Star FBV 500

SEMIAUTOMATIC PACKAGING Doc.: AL1.
1_6M_UK
MACHINE “STAR FBV 500” Printed: 19/09/06
Page: 1
INDEX PAGE
1 GENERAL WARNINGS ................................................................................................... 2

1.1 Reproduction prohibited ......................................................................................... 2
1.2 Standard reference ................................................................................................ 2
1.3 Indications for maintenance intervention.................................................................. 2
2 INTRODUCTION MACHINE LAY-OUT .............................................................................. 3
3 TABLE SHOWING THE DIFFERENT PACKAGING FORMATS AVAILABLE .............................. 4
4 TECHNICAL FEATURES ................................................................................................. 5
5 INSTALLATION............................................................................................................. 6
6 WIRING ....................................................................................................................... 7
7 PNEUMATIC CONNECTION ............................................................................................ 8
8 START-UP .................................................................................................................... 9
9 OPERATOR PANEL ...................................................................................................... 10
10 LIST OF CONTROLS ON SIDE HATCH........................................................................ 11
11 LIST OF ALARMS TYPES .......................................................................................... 12
12 WELDING HEAD INTERMITTING DEVICES PHASE VERIFICATION ............................... 13
12.1 Manual synchronising procedure ........................................................................ 15
13 ADJUSTMENTS INTRODUCTION ............................................................................... 19
13.1 Adjusting infeed edges ...................................................................................... 19
13.2 Adjusting outfeed edges and bag pressing bar .................................................... 19
13.3 Adjusting opening and closing of sealing head..................................................... 20
13.4 Adjusting bottom sealing bar ............................................................................. 21
13.5 Adjusting top sealing bar ................................................................................... 21
13.6 Adjusting and checking cutting blade and edge-stretching plate............................ 22
13.7 Adjusting infeed and positioning former.............................................................. 25
13.8 Adjustment of infeeding trolley for bag tensioning ............................................... 28
14 THERMOSALD 3E STRUCTURE (CONTROLS AND FUNCTIONS) .................................... 30
14.1 Start up / base configuration + Multilanguage panel ............................................ 30
14.2 Instructions to use the Multilanguage panel ........................................................ 31
14.3 Maintenance..................................................................................................... 32
14.4 Machine data list............................................................................................... 33
14.5 Setting data list ................................................................................................ 34
14.6 Fault and warnings list (causes – remedies) ........................................................ 36
14.7 Pre-heating and welding temperature adjustment................................................ 39
14.8 Modify time (ex. h02)....................................................................................... 39
15 ASSEMBLING AND DISASSEMBLING SEALING BARS ................................................... 41
16 MAINTENANCE........................................................................................................ 44
16.1 Pneumatic parts................................................................................................ 52
16.2 Electrical parts.................................................................................................. 52
16.3 Motor serial “BA71”........................................................................................... 53
16.4 Motor “BM63”................................................................................................... 56
17 List of spare parts ................................................................................................... 59
18 ATTACHMENTS ....................................................................................................... 63
18.1 Pneumatic diagram ........................................................................................... 63
18.2 Electric diagram................................................................................................ 64
18.3 General drawings.............................................................................................. 65
CB PACKAGING 26010 Bagnolo Cremasco (CR) ITALY Strada di Lottizzazione- Corner Via L. Da Vinci
Tel. (+39 0373) 649620 Fax (+39 0373) 649611 www.cbpackaging.it e-mail info@cbpackaging.it
SEMIAUTOMATIC PACKAGING Doc.: AL1.1_6M_UK
Page: 2
1 GENERAL WARNINGS
1.1 Reproduction prohibited
THIS MANUAL IS PROPERTY OF CB PACKAGING - REPRODUCTION OR TRANSFER OF THE

CONTENTS OF THIS MANUAL IS PROHIBITED. ALL RIGHTS RESERVED.
1.2 Standard reference
98/37CE MACHINERY DIRECTIVE

73/23/CEE LOW VOLTAGE DIRECTIVE
UNI EN 292 SAFETY OF THE MACHINERY
CEI EN 60204/1 MACHINES ELECTRICAL EQUIPMENT
89/336/CEE, 92/31/CEE RULES ON ELECTROMAGNETIC COMPLIANCE
1.3 Indications for maintenance intervention
FOR MAINTENANCE INTERVENTIONS AND FOR ANY SPARE PARTS ORDER, PLEASE CONTACT:
CB PACKAGING
STRADA DI LOTTIZZAZIONE ANGOLO VIA LEONARDO DA VINCI,
26010 BAGNOLO CREMASCO (CR) - ITALY
TEL +39 0373 649620 FAX +39 0373 649611
www.cbpackaging.it E-MAIL info@cbpackaging.it
Rev. Date Description Issued by:
SEMIAUTOMATIC PACKAGING MACHINE STAR

0 Settembre 2006 Cinzia Filipponi
FBV 500
Page: 3
INTRODUCTION MACHINE LAY-OUT
THIS MANUAL PROVIDES THE INFORMATION NECESSARY FOR OPERATING THE SEALING
MACHINE CORRECTLY, FOR PERFORMING MAINTENANCE INTERVENTIONS AND
ADJUSTMENTS AND FOR THE MACHINE ON-BOARD SAFETY SYSTEM.
THE “STAR FBV 500” SEMIAUTOMATIC PACKAGING MACHINE FOR PACKING PRE-FILLED
SACKS, BAGS AND PACKETS CONTAINING DISPOSABLE PRODUCTS SUCH AS DIAPERS FOR
BABIES AND INCONTINENT ADULTS OR ROLLS OF PAPER.
Page: 4
2 TABLE SHOWING THE DIFFERENT PACKAGING FORMATS AVAILABLE
A B C D
MINIMUM 120 100 150 140
MAXIMUM 500 200 550 190
D = B/2 + 60 MM
THE USER CAN CALCULATE THE DIMENSIONS OF STRIPS D REQUIRED BY THE SEALING UNIT
FOR PERFECT FORMING AND SEALING.
NOTE: THE PACKAGING MACHINE CAN REACH A MAXIMUM FORMAT OF B = 250 mm; FOR
OBTAINING THIS FORMAT, IT IS NECESSARY SUBSTITUTE THE HEXAGONAL AXIS ON THE
UPPER WELDING HEAR AND INSTALL THE 80 mm AXIS (SUPPLIED WITH THE MACHINE),
THEN SET THE DESIDERED STROKE ON THE CONNECTING ROD.
FOR THESE FORMAT DIMENSIONS IS SUGGESTED TO INSTALL A HEAD CLOSING REDUCTION
GEAR, WITH RATIO I = 1/15
Page: 5
3 TECHNICAL FEATURES
POWER SUPPLY: Voltage available as per customer request

MAXIMUM ABSORPTION: 4 Kw
COMPRESSED AIR SUPPLY: 5 BAR
COMPRESSED AIR CONSUMPTION: 150 Lt/minute
SEALING WIDTH: 3 mm
SEALING TYPE: PULSED
PRODUCTIVE CAPACITY (SPEED) MIN. TIME 0.6 = 26 STROKES A MINUTE
MAX. FILM THICKNESS: 100 MICRONS
DOUBLE WELD
SEALING LENGTH: 500 MM
MECHANICAL ZIG-ZAG CUTTING SYSTEM: 8 - 10 mm.
STRIP OPENING :TOP: BY VACUUM SYSTEM
BOTTOM: BY SUCTION FAN
HEAD CLOSING: BY IP 80 + REDUCTION GEAR RMI 50 FL LFB I = 1/10 + SELF-BRAKING
MOTOR, 1680 RPM /min1
BAG INSERTION: BY REDUCTION GEAR RMI 50 FL LFB I =1/7 + SELF-BRAKING MOTOR, 1400
RPM /min1
HEAD-CLOSING DRIVE: BY MEANS OF PULLEYS AND TIMING BELT, 1400 H
BAG-INSERTION DRIVE: BY MEANS OF ½” PINIONS Z = 30 + SINGLE ½” CHAIN
GRAPHIC DISPLAY PANEL FOR MACHINE ALARMS, SETTING AND OPERATION, IN ORDER TO
MANAGE A VAST RANGE OF BAG DIMENSIONS
PARTS FOR COMPRESSED-AIR SYSTEM (FESTO)
SAFETY BARRIERS, STI MICROSAFE
Page: 6
4 INSTALLATION
THE MACHINE IS TESTED AND APPROVED ON THE MANUFACTURER'S PREMISES IN ORDER TO

ENSURE THAT ITS OPERATION PROVIDES MAXIMUM OPERATOR SAFETY WHEN IT IS
DELIVERED.
UPON TAKING DELIVERY OF THE MACHINE CHECK THE PACKAGE FOR DAMAGE. CHECK ALL
ELECTRICAL PARTS AND PARTS FOR COMPRESSED-AIR SYSTEM CAREFULLY.
THE SEALING MACHINE HAS BEEN DESIGNED TO ENSURE GOOD STABILITY DURING THE
PRODUCTION CYCLE.
THE STAR FVB 500 SEALING MACHINE IS FITTED WITH FEET WITH SHOCK ABSORBERS
THAT ARE PREFECTLY ADAPTED TO THE GROUND.
Page: 7
5 WIRING
WARNING: THIS OPERATION MUST BE PERFORMED WHEN THE MACHINE IS STOPPED AND
LOCKED OUT!
VOLTAGE: SEE “CE” CARD ON THE MACHINE

