
outlet face should be parallel to the star wheel guard inlet)
1.2 When disassembling, open the disassembly and opening handle and pull it
outward. After loosening and removing the cantilever screw, pull out and the screw
can be replaced.

2 .screw and bottle star wheel adjustment.

17
2.1 After the adjustment of the bottle star wheel and bottle drag is completed, the
position of the screw and the star wheel can be adjusted.
2.2 Loosen the 2 adjustment stop screws to rotate the screw. Place a bottle in the
screw. Slow jog operation When the bottle comes out of the screw, enter the star
wheel, as shown above.
2.3 Jog operation, smooth bottle into the bottle, squeeze the bottle.
10. Labeling drum and bottle adjustment

1 the jog operation first makes the main shaft, the indenter, and the drum shaft three
points basically in a straight line.
2 Turn the small machine power adjustment screw clockwise. At this time, the drum
should be turned clockwise to make the other three points on the front strip into one
line.

3 First adjust the small machine lift, so that the front strip is in the middle of the bottle
labeling position. Then adjust the mobile small machine so that the front strip is in

18
contact with the bottle.

11. Small drilling crew

As shown above;

1 small machine lift is used to adjust the bottle labeling position, when changing the height
of the bottle type labeling position is used. 2 When the small machine moves
forward and backward for labeling, the front drum of the labeling drum is in
contact with the bottle, and the label can be taken away when rotated.

Chapter 3 Introduction to the Operation Panel ------

1. As shown above: Introduction to temperature controller

1 glue roller 2 glue machine 3 spray strip 4 cutter roller

19
 Set the temperature range: 1 rubber roller (150-200) depends on the ambient
temperature, and hot melt adhesive.

2 glue machine (140-160)

3 spray strip (100-120)
4 cutter roller (30-50)
The above temperature settings are based on actual conditions.
A jog button; for manual operation, handling mechanical problems, observing equipment
operation. Click on the device to move it. Keep pressing and not releasing, the device will
keep turning. It depends on how the operator operates.

B Manual bidding; for manual operation, when the equipment is running (no longer
automatically), press the manual bid to send a label. If you keep pressing it, you will always
send the mark. It depends on how the operator operates.

C color indicator light; used to observe whether the color code sensor works normally when
the device is running the label.

D glue roller indicator; used to observe whether the glue roller is working properly when
the equipment is running and labeling.

E Emergency stop button; used when an emergency stop occurs when there is a problem
with the device.

F power button; the indicator will light when turned on, indicating that the device is
powered.

G speed control knob; when the device is running and labeling, turn on the

button. When the high-speed start sensor in front of the bottle

detects that there is a bottle and the device maintains the high-speed operation labeling
state, the production speed can be adjusted by the speed control knob. It cannot be
adjusted at low speed.

20
 8. Operation
1. Operation screen introduction

1） Device low speed start button.

2） Melter start switch.

3） Control vacuum motor operation button

4） Control the glue coating roller glue signal, apply the glue when the
label is detected after opening, and the glue roller does not work after closing.

5） Control the feeding motor to run automatically. When the device is

running after opening, the bottle sensor detects that there is a bottle and starts to send
the label. After closing, it will not send the label.

6） Stop mechanism switch button

7） Control device high speed, low speed operation button

8） Adjust the pressure tightness between the indenter and the bottle.

9） Turn on the maintenance light

10） Click the parameter button to enter the parameter

21
As shown above; 4 types of bottle type, corresponding to 4 different parameters, the
internal parameters of the bottle type have been adjusted according to the user before
leaving the factory. When replacing the bottle type, select the selection page as shown
below

22
 1. Press and hold the button to confirm the parameter and enter
the bottle type replacement prompt interface (as shown below).

Click the button parameter to select the replacement.

