USER AND MAINTENANCE MANUAL

IN LINE STAND-UP POUCH BLOW FILL SEAL MACHINE

MODEL IL-D4N 100 G

Date Manufactured :

Customer : Yan-Yan

BAGONG PAG ASA ENGINEERING

 TABLE OF CONTENTS

1. Introduction….………………………....……………………………………………………………. Page 3
2. Warranty.……………………………………………………………………………………………….. Page 3
3. Client’s Scope………………………………….……..……………………………….….…………. Page 3
4. Machine Description.……..……………………………………………….…………….………. Page 4
4.1. Machine Description.……………………………………………………………………….…… Page 4
4.2. How it Operates..……………………………………………………………….…….…….…….. Page 4
4.3. Main Assemblies of the Equipment.…………………….…………….….….……. Page 5
4.4. Technical Information.…………..……………………………………………….…...…. Page 6
4.5. Description of Assemblies.…………..………………….…………………….…...….. Page 7
4.5.1 Main Drive motor.……………………………………………………….……………….…….…. Page 8
4.5.2 Pouch supply Assembly ……………………………………………………..……….……..…. Page 9
4.5.3 Pick And Place …………………………….………………………..….…………………………… Page 11
Pouch Opener Page 12-13
4.5.4 Pouch Blowing Assembly ……………………………………………….……….…….……… Page 14
4.5.5 Nozzle Assembly……Filling Assembly……………………….……….…………………… Page 15-16
4.5.6 Cool Sealing Assembly…Heater Sealing Assembly……....………………………. Page 17-18
4.5.7 Collapser Assembly………..……………………………………………………………… Page 19
4.5.8 Pouch Transfer……………………………………………………………...…………..….…….. Page 20
4.5.10 Other Auxiliary Assemblies/HMI……………………………………….....…….………… Page 21
Vacuum pump …………………………..…….…….… Page 21
5. Using the Machine…………………………………..………………….……….……………….. Page 22
5.1. Command and Function Indicator.………………………….……………………..….…. Page 23
5.1.1 Main Electrical Board…………………………………………………………………..…….….. Page 23
5.1.2 Main Control Board………………………………………………………………….…....……… Page 23
5.1.3 Secondary Emergency Stop……………………………………………….…….………….… Page 23
5.1.4 Fault Indicator Capability………………………………………………….….…….………… Page 23
5.2. Starting the Machine…………………………………………………………….…...…………. Page 24
5.2.1 Pre-start Checklist…………………………………………………………..…..……….….…… Page 24
5.2.2 Machine Stop……………………………………………………………….………..…….……….. Page 25
5.2.3 Test Over Safety Devices………………………………………………….…….….………… Page 26
6. Maintenance.…………………………………………………………..…….……………..…….… Page 27-28
6.1. Daily…………………….……………………………………………………….………...............…. Page 29-32
6.2. Weekly…………………………………………………………………..……….……..............…… Page 33
6.3. Monthly……………………………..……………………………….……………….…………….….. Page 34
7. Fault Detection and Trouble Shooting………………….………………….………..….. Page 36
7.1 Description of Faults and Corrective Action…..……….………………………...….. Page 37
7.2 Possible Troubles……………………………………………….………………………….…...… Page 37
8. Timing and Adjustments………………...………………….…………………….….......…. Page 37
8.1 Conveyor Chain Timing…………………..…………………………………………..………… Page 38
8.2 Pick N Place Adjustment………………………..…………………………………..…………. Page 38
8.3 Pouch Magazine Adjustment………….…………………………………………..………… Page 38

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1. INTRODUCTION

1.1 The present manual provides useful information regarding correct use of
the IL D4N SUP Blow Fill Seal Machine
1.2 We suggest that the user observes these regulations in order to obtain best
performance from the machine.
1.3 The machine has been provided with all the safety items necessary to avoid
damage to its part.
1.4 In the case repair is necessary, the user may refer to Bagong Pag-asa
Engineering for advice or request a technician to perform a visit.
1.5 Eventual disagreement between the present manual and its figure with
respect to the machine are derived from the continuous improvement
being done by BPE’s engineering team.
1.6 Therefore production of our machine is subject to modifications without
any obligation on our part to communicate changes and updates of the
present instruction to the client.