FREQUENCY: 50/60 HZ
INSTALLATION PROCEDURE:
CONNECT THE MACHINE TO THE POWER SUPPLY BY MEANS OF AN INSULATED EARTHED
CABLE WITH A MINIMUM SECTION OF FOUR mm 2 AND CONNECT TO CONNECTORS (R, S, T)
+ EARTH. USE A 16 AMP PLUG (3 POLES + EARTH).
AFTER THE WIRING UP, CLOSE THE GUART.
NOTE: VERIFY THAT THE ROTATION SENSE OF THE WELDING HEAD AND FAN, CORRESPOND
TO THE REFERENCE ARROWS ON THE MACHINE.
R,S,T +
EARTH
Page: 8
6 PNEUMATIC CONNECTION
CONNECT THE MACHINE TO THE POWER SUPPLY AT POINT (X). THE COMPRESSED AIR
SUPPLY MUST BE AS DRY AS POSSIBLE. OPTIMUM AIR SUPPLY PRESSURE IS five BAR.
THE COMPRESSED AIR UNIT CONSISTS OF:
1. INSERTION VALVE EVP742-5Y0-04FA
2. REDUCTION-GEAR FILTER EAW 4000-F04 WITH GAUGE
3. SOLENOID VALVE UNIT, TYPE SY5120-5Y0-01F
4. FLOW ADJUSTER
5. PRESSURE REDUCER LRMA-QS-6
3
5
Page: 9
7 START-UP
1. MAKE SURE THAT ALL THE MECHANICAL ADJUSTMENTS ARE CORRECT IN ORDER TO
PREVENT MECHANICAL COLLISIONS.
2. MAKE SURE THAT THE ELECTRICAL AND COMPRESSED-AIR SYSTEMS ARE IN PERFECT
ORDER AND THAT THE MACHINE IS CONNECTED TO THE POWER AND COMPRESSED AIR
SUPPLIES.
3. TURN MAIN SWITCH TO POSITION (1), ON DISPLAY EDS 2001 THE CHARACTERS H04 WILL
APPEAR.
4. PRESS (X) ON OPERATOR PANEL UNTIL THE CHARACTERS H00 APPEAR ON THE DISPLAY.
THE MACHINE IS NOW IN “STAND-BY” STATUS.
PRESS “START” (I) KEY ON OPERATOR PANEL TO RUN MACHINE IN AUTOMATIC MODE.
Page: 10
8 OPERATOR PANEL
ON THE OPERATOR PANEL IN THE FRONT OF THE MACHINE THERE IS THE START BUTTON
(I), THE STOP BUTTON (0), THE RESET BUTTON (X), ARROW KEYS → AND ← FOR RUNNING
STEP-BY-STEP CYCLE AND THE EMERGENCY RED MUSHROOM-HEAD BUTTOM. IF THIS IS
PRESSED THE MACHINE SHUTS DOWN IMMEDIATELY AND THEREFORE ALL MOVING PARTS
ARE STOPPED.
THE MACHINE MAY ALSO SHUT DOWN IMMEDIATELY IF PARTS OF THE BODY OR OTHER
OBJECTS ACCIDENTALLY GO PAST THE YELLOW PROTECTION BARRIERS.
1 2 1. START
5
2. STOP
3. RESET
4. STEP-BY-STEP CYCLE
3 5. EMERGENCY SWITCH
Page: 11
9 LIST OF CONTROLS ON SIDE HATCH
THE HATCH ON THE CONTROL PANEL CAN BE OPENED AND CONTAINS THE DISPLAYS EDS
2001 AND 3E THERMOSALD .
THEY CAN BE USED TO RUN MACHINE OPERATION AND ADJUSTMENT COMMANDS.
1. EDS 2001: ENABLES ALL THE ADJUSTMENTS TO BE CARRIED OUT THAT ARE REQUIRED
TO SET SEALING TIMES, FORMING TIMES, ETC.
FOR COMMISSIONING, SEE ATTACHED MANUAL.
2. 3E (TERMOSALD): PULSE THERMOSTAT THAT ENABLES OPTIMUM SEALING RESULTS TO

BE ACHIEVED: PREHEATING TEMPERATURE (IN °C OR °F) AND SEALING TEMPERATURE CAN
BE SET DIRECTLY ON THE PANEL.
FOR COMMISSIONING, SEE ATTACHED MANUAL.
Page: 12
10 LIST OF ALARMS TYPES
THE FOLLOWING ALARM SIGNALS MAY APPEAR ON THE DISPLAY OF MICROCONTROLLOR

“EDS 2001”:
H00 NO ALARM CURRENT; THE MACHINE CAN START ITS PRODUCTION CYCLE.
H01 EMERGENCY MUSHROOM-HEAD PRESSED OR SAFEGUARDS OPEN
H02 THERMAL ALARMS QF1, QF2, QF3 OR "3E" THERMOREGULATOR ALARM, CHECK THE
CONDITIONS OF THE FOLLOWING THERMAL CUTOUTS IN THE ELECTRIC BOARD :
QF1: SUCTION FAN THERMAL CUTOUT (4A)
QF2: SEALING HEAD MOTOR THERMAL CUTOUT (2.5A)
QF3: PUSHER MOTOR THERMAL CUTOUT (1,6A)
ALSO CHECK THAT THE THERMOREGULATOR DISPLAY IS NOT VISUALISING ANY ALARM
SIGNALS (SEE MANUAL "3E")
H03 PUSHER TIME-OUT ALARM ; CHECK THE POSITIONING OF THE SENSOR "B1" PLACED
UNDER THE LOADING SLIDE. WHEN THE PUSHING TROLLEY IS POSITIONE FOR THE
LOADING, THE SENSOR "B1" MUST BE INTERCEPTED. VERIFY THE FRICTION TENSIONING.
(B2 SENSOR IN CASE OF PACKAGING MACHINE SET FOR THE WET WIPES)
H04 SEALING BARS CYCLE TIME-OUT ; MAKE THE FOLLOWING CHECKS:

1. IN THE NORMAL REST CONDITIONS THE PLC INTPUT ( I Ø.7) MUST BE ON (RED LED ON)
AND THE PHASE MICROSWITCH (FC2) ON THE INTERMITTER SHOULD BE "FREE” (FREE
CONTACT); THEN CHECK THE CONDITIONS OF THE PHASE MICRO, THE CORRECT POSITION
OF THE CAMS ON THE INTERMITTER SHAFT. AFTER HAVING CARRIED OUT THE NECESSARY
CHECKS, PRESS THE RESET BUTTON ON THE OPERATOR PANEL.
2. IN THE NORMAL REST CONDITIONS THE PLC INTPUT ( I Ø.5) SHOULD BE ON AND THE
SENSOR "B3" SHOWING THAT THE BARS ARE OPEN, SHOULD DETECT THE SCREW ON THE
LOWER HEAD; CHECK THE CONDITIONS AND POSITION OF THE SENSOR IN RELATION TO
THE LOWER SEALING BAR, THEN PRESS RESET ON THE OPERATOR PANEL.
Page: 13
11 WELDING HEAD INTERMITTING DEVICES PHASE VERIFICATION

TO CHECK IF THE TWO PHASE CAMS ARE CORRECTLY POSITIONED, COMPLY WITH THE
FOLLOWING INSTRUCTIONS AND SEE “B” DRAWING.
THE ANGLE CREATED BY THE TWO CONTROL PLATES, CORRESPONDS TO THE INTERMITTOR
STOP DEGREES (a = 60°) PLUS THE VARIABLES DUE TO MOTOR INERTIA WHILE IT IS
ROTATING (b = 30°).
THEREFORE:
Y = a + b = 60° + 30° + = 90°
SEE DRWG. “B”
PROXIMITY
CONTROL
PHASE PLATE
CAM PHASE
(COLOURED IN
RED)
ROTATION
DIRECTION
ON THE INTERMITTOR INCOMING SHAFT, VISUALISE THE KEY ON WHICH THE PHASE
CONTROL CAM IS FITTED. THE KEY SHALL FACE UPWARDS AND ON THE OUTGOING SHAFT
AXIS (SEE DWG.A) SO THAT THE INTERMITTOR IS CORRECTLY SET IN THE “SYNCHRONIZED
PAUSE” CONDITION.
Page: 14
• DRWG.”A” (HEAD OPEN

OUTPUT SHAFT
COUPLER
X= INTERMITTOR STOP
PHASE ANGLE
PHASE
CONTROL
CAMS
ROTATION
DIRECTION
MAIN
PULLEY
PAUSE IN PHASE
INPUT SHAFT
REFERENCE KEY
Page: 15
11.1 Manual synchronising procedure
TO SYNCHRONISE THE MACHINE, THUS PUTTING THE MOVEMENT OF THE WELDING BARS IN
PHASE WITH THE MOTORISATION, THERE IS A MANUAL PROCEDURE TO BE EXECUTED AS
FOLLOWS:
- WITH THE COUPLER OF THE MAIN OUTGOING PULLEY “IP80”, FREE THE WELDING HEAD
TRANSMISSION FROM THE MOTORISATION (SEE DRWG. D)
- INSERT THE “DISENGAGE” KEY IN THE CAP OF THE MOTOR IN QUESTION AND TURN IT
UNTIL YOU HAVE MANUAL DISENGAGEMENT OF THE “MOTOR BRAKE” (SEE DRWG. D)
Page: 16
N° 6 ALLEN KEY
DISENGAGEMENT KEY
INTERMITTOR IP80
TRANSMISSI
ON BELT MOTOR CAP
COUPLER
OUTPUTRSH
MOTOR
INPUT SHAFT
GEAR MOTOR
MAIN PULLEY
N.B. AFTER DISENGAGING THE BRAKE MANUALLY, THE

OUTGOING SHAFT MUST TURN “IDLING”!
- SUBSEQUENTLY INSERT A N° 6 ALLEN KEY IN THE HOLE OF THE KEY AND MANUALLY MOVE
THE MOTORISATION IN THE CORRECT DIRECTION OF ROTATION.
- ROTATE AND MOVE THE PREVIOUSLY DESCRIBED REFERENCE KEY TO THE “SIYNCRONIZED
PAUSE” POSITION. (SEE DWG A)
- CHECK THE POSITION OF THE PHASE CONTROL PLATES PLACED ON THE CAM (SEE DWG. B)
- MANUALLY OPERATE THE TWO CONNECTING ROD-HANDLE SYSTEMS AND POSITION THEM
IN THE HEAD OPEN CONDITION (SEE DWG. E)
Page: 17
DRWG.”E”
ROTATION DIRECTION
UPPER CONNECTING
ROD-HANDLE
POSITION THE TWO CONNECTING