4. Parameter modification page

5. The default values generated as shown above are as follows

23
6. According to the actual label length, you need to adjust the following

parameters;

7. Adjust the position of the label color punctuation

24
Introduction of Sensors and Limit Switches of Various Parts of the Equipment

1. KEYENCE Keyence PZ-G42N sensor introduction

Figure:

As shown in Figure F, the PZ-G42N sensor has two control modes;

1) L into the light mode; the green light is always on, the red light is not on, when the
bottle is turned off, the red light is on when the bottle is turned on, and the signal is
output.
2) D non-light-in mode; red and green lights are always on, when the photoelectric
switch shines on the passing bottle, the red light is off, and when the red light is on
again, the signal is output.
3) MAX increases the detected signal strength and MIN attenuates the signal strength.
(Adjusted according to the detected object)

25
2. Panasonic Gods LX-101 sensor introduction

Indicator light Detection head

As shown in the figure; God sees LX-101 sensor two control modes;

Note: Color code/color mode; according to different purposes, the COLOR item of
NAVI mode should be used to set the color code/color mode before debugging
settings.

Color mark mode Detects the amount of light in the light receiving part of the
illuminator

Color mode Detects based on the color ratio of the detected object and is used
to detect special colors

1） The start state RUN shows a light green light, press the button three
times, the yellow light points to the COLOR position.

2） Used to select mode

26
 3） Press the button three times to return to the start state. (The above
is the mode debugging option)

One; after selecting the color mode, press the key once, the yellow light points
to TEACH

1) Move the label and press the button once for the detection point. The yellow
color will always blink.

2) Move the label and press the key once to the darker position outside the
detection point, waiting for the light green light to illuminate, and the setting is
completed.

3) Pulling the label back and forth When the detection point passes the detection head,
the orange indicator will flash once, and the sensor is set successfully.

Second; after selecting the color code mode, press the key once, the yellow light points
to TEACH

1) Move the label and press the button once for the detection point, wait for the
green light to illuminate and the setting is
completed.

2) Pull the label back and forth. When the detection point passes the detection head,
the orange indicator will flash once, and the sensor is set successfully.
Note: The sensor detects a complete label. The detection point can only appear once from
beginning to end. There can be no other colors like the color point in the middle.

27
Equipment Operation Instructions

1.1 Boot operation precautions

1). Check compressed air (pressure is maintained at 0.4MPa-0.6MPa)
2). When turning on the power, you must wait for 40-50 minutes, and wait for the
temperature of the heating part to reach the set value before starting the device.
3). Check if the hot melt machine needs to add glue.
4). Check if the marking direction is correct.
5). Check if there is a label in the rubber backing tank to block the rubber back hole, so as
to prevent the glue from being unsmooth and blocked.

1.2 Operation process

1). Start the power switch, wait for 40-60 minutes, open the compressed air valve (the
air pressure is kept above 0.4MPa), and then turn on the equipment normally after the
above preparation is completed.

28
Chapter 7 Causes and Treatment of Mechanical Failures

1.1 Incoming bottle star wheel abnormality: When the equipment encounters the
inverted bottle, the star wheel is stuck and the torque limiter bounces. When the limit
switch X16 detects the signal, the alarm is triggered and the main unit stops running.
The touch screen will display “Incoming star wheel abnormality .. ”, and then rotate
the star wheel to reset the torque limiter.

Click the button to eliminate the alarm. (The

bottle star wheel alarm is the same as above)

1 into the bottle star wheel proximity switch, signal point X16
2 out of the bottle star wheel proximity switch, signal point X27

29
3 bottle screw proximity switch, signal point X15

1.2 Host exception:

1 equipment running card bottle serious case
2 In the case of improper operation of the card cutter, the torque limiter under the
cutter bounces, and when the proximity switch X17 detects the signal, an alarm is
triggered.

Disposal method; loosen the fixing screw at No. 1 counterclockwise, then adjust the screw
at the No. 2 clockwise, press the jog button to operate the machine.

30
Note: If the device is running repeatedly, the host abnormal alarm occurs several times,
that is, the torque limiter above the main motor is too loose, need to be tightened, turn
clockwise and adjust counterclockwise. It can be bounced when it is transferred to the
card cutter, and it will not be bounced during operation.

1.3 Broken label: Before the labeling process, the label is disconnected, or the label is
used up, triggering an alarm. Replace the finishing path and click

the button to eliminate the alarm.

1.4 Material rack shortage: When the X12, X13 rack sensor detects that the label is
running out, the device goes from high speed to low speed, and the yellow indicator
alarms.