2. WARRANTY
2.1 Bagong Pag-Asa Engineering warrants that this machine is free of
manufacturing defects and that it’s accessories are ready for use

3. CLIENTS SCOPE

3.1 Clients responsibility shall cover the following :

3.1.1 Physical arrangement off equipment at the plant.

3.1.2 Lifting and transporting device inside the plant.
3.1.3 Power supply and other utilities
3.1.4 Lubrications

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1. MACHINE DESCRIPTION AND TECHNICAL INFORMATION

1.1 Machine Description :

1.1.1 The SUP IN LINE BLOW FILL SEAL MACHINE Model IL D4N is specifically designed to
pack viscous non viscous liquid into various Stand-up Pouches. However, a separate
pouch carrier will be supplied if the client intends to utilize the machine using
different pouch width.

1.2 How it operates :

1.2.1 Feeding of pre-formed pouches to the pouch magazine are done manually
1.2.2 Automatic loading off pre-form pouches inside the pouch carrier conveyor
1.2.3 Hands free opening and blowing of pre formed pouches
1.2.4 Hands free filling of pouches to the desired volume.
1.2.5 Hands free sealing of successfully filled pouches
1.2.6 Hands free cool sealing and embossing off manufacturing or expiry date. Coder shall
be separately supplied.
1.2.7 Hands free discharging of pouches from the carrier to the slide chute.
1.2.8 Machine speed is rated at 30 cycles per minute (depending on volume and liquid to
be filled)

1.3 Main Assemblies of the Equipment (See fig. 2)

1.3.1 Main Drive Motor Assembly

1.3.2 Pouch Magazine
1.3.3 Pick N Place
1.3.4 Pouch opening / Blowing Assy.
1.3.5 1st Stage Filling Assembly
1.3.6 2nd Stage Filling Assembly
1.3.7 Heating assembly
1.3.8 Cool Sealing assembly
1.3.9 Pouch Transfer Assembly
1.3.10 Air supply and valve station assembly
1.3.11 Auxiliary Components

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Machine Description and Technical Information

1.1 Technical Information

Electrical power supply 220 Volts, 3 phase / 60 Hz with ground

Conductors. 440 Volts, single phase
Operating Voltages 220 Volts / 24 VDC
Power Consumption
Main Drive 1 HP Sumitomo, 3 phase, 1750 RPM, 60
Hz
220 volts, Gear ratio 1:50
Aux motors
Vacuum pump Orion, 220 VAC 3 phase, 1.5 HP
Pneumatic Supply 6 to 7 bars
Filling Capacity 200 to 400 ml
Pouch width capacity 100 mm
Filling temperature 90o Celsius max.
Speed 30 cycles per minute max.
Product tank & level control Level Sensor, Autonics
Cycle and function control PLC / HMI/ Proximity sensors
Absolute encoder
PLC Mitsubishi FX3U – 80MR/ES – A
Error diagnostic Displayed at HMI

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Machine Description and Technical Information

3.2 Description of Assemblies

3.2.1 Main drive motor assembly (See Fig. 3)

 Motor (PN 27): Generates the motion of the entire system. The Motor is 3
Phase, 1380 RPM. The drive motor has a dedicated frequency inverter for
speed control purposes.

 Reduction Gearbox : Reduces the motors RPM by 50 times (1:50)

 Maltese Drive (PN 11): The Maltese drive is responsible for the start and stop
motion of the machine. It comprises of a 6 quadrant cam (PN 11), a bronze
positioner (PN 10) and a cam roll bearing (PN 12). Motion is transmitted
through the double strand sprocket at LH and RH side of the machine.

 Safety assembly (PN 25 to 31): Prevents serious damage on the machine by

means of a customized mechanical actuator installed on the main drive motor
base assembly. This will automatically trip the machine thru the proximity
switch in case of dragging on the conveyor side occurs. A separate safety
switches are installed on the conveyor to detect chain slack or conveyor link
failure.