RODS ON THE SAME AXIS!
LOWER CONNECTING
ROD-HANDLE
ROTATION DIRECTION ⇒
- MAKE SURE THAT “B3 PROXIMITY SWITCH” PLACED ON THE LOWER SUPPORT PLATE IS
ENGAGED (RED LED ON) (SEE DWG. F)
Page: 18
READING SCREW
“B3” PROXIMITY
RED LED
LOWER
SUPPORT
PLATE
- AT THIS POINT, WITH THE HEAD OPEN AND THE INTERMITTOR IN PHASE,
LOCK THE MAIN PULLEY COUPLER SCREWS AND ONCE AGAIN RESTRAIN TRANSMISSION AND
MOTORISATION.
- PROCEED STEP-BY-STEP AND CHECK THAT THE WELDING HEAD OPENING

AND CLOSING CYCLE IS CARRIED OUT CORRECTLY.
Page: 19
12 ADJUSTMENTS INTRODUCTION
BEFORE STARTING SEALING WITH THE “STAR FBV 500” THE OPERATOR CAN AND MUST MAKE
A FEW BASIC ADJUSTMENTS TO ADAPT THE MACHINE TO THE PACKAGE THAT IT IS TO SEAL.
N.B THE MACHINE MUST BE SWITCHED OFF AND LOCKED OUT BEFORE THE FOLLOWING
OPERATIONS ARE CARRIED OUT!
12.1 Adjusting infeed edges
USE THE SIDE KNOBS TO ADAPT THE EDGES TO THE WIDTH (A) OF THE BAG SO THAT IT IS
SLIGHTLY COMPRESSED. THE EDGES CAN NEVERTHELESS BE SLIGHTLY WIDENED TO
FACILITATE BAG LOADING.
12.2 Adjusting outfeed edges and bag pressing bar
USE THE TAKE-UP HANDLES TO COMPRESS BAG WIDTH (A) THEN, ACCORDING TO BAG
HEIGHT (B), ADJUST THE BAR'S M8 SCREWS SO THAT THE BAG-PRESSING PADDLES
SLIGHTLY COMPRESS THE BAG.
THESE TWO OPERATIONS ENABLE THE BAG TO BE 'FRICTIONED'. OTHERWISE, IT COULD BE
EJECTED DIRECTLY BY THE PUSHER.
Page: 20
SUPPORT PLATE
BAG-HOLDING
PNEUMATIC
PADDLES
HANDLES
NOTE: FOR THE FORMATS WITH SMALL WIDTH (A), VISUALIZE ONE SINGLE BAG-HOLDING
PADDLE AND POSITION IT IN THE MIDDLE OF THE BAG
NOTE2: IN CASE THE MACHINE IS SET FOR PACKAGING THE WET WIPE MULTIPACK BAG,
THE MACHINE WILL BE SUPPLIED WITH FIXED BAG-HOLDING PADDLES.
PADDLES
FOR FIXING
THE WET
WIPES
12.3 Adjusting opening and closing of sealing head
THIS IS THE MOST IMPORTANT OPERATION FOR THE “STAR FBV 500”, IF THIS OPERATION IS
CARRIED OUT CORRECTLY, THE SEALING PROCESS CAN BE OPTIMISED.
AFTER ADJUSTING THE INFEED AND OUTFEED EDGES AND THE BAG PRESSING BAR THE
HEIGHT 'B' OF THE BAG THAT IS TO BE SEALED HAS TO BE CONSIDERED.
TO SIMPLIFY THE ADJUSTING PROCESS, LET US SUPPOSE THAT A BAG NEEDS TO BE SEALED
WHOSE HEIGHT 'B' IS 120 mm. WE THEREFORE PROCEED AS FOLLOWS:
Page: 21
12.4 Adjusting bottom sealing bar
ASSUMING THAT THE BAG MUST BE SEALED AT THE CENTRE THE 'SEALING STROKE' OF THE
BOTTOM BAR MUST BE 60 mm.
TO ACHIEVE THIS STROKE, USE THE BOTTOM CONNECTING ROD-CRANK (1) SYSTEM. USE
THE 'REFERENCE NOTCHES' ON THE CONNECTING ROD-CRANK TO CREATE A OFFSET OF 30
mm BETWEEN THE ROTATING SHAFT (2) AND THE FIXING PIN OF THE ARTICULATED HEAD
(3) (AFTER 180° OF ROTATION 30+30=60mm "SEALING STROKE").
AT THIS POINT, ADJUST THE HEXAGONAL ROD (4) AND PLACE THE BOTTOM BAR JUST
BELOW THE DISCHARGE CHUTE.
BEFORE CARRYING OUT ANY ADJUSTMENT, LOOSEN ALL NUTS AFFECTED AND TIGHTEN
THEM AGAIN AFTERWARDS.
N.B TO CHECK THAT THE SET STROKE IS CORRECT, USE THE 'STEP-BY-STEP' BUTTON ON
THE CONTROL PANEL TO CLOSE THE HEAD AND CHECK THAT THE BOTTOM STROKE FROM
THE DISCHARGE CHUTE TO THE TOP OF THE BAR IS 60 mm, AS PREVIOUSLY SET.
3
2
Offset between rotation
shaft (2) and pin (3) =
30mm
1
12.5 Adjusting top sealing bar
THE 'SEALING STROKE' OF THE TOP SEALING BAR IS ALSO ADJUSTED ACCORDING TO THE
SAME PRINCIPLE BY MEANS OF THE TOP ADJUSTING ROD-CRANK (1) SYSTEM.
BUT IN THIS CASE, THE OFFSET BETWEEN THE ROTATION SHAFT (2) AND THE PIN FOR
FIXING THE ARTICULATED HEAD (3) MUST BE 34-35 mm. THE 'SEALING STROKE' IS
THEREFORE INCREASED BY 8-10 mm. WHEN THE TWO BARS MEET, THE SHOCK-ABSORBING
CENTRAL CYLINDER (4) WILL INTERVENE AND EXERT A PRE-SET PRESSURE OF 3 TO 4 BAR.
Page: 22
NEXT, USE THE HEXAGONAL ROD (5) TO BRING THE TOP SEALING BAR JUST ABOVE THE BAG
TO BE SEALED (TO CHECK, INSERT THE BAG BELOW THE HEAD) AND THEN TIGHTEN THE
SCREWS.
N.B. USE THE STEP-BY-STEP BUTTON ON THE OPERATOR PANEL TO CHECK HEAD OPENING
AND CLOSING. THE CENTRAL CYLINDER MUST COMPRESS BY 3-4 mm.
2
Offset between the rotation
shaft (2) and the pin (3) ≅
3 34-35 mm
12.6 Adjusting and checking cutting blade and edge-stretching plate
- MANUALLY ACTIVATE THE SOLENOID VALVE (EV1) TO CHECK THAT THE CUTTING BLADE
EMERGES ROM THE TOP SEALING BAR.
- THE CUTTING BLADE IS SCISSOR-SHAPED AND MUST 'PROTRUDE' DURING THE CUTTING
PHASE ABOUT 15 MM BEYOND THE TOP SEALING BAR (6) AND ABOUT 10 MM FROM THE
BOTTOM BAR.
- TO ADJUST THE PROTRUSION OF THE BLADE FROM THE TOP BAR, PROCEED AS FOLLOWS:
1- LOOSEN NUTS (2)

2- ADJUST HEXAGONAL BAR (1) AND POSITION THE BLADE.
Page: 23
3- ENSURE THAT THE BLADE SUPPORT BAR (3) DOES NOT KNOCK AGAINST THE EDGE-
TENSIONING PLATE (4) UNDERNEATH DURING THE CUTTING PHASE.
-CHECK THAT WHEN THE TOP IS CLOSED (SEALING PHASE) THE CENTRAL CYLINDER (5)
COMPRESSES BY 2-3 MM AND THAT ABOUT 3-BAR PRESSURE IS SET ON THE ADJUSTER (SEE
CHAPTER ON TOP-HEAD ADJUSTMENT).
- TO POSITION THE EDGE-TENSIONING PLATE CORRECTLY,
1- RELEASE SPRINGS (9) BY MEANS OF RINGNUTS (10) AND LOOSEN THE THREADED PIN
(13).
2- LOOSEN THE RINGNUTS (12) AND MOVE THE RODS (11) CONNECTED TO THE EDGE-
TENSIONING PLATE SO THAT THE POINT IS SLIGHTLY BELOW THE TOP SEALING BAR (6).
3- ADJUST THE THREADED PINS (13) AND PLACE THE SPRINGS UNDER PRESSURE (9).
4- TIGHTEN THE RINGNUTS (10).
- DURING THE CLOSING PHASE, CHECK THAT THE POINT OF THE EDGE-STRETCHING PLATE
(4) FIXES THE NYLON BELOW (LOCATED IN PLATE (8)).
- ALSO CHECK THAT THE WASHERS (14) HAVE A GAP OF AT LEAST 0.5 TO 1 MM.
Page: 24
ADJUSTING AND CHECKING CUTTING BLADE AND EDGE-TENSIONING PLATE.
1- HEXAGONAL BAR
2- LOCKING NUT
3- BLADE SUPPORT BAR
4- EDGE-TENSIONING PLATE
5- CENTRAL CYLINDER
6- TOP SEALING BAR
7- BOTTOM SEALING BAR
8- PLATE FOR NYLON
9- SPRING
10- SELF-LOCKING RINGNUT
11- BAR
12- SELF-LOCKING RINGNUT
13- THREADED PIN
14- WASHER
Page: 25
12.7 Adjusting infeed and positioning former
IN THE “STAR FBV 500” SEALING MACHINE, BAG FORMING OR GUSSETING IS MECHANICAL
AND MAKES USE OF HEAD DESCENT AND ASCENT.
THE BAG-FORMING UNIT COMPRISES THE FOLLOWING PARTS:
1- PLATE FOR ADJUSTING AND POSITIONING ROTATION FULCRUM
2- ROTATION SHAFT (FULCRUM)
3- SUPPORTING SHEETING
4- BEARING
5- DELRIN CAM
6- FORMER ARROW
7- CONNECTING SPRING
8- ADJUSTING BLOCK
1
2 8
5
3
7
6
Page: 26
TO EXPLAIN WHAT THE CONVENTIONAL FORMER ENTRY SHOULD BE IN RELATION TO THE