1.5 high and low speed did not respond:The reasons are:
1 high speed switch is not open
2 high-speed start sensor X23 detection signal instability
3 back end betting bottle high speed off sensor X26 always has a signal
4 lack of material X12 or X13 alarm
5 sensor damage

Treatment: Check one item for exclusion.

1 turn on the high and low speed control switch
2 check the high speed start sensor X23 to always have a signal
3 check the high speed off sensor X26 has no signal
4 Install the entire roll of labels so that the X12 and X13 remain signaled. 5
replacement sensor

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 1.6 Stop bottle out of control:

1.The reasons are as follows: 1 The feed switch is not turned on.

2. Stop Bottle Release Sensor X24 And Gate Close Sensor X25 Detection Signal Is Unstable

3 Block Solenoid Valve Y5 Is Damaged

Treatment: Check one item for exclusion.

1 open the feed switch
2 re-adjust the sensor signal
3 replacement solenoid valve

1.7 The cutting length error is greater than 2mm:

The reasons are: 1 label length setting is incorrect 2

The initial displacement value is set to be biased 3
label tension is too large

4 labeling drum superscript position is too large

Approach:
1 set the correct label length
2 adjust the initial displacement value
3 replacement label
4 adjust the valve to reduce the negative pressure

1.8 color punctuation position is wrong:

The reasons are: 1 label length setting is incorrect

The 2-color sensor X3 detects that the signal is unstable. 3

labeling drum suction is too large, pull the standard.

Approach:

1 set the correct label length plus 1mm

2 adjust the color sensor from the new

3 Adjust the cut point displacement value parameter each time the cut color point is at the
same position

4 As shown below: In the case of the same length of the label,

after changing the parameters, manually cut 3-5 labels, observe the change of the black
point position of the label, and adjust to the position we want.
32
1.9 There is a deviation between the front and rear positions of the vacuum drum on
the label:
The reasons are:

1) the label tension is too large and the single label is not flat

2) labeling drum and cutter roll negative pressure adjustment is improper

3) Auxiliary blowing air volume is too large

Adjustment method:

i) Replacement label
ii) Adjust the negative pressure valve to the applicable
pressure
iii) Reduce the amount of blowing air

33
2.0 Uneven coating:

The reasons are as follows:

1) The glue machine is short of material and the amount of glue is not enough.
2) Glued roller surface has label jam.
3) Scraping rubber sheet wear deformation.
4) Labeling drum boss strips wipe.

Deformation approach:

1) Add hot melt adhesive block.

2) Clear surface label.
3) Replacement of the scraper board.
4) Replace the labeling drum boss strip.

34
2.1 Turning the standard:
The reasons are as follows:

1) When the glue is applied, the glue is pressed against the vacuum drum too tightly.

2) Labels are too much glue

On the 3 label, the front end of the vacuum drum is behind.

Approach:

1) Micro adjustment of the glue roller and vacuum drum spacing.

35
1) fine-tuning the tight scraping rubber sheet
2) Loosen the vacuum drum and adjust it counterclockwise. Lock and test
several labels to observe.

2.2 labeling is not tight:

The reasons are:

1 too little glue on the front end of the label

2 The front end labeling position is wrong.

3 labeling curved plate and vacuum drum clamp bottle too loose

Approach:

1) Fine-tuning loose squeegee.

2) Adjust the position of the big star wheel into the bottle.

3) Adjust the tightness of the label bending plate and the vacuum drum bottle

3.1 Labeling misalignment error is large (normally within plus or minus 1.5):

The reasons are as follows:

1) The unevenness of the whole roll of labels.

2) Auxiliary blowing air volume is too large.
3) Labeling the curved plate, the bottle and the vacuum drum are not
adjusted vertically.
4) Bottle deformation bottom is not flat

Approach:

1) Requires label manufacturers to do

quality.
2) Adjust the amount of auxiliary blowing.
3) Adjustment mechanism to make the label bending plate, the bottle and the
vacuum drum vertical.
4) Remove the deformed bottle.

36
3.2 Labeling misalignment in the same direction: Processing method Adjust the left
and right tilt of the cutter mechanism, fine-tune the screw clockwise, the cutter
mechanism will tilt to the left, and the front end of the vacuum drum on the label will
increase. The opposite is true. (The labeling error is affected by the height of the label
on the vacuum drum boss)

3.3 Early bidding or late bidding: The reason is that the bottle sensor X7 detects the
bottle's elapsed time and affects the bidding time.
Treatment method: adjust the position of the bottle sensor X7 to the right angle.