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Machine Description and Technical Information

3.2.2 Pouch Supply assembly

 This assembly is responsible for the transfer of the pre form stand up pouch
from the pouch magazine to the pouch pocket of the carrier chain conveyor.

 The pouch supply assembly is divided into 3 parts :

- Pouch magazine: Where the pack off pre form stand-up pouch are fed
manually into the stainless chutes awaiting pick up by the Pouch picker.
(See fig. 4)

- Pick N Place: Composed of the pouch picker and pouch positioned (Fig
5). The pouch picker are composed of 2 guided cylinder lower (PN 15)
and upper (PN 11) that are mounted on a common cylinder base. Sets
of rubber sucker cups connected to a vacuum generator create
vacuum as the sucker cups comes in contact with the pouch at the
pouch magazine. The upper cylinder retracts as the pouch positioner
places the pouch on the pouch pocket. The lower cylinder retracts the
moment the pouch positioned cylinder reaches its full stroke. At this
position, the vacuum is cut off and the pouch is release resting inside
the pouch pocket. Sensors are mounted on the lower guided cylinder
of the pouch picker. The sensor makes sure that the guided cylinders
(PN 10 & PN 13) are in retracting position before a certain cycle is
executed to avoid damage on the assembly in case of cylinder failure.
A corresponding error is displayed on the HMI if the mentioned
condition occurs.

- Pouch positioner (See fig 5) is responsible for placing the pouch to the
pouch pocket at the SS carrier chain conveyor. A common mounting
base (PN 10) attached to Cylinder (PN1) holds the upper cylinder
(PN11) & the lower cylinder (PN15). At retract position, the pouch
picker picks a pouch at the pouch magazine. At push position, the
pouch picker is at maximum down position ready to release the SUP
inside the pouch pocket.

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Machine Description and Technical Information

4.5.3 Pouch Opening assembly

 The pouch opening assembly prepares the Pre – form SUP to receive the liquid
product. The pouch opening assembly have two sub assemblies :

- Pouch Opener: (Fig 6) Sets of vacuum sucker cups are mounted on a

customized cylinder assembly. A compact cylinder (PN1) holds a mounting
bar (PN3 & PN4) where sets of vacuum rubber sucker cups are attached.
The same assembly is mounted on the opposite side of the pouch. At push
position, the sucker cups, grabs the opposite side of the pouch and slightly
open the pouch in preparation for air blowing. At retract position, the
vacuum is released. Vacuum is controlled by a customized vacuum valve
attached to a vacuum pump.

- Pouch Blowing: (Fig. 7) sets of cone type plastic nozzles are mounted on a
round air cylinder (PN3). At push position, the nozzles dives inside the half
open pouch and injects air to fully open the pouch. A digital pressure sensor
(PN1) is attached on each nozzle to detect presence of back pressure on the
pouch. Presence of back pressure is an indication that a pouch is present
and was fully blown. Absence of back pressure is an indication that no
pouch is present at inside the pocket or was not fully blown giving signal to
the corresponding filling nozzles not to open.

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 4.5.4 Filling Assembly (No pouch – No fill) (Fig
8 and 8A)

 A customized two (2) stage filling nozzles

dozes the correct volume of liquid to a successfully
open pouch. The 1st stage doze the initial volume
and the 2nd stage completes the required product
volume. A dedicated timer for each filling nozzles
controls the desired volume to be doze.

 An overhead 316 Stainless Steel tank

constantly supply liquid product to filling nozzles. A
level sensor control the pneumatic valve installed
on the product supply line. The valve automatically
open and shut off to maintain a constant level on
the tank.

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 Machine Description and Technical Information

4.5.4 Heating Sealing Assembly. (Fig 9)

 A dedicated heat sealer is assigned for each pouch pocket. A detachable

400 watts cartridge heater (PN25) inserted inside a bronze bar (PN18)
conducts fusion on the pouch. Compact cylinder (PN2) holds the arm shafts
(PN9 & PN10) where the heater arm is attached. (See Fig. 9) A
thermocouple (PN26) attached to a digital 16hermos controller regulates
the temperature of the heater bar. The heater bar is interlocked to the
pressure sensor and filling nozzles for a no fill no seal condition.