BAG (1/3 OF HEIGHT), WE HAVE PROVIDED AN EXAMPLE HERE.
SUPPOSE THAT WE NEED TO FORM A BAG WHOSE DIMENSIONS ARE:
A=120mm H=100mm B=(1/3 H) 33.3mm
TO DECIDE THE ROTATION FULCRUM (X), WE APPLY THIS FORMULA:
X= K + (1/2 A - 1/3 H) X= 110 + (60 – 33) = 136.7 mm
WHERE K IS OUR CONSTANT AND CORRESPONDS TO THE DISTANCE THAT EXISTS BETWEEN
THE CENTRE OF THE SLOTS AND THE POINT OF THE ARROW.
Page: 27
AFTER FIXING THE ROTATION FULCRUM, MOVE THE CAM AND MOVE THE POINT OF THE
FORMER ARROW SO THAT IT IS ABOUT 8-10 mm FURTHER TO THE OUTSIDE THAN THE
DISCHARGE EDGES SO THAT HALF OF THE BEARINGS ON THE CAM COVERS THE FLAT TRACK
(ASCENT) AND HALF COVERS THE TILTED TRACK (DESCENT) AND THEN TIGHTEN THE
SCREWS.
THE TILT OBTAINED BY THE FORMER IS OUR WORKING TILT (FOR A 120-mm BAG).
THE FORMING PROCESS MAY NEVERTHELESS VARY ACCORDING TO CUSTOMER NEEDS AND
THE BAG THAT REQUIRES SEALING.
ADJUSTING FORMER ARROWS: AFTER ADJUSTING THE OPENING AND CLOSING OF THE HEAD
AND AFTER CHECKING THAT THE SEALING TRACE IS CORRECT, ADJUST THE FORMER
ARROWS.
FOLLOW THIS PROCEDURE:
- CLOSE THE HEAD AND PRESS THE MUSHROOM-HEAD EMERGENCY SWITCH TO
SWITCH OFF THE MACHINE.
- LOOSEN M8 FIXING SCREWS (1), MOVE THE FULCRUM (2) SO THAT THE ARROWS (3)
ARE AT THE "SEALING CENTRE" AND THEN TIGHTEN THE SCREWS
- LOOSEN M8 FIXING SCREWS (4) AND MOVE THE FULCRUM (2) SO THAT THE ARROWS
(3) ARE PARALLEL TO THE DISCHARGE CHUTE AND ENTER ABOUT 1/3 UP THE HEIGHT
'B' OF THE PRODUCT NEEDING TO BE PROCESSED (USE OUTFEED EDGES AS
REFERENCE).
- MOVE THE TWO DELRIN CAMS (5) AND SUPPORT WITH BEARINGS (6) FITTED TO
SUPPORT SHEETING (7) ON THE CAM'S FLAT TRACK; CONNECT THE TWO PIECES OF
SUPPORT SHEETING (7) BY MEANS OF THE SPRING (8). HALF OF THE BEARINGS MUST
COVER THE FLAT TRACK AND HALF MUST COVER THE TILTED TRACK.
- PRESS THE RESET BUTTON TO RESET THE EMERGENCY SWITCH AND OPEN THE HEAD.
N.B. ALWAYS CHECK THE DIRECTION AND PRESSURE OF THE BLOWN ON EACH SINGLE
ARROW
3
7
1 6
2
5
Page: 28
12.8 Adjustment of infeeding trolley for bag tensioning
THE " STAR FVB 500" SEALING MACHINE HAS A PUSHER THAT ENABLES THE BAG TO BE
CONVEYED TO THE HEAD, WHERE SEALING CAN TAKE PLACE.
THE MACHINE IS SUPPLIED WITH THREE BAG-PUSHING PADDLES (10mm, 200mm, 300mm)
THAT ARE FITTED TO MATCH BAG WIDTH (A). MOVE THE SUPPORT PLATE FITTED TO THE
RUNNING TROLLEY TO INCREASE OR DECREASE BAG TENSION. BAG TENSION ALSO DEPENDS
ON THE FRICTIONING SYSTEM DESCRIBED ABOVE.
NOTE: MAKE SURE THAT THE PRODUCT IS ALWAYS PUSHED BEYOND THE SEALING STATION.
NOTE: WHEN THE BAG IS BEING LOADED INTO THE MACHINE IT IS VERY IMPORTANT TO
'FIT' THE BAG OVER THE BAG PUSHING PADDLE. THE BOTTOM AND TOP EDGES MUST
THEREFORE BE SEPARATED FROM THE BAG PUSHING PADDLES!
NOTE1: IN CASE THE MACHINE IS SET FOR PACKAGING THE WET WIPE MULTIPACK GAB,
THE MACHINE WILL BE SUPPLIED WITH A PRE-DETERMINED PUSHING PADDLE.
Page: 29
MULTIPACK
WET WIPE
PUSHING
PADDLE
Page: 30
13 THERMOSALD 3E STRUCTURE (CONTROLS AND FUNCTIONS)
13.1 Start up / base configuration + Multilanguage panel
- Do a master reset as follows:

Press simultaneously on Multilanguage panel key ARROW DOWN + key ARROW UP for 6
seconds
The 4 led on thermoregulator light up for 3 seconds
– Do a calibrating as follows:
Press on Multilanguage panel key CAL for 3 seconds
The 4 led on thermoregulator lighten for all calibrating time
– At the end of calibrating the thermoregulator is ready to start: Set the pre-heat temperature
and seal temperature in the menu TEMPERATURE pressing key MODE.
– To return to the main page simply pressing red key RES
NOTE: For next calibrating press on Multilanguage panel key CAL+MODE+CAL, the 4
led on thermoregulator lighten for all calibrating time.
Page: 31
13.2 Instructions to use the Multilanguage panel
NOTE1: From everywhere it’s possible to return to the basic page pressing the key RES.
NOTE2: To change from 0 to 1 a generic data: “ = 000 ”

Press key MODE to enable changes, you can read: “ ? 000 ”
Press key ARROW UP to change the data: “ ? 001 ”
Press key MODE to disable changes: “ = 001 ”
NOTE3: Before save data it’s requested a confirm:

????CONFIRM????
YES=MODE NO=RES
PANEL ORGANIZATION
BASE PAGE LEVEL 1
(press key MODE)
TEMPERATURE BURN-IN MACHINE DATA LEVEL 2

DIAGNOSTICS MASTER-RESET INFORMATIONS LEVEL 2
EMERGENCY TEST SETTING DATA LEVEL 2
(press key MODE)
(TEMPERATURE) (DATI SETTING) (MACHINE DATA)

PRE-HEATING TEMP. LEVEL 3
WELDING TEMP.
(INFORMATION) LEVEL 3
LEVEL 3
(DIAGNOSIS) LEVEL THEORETIC CALCULATIONS
ASSISTANCE LEVEL 3
TECHNIC ANALYSIS SOFTWARE VERSION
LEVEL 3
LEVEL 3
LEVEL 3
LEVEL 3
LEVEL 3
Page: 32
13.3 Maintenance
A. CHANGING THE WIRE RESISTANCE WITH MACHINE COLD

( i.e. Welding bar at ambient temperature )
Have you to change the wire resistance with the machine at ambient temperature, because of a
programmed maintenance?
Pre-heat and seal commands are off; the machine is at ambient temperature; The wire
resistance have little differences in measure; for optimum accuracy it is possible to do an
automatic cold balance to compensate the differences; it is possible doing a burn-in cycle after,
to become stable electric characteristics.
1 – Switch off power, release pre-heat and seal commands, let the welding bar getting cold
down.
2 – Install the new wire resistance, switch on power.
3 – Make the CALIBRATING
Normally is not necessary change ambient temperature (welding bar temperature) in the
SETTING DATA and doing a burn in cycle at the end of calibrating.
4 - THE MACHINE IS READY TO WORK.
NOTE: After the BURN IN cycle, wire resistance modify a little its electric
characteristic, but are stable. If pay attention can observe that temperature of wire
resistance is some degree lower then before burn_in cycle. Do not modify
temperature by rotating balancing trimmer (used only in the course of first start up,
after a master reset) or pressing the up/down keys to do an automating balancing
(used only after a change of the wire resistance)
B. CHANGING THE WIRE RESISTANCE WITH MACHINE HOT

( i.e. welding bar cooling down , but hot too because of inertia )
Have you to change the wire resistance with the machine hot, with the production in progress,
without waiting that welding bar temperature falls down at ambient temperature?
A wire resistance change, with the machine hot, with the production in progress, is less accurate then
a change with the machine cold, in a programmed maintenance, because the automatic cold
balancing must not be done (an automatic cold balance is done to compensate the differences in
measure of the wire resistance).
If the application needs a very high precision, it is possible doing a quick change of the all
welding bar with wire resistance, and go on with the preceding procedure of Changing The wire
resistance With Machine Cold.
1 – Switch off power, release pre-heat and seal commands, let the welding bar cooling down.
2 – Install the new wire resistance, switch on power.
If the machine is hot, must not do the automatic cold balancing.
3 – Only if necessary do the BURN-IN CYCLE (3 thermal cycles)
Verify if burn-in is necessary in the specific application, looking at the quality of the first
seal.
4 - THE MACHINE IS READY TO WORK.
Page: 33
C. TROUBLES HOOTING
PROBLEM: Alarm Fxxx appears on the display - VERIFY alarm list in this book (ANNEX D)
PROBLEM: In Balancing the wire resistance is hot
VERIFY that logic and power supply are in the same phase
PROBLEM: On the display You can see oscillating temperature - VERIFY that contacts of wire
resistances are good. Verify that connections are not linked together, verify machine data and, if
they are not regular, do a master reset and a following calibration with machine cold.
D. THERMOREGULATOR MAINTENANCE
Depend on the working environment, in every way not more then every 180 days.
1 – Verify that all the thermoregulator terminals are screw tight

2 – Verify the right function of the emergency output floating contact (press the key mode as
requested at power on periodically; the output relay must open power circuit)
E. WELDING BAR MAINTENANCE

Depend on the working environment, in every way not more then every 20 days.
1 – Verify that the reference and power terminals are screw tight
2 – Verify that the connections of the wire resistance are good without oxidation.
3 – Verify the teflon and the isolation of welding bar
13.4 Machine data list
NOTE – The machine data must be changed only by skilled workers with experience, after
getting in contact with our technical office; the necessity to change some machine data, may be
in specific applications.
TO ENTER: from secondary menu MACCHINE DATA press key MODE.

