Type
FP-80T Type
Manufacturing No.
Date of Manufacture
Date of Purchase
Date of Final
Acceptance
Packaging Machine for Rectangular Teabag
FP-80T Type
Instruction Manual
Attention
Before operating the machine, please read this instruction manual
carefully for correct operations.
Please keep this manual in a designated place for ready reference.
Fuso Industries Co., Ltd.
1404-33, Sabaka, Kikugawa-shi,
Shizuoka-ken 439-0003 Japan
TEL: (0548) 27-2316
FAX: (0548) 27-2318
Introduction
Introduction
Thank you for purchasing our Packaging Machine for Rectangular Teabag FP-80T type.
This instruction manual describes the safety information, the operation procedure, and the
maintenance procedure for users to properly understand how to handle the machine, and to use the
machine safely and efficiently.
Please read this instruction manual before setting up or operating the machine.
Please keep this instruction manual near the machine for quick reference whenever you need
information.
i
Warranty
Warranty
−
The warranty period of FUSO INDUSTRIES CO., LTD. FP-80T type is 6 months from the date
of purchase.
−
We warrant the product for a defect which occurred within the warranty period.
−
If any defect has occurred on the FP-80T type machine within the warranty period, we will repair
the product or replace parts.
−
This warranty applies only for the initial customer whom we contracted. This warranty does not
apply for the customer who purchased the resale product.
−
This warranty on the product is applicable only in Japan.
−
Following case will be charged even within the warranty period.
−
•
Replacement of consumable parts
•
Malfunction or damage of this product caused by misuse, repair, and remodeling without our
consent
•
Malfunction or damage of this product caused by moving the machine to the installation
location/tipping over/falling after delivery
•
Malfunction or damage of this product caused by fire disaster/earthquake/windstorm and
intense rainfall/thunderbolt, other natural disaster and earth shock
Consumable parts are not warranted.
For details, see "7.2 Consumable Parts List".
Standard Lifetime Based on the Design
−
Lifetime of this machine based on its design is 10 years (excluding consumables). Use beyond its
lifetime may lead to aging degradation and cause fire or damages.
ii
Disclaimer
Disclaimer
Warranty written in the contract exchanged with you is the only one for Fuso Industries Co., Ltd.
Following statement is neither to warrant additionally nor to revise the existing warranty.
Fuso Industries Co., Ltd. liability under this warranty shall not be available for the followings.
−
Damages caused by conditions such as installing this machine in an unsuitable environment
−
Damages caused by conditions such as contacting the peripheral devices, falling, leaking, and
immersion to liquids and gases
−
Damages caused by conditions such as voltage change, supply of inadequate materials, and
utilities
−
Damages caused by conditions such as connection or remodeling without our consent
−
Damages caused by conditions such as inappropriate operation and maintenance
−
Damages caused by conditions such as abuse, misuse, incorrect operation, and unauthorized use
−
Damages caused by conditions such as using the parts or performing services not supplied by our
authorized supplier.
−
Even though damages are caused by natural disaster, product liability of manufacturers is not
applied to Fuso Industries Co., Ltd.
iii
Important Information
Important Information
Intended Usage of Machine
This machine is designed for packing tealeaves and to manufacture tea bags.
For specifications and specification limits of the machine, see "2 Overview of Machine".
Operation, cleaning/washing, and maintenance of the machine should be performed by an operator
who technical knowledge, danger of the machine and its avoidance training.
Observe all related federal/national and local codes and regulations.
Unintended use and failure to follow safety instructions and accident avoidance precautions may result
in following risks.
−
Threat to your health and life
−
Hygiene problem such as foreign matter mixing in the product
−
Damage to the machine
To Use the Machine Safely
We can not foresee all risks such as remaining risk on the machine and human error, that is attribute
risk to human and to environmental condition of the machine.
There are many "must", "must not" and "can not" to operate this machine. All compliance cannot be
covered by this instruction manual and safety labels. Consequently, attention to general safety measure
is required as well as described in this instruction manual, for any operation with this machine.
Followings are important points for safety operation to operators including controller/manager
involved in the machine.
−
Before using the machine, please read this instruction manual and understand its contents to
steadily follow safety procedures on the manual.
−
Operating the machine, maintenance, inspection work should be done by well-trained operator for
technical knowledge, danger of the machine and its avoidance training.
−
Nobody can approach to the machine during operation/maintenance work, except well-trained
operator for technical knowledge, danger of the machine and its avoidance training.
−
The machine installation and remodeling should be requested to us, Fuso Industries Co., Ltd. or
our agent.
−
Laws and regulations of relevant country and administrative organs need to be followed.
−
To avoid an accident, do not unintended use and operation and maintenance work without
description in the instruction manual.
−
Workers, including chief administrator should take part in an activity to safety ensuring and
hygiene control, and try to prevent a disaster.
−
Comply with followings for maintenance work of electric control.
•
Well-trained operator should work on it, who is educated for electric control on the machine
as well as general electric work knowledge and trained for risk of electric control and its
avoidance training.
•
Turn the [MAIN POWER] switch OFF when performing maintenance/inspection of electric
equipment.
There is a possibility to be energized even [MAIN POWER] switch is turned "OFF", if option
such as ancillary facility plug equipped or electric power supplies not to other machine but to
electric system of this machine. In those cases, ensure to shutdown the power supply side.
iv
Important Information
About this Instruction Manual
−
This instruction manual is made for a person whose native language is English. If nonnative
speaker of English handle this machine, safety instruction must be carried out thoroughly at
customer's side.
−
Copyrights of this instruction manual is reserved by Fuso Industries Co., Ltd. No part of drawing
and technical document including this instruction manual may be reproduced in electronic media
or any form, without the prior written consent of Fuso Industries Co., Ltd.
−
This instruction manual includes description of optional equipment.
−
Photographs and drawings described in this instruction manual may differ from the actual
machine.
−
Any loss of or damage to this instruction manual should be ordered immediately to us, Fuso
Industries Co., Ltd. or our agent. Failure to use with this instruction manual may cause an
accident.
−
In the event of transferring this machine to next owner, this instruction manual must be with it to.
Contact Information
If you need further information and have any questions, contact below address.
■
Fuso Industries Co., Ltd.
Fuso Industries Co., Ltd. Headquarters 1st Factory/Sales Division
1404-33, Sabaka, Kikugawa-shi, Shizuoka-ken 439-0003 Japan
TEL: (0548) 27-2316
FAX: (0548) 27-2318
Fuso Industries Co., Ltd. 2nd Factory
1404-6, Sabaka, Kikugawa-shi, Shizuoka-ken 439-0003 Japan
TEL: (0548) 27-2355
FAX: (0548) 27-2488
Fuso Industries Co., Ltd. Packaging and Procurement Division
1404-113, Sabaka, Kikugawa-shi, Shizuoka-ken 439-0003 Japan
TEL: (0548) 27-2733
■
FAX: (0548) 27-2839
Agent
In the event of making a contract with our agent, please make sure that name, address and TEL/FAX
numbers are listed on it.
(Name of agent/address/contact information)
v
Contents of this Instruction Manual
Contents of this Instruction Manual
This instruction manual contains following sections.
Name of Section/Chapter
Warranty, Disclaimer
Contents
Listed our warranty and warranty period.
Exception of warranty is included in disclaimer.
Important Information
Described important information about this machine and
instruction manual.
Described revision record after this instruction