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Machine Description and Technical Information

4.5.4 Cool Sealing Assembly. (Fig. 10)

 The cool sealing assembly smoothens and maintains a good sealing

appearance on the pouch. Each assembly have two (2) bronze bar
mounted separately opposite two separate compact cylinder (PN2). (See
fig 10). One side of the cooling bronze bar is lined with a silicon rubber
(PN25). Using water as coolant is an option.

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Machine Description and Technical Information

4.54. Collapser Assembly

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Machine Description and Technical Information

4.5.4 Pouch Transfer / Discharge

 The assembly grabs the pouch on the pouch pocket and transfers it to a
receiving chute or conveyor. Upon reaching the idling motion of the carrier
conveyor, a tie rod type cylinder (PN21) pushes and positions the gripping
head directly on the upper lid of the SUP. Sets of compact Cylinder (PN2)
grabs the pouch upper lid and pulls it out of pouch pocket. The pouch is
then release on a receiving slide chute or conveyor. (See fig. 11)

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Machine Description and Technical Information

4.5.5 Pouch Conveyor (Fig 12)

 The pouch conveyor is a double pitch stainless roller chain, 1 ½” pitch

attach to a 3 ¼ width table top. Sets of PVC pockets serve as pouch carrier
are bolted on a stainless steel stud post welded on the stainless steel table
top. A set is consist of two (2) side pockets and one (1) center pocket
design to handle pouch 100 mm width.

4.5.6 Solenoid valve station and tank assembly

 The solenoid valve station are consist of six (6) solenoid valve manifold
A/B/C/D/E/F where sets of 3/2 way solenoid valves are mounted. The
manifold consists of four components, filter / regulator / lubricator and an
air release valve. A digital air pressure indicator is separately installed on
Manifold B & C which automatically stops the machine in case of low air
supply. Manifold A which supply air to the vacuum generator and pouch
blower is not equipped with an automatic oil lubricator but instead have a
dual mist filter to ensure clean air supply.

4.5.7 Other auxiliary assemblies

 HMI
- The machine is controlled thru an HMI with a 12” colored display
screen. The HMI have a customized touch screen operation to control
the entire operation and motion of the machine. It is connected to an
Omron PLC model CP1L with expansion modules. Timing of the
machine is based on the pulses emitted by the rotary encoder mounted
to the main drive reduction gearbox.
-
 Vacuum pump
A vacuum pump is responsible for the suction produce thru the rubber
sucker cupsat the pouch opener assembly. A Customized vacuum valve
with a stainless steel header delivers and controls the vacuum action by
the rubber sucker cups.

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5 USING THE MACHINE

5.1 Command and function Indicator

5.1.1 Main Electrical board is located at the centermost, RH side of

the machine table. This houses electrical components such as PLC,
Frequency inverter, breakers, contactors, relays and terminal
boards.

5.1.2 Main Control board is located at the upper portion RH side of

the machine above the main electrical box. The board holds the
HMI, Emergency Stop Button, Main Drive ON and OFF Button,
Heater
Selector switches and Digital Thermo Controller.

5.1.3 A Secondary Emergency Stop board is located at the back LH

side of the machine just above the transfer section.

5.1.4 Fault Indicator capability is incorporated in the HMI board.

Every fault that will occur on the machine will be identified and
displayed on the HMI screen.

 Pick N place error

 Pouch opener error
 Pouch conveyor error
 Main drive motor error
 Air pressure error

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Using the Machine

5.2 Starting the machine

5.2.1 Pre start check list Auto Mode - Before proceeding in

automatic cycle, be sure to check the following :

 Make sure all air valves are fully open and all pressure
regulators on the solenoid valve stations are properly
set to its required pressure.

- Regulator A 60 Psi rating

- Regulator B 80 Psi rating
- Regulator C 80 Psi rating
- Regulator D 80 Psi rating

 Check that liquid on the product hose are free from air
pockets.