TO OUTPUT: press key RES and follow guide.
• RATED CURRENT = 60 / 90 / 120 (AMPERE)

Not changeable, it shows the nominal current of the model used (consequently the short
circuit current will be I_short_circuit=Inominal x 2.5)
• HEATING INCREASE DEGREE / 10 MS = 4 (U.M.)
It is the speed of temperature increase following a pre-heat or a sail command [Units
degree / 10 ms]. Increase this parameter means decrease time necessary to hot the wire
resistance to pre-heat temperature, i.e. increase speedy, increase overshoot, increase wire
resistance wear and tear.
• PROPORTIONAL GAIN KV = 100 (U.M.)
Loop integral gain. Increase this parameter means to increase the precision of the target
temperature, increase the speedy, increase the stability of the system.
Increase too much means to introduce a temperature overshoot following a pre-heat or
sealing command.
• INTEGRAL GAIN KI = 100 (U.M.)
Page: 34
Loop integral gain. Increase this parameter means to increase the precision of the target
temperature, increase the speedy, increase the stability of the system.
Increase too much means to introduce a temperature overshoot following a pre-heat or
sealing command.
• KI OPERATING LIMIT = 60 (%)
Limits the maximum value of the integral gain KI; increasing this value, overshoot with
the machine cold increases.
• DERIVATIVE GAIN KD = 40 (U.M.)
Loop derivative gain. Increase this parameter means increase speed of the loop and then
increase speed of the system.
Increase too much means to do the system and temperature less stable.
• HEATING FACTOR = 1.9 (U.M.)
This parameter modify the temperature characteristic of the thermoregulator.
Increase this parameter means increase the temperature of the wire resistance.
• INITIAL TEMPERATURE = 0 (DEGREE)
Degree Value relating to “0” of AD converter.
• PARTIAL SHORT CIRCUIT FACTOR = 1.1 (U.M.)
This parameter is used to set an instantaneous current threshold, above which a partial
short-circuit occurs and the thermoregulator sends fault signal F097.
• FAULT DISABLE = 0 (U.M.)
Disable any alarm; use much caution; sometime it can help to continue the production;
alarm disable must be considered temporary and it’s necessary understand immediately
the cause of the trouble.
• CONFIGURATION (MODE) = 0
The thermoregulator is designed to develops 2 type of functions:
0 = standard function IMPULSE SEALING.
1 = function HOT BAR.
• CONFIGURATION PANEL = 2
The thermoregulator is designed for 5 type of functions:
0 = function only with potentiometers (at first start up)
1 = function with potentiometers and display: the temperature set on display in pre-heat
and seal is the maximum value, with potentiometers can decrease (also with analog input).
2 = function only with display.
3 = predisposed for CAN BUS
4 = predisposed for PROFIBUS
• CONFIGURATION (SERIAL INTERFACE) = SERIAL 485 OFF
Thermoregulator can exchange data with supervisor by RS485 interface.
• SERIAL ADDRESS RS485 = 0
Unit address for serial interface RS485; value admitted 0-15
13.5 Setting data list
NOTE – The setting data must be changed only by skilled workers with experience, after getting
in contact with our technical office; the necessity to change some machine data, may be in
specific applications.
TO ENTER: from secondary menu SETTING DATA press key MODE.

TO OUTPUT: press key RES and follow guide.
Page: 35
• LANGUAGE SELECTION = ITALIAN

It’ possible select up to 6 language: ITALIAN, ENGLISH, FRENCH, GERMAN, SPANISH,
FREE
• DEGREES SELECTION = CELSIUS
Select the temperature display in Celsius or Farheneit degrees.
• CALIBRATING TEMPERATURE = 30 (DEGREE)
Set the calibrating temperature; it inform the thermoregulator of the wire resistance
temperature at the time of calibrating; if machine is cold the calibrating temperature is
equal to the ambient temperature.
• MAXIMUM SEALING TEMPERATURE = 220 (DEGREE)
Limit of the temperature set in pre-heat and seal.
• MAXIMUM SEALING TIME = 0.0 (SECONDS)
Set the maximum sealing time; if sealing time is longer than this value, thermoregulator
sends fault signal F085.
000 means that control is not active and it is possible to do continuos sealing.
• BURN IN TEMPERATURE = 160 (DEGREES)
Hot temperature in a burn-in cycle.
Note: the burn-in cycle is used to stabilise wire resistance in temperature; it executes 3
cycles of heating and cooling .
• BURN IN TIME = 30 (SECONDS)
Heating time in seconds of the Burn_in cycle.
Note: the Burn-in cycle is used to stabilise bands in temperature; it executes 3 cycles of
heating and cooling .
• BURN IN CYCLE NUMBER = 3 (U.M.)
Numbers of heating and cooling phases in a burn-in cycle; a standard burn-in cycle
Includes 3 phases of heating at burn-in temperature and 3 phases of cooling at 100
degrees.
• TEMPERATURE GRADIENT FOR CALIBRATING START (DEGREES/10SECONDS)
Set the maximum speed of cooling in degrees/10seconds; upper this value the calibrating
is disabled and a warning 38 is displayed. Increasing this parameter can loose precision
of calibrating.
• ENABLE COMPENSATION WITH SYSTEM COLD (SCC) = 0 (U.M.)
Not developed; enable the special function of a different initial seal temperature. For more
information do not hesitate to contact our technical office.
• SEAL TEMPERATURE WITH SYSTEM COLD (WITH SCC=1) = 220 (GRADI)
Not developed; it’s the seal temperature of the first seals, when temperature of the band
is less then structure temperature. For more information do not hesitate to contact our
technical office.
• STRUCTURE TEMPERATURE WITH SYSTEM COLD (WITH SCC=1) = 80 (GRADI)
Not developed; if sealing band temperature is less then structure temperature, the seal
temperature will be equal to SEAL TEMPERATURE WITH SYSTEM COLD. For more
information do not hesitate to contact our technical office.
• TIME WARN66 = 3 (SECONDS)
In the case of frequency instability, caused by power factor correction, the thermoregulator
display warning 66, without to stop the production; this parameter indicates the seconds
that the message is displayed.
Page: 36
13.6 Fault and warnings list (causes – remedies)
NOTE - To reset every alarm give external reset command or press reset button RES on the
panel
NOTE – when an alarm happens, on the thermoregulator the led red of alarm light; it’s possible
to know the number of alarm reading the Multilanguage panel or reading the number of
lightening of led red and green:
ALARM NUMBER = NR. IMPULSES OF LED GREEN x 10 + NR.IMPULSES LED RED
WARNING - ALARM CAUSES

Remedies
ALARM A TERMOREGULATOR OFF AND DISPLAY OFF

Verify power, Logic supply fault, call the supplying builder.
ALARM B TERMOREGULATOR WITH LED OFF AND DISPLAY ON
Circuit of synchronism fault, call the supplying builder.
ALARM C TERMOREGULATOR WITH LED ON AND DISPLAY ON AND INDICATION
"3E + THERMOSALD"
Verify cable connection display
F06 EEPROM FLASH WRITE
Switch off and switch on the equipment and call the supplier
F07 A/D CONVERTER
Switch off and switch on the equipment and call the supplier
F08 INTERNAL TRASMISSION I2C-X
Switch off and switch on the equipment
F09 INTERNAL TRASMISSION I2C-EEPR
Switch off and switch on the equipment and verify parameters
F19 RS485 MASTER - CHECKSUM ERROR
Verify checksum selection on the Master or Slave
F20 RS485 SLAVE - CHECKSUM ERROR
Verify checksum selection on the Master or Slave
F21 RS485 SLAVE - OE ERROR-OVERRUN
Following data arrived before reading the previous
F22 RS485 SLAVE - FE ERROR-FRAME ERROR
Data stop bit not arrived
F23 RS485 MASTER – NO ANSWER FROM SLAVE
After a Master calling no answer received from the slave
F24 RS485 SLAVE – TOO DATA REQUESTED FROM MASTER OR WRONG
ADDRESS
Master ha s requested to the slave too many data or a wrong address
F25 RS485 SLAVE – BUFFER FULL
Slave Buffer is full because of too many data transmitted or too frequently
transmitted
F26 RS485 MASTER - OE ERROR-OVERRUN
Following data arrived before reading the previous
F27 RS485 MASTER - FE ERROR-FRAME ERROR
Data stop bit not arrived
Page: 37
F28 RS485 MASTER - TOO DATA REQUESTED FROM SLAVE OR WRONG

ADDRESS
Slave ha s requested to the master too many data or a wrong address
F29 RS485 MASTER - BUFFER FULL
Master Buffer is full because of too many data transmitted from the slave
F33 NO VOLTAGE ON POWER TRASFORMER
Verify power on CN1/L1,L2, verify power transformer circuit
F34 DON'T USE
F35 CALIBRATION REQUEST
Used in distance control RS485
F36 CALIBRATING IN PROGRESS
Used in distance control RS485 to know when calibrating end.
F38 THE MACHINE IS WAITING A COOLING DOWN DURING A CALIBRATION
PROCEDURE
Wait please
F46 NO CURRENT SIGNAL
Verify wire resistance connection, TA connection
F47 TA SIGNAL WRONG TURNED
Turn TA connection
F48 PRE-HEATING POTENZIOMETER NO CONNECTED OR CABLES BROKEN
Verify pre-heating potentiometer connections and cables
F49 SEALING POTENZIOMETER NO CONNECTED OR CABLES BROKEN
Verify sealing potentiometer connections and cables
F51 WIPER-I
Switch off and switch on the thermoregulator; if problem persist call the supplying
F52 WIPER-V
F53 WIPER-VGROSS
F54 WIPER-VFINE
F60 RESET WITH CALIBRATING IN PROCESS
Repeat the calibrating
F61 BALANCE UNSUCCESSFULL
F62 BALANCE V UNSUCCESSFULL
F63 BALANCE VGROSS UNSUCCESSFULL
F64 BALANCE VFINE UNSUCCESSFULL
F65 BALANCE UNSUCCESSFULL
F66 MAIN PHASE SYNCHRONISM
Reset the thermoregulator if problem persist call the supplying
F69 CURRENT TO GROUND
Verify wire resistance in the machine touch ground.
F71 FAULT HARDWARE –15V INTERNAL
Page: 38
Reset the thermoregulator; if problem persist call the supplying

