Instructions：
This instructions consist of several parts which are summary, schematic diagram of the machine, main technical parameters, installation and debugging, functions and use of the electrical elements, daily operation and equipment maintenance as well as lubrication of the machine，common faults and the corrections, and schematic graphic of the electrical appliance, and etc. In order to make the instructions we generate make sense, please do have the operator of the machine read it before put the machine into use.
If you have any questions about the instructions and the machine, please report to your boss and contact us in time. It is our pleasure to serve you.
Special Statement:
★ This instructions can only apply to the very model paper machine you purchase. We cannot assure its correction if you apply it to other models or paper machine supplied by other manufacturer.
★ Because of the need to match the requirements of market and customers, we will constantly upgrade our products which will make the instructions change accordingly without further notice.
Security Warning!
To assure security of person and the equipment, you have to obey the follows:
★ The operator of the machine must read this instructions firstly and operate as instructed. The operator must be trained and qualified.
★ Person who operate and maintain this machine must apparel qualified personal protective equipment and use qualified tools.
★ Make sure there is no junk on transportation paper tape, paper aluminum strip, feeder and the paper guide rails and so on so that the machine can work without constraints.
★ Make sure there is no person inside the machine before start it.
★ Stop the machine and disconnect the power sully when you maintain, repair and clean the machine.
★ Check frequently if the security guard and the security equipment is effective. When the machine work abnormally, please stop to use it.
★ When the machine goes out of order, please report to your boss immediately and warn others who operate this machine to be careful about it at the same time.
★ When the machine works, do not put your limb or any other part of your body on the machine or approach the working parts.
★ When the machine works, do not climb to the top of the machine.
★ Keep the working area and the machine clean and tidy; remove the smooth materials such as oil and grease on the floor immediately and do not leave any other tools or junk on the floor so that no one will hurt because of slipping or falling into the machine.
★ Follow the instructions strictly and regularly lubricate the machine to help make the machine work well.
Working Environment Conditions for the Machine
It is recommended to have the machine work under the following conditions.
- The attitude is no higher than 1000m.
- The temperature of medium around ranges from 0 to 50℃.
- Relative humidity is 35～90% and no frost.
- The power fluctuation is no more or less than 10%.
- In case of failing to meet electromagnetic compatibility standards while the machine is working as the examples below, you should take action accordingly:
- Somewhere static electricity interferes with.
- Somewhere the electric field is strong.
- Somewhere radioactive substance exists.
Section One: Summary
ZH-800 auto high-speed stereo paper box forming machine is the new product of our company. It can form precisely and has high output which makes it and ideal equipment for processing paper boxes and trademarks in packaging industry. With new technology, this machine is able to transport, feed, form and collection paper automatically. The human-computer interface shows the working speed and state of the machine as well as the causes of fault and how to shoot it. The main motor is controlled by imported transducer that carries out stepless speed change and help the machine word steadily. The transportation paper tape is heat resistant and highly strong which brings high strength and low deformation. The paper guide rails are strong and precision which contributes to high tensile strength and long service life. The cam intermittent mechanism designed specially helps the paper feeding go steadily even at high working speed. ZH-800 can meet different paper feeding requirements by adjusting the travel time of the cam in case customers choose paper of different sizes.
Section Two: Schematic Diagram of the Machine
As illustrated by following diagram, this machine is mainly divided into several parts as below:
Ⅰ.Paper feeding part: including transportation paper tape, paper feeding board, pressing wheel and paper feeding cam, and etc..
Ⅱ.Paper delivering part: including dynamic rubber wheel and pressing wheel, paper delivering guide rails, paper delivering intermittent chains, side rails and steel strips, and etc..
Ⅲ.Sealing part: including glue extruding wheel, sealing motor, sealing wheels and glue, and etc..
Ⅳ.Forming structure: This part is ordered by customers according to their need. It will change properly according to the different structure of paper customers process.
V.Discharging part: This is the last working procedure of the machine, counting and collecting products which will later be packed by workers successively.
In addition, there is an important part of the machine: electric control system.
Section Three: Main Technical Parameters of the Machine
Max. Paper Size： 300 x 300mm（formed）
Min. Paper Size： 50 x 50mm（formed）
Theoretical Producing Speed: 20-35pcs/min
Available Paper: white cardboard，single film，double
film，thin corrugated paper, and etc..