37
 3.4 Label Cuts Constantly:
The reasons are:
1) Cutting knife wear.
2) The stationary knife screw is loose and not perpendicular to the rotary knife.

3) Static launch is not enough distance.

Approach:
1) Replacement blade.

2) Adjust the verticality of the push knife and the rotary knife.

3) Counterclockwise fine adjustment to control the screw pushed out by the stationary
knife.

38
 a. does not send the standard:
The reasons are: 1 servoalarm 2 wiring loose
3 servo damage

Approach:
1) Check the instructions and follow the instructions to deal with the problem.

2) check wiring

3) .replacement (maintenance) servo

Encoder adjustment

1) The encoder below the small machine does not need to be adjusted after the first
adjustment is completed. (If you need to adjust the reason: there is an angle display on the
touch screen. 1. When the angle is not displayed, the angle is not rotated by 360 degrees.)

2) Adjustment method; when the rotary knife and the stationary knife coincide, the angle
can be adjusted to 230 degrees.

3.1 Electrical problems Please check the electrical drawings or contact the
company after sales.

39
2. Sensor and limit switch I/O meter

1 high-speed start sensor ----------------------- front-end has always been a high-speed

operation of signal equipment
2 baffle release sensor ----------------------- The front end always has a signal stop
bottle to open the supply bottle
3 bottle sensor ------------------------------ Check that there is a bottle into the start to
send the mark
4 high-speed stop sensor ------------------------ back-end gambling bottle has been
running signal equipment at low speed
5 baffle close sensor ---------------------- The back end bet bottle has a signal to close
the stop bottle to stop the supply bottle
6 off-label sensor -------------------------------Detecting the label front-end label break
stop device operation
7 rack sensor 1 ------------------------------ Detect the remaining label to stop high speed,
alarm reminder to replace

8 rack sensor 2-----------------------------Detect the remaining label to stop high speed,

alarm reminder to replace
9 color standard sensor ------------------------------ detection distinguishes the color
point of the label
10 screw limit switch (located under the machine)--------------------- screw abnormal
alarm when card
11 big star wheel limit switch (located under the machine)-------------------------big star
wheel abnormal alarm when card

12 host limit switch (located under the machine) ------------------------ host abnormal
alarm when card cutter

40
PCL; I/O correspondence table

41
9.Maintenance

NOTE:

A) During maintenance, be sure to turn power OFF

B) Take special care not to mis-insert the Air Tube

GENERAL PRECAUTION

Always keep the machine clean to prevent entry of dust or dirt. Carefully note dis- connector or poor
contact, to be sure all Air Tubes are securely tightened.

Ensure the electric power and air supply are OFF, when the machine is not operating.

PERIODICAL CHECK

i) Loose wiring, terminals and connectors

ii) Loose air tubes and connectors

iii) Dust or dirt in ventilation holes

iv) Panel compartment cleaning

v) Panel surface cleaning

vi) Air pressure reading

vii) Electric supply voltage

viii) System ERROR detection Alarm

42
 Maintenance Items
Maintenance Content
1. Wipe the vacuum drum and the cutting blade daily with a clean
cloth to keep it clean.

2. For internal lubrication, add butter once a week (No. 0 lithium grease).

3. Remove the original oil with a clean soft cloth before applying the
lubricant to the surface.

4. Check all rotating belts for breaks or severe breakages in a timely manner.

5. Lubrication between the conveyor chain plate and the wear-

reducing strip shall be carried out to produce general products with
lubricating oil or grease, to produce products with high food hygiene
requirements, and to lubricate the conveyor chain plate and the wear-
reducing strip by means of circulating spray.

6. Check the amount of wear between the conveyor chain plate and the
anti-friction strip after every 6 months of operation. If the wear is excessive,
replace the anti-friction strip or the conveyor chain plate in time.

Check the fixed state of the frequently disassembled parts every month, and
whether the fittings are good, such as whether the screws are loose or not, and
whether the bearings are loose. If the part is found to have rust spots, it should
be immediately derusted, painted or rustproof.