F72 FAULT HARDWARE +15V INTERNAL
F73 FAULT HARDWARE +5V INTERNAL REFERENCE
F76 IREAD TOO HIGH
Verify if short circuit on the wire resistance
F78 THERMOREGULATOR NOT CALIBRATED
Do a calibrating
F79 FAULT OF EMERGENCY CIRCUIT
Verify contactor power, verify emergency chain
F081 FAULT HARDWARE - CHECK-SUM
Data in the eeprom wrong, pay much attention please
Press button RES, verify TEMPERATURE, SETTING, MACHINE, DATA;
call the builder
F082 LOGIC SUPPLY (CN2) AND POWER SUPPLY (CN1) HAVE DIFFERENT
PHASES
Verify that the supplies have the same phase
F083 REFERENCE CABLE WRONG TURNED
Turn reference cable: (CN1/3 WITH CN6/1 - CN1/4 WITH CN6/2)
F085 SEALING TIME HIGHER THEN MACHINE DATA "SEALING TIME"
Increase machine data sealing time (If 0 the control is off).
F089 WIRE RESISTANCE BROKEN IF THE WIRE RESISTANCE ARE PARALLEL
CONNECTED
Verify the wire resistance.
F090 SHORT CIRCUIT BETWEEN THE WIRE RESISTANCE OR BETWEEN A WIRE
RESISTANCE AND GROUND IN THE CASE OF HIGH CURRENT
Verify wire resistance, verify power connection between thermoregulator and wire
resistance
F092 POWER PART FAILURE
F093 WIRE RESISTANCE BROKEN DURING A SEAL
Verify power on the transformer, Verify voltage on CN/1 CN/2 connector, verify
breaking of power cables, verify breaking of wire resistance.
F094 REFERENCE SIGNAL CABLE FROM BANDS IS INTERRUPTED
Verify the connection of reference signal cable from band ( CN6/1 - CN6/2 )
F095 MAIN SUPPLY SYNCRONISM DOES NOT MUCH MACHINE REQUIREMENTS
Internal hardware problem, call the supplying builder
F096 FAULT V-I TOO HIGH
Saturation of the voltage circuit, verify connection, probable break of one wire
resistance, if wire resistances in parallel.
F097 PARTIAL SHORT CIRCUIT BETWEEN THE WIRE RESISTANCE
Verify wire resistance into machine probably not perfectly isolated.
If the problem persist repeat burn-in procedure or do calibrating.
To reduce the problems increase machine data partial short circuit
F099 FAULT GENERIC
call the builder
Page: 39
13.7 Pre-heating and welding temperature adjustment
Push MODE on the Thermosald display: appears “TEMPERATURE” and “ MENU SET MENU”
Push again MODE: appears “ TEMP. PRERISCALD. = ……(degrees)
Push again MODE: appears “ ? ” instead of “ = “
- Push “ ↑ “ the degrees increase

- Push “↓ “the degrees increase
Push MODE : appears again “TEMP. PRERISCALD. = ……( degrees)
Push “ ↑ “ or “↓ “appears welding temperature and repeat the operations from point 3.
Once modified the temperatures, push “RESET” appears “CONFIRM” and “YES = MODE NO =
RESET”.
- Push MODE if you want to confirm
- Push RESET if you do not want to confirm
In both cases appears “ TEMPERATURE MENU” and “SET MENU”
8) Push RESET: appears the initial page PRE……… SALD……… TEMPERATURE = ………………
13.8 Modify time (ex. h02)
IN THE SEALING MACHINE " STAR FVB500" THE FOLLOWING CYCLE TIMES CAN BE
MODIFIED :
E01Æ H01: SEALING START DELAY TIME , AFTER CUT START.

E02Æ H02: SEALING TIME
E03ÆH03: BAG STOPPING PNEUMATIC CILINDERS START DELAY TIME
E04ÆH04: WELDING HEAD CLOSULE ADVANCE TIME (ONLY OF MULTIPACK WET WIPE
MACHINES)
BY DEFAULT, THE MACHINE IS DELIVERED WITH THE FOLLOWING TIMES:
E01Æ H01 (2 dec/sec)

E02Æ H02 (4 dec/sec)
E03Æ H03 (6 dc/sec)
E04ÆH04 (1 dec/sec)
ACCORDING TO THE TYPE OF BAG, THE OPERATOR HAS TO INTERVENE ONLY ON THE
SEALING TIME; TO MODIFY THE TIME "H02" FROM THE PLC "EDS 2001" PROCEED AS
FOLLOWS:
Page: 40
-ON THE PLC "EDS 2001" PRESS THE KEY " S " AND RECALL THE PARAMETERS " EXX ". WITH
THE ARROW KEYS " ↑ ↓ " VISUALISE THE PARAMETER CONCERNED, IN THIS CASE " E02"
-PRESS THE KEY " S " AND GO TO THE PARAMETER " HXX " (THE TIME IS EXPRESSED IN
HUNDREDTHS OF SECONDS E.G. H040)
-PRESS THE ARROW KEYS "↑ ↓" TO MODIFY THE TIME
-TO MEMORISE THE TIME MODIFIED, PRESS THE KEY " S ", AND RETURN TO THE PARAMETER
"E02"
-PRESS THE KEYS "↑ ↓" AND BRING THE PARAMETER "E02" TO THE PARAMETER "E00".
-NOW PRESS THE KEY " S " AND GO TO THE PARAMETER " F- - " .
-PRESS THE TWO ARROW KEYS "↑↓" AT THE SAME TIME; THE TWO DASHES " - - "
DISAPPEAR AND ONLY THE LETTER " F " IS VISUALISED.
N.B. THE TWO DASHES ARE VISUALISED ONLY WHEN THE VALUE HAS BEEN PREVIOUSLY
CHANGED.
-PRESS THE KEY " S " AND RETURN TO THE PARAMETER "H00"; NOW THE MACHINE HAS
ACQUIRED THE NEW SEALING TIME AND IT IS IN "STAND BY" CONDITION.
N.B. NOW THE NEW “SEALING TIME” SET CAN BE TRIED, AT THE SAME TIME IT IS ENTERED,
SO AS TO AVOID THE PASSAGES PROVIDED BY THE PCL.
HOWEVER, ONCE THE BEST “SEALING TIME” HAS BEEN FOUND, IT MUST BE MEMORISED!!
H99 RESET OF API CYCLE TIMES: PUSH AT THE SAME TIME FOR 5 SECONDS THE BOTTOMS
“RESET” AND “STOP” ON THE OPERATOR PANEL. THE DISPLAY “EDS 2001” WILL VISUALIZE
THE PARAMETERS “H99”.
AFTERWARDS, MODIFY THE PARAMETERS RELATED TO THE LETTER “A” AND COMPUTERIZE
BY THE PROCEDURE FOR THE TIMES MODIFICATION.
Page: 41
14 ASSEMBLING AND DISASSEMBLING SEALING BARS
THE SEALING MACHINE “STAR FBV 500” IS PROVIDED WITH DOUBLE SEALING BAR, WHICH
CAN BE EASILY REMOVED TO REPLACE ALL ITS COMPONENTS.
BEFORE CARRYING OUT THE DISASSEMBLING OPERATIONS MAKE SURE THAT THE MACHINE
IS SWITCHED OFF AND THEN PROCEED AS FOLLOWS:
LOWER SEALING BAR:
-DISCONNECT THE BARS FROM THE POWER SUPPLY, BY MEANS OF THE GOLDEN TERMINALS
THAT LOCK THE CONDUCTION CABLES.
-DISCONNECT THE TWO AIR TUBES FOR COOLING THE RESISTANCE (DIAM. 6mm)
-LOOSEN THE FASTENING SCREWS M8, THEN PULL OUT THE BAR.
CONDUCTION
CABLES
FASTENIN
G SCREWS
COOLING M8
AIR JOINTS
FLATHEAD
SCREW M4
TEFLON TUBE ø4 HAS TO SCREWS M4 FOR

FINISH HERE FASTENING
RESISTANCE
REPLACING THE RESISTANCE: OUR RESISTANCES HAVE AN AVERAGE LIFE OF ABOUT 500
WORKING HOURS, EVERY TIME THE RESISTANCE IS REPLACED, IT ALSO IS ADVISABLE TO
REPLACE THE RED SILICON SECT. 4x5 AND THE TEFLON COVERING;
PROCEED AS FOLLOWS:
- UNSCREW THE FLATHEAD SCREW M4 AND REMOVE THE TENSIONER BLOCK IN BRONZE
FROM THE SEALING BAR
LOOSEN THE SCREWS M4 HOLDING THE RESISTANCE AND PULL OUT .
-REPLACE THE STRIP OF RED SILICON BELOW AND INSERT IT WITHOUT SUBMITTING IT TO
TENSIONING.
- INSERT A NEW RESISTANCE COMPLETE WITH TEFLON TUBE (DIAM. 4mm)
Page: 42
N.B.1 THE TEFLON TUBE MUST BE CUT TO MEASURE, AND ALSO COVER THE VISIBLE
COPPER PART.
N.B.2 BLOCK THE NEW RESISTANCE WITH THE TWO SIDE PLATES, AND HOUSE THE
RESISTANCE IN THE GROOVE MADE IN THEM, THEN BLOCK WITH THE FASTENING SCREWS.
RESISTANCE
LENGTH
COVERING
TEFLON
FASTENING
SPRIN SCREW
SIDE PLATE
-NOW RE-INSERT THE BRONZE BLOCK THAT WAS PREVIOUSLY FREED, IN THE SEALING BAR
(THE FLATHEAD SCREW M4 MUST NOT LOCK THE BLOCK).
-CHECK THAT THE RESISTANCE IS CORRECTLY ALIGNED AND THAT THE TENSIONER SPRINGS
WORK IN COUNTER-POSITION.
-INSERT IT INTO THE MACHINE AND RE-CONNECT IT WITH THE PNEUMATIC AND ELECTRIC
MAINS.
UPPER SEALING BAR:
THE CHARACTERISTICS OF THE UPPER SEALING BAR ARE THE SAME AS THOSE OF THE
LOWER BAR.
Page: 43
IT IS VERY IMPORTANT HERE THAT THE RESISTANCE IS PERFECTLY ALIGNED TO THE BAR.
FOR REPLACING FOLLOW THE PROCEDURE FOR THE LOWER SEALING BAR.
NOTE FOR RE-INSTALLING THE WELDING BARS INTO THE MACHINE, REFER TO THE
FOLLOWING DRAWING:
FOR THE WELDING BAR INSTALLATION, TAKE INTO