White Cardboard: 200～600g/m²
Main Motor Power： 4KW
Overall Dimension：（LxWxH） 3000 x 1200 x 1600mm
Total Weight: 2T
Section Four: Installation and Debugging
When customers get the machine, it is supposed to inform the manufacturer or the agent in the first place so that it can sent person to carry out installation and debugging as soon as possible. After the very person sent arrives, open the package of the machine to check if the equipment is intact and to check if the accessories, tools and the elements specially ordered are complete according to the packing list and the purchase contract.
When loading or unloading the machine, please refer to the schematic diagram above. The forklift should insert at the bottom of the machine toward the direction it feeds paper, and after the machine stays safe, move it.
Customers can use hoist and move the machine with other methods according to their actual situation. However, the safety of the machine must be guaranteed.
It is suggested to install the machine or steel and concrete foundation, the foundation should be no thinner than 120mm. If the machine has to been installed on other floor above the ground, it should obtain consent of the architectural design department. Only under the condition that the bearing capacity of the floor is strong enough can the machine be installed, and it must be installed in somewhere that has bearing beam and columns so as to assure security.
When installing the machine, it is supposed to make room for operation and maintenance around the machine. See below.
When installing the machine you should lay it flat by adjusting the screw at its bottom and consolidate it with thin iron sheets and wedges. Adjust the screw at the bottom of the discharging part to make it flat against floor. The precision of spirit level used during this process is suggested to be 0.05mm or 0.1mm.
Section Five: Function and Use of Electrical Control Elements of the Machine
- I. Summary
VLB-800 auto high-speed stereo paper box forming machine adopts new technology to make it able to transport, feed, form and collection paper automatically. The whole machine uses human-computer interface of industrial grade and imported elements such as SIEMENS PLC and SIEMENS frequency converter to display and detect real-time the working speed of the machine, processed paper number, total working time, working position of the platform, feeding and discharging time and faults that may occur during the whole working process, thus making it convenient to the operator to handle the machine and debug.
This machine uses three-phase four-wire AC380V，50HZ power supply and connect to special protective ground wire PE. The master switch emergency stop is on the door of the discharging cage. When the cage opens, the machine will be automatically power off and stop working. The main control loop adopts isolation transformer, 380V AC put-in and 220V AC put-out. The transducers have 24V regulated power supply to guarantee the stability of all electrical components. The motor has overheat protection with thermal relay to avoid damage from overheat. A safety detecting switch is arranged at each action part of the machine, so that the machine will stop immediately after an dangerous action is completed, greatly ensuring the security of machine and person.
3、The working environment of the electrical system should meet the following requirements:
（1）Attitude no higher than 1000m.
（2）The temperature of medium around ranging from -10℃ to 50℃.
（3）Relative humidity from 35%~90% and no frost.
（4）Power supply fluctuation no more than 10%.
（5）No flammable and corrosive gases around, avoiding dust, iron powder and water.
（6）Avoiding direct vibration, hit, and sunlight.
（7）Taking appropriate measures where electrostatic interference and radioactive substance exists and the electric field intensity is strong.
- II. Installation and Debugging
1、When customers get the machine, open the package in the first place to check if the electrical components,lines and the connectors are intact and if the screws are fastened. Open the electric box to check whether the electrical components are fixed well and the terminal connection is loose or not. After the machine and the connectors are connected, plug in the electric box according to customers requirements.
2、When the distance between the machine and the power supply terminal is less than 30m, match copper core cable of 10mm²four core standard. Thee two ends of the cable should be pressed firmly with proper cold pressing pieces to in case of fire and machine damage due to disconnection. L1,L2,and L3 connect to three-phase line and PE connects to protective earth wire.
3、After the machine is connected, check if the power voltage meets the requirements of the machine with universal meter and if the power cord is connected well. If everything is right, then close the door of the electric box and turn on the power switch, thus switching on the power of the machine control circuit.
III. Function and Operation of the Components
1. After connecting the three-phase line, turn on the mains supply inside the electric box.
2. Then turn on the main switch on the control panel and the following interface will appear.
Button panel and screen of the control panel:
- Start：When the machine is in normal condition, press “Start”and the machine will start working. At the same time a green flickering ball will appear beside the button, which means the machine is working.