7. Keep the surface of the machine clean and do not place other items
on the machine.

8. If the glue machine is heated for more than 3 days for a long time,
the hot melt adhesive will be carbonized and yellowish and black, and the
new rubber block will be cleaned and replaced before production.

9. Power distribution boxes, motors, sensors and other electrical

components are strictly prohibited from water or corrosive liquids.

10. The cable should not be placed close to wet or water and corrosive
liquids to prevent premature aging of the cable insulation.

11. If you encounter difficulties during adjustment, repair or

maintenance, please contact our customer service.

43
10. Troubleshooting

SYMPTOM POSSIBLE CAUSE REMEDY

- STOP switch fault
- Replace the switch
- PLC contact fault
- Replace the PLC
STOP switch no function - PLC software
- Restart power
interlocking
- Reconnect wire
- Wire open circuited
- Adjust the bottles on
- Bottle get blocked on conveyor
conveyor - Adjust the spring of overload
Star Wheel stop frequently - Overload protector is protection to make it tight
too loose
- Check the sensor, clean the
- Photoelectric sensor
optical head, as has been
failure
damaged is replaced.

- Please set the air to 0.4-0.8

Capper head not turning - Insufficient air supply
mpa
- START switch fault
- Replace the switch
- PLC contact fault
START switch no - Replace the PLC
- PLC software
function - Restart power
interlocking fault
- Reconnect wire
- Wire open circuited

44
11. Spare Part List
i) Electrical and Mechanical

Item Description Model/ Part No Qty

1 PLC Delta DVP40ES200R 1
3 Power Supply MEAN WELL EDR-120-24 1
4 MCB Schneider 4 Pole 6A 1
5 MCB Schneider 1 Pole 10A 3
6 MCB 1 Pole 6A 2
7 Sensor IFM203 1
8 HMI FUJI TS1070i 1
9 Servo Drive Delta ASD -A2-1021-B 1
10 Inverter Danfoss VLT Micro Drive 2

45
12. Rotary OPP Hot Melt Labelling Diagram

i) Control Panel Layout

ii) Schematic Diagram

46
 0 1 2 3 4 5 6 7 8 9

EMEC Packaging Solutions Sdn Bhd

PT 13532, Jalan Banting Pandamaran
42000 Pelabuhan Klang
Selangor Darul Ehsan, Malaysia
Tel No : +603 3168 6300 / +603 3165 1344
E-MAIL : INFO@EMEC-CORP.COM
B
WEBSITE : WWW.EMEC-CORP.COM (REG: 1213057-T)

Company / customer
C Project description BLOW
ROT OPP MOULDING
Hot Melt Labelling Machine

Job number

Project name BLOW MOULDING

Type ROT OPP Hot Melt Labelling Machine
Place of installation
D

Created on 18/7/2020
Edit date 21/7/2020 Number of pages 18

2
Date 18/7/2020 Project Name : Project Description : Job Number : = CA1
BLOW MOULDING BLOW MOULDING
Edited By WIN7 + EAA
Approved By Company Name : Page Description : Remarks : Page 1
Revision Date of Revision Reason of Modification Approved Date Page 1 / 18
 0 1 2 3 4 5 6 7 8 9

A
200A
QF100

6 5
2.8:A / L1 L1 / 2.2:A
4 3
2.8:B / L2 L2 / 2.2:B
2 1
2.2:D / L3 L3 /

2.2:D / N N / 6.0:B

B 2.2:D / E E / 9.1:B

1 3 5 1
FU1-3 QF102
16A 16A 2
2 4 6

13
COOLING
1 2 5 FAN
TC1
6KVA 1 M 2
380V/200V 1~
L3 N E
2.2:B 2.2:B 2.2:B
3 4 6

E
A B C
3.1:A 3.1:A 3.1:B

1 3
Date 20/7/2020 Project Name : Project Description : Job Number : = CA1
BLOW MOULDING BLOW MOULDING
Edited By WIN7 + EAA
Approved By Company Name : Page Description : Remarks : Page 2
TRANSFORMER POWER SUPPLY
Revision Date of Revision Reason of Modification Approved Date Page 2 / 18
 0 1 2 3 4 5 6 7 8 9