 Thru the HMI, set the machine in manual mode and

individually actuate all cylinder assemblies to check for defective
cylinders. After completing the manual check,
set the machine in auto mode and double check cylinders are
on its proper position.

- Pouch positioner cylinder Retract

position
- Pouch picker upper cylinder Retract
position
- Pouch picker lower cylinder Retract
position
- Pouch opener cylinders Retract
Position
- Pouch blowing Cylinder Retract
position
- Filling nozzle cylinders Push Position
- Heater Cylinders Retract

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 Position

- Cool sealing Cylinders Retract

Position
- Pouch Grip Cylinders Retract
Position
- Pouch Discharge positioner Retract
position

 Check that the pouches loaded on the pouch magazine

reaches the upper limit marker of the pouch magazine.
 After performing the above mentioned check list, the
machine is now ready for operation.

Using the Machine

5.2.2 Machine Stop

 Voluntary stop of the machine will occur by pushing the stop cycle push
button on one of the control board. The machine completes the cycle by
performing the end work of each group then stops the cycle. Pushing the
start button will start the machine performing the first function of the
machine cycle.

 Emergency stop will be performed by pushing the emergency push button.

The emergency stop must be used only when the safety of the machine
and of the operator can be put into danger and for immediate stop of the
machine. Two (2) emergency push buttons are available for this purpose.

5.2.3 Test over safety device

 Periodically it is necessary for operator and maintenance to test the safety

devices of the machine. This procedure must be executed as part of the
normal maintenance.
 Emergency Push Button - with the machine on auto mode, push each
emergency push button and verify that the emergency lamp of the tower
red light is ON (Red blinking light). Verify also that the fault is displayed on

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  the HMI screen. Depressed the emergency push button and perform the
procedure twice.

 Main drive motor safety- with the machine in auto mode, apply pressure
on the spring to disengage the sensor from its actuator. The sensor light
must turn OFF. Verify also that the fault is displayed on the HMI screen.
Push the reset mode on the HMI screen and perform the procedure twice.

Using the Machine

Test over safety devices

 Pouch Conveyor Safety -with the machine in auto mode, press the spring
loaded actuator. The sensor red light must turn ON. Verify also that the
fault is displayed on the HMI screen. Push the reset mode on the HMI
screen and perform the procedure twice.

 Pouch Picker Sensor - with the machine on test mode, manually actuate
the pick n place cylinder thru the HMI. The sensor light on the HMI must
turn OFF as soon as the cylinder arm pushes and must turn-on as the
cylinder arm retracts. Perform the procedure twice on all cylinders.

 Pouch Opener sensor - with the machine in test mode, manually actuate
the pouch opener cylinder thru the HMI. The sensor light on the HMI must
turn OFF as soon as the cylinder arm pushes and must turn-on as the
cylinder arm retracts. Perform the procedure twice on all cylinders.

 Pressure switch – with the machine in auto mode, close the main air valve
and slowly decrease the pressure thru the regulator of solenoid valve
station B. Error message on the machine will appear as the pressure drops
to 4 bars. Restore the pressure regulator to its original pressure after
wards.

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6 . Maintenance

For the purpose of maintaining the machine in good and efficient condition, the
following maintenance program is highly recommended.

6.1 Daily

6.1.1 Check oil level on all oil lubricators. Use SAE 32. Fill if
necessary. Take note of presence of contaminants

6.1.2 Open and clean the filters.

6.1.3 Manually drain the main tank air reservoir. Report

immediately presence of contaminants on the drain outlets
(water, oil).

6.1.4 Check tightness of pouch positioner air cylinder locking nut.

Tighten if found loose.

6.1.5 Check sucker cups for possible wear and defects

 Pick N Place
 Pouch Opener

6.1.6 Perform the test over safety devices regularly (5.2.3)

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Maintenance

Check alignment of pockets with respect to the following:

- Make sure that the timing marks on the carrier chain conveyor, LH and
RH is perpendicular on the timing arrow on the conveyor chassis. (See
fig 13) If not align, conduct alignment procedure.