- Stop: When the machine is working, press ”Stop”and the machine will stop working. When press the emergency stop button, there will be a red flickering ball beside this button，and then the machine will be unable to start or jog. (Attention：Any emergency stop button pressed will make the machine fail to start; the emergency button has self locking function and it can only reset by rotating in the direction of the arrow.)
- Jog：When the machine stops working, press “Jog”and the machine will start working. At the same time a yellow flickering ball will appear beside it which means the machine is jogging. If you release the button, the main machine will stop.
- Marking Button
When pressing the “Marking On” button, each time a lot arrives, the marking magnetic valve will start and mark once; when pressing “Marking Off” button, the marking magnetic valve will not work.
- Glueing Button
When the “Glueing On” button is on, the glueing motor will rotate automatically even the machine stops working. When the machine starts or jogs or stop in emergency, the glueing motor stops rotating. When the “Glueing Off” button is on, the glueing motor will not work.
- Sealing Button
When pressing“Sealing On” button, the sealing electromagnetic valve will push down if there is a signal of material shortage. When the material shortage is within a travel of 500mm and there is no paper box, the sealing electromagnetic valve will close and rise. When pressing “Sealing Off” button, the sealing electromagnetic valve will take no action.
- Speed Display
Current speed display
- Single click this area to enter time adjust interface.
Set the right date and time and then press “Correct ” button to correct date and time.
- ”Clutch”Button When turning on “Clutch”, the clutch electromagnetic valve will take action, the clutch cylinder will open, the feeding roller and the delivering cam will be apart so that no paper will be delivered.
- IV. Parameter Setting
The figure below is subject to the actual parameter of the machine. Note: The system parameter password of factory default is “666666”.
Warning
Door not close: When the door does not close well, it will prompt.
Variable-frequency Drive Fault：When the frequency converter goes wrong, a warning will appear. Then you should check the fault code of the frequency converter and diagnose the fault referring to the instructions.
Attentions
- Do not touch the screen with sharp substance in case of scratch.
- The encrypted interface by the manufacturer can not be entered forcibly, or the machine can not work normally if the data is changed.
- V. Maintenance
After the machine works for a time, the fixed electrical components may be loose due to the vibration of the machine, so they are supposed to be checked and fastened regularly to avoid fault caused by loosening. The working of this machine may bring out scraps of paper and dust which will possibly block the light of the photoelectric switch, making the photoelectric switch invalid or making the machine fail to complete certain action, hence influencing the normal working of the machine. It is suggested to check and clean the electrical components gently and carefully every week to ensure their normal function, and position and state of the components cannot be changed. Clean the surface of every motor often to maintain its heat dissipating capability and to prolong its service life. Check the electrical components inside the electric box as well to keep it clean inside.
★ Person who maintains the electric control system of the machine must be technician mastering knowledge of electric control and wears and uses labor protective supplies according to relevant regulations. Besides, the tools must be qualified.
★ Maintenance of the machine must be implemented when the general supply is disconnected to avoid accident.
- VI. Common ElectricalFailures and Troubleshooting
- Paper feed table does not lift manually: Firstly check if the PLC lifting signals 00102 and 00103 are connected. If not, remove the paper feed button plate to check the wiring. Otherwise, check if the up and down limit switchof the paper feeder and the super high switch acts. If it acts, find the cause and reset the switch.
- Paper feed table does not lift automatically: If it can lift manually well, check whether the time setting for automatic lifting of paper feeding is too short, whether the automatic lifting switch signal is normal, and whether the automatic lifting switch SA2 is on the left or right.
- Paper collection table dose not descend automatically: If it can descend manually well, check whether the time setting for automatic descending is too short and whether the automatic descending sense switch is normal.
- Motors stop rotating during work: Check whether there is warning of the frequency converter or not, if there is, take down the warning code and find the reason according to the instructionsof the converter and then solve the problem.
- Paper collection table lifts slightly but does not lift manually: Check if the limit switch on the paper pile is blocked or the light received and sent by the photoelectric switchis in right position.
- The other methods of troubleshooting has been introduced on the human-computer interface and you can shoot troubles referring to it.