2.4:E / A

2.4:E / B

2.5:E / C

1 3
QF103
6A 2 4

PC1 PC2 PC3 PC4 PC5 PC6 PC7

/15.3:B /14.3:B
/16.3:B
/17.3:B
L N

C
FX5U-80MT 16EYT 16EYT 4DA 4DA 4DA 4DA

L1 N
TU1
200V
GS2110
V+ V-
GP1
D + -

5 4
4.2:B 9.0:E
E

2 4
Date 18/7/2020 Project Name : Project Description : Job Number : = CA1
BLOW MOULDING BLOW MOULDING
Edited By WIN7 + EAA
Approved By Company Name : Page Description : Remarks : Page 3
POWER DISTRIBUTION
Revision Date of Revision Reason of Modification Approved Date Page 3 / 18
 0 1 2 3 4 5 6 7 8 9

4.8:A / A A / 4.0:A

4.8:A / B B / 4.0:A

4.8:B / C C / 4.0:B

3.2:E 9.1:E 9.3:E 4.8:B 5.2:B 9.1:E 9.4:E 4.3:B

5 Y0 Y4 0V 4.8:B 5 Y1 Y5 0V 4.3:B

1 3 5 1 3 5
QF3 QF4
/5.1:B /5.5:B
16A 2 4 6 16A 2 4 6

DICOM OPC PP NP DOCOM CR DICOM OPC PP NP DOCOM CR

20 12 10 35 46 41 20 12 10 35 46 41
A1 B1 C1 A2 B2 C2
C CN1 CN1

VF1 MR-J3-E SERVO VF1 MR-J3-E SERVO

AMPLIFIER AMPLIFIER
CN2 CN2
U1 V1 W1 CN1 U2 V2 W2 CN1
42 15 19 43 44 47 48 42 15 19 43 44 47 48
EMG SON RES LSP LSN DOCOM ALM EMG SON RES LSP LSN DOCOM ALM

x1 x1

D CODER CODER
EMERGENCY STOP

ON

RESET

LEFT LIMIT POSITION

RIGHT LIMIT POSITION

EMERGENCY STOP

ON

RESET

LEFT LIMIT POSITION

RIGHT LIMIT POSITION

x2 x2

X040 X041

U1 V1 W1 U2 V2 W2
FAULT

FAULT
M M
MOTOR 1.5KW MOTOR 1.5KW
STATION PROPULSION 3 CLAMPING SERVO 3

3 5
Date 20/7/2020 Project Name : Project Description : Job Number : = CA1
BLOW MOULDING BLOW MOULDING
Edited By WIN7 + EAA
Approved By Company Name : Page Description : Remarks : Page 4
SERVO CIRCUIT 1
Revision Date of Revision Reason of Modification Approved Date Page 4 / 18
 0 1 2 3 4 5 6 7 8 9

5.8:A / A A / 5.0:A

5.8:A / B B / 5.0:A

5.8:B / C C / 5.0:B

4.7:B 9.2:E 9.4:E 5.8:B 9.0:E 9.2:E 9.4:E 5.3:B

5 Y2 Y6 0V 5.8:B 5 Y3 Y7 0V 5.3:B

1 3 5 1 3 5
QF3 QF4
/4.1:B /4.5:B
25A 2 4 6 10A 2 4 6

DICOM OPC PP NP DOCOM CR DICOM OPC PP NP DOCOM CR

20 12 10 35 46 41 20 12 10 35 46 41
A3 B3 C3 A3 B3 C3
C CN1 CN1

VF1 MR-J3-E SERVO VF1 MR-J3-E SERVO

AMPLIFIER AMPLIFIER
CN2 CN2
U3 V3 W3 CN1 U4 V4 W4 CN1
42 15 19 43 44 47 48 42 15 19 43 44 47 48
EMG SON RES LSP LSN DOCOM ALM EMG SON RES LSP LSN DOCOM ALM

x1 x1

D CODER CODER
EMERGENCY STOP

ON

RESET

LEFT LIMIT POSITION

RIGHT LIMIT POSITION

EMERGENCY STOP

ON

RESET

LEFT LIMIT POSITION

RIGHT LIMIT POSITION

x2 x2

X042 X031

U3 V3 W3 U4 V4 W4
FAULT

FAULT
M M
MOTOR 1.5KW MOTOR 1.5KW
STRETCH SERVO 3 FEED SERVO 3

4 6
Date 20/7/2020 Project Name : Project Description : Job Number : = CA1
BLOW MOULDING BLOW MOULDING
Edited By WIN7 + EAA
Approved By Company Name : Page Description : Remarks : Page 5
SERVO CIRCUIT 2
Revision Date of Revision Reason of Modification Approved Date Page 5 / 18
 0 1 2 3 4 5 6 7 8 9