NOTE:
TIMING IS APPLICABLE FOR IL-D8N-100G & IL-D4N100G

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Maintenance

Check alignment of pockets with respect to the following:

- Pouch picker and positioner. Pouch picker must be on the center

between the pouch pockets. Use the dummy pouch as centering
reference. (See fig. 14).

Check alignment of pockets with respect to the following:

- Pouch magazine. After achieving correct alignment of the pouch

picker. Check that the pouch at the pouch magazine is positively in
contact with the sucker cups. The lower and upper cylinder must be at
push position. At Auto mode, activate the pick n place screen and run
a complete cycle to check that pouches slid smoothly on the pouch
pocket. Make fine adjustment on the magazine if necessary. (See fig
15)

NOTE:
ALIGNMENT IS APPLICABLE FOR IL-D8N-100G & IL-D4N-100G
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Maintenance

Check alignment of pockets with respect to the following:

- Pouch Blowing. Nozzle tip must be at center of the pouch carrier. Insert
the dummy pouch on the carrier to check the correct position of the
nozzle tip. (See fig. 16)
- Pouch opener. Make sure that the suction cups are slightly in contact
with the dummy pouch. (See fig. 16A)

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Maintenance

Check alignment of pockets with respect to the following:

- Filling nozzles. Make sure that the nozzle tip is at center of the pouch
carrier. Use dummy pouch as centering reference. Nozzle tip must be
at least 9 mm away from the dummy. (See fig. 17)

NOTE:
ALIGNMENT IS APPLICABLE FOR IL-D8N-100G & IL-D4N-100G

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 33
Maintenance

Check alignment of pockets with respect to the following:

- Heat and cool sealers. Make sure that the bars meet at the center of
the dummy pouch for heater and cooler bars. (See fig. 18)

NOTE:
ALIGNMENT IS APPLICABLE FOR IL-D8N-100G & IL-D4N-100G

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Maintenance

6.1.7 Lubrication

 Guide rods. Apply 2 to 3 drops of light oil.

- Pouch positioner
- Pouch picker Guided cylinder, upper and lower
- Pouch opener cylinder
- Pouch transfer and lifter cylinder

 Cylinder rods. Apply 2 to 3 drops of light oil

- Heater assembly
- Cooling assembly

 Main Drive roller chain. Spray with medium oil

 Geneva cam bronze positioner. Apply with retinax grease surface of the
Geneva cam and bronze positioner. Make sure grease will not reach reset
sensor of the main drive.

6.1.8 Cleaning

 At the end of every shift, clean the conveyor chain thru the main hole at
the conveyor chassis. Run the conveyor and spray with clean water.
Make sure that the Vacuum Pump is OFF during the process of cleaning.

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Maintenance

6.2 Weekly

6.2.1 Check all air cylinders for leaks

6.2.2 Check all fittings and hoses for possible leaks
6.2.3 Check solenoid valve station for possible leaks
6.2.4 Check pouch carrier mounting bolts. Tighten if found loose. After
tightening, insert the pouch pocket feeler gauge. The feeler gauge
must smoothly fit the pockets. If not, align the pockets.
6.2.5 Lubrication
 Apply two shots of grease on flange bearing of the drive and
idler conveyor.
 Apply two shots of grease on Geneva cam drive shaft flange
bearing.

6.3. Monthly

6.3.1 Check gearbox oil level. Replenish if not in level.

6.3.2 Check for possible wear and unusual sound
 Main drive motor
 Vacuum pump motor
6.3.3 Check condition of bearings
6.3.4 Drive and idler flange bearing
6.3.5 Drive motor pedestal bearing
6.3.6 Geneva cam drive shaft pedestal bearings
6.3.7 Geneva cam drive shaft flange bearing
6.3.8 Roller chain and sprockets for wear

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7. Fault Detection and Trouble Shooting

The machine is capable to identify and specifically display faults in the LCD screen of
the HMI.

7.1 Description of Fault and corrective actions

7.1.1 Pick N Place Lower

 Cause :
- The cylinder actuator failed to trigger the sensor.
 Action :
- Check air leak or possible passing air on the piston seals.
- Check adjustment of air flow control attached to the cylinder.