VII. Daily Operation of the Machine
1.Paper Feeding Device
- a. Requirement of paper: The paper must be neat and smooth without cutting hair, and the two positioned edges must be vertical. The paper should be smoothed before put into the machine and there should be no adhesion between the paper.
- Adjust the side shield of the feeder to a predetermined position according to the width of the paper, and put the paper on the paper feeding table. When the paper bends and deforms greatly, the paper pile will convex or concaveobviously. Then you should take the paper pile out and smooth it and put it in a proper position, trying to make the paper as smooth as possible.
★ The tightness of the paper feeding tape should be adjusted in accordance, otherwise the paper may go askew.
Adjust the paper feeding pressing wheel to a proper position. The picture below is for reference for adjustment.
Pressure of paper roller, the or so direction should be generally with paper tape for, before and after the direction should be placed on the gauge block before the arrival of the trailing edge of the paper, in order to keep the paper and paper cutter on the tight.
Pressure roller and pressure shall be on the lost tape paper the brush wheel, and the pressure should be uniform.Pressure adjustment below.
2.Preparation of sealant
Paper number, observe the paper chart, after everything is normal, with glue sponge (about 9 to 10 mm thickness and back door with adhesive).On the paper need to be watered on position, with kumite rubber sponge cutting knife, has reached to the ideal effect.Then put the water soluble glue injection plastic bucket, not too full.
3.Molding to prepare
Proper adjustment according to the different carton specifications
Section 7 Machine tool maintenance and lubrication
- when the machine after a period of time (a month), have to refill the feed CAM lubricating oil regularly, and the chain lubricating oil.
- intermittent CAM mechanism used in the lubricating oil for 220 industrial gear oil, the oil filling every three months at a time.Machine to the user to use a month later, the intermittent mechanism must be checked.The main is to check the chain link and the shaft connection is loose.
3.every three months, check the main drive of moving platform die cutting parts of lubrication and wear condition.
If discovery is unusual, timely stop check.And shall promptly notify the manufacturer send repair and replacement.Before the change shall not continue to use the machine.
- every six months, should check the status of a main motor belt and if there is any breakage, it should be replaced in a timely manner.
Methods: to check the leather belt, such as the need to change, loosen the main motor, belt first take off from the motor pulley, gradually will be at the bottom of the belt from the pulley and the bottom of the bracket.There will be a new belt change according to the reverse steps.
Chains do not pull too tight.
Section 8 Common faults and ruled out
Here are some of the mechanical part of the common faults and elimination method, electric parts, please refer to section 5 five parts.
Part one, the paper:
1, paper skewed
Possible reasons:
(1), lose on both sides of the paper support block imbalance.Requirements on the feeding table and highly consistent paper pile surface and relative paper heap center symmetric.
(2), on the feed conveyor belt and paper position is wrong, lose tape tightness is differ, etc all can cause the paper to skew, check the above exclude them one by one.
2, the paper appear double or more card or paper
Possible reasons:
(1), paper adhesion.Printing, stationery, coated paper, paper cutting hair, static, wet adhesion, easy to cause paper, therefore, must be in front of the die cutting on the paper.
(2), paper knife block and lose tape between the gap is too big, or too small may cause out of paper
3, the o ring groove pulley wheel and lost tape between the abnormal pressure
Possible reasons:
(1), Geneva wheel pressure wheel and the paper tape of abnormal pressure.
Second, the paper feed part
1, paper about inequality:
Possible reasons:
Walk about paper chain caused by asymmetric, can adjust the feeding chain up tight round position.
2, paper, upper and lower arch:
Possible reasons:
(1) may be paper pressure bar and walk paper nylon guide clearance between abnormal.
Part three, glue
1, glue points:
Possible reasons:
(1), the gel point is too big or too small, will affect the quality of molding glue.
(2), glue too little or too much of a roller, and also affects the quality of molding glue:
2, the location of the lugs and the tire
abnormal:
This is mainly because when check no paper sent to 500 mm, cylinder automatic contraction, the lugs and the release of a roller, and then if still no release of the lugs and play roller, and adjustable screw, make it to the appropriate location.
Four, molding parts
1, abnormal shape:
Possible reasons: all kinds of paper forming associated with mold.
Part five, the discharging
1, the abnormal discharge:
Possible reasons: the discharging gap between cage in stainless steel and paper box, can adjust the handle.