16A

A QF5

6 5
6.8:A / L11 L11 / 6.0:A
4 3
6.8:A / L21 L21 / 6.0:A
2 1
6.8:B / L31 L31 / 6.0:B

2.8:B / N N/

1 3 1 3 1 3 1 3
KM1 KM2 KM3 KM4
/10.8:E 2 4 /10.8:E 2 4 /10.8:E 2 4 /10.9:E 2 4

1 5 4 1 5 4 1 5 4 1 5 20
C
FR1 FR3 FR4 FR5
/11.5:B 2 6 X44 /11.6:B 2 6 X46 /11.6:A 2 6 20 /11.6:B 2 6 X47

D
U6 V6 W6 U8 V8 W8 U9 V9 W9 U10 V10 W10 U11 V11 W11

M M M M M
M6 M8 M9 M10-1 M10-2
0.09KW/1A 3~ 2.2KW/4.8A 3~ 0.25KW/2A 3~ 0.09KW/1A 3~ 0.06KW/1A 3~
ROTATING CHAIN BOTTLE COOLING SUPERIOR EMBRYO ORGANIZE EMBRYO BOTTLE EMBRYO CULLING
PE PE PE PE PE

5 7
Date 20/7/2020 Project Name : Project Description : Job Number : = CA1
BLOW MOULDING BLOW MOULDING
Edited By WIN7 + EAA
Approved By Company Name : Page Description : Remarks : Page 6
MOTOR CIRCUIT
Revision Date of Revision Reason of Modification Approved Date Page 6 / 18
 0 1 2 3 4 5 6 7 8 9

7.9:A / L11 L11 / 7.0:A

7.9:A / L21 L21 / 7.0:A

7.9:B / L31 L31 / 7.0:B

B
1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3

QF6 QF7 QF8 QF9 QF10 QF11 QF12 QF13 QF14

63A 63A 63A 63A 63A 63A 63A 63A 63A
2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4

501 502 503 504 505 506 507 508 509

APR1 APR2 APR3 APR4 APR5 APR6 APR7 APR8 APR9

L1 L1 L1 L1 L1 L1 L1 L1 L1

14.6:C / A01+ A1(+) 14.6:C / A02+ A1(+) 14.6:D / A03+ A1(+) 14.6:D / A04+ A1(+) 15.6:C / A05+ A1(+) 15.6:C / A06+ A1(+) 15.6:D / A07+ A1(+) 15.6:D / A08+ A1(+) 16.6:C / A09+ A1(+)

14.6:C / A01- A19(-) 14.6:C / A02- A19(-) 14.6:D / A03- A19(-) 14.6:D / A04- A19(-) 15.6:C / A05- A19(-) 15.6:C / A06- A19(-) 15.6:D / A07- A19(-) 15.6:D / A08- A19(-) 16.6:C / A09- A19(-)

T1 T1 T1 T1 T1 T1 T1 T1 T1

301 N1 302 N1 303 N1 304 N1 305 N1 306 N1 307 N1 308 N1 309 N1

D
R11 R21 R31 R41 R51 R61 R71 R81 R91

R12 R22 R32 R42 R52 R62 R72 R82 R92

R13 R23 R33 R43 R53 R63 R73 R83 R93

R14 R24 R34 R44 R54 R64 R74 R84 R94

R15 R25 R35 R45 R55 R65 R75 R85 R95

6 8
Date 20/7/2020 Project Name : Project Description : Job Number : = CA1
BLOW MOULDING BLOW MOULDING
Edited By WIN7 + EAA
Approved By Company Name : Page Description : Remarks : Page 7
HEATING CIRCUIT 1
Revision Date of Revision Reason of Modification Approved Date Page 7 / 18