CONSIDERATION THE COUPLING PLUG
Page: 44
15 MAINTENANCE
THE “STAR FBV 500” CONSISTS OF MECHANICAL, ELECTRICAL AND COMPRESSED-AIR

SYSTEMS THAT ENSURE LONG-TERM MAINTENANCE-FREE OPERATION.
FOR BEING SURE OF A GOOD MACHINE EFFICIENCY, FOLLOW CAREFULLY THE TABLES HERE
BELOW.
ISOLATE ELECTRICALLY THE MACHINE BEFORE EFFECTING EACH KIND OF WORK ISIDE THE
CONNECTIONS.
NOTE: THE HOURS NUMBER FOR WHICH THE MACHINE HAS WORKED, MUST BE DETERMINED
BY THE CUSTOMER ON THE BASIS OF THE WORK SHAFTS EFFECTED IN ITS FACTORY.
THE PERSON IN CHARGE OF THE MAINTENANCE HAS TO NOTE THE HOURS NUMBER, IN
ORDER TO BETTER IDENTIFY THE MAINTENANCE FREQUENCY.
TABLE1 WELDING HEAD GROUP
REF. DESCRIPTION HOURS/FREQ. LUBRICANT

A Check the transmission toothed belt tension and 1500 /
eventually act with the specific tie rod
B Check the welding head motor braking group 2500 /
conditions.
C Verify the perfect sliding of the ball sleeves on the 2000 TRIBO STAR
tempered axis; remove the toothed belt and try 2EP
manually
D Check the transmission shafts rotation Koyo 500 TRIBO STAR
conditions and eventually lubricate. 2EP
E Lubricate periodically the articulated heads on the 500 TRIBO STAR
rotation connecting rod 2EP
F Verify the perfect sliding of all pneumatic cylinders, 500 /
remove the compressed air and verify manually
G Check the perfect efficiency of the roller micro 500 /
positioned on the lower rotation shaft; verify
manually the correct mechanical function of the
micro.
NOTE: Do not move the cam position placed on
the shaft!
H Check periodically the perfect efficiency of all 500 /
electrovalves and relative electric connections; with
the machine fed by compressed air, act manually
on each single electrovalve and verify the
efficiency.
I Check periodically the formers connecting spring 300 /
conditions.
L Check periodically the welding bars conditions and 2000 /
all its components; verify the cutting blade
efficiency (see Chapt. Related to welding bar
installation)
Page: 45
REF.A
WELDING
HEAD
MOTOR
ACT ON M10 SCREW

FOR ADJUSTING
VERIFY THE THE BELT TENSION
TOOTHED BELT
TENSIONING
REF.B
SELFBRAKING
MOTOR SERIAL
BA71 WELDING
HEAD
NOTE: VERIFY THE WEAR CONDITION OF THE BRAKE DISC, BE SURE

THAT THE THICKNESS IS NOT LESS THEN 2MM
THE DISTANCE BETWEEN THE ELECTROMAGNET AND THE DISC MUST BE
OF 0,2 – 0,4 MM (FOR THE ADJUSTMENT, TAKE AS REFERENCE THE
MOTOR SERIAL BA PAR. 16.3 PAGE 54)
Page: 46
REF.C VERIFY THAT THE

TEMPERED AXIS
DO NOT PRESENT
DASMAGES
CHECK THE BALL

SLEEVES STATUS
REF.D LUBRICATION LOWER SHAFT

NOZZLES KOYO
LUBRICATION
UPPER ROTATION NOZZLES
SHAFT KOYO
Page: 47
RIF.E VERIFY THE

BALL
ARTICULATION
CONDITIONS
LUBRICATION
NOZZLES
REF.F VERIFY MANUALLY RIF.G

PNEUMATIC CYLINDERS
SLIDING
PHASE
CONTROL
MECHANICAL
CAM ON THE
NOTE: VERIFY THE PNEUMATIC
ROLLER MICRO
CYLINDER RELATED TO THE EDGE
SUCTION OPENING/CLOSING
Page: 48
REF.H
PRESSURE MAIN
REGULATOR ELECTROVALVE
MACHINE REDUCTION
ELECTROVALVES GEAR FILTER
RIF.I
DERLIN CAM FOR
FORMERS
FORMERS
CONNECTING
SPRING
Page: 49
TAB.2 PUSHER GROUP

M Check the transmission chain tension and 1500 /
eventually act with the specific tension rod;
NOTE For effecting all maintenance intervention on
the pusher group, it is necessary remove the sides
and the steel surface
N Check the chain guide green profile conditions 1500 /
O Check the linear bushes sliding on the two shafts; 1500 /
NOTE The internal bushes are subjected to wear
P Verify the perfect efficiency of the proximity 2000 /
sensor. NOTE Do not remove the sensor position
determined by the supplier
Q Check the braking group conditions of the pusher 2500 /
group motor.
REF.M PUSHER GROUP REF.N

CHAIN
TRANSMISSION
VERIFY THE CONDITIONS

OF THE TWO GREEN
SCREW M10 FOR PROFILES OF THE CHAIN
CHAIN GUIDE
TENSIONING
Page: 50
RIEF. O RIE.P
INTERNAL RING READING PLATE
SLIDING
SHAFT
PUSHER SLIDE
SLIDING BUSHES
VERIFY THE PROXIMITY SENSOR,
INTERNAL RINGS VERIFY THE LED
CONDITIONS SWITCHING ON!
REF.Q SELF BRAKING MOTOR SERIAL BM 63 PUSHER GROUP
SLIDING
SHAFT
NOTE: VERIFY THE WEAR STATUS OF THE BRAKE DISC, BE SURE THAT THE
THICKNESS IS NOT LESS THEN 2MM.
VERIFY THAT THE PART BEWEEN THE MOBILE ARMATURE AND THE
ELECTROMAGNET IS 0,2 – 0,4 MM (SEE PAR. 16.4 PAG 57 FOR MOTOR SERIE BM )
Page: 51
TAB.3 ELECTRICAL COMPONENTS

R Open the electric panel and remove possible 200 /
impurities; verify the perfect efficiency of the
connections and the fuses
S Protect and maintain clean the machine control 200 /
panel with any neutral detergent.
REF.R
ELECTRIC
PANEL
REF.S
CONTROL PANEL
Page: 52
15.1 Pneumatic parts
EVERY WEEK, CHECK THE EFFICIENCY OF THE COMPRESSED-AIR PARTS (CYLINDERS, SLIDES,
SOLENOID VALVES, ETC). REMOVE THE AIR PRESSURE AND CHECK THAT THE GUIDE RODS
AND CYLINDERS RUN SMOOTHLY.
15.2 Electrical parts
THE ELECTRICAL PARTS DO NOT REQUIRE ANY SPECIAL MAINTENANCE, BUT CHECK THE
CONNECTIONS EVERY WEEK.
IMPORTANT: IN ORDER TO OBTAIN PERFECT MACHINE OPERATING EFFICIENCY, PREVENT

DUST OR OTHER IMPURITIES FROM SETTLING ON THE SAFETY BARRIER!
Page: 53
15.3 Motor serial “BA71”
Page: 54
Page: 55
Page: 56
15.4 Motor “BM63”
Page: 57
Page: 58
Page: 59
16 LIST OF SPARE PARTS
THE MACHINE'S PARTS HAVE BEEN DIVIDED INTO THREE GROUPS SO THAT THEY CAN BE
IDENTIFIED MORE EASILY. THE TABLES THAT FOLLOW DESCRIBE AND QUANTITIFY THE
MAIN SPARE PARTS.
LIST OF MATERIAL SUBJECT TO WEAR (ATTACHED DRAWING GBL02861)
STORE CODE. DESCRIPTION Q.TY POS.

58A00027 CUTTING BLADE 8 LIFE ≅ 2.000 h) 1 62
T39090 SPRING FOR FORMERS ( TIME ≅ 4.000 h) 1 47C
PROSIL R4/5 RED SILICON 4 x 5 x 520 (TIME ≅ 700 h) 2 54C
BOADF45.3R TEFLON TAPE BOADF 45.3R (TIME 2000 h) 1 roll 56C
24380011 TEFLON TUBE ø4 mm (TIME 300 h) 2 55C
3ES001/900A TEFLON COATED RESISTENCE (TIME 700h) 2 14C
N.B. REGARDING THE MATERIAL SUBJECT TO WEAR, WE ADVISE PURCHASING AN UPPER

SEALING BAR, A LOWER SEALING BAR AND A CUTTING BLADE SO THAT CHANGES CAN BE
MADE RAPIDLY AND PROGRAMMED.
STRUCTURE GROUP (ATTACHED DRAWING GAA02864)
STORE CODE DESCRIPTION Q.TY POS.

64A00835 IP80 3ST. (300°-60°) S.R.I.C. (A-C) MOTORIZZATO 1 18
PTM15 CENTRIFUGAL FAN TYPE PTM 15 1 02C
42231 TAKE-UP HANDLE 42231 MR.80 P-M10x40 2 05C
14105 HINGE Cod.14105 2 09C
PE54351 ANTIVIBRATION FEET M20 Part.132 Art.54351 4 01C
SEALING HEAD GROUP (ATTACHED DRAWING GBL02861)
STORE CODE DESCRIPTION Q.TY POS.