7.1.2 Pick N Place Upper

 Cause
- The cylinder actuator failed to trigger the sensor.
 Action :
- Check air leak or possible passing air on the piston seals.
- Check adjustment of air flow control attached to the cylinder.

7.1.3 Pouch Blowing error

 Cause :
- The cylinder actuator failed to trigger the sensor.
 Action :
- Check air leak or possible passing air on the piston seals.
- Check adjustment of air flow control attached to the cylinder.
7.1.4 Main Drive Error
 Cause :
- The actuator loses its contact.
 Action :
- Check for possible drag on the conveyor.
- Check condition of actuator spring. Adjust or replace spring if
necessary.

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Fault Detection and Trouble Shooting

7.1.5 Conveyor Error alarm

 Cause :
- The actuator arm is actuated.
 Action :
- Check flange bearing at drive and idler portion for possible wear.
Worn-out bearing causes slack on the conveyor chain.

7.1.6 Low air pressure alarm

 Cause :
- The air pressure is below the minimum value.
 Action :
- Check the air pressure on the main pressure meter and adjust if not in
range.
- Check also supply of air pressure coming from the main line.
- Check adjustment of the pressure switch.

7.2 Possible Troubles

7.2.1 Unpicked pouch at magazine

 Possible Cause :
- Vacuum is insufficient
- Possible wear on sucker cups
- Misaligned gripper
- Over or under supply of pouch
- Stocked pouch at magazine

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Fault Detection and Trouble Shooting

7.2.2 Misplaced pouch at pockets

• Possible Cause:
- Vacuum is insufficient
- Possible wear on sucker cups
- Misaligned gripper
- Over or under supply of pouch
- Stocked pouch at magazine
- Conveyor timing is off

7.2.3 Occurrence of misblown pouch

• Possible Cause:
- Worn-out sucker cups
- Misaligned cups
- Misaligned suction cups
- Incorrect vacuum pressure
- Misaligned blowing nozzle
- Defective pouch
- Cylinder throttle nozzle not properly adjusted

7.2.4 Filling nozzles not responding

• Possible Cause:
- Pouch blowing back pressure adjustment insufficient
- Blowing nozzle height adjustment to high
- Defective pressure sensor.
- Malfunctioning solenoid valve

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8. Timing and Adjustment

8.1. Conveyor chain timing

Position the timing mark on pocket no. 7 at the timing arrow located at the
conveyor chassis underneath the pouch magazine. At this position, the timing mark at
pocket no. 1 must be position at the timing arrow located at the pouch discharge portion.
Loosen the 8 hexagonal bolt of the main drive motor sprocket of the lane to be adjusted.
Dis-engage the sprocket by using the bolt sprocket loosener. Remove the bolt sprocket
loosener. Align the timing mark and timing arrow. Points of the arrow must be aligned
with each other. At this position, the timing mark at pocket no. 1 and timing arrow at the
pouch discharge portion must be in same position. After achieving the desired alignment,
fasten the 8 hexagonal bolts.

NOTE: The bronze positioner should be inside the Geneva cam quadrant before loosening
the 8 hexagonal bolts. Make sure that the machine is turn off.

8.2 Pick N Place Adjustment

Make sure that the Carrier chain conveyor is correctly aligned before aligning the
Pick n Place pouch gripper. In Manual mode, set the positioner cylinder in push position
(down). See to it that the sucker cups are at center between two pockets. Still in manual
mode, grab a pouch by actuating the Pick n Place button at the Screen. While the
positioner is still in retract position, check if the pouch is aligned with the pouch pocket
slot. Pouch must slide perfectly on the pocket slots. Make necessary adjustment on the
adjustment slot of the pouch gripper if necessary.

8.3 Pouch magazine adjustment

Make sure that the carrier chain conveyor is properly timed and the pouch picker
is properly aligned before aligning the pouch magazine. The pouch magazine is misaligned
if frequent misplacement of pouches on the pockets is occurring. Perpendicular and
horizontal alignment can be made thru the adjustment slots.

38

BAGONG PAG ASA ENGINEERING