UCP205 STRAIGHT SUPPORT UCP 205 3 01C
UCFC205 ROUND FLANGE SUPPORT UCFC205 1 16C
KB2558PP BALL COUPLING MAM25WW-25/40/58 8 05C
RJUM-01-16 LINEAR BUSHING IGLIDUR RJUM-01-16 8 08C
6205-2RS1 CUX 6205 2RS1 4 15C
6002-2RS1 CUX 6002-2RS1 4 19C
6200-2RS1 CUX 6200-2RS1 2 20C
CD1400H150 TIMING BELT 1400H 1 22C
ECDQ2B40-20D CYLINDER ECDQ2B40-20D 2 25C
ECDQ2B63-20D CYLINDER ECDQ2B63-20D 1 26C
CD85N16-25-B CYLINDER CD85N16-25-B 1 24C
LRMA-QS-6 REDUCTION UNIT LRMA - QS - 6 1 33C
SY5120-5YO-01F SOLENOID VALVE SY5120-5YO-01F 6 46C
SS5Y5-20-06-00F PLATE BASE SS5Y5-20-06-00F 1 49C
Page: 60
DIN43650C/LED24 CONNECTOR DIN43650C/LED24 5 52C

SIKAC10M ARTICULATED HEAD M10 DX 4 03C
SILKAC10M ARTICULATED HEAD M10 SX 2 04C
INSERTION UNIT (ATTACHED DRAWING GBB02862)

HP0.25BM63B4B5 SELF-BRAK. MOTOR.BM63B4HP=0.254P 50HZ B5 2MOR 1 01C
RMI40FLLFB1/7 REDUCTION UNIT RMI 40 FL LFB I=1/7 PAM 63 B5 1 02C
6006-2RS1 CUX 6006-2RS1 2 07C
61904-2RS1 CUX 61904-2RS1-SKF 1 13C
MRSJUM-05-20 BUSHING IGLIDUR MRSJUM-05-20 4 14C
PROFILO BL1 CHAIN GUIDE PROFILE TYPE BL1 2mt 17
PNEUMATIC GROUP (ATTACHED DRAWING GPN06671)

EVP742-5YO-04FA INSERTION VALVE EVP742-5YO-04FA 1 04C
EAW4000-F04 REDUCTION UNIT FILTER EAW4000-F04 1 03C
DIN-S/LED CONNETTORE DIN-S/LED 1 02C
Page: 61
ELECTRIC MATERIAL
STORE CODE DESCRIPTION Q.TY'

CELM 1500VAO-35 TRANSFORMER 1500-VA 1
3ESD0045M THERMOREGULATOR 1
3ESD0035G CABLE FOR THERMOREGULATOR 1
3ESD0039G DIGITAL PANEL 1
S8PE-F24024CD THREE-PHASE FEEDER 400V 240W 10A 1
0.5808 FUSE HOLDER 1
10-130-04-4A FUSES 4° 1
J7M-AM-6.3 AUTOMATIC SWITCH 1
J73M-AM-11-E AUXILIARY CONTACT 5
J7K-BM-10-D CONTACTOR 24V DC 1
J7M-AM-4 AUTOMATIC SWITCH 1
LA2-25-1753 PANEL SWITCH –BRETER- 1
LFS2-N-6-175 YELLOW/RED KNOB 1
LA2-G2853 DOOR/LOCK EXTENSION 4
RELEISB4KW STATICAL REMOTE CONTROL SWITCH 1
AB1VVN1035V TERMINAL 10MMQ 5
AB1VV435U TERMINAL 4MMQ 28
AB1ACN10 TERMINAL MAKE 10MMQ 1
AB1ACN4 TERMINAL MAKE 4MMQ 1
EDS2001 PLC EDS2001 1
P9XER4R EMERGENCY MUSHROOM-SHAPED BUTTON 1
P9B02VN N.C. CONTACT BLOCK 1
410853 CONTROL KEY-BOARD 1
F3SB182PBYOMG TRANSMITTER+RECEIVER BARRIERS 1
F39-JB2ABYOMG CONNECTING CABLE FOR BARRIERS 1
E3F2-DS10B4-P1 PHOTOCELL SENSOR 1
L90500 CABLE FOR PHOTOCELL SENSOR 1
E2ELX1R5F1M3 PROXIMITY SWITCH 3
V70500/C SWITCH CONNECTION CABLE 2
D4MC-5020 LIMIT-SWITCH MINIATURE 1
ZA2BV04 RED LUMINOUS PILOT LAMP 1
ZA2BV6 LUMINOUS PILOT LAMP BODY 1
BA9S LAMP 1
CONNCRIMP16PINF CRIMPING CONNECTOR 2
PLC-ESP2 CONNECTOR FOR PLC EDS2001 1
CANALA40X60 RACEWAY 40 X 60 4MT
BARRAOMEGA3AF GUIDING BAR OMEGA 1MT
3ESD0072 CABLE FLEXISTON 6MMQ 10MT
G2R-1-S RELAY 1
P2RF-05 RELAY BASE 1
16PAWG16 FLAT CABLE 16 AWG 16 WIRES 0.50M
T
Page: 62
LEG37389 COPPER GROUND BAR 0.20M

T
551400 SPACERS FOR GROUND BAR 2
GPS130-130-75 BOX WEIDMULLER 1
WEN173968 2-POLE JUMPER WEIDMULLER 2
WEN174675 TERMINAL 10SQ.MM WEIDMULLER 4
AB1AB8P35 TERMINAL STOPPER TELEMECANIQUE 7
AB1AB8P35 TERMINAL STOPPER TELEMECANIQUE 5
O485300000 COVERING SECTION WEIDMULLER 0.20M
T
O485660000 SUPPORTING PLATE WEIDMULLER 2
G75-3A3B SECURITY RELAY 2
P7S-14F SPACER FOR TERMINAL 2
CAV25X MULTICAVO 25 CABLES (24+EARTH 1MMQ) 3MT
Page: 63
17 ATTACHMENTS
17.1 Pneumatic diagram
Page: 64
17.2 Electric diagram
Page: 65
17.3 General drawings

Star FBV 500

Uploaded by

Copyright:

Available Formats

You might also like

Star FBV 500

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Star FBV 500

Uploaded by

Copyright:

Available Formats

SEMIAUTOMATIC PACKAGING Doc.: AL1.

MACHINE “STAR FBV 500” Printed: 19/09/06

1 GENERAL WARNINGS ................................................................................................... 2

MACHINE “STAR FBV 500” Printed: 19/09/06

1.1 Reproduction prohibited

THIS MANUAL IS PROPERTY OF CB PACKAGING - REPRODUCTION OR TRANSFER OF THE

1.2 Standard reference

98/37CE MACHINERY DIRECTIVE

1.3 Indications for maintenance intervention

Rev. Date Description Issued by:

SEMIAUTOMATIC PACKAGING MACHINE STAR

MACHINE “STAR FBV 500” Printed: 19/09/06

INTRODUCTION MACHINE LAY-OUT

MACHINE “STAR FBV 500” Printed: 19/09/06

2 TABLE SHOWING THE DIFFERENT PACKAGING FORMATS AVAILABLE

MACHINE “STAR FBV 500” Printed: 19/09/06

POWER SUPPLY: Voltage available as per customer request

MACHINE “STAR FBV 500” Printed: 19/09/06

THE MACHINE IS TESTED AND APPROVED ON THE MANUFACTURER'S PREMISES IN ORDER TO

MACHINE “STAR FBV 500” Printed: 19/09/06

VOLTAGE: SEE “CE” CARD ON THE MACHINE

MACHINE “STAR FBV 500” Printed: 19/09/06

THE COMPRESSED AIR UNIT CONSISTS OF:

1. INSERTION VALVE EVP742-5Y0-04FA

2. REDUCTION-GEAR FILTER EAW 4000-F04 WITH GAUGE

3. SOLENOID VALVE UNIT, TYPE SY5120-5Y0-01F

5. PRESSURE REDUCER LRMA-QS-6

MACHINE “STAR FBV 500” Printed: 19/09/06

MACHINE “STAR FBV 500” Printed: 19/09/06

MACHINE “STAR FBV 500” Printed: 19/09/06

9 LIST OF CONTROLS ON SIDE HATCH

2. 3E (TERMOSALD): PULSE THERMOSTAT THAT ENABLES OPTIMUM SEALING RESULTS TO

MACHINE “STAR FBV 500” Printed: 19/09/06

10 LIST OF ALARMS TYPES

THE FOLLOWING ALARM SIGNALS MAY APPEAR ON THE DISPLAY OF MICROCONTROLLOR

H01 EMERGENCY MUSHROOM-HEAD PRESSED OR SAFEGUARDS OPEN

H04 SEALING BARS CYCLE TIME-OUT ; MAKE THE FOLLOWING CHECKS:

MACHINE “STAR FBV 500” Printed: 19/09/06

11 WELDING HEAD INTERMITTING DEVICES PHASE VERIFICATION

Y = a + b = 60° + 30° + = 90°

SEE DRWG. “B”

MACHINE “STAR FBV 500” Printed: 19/09/06

• DRWG.”A” (HEAD OPEN

MACHINE “STAR FBV 500” Printed: 19/09/06

11.1 Manual synchronising procedure

MACHINE “STAR FBV 500” Printed: 19/09/06

N.B. AFTER DISENGAGING THE BRAKE MANUALLY, THE

MACHINE “STAR FBV 500” Printed: 19/09/06

POSITION THE TWO CONNECTING

MACHINE “STAR FBV 500” Printed: 19/09/06

- PROCEED STEP-BY-STEP AND CHECK THAT THE WELDING HEAD OPENING

MACHINE “STAR FBV 500” Printed: 19/09/06

12.1 Adjusting infeed edges

12.2 Adjusting outfeed edges and bag pressing bar

MACHINE “STAR FBV 500” Printed: 19/09/06

12.3 Adjusting opening and closing of sealing head

MACHINE “STAR FBV 500” Printed: 19/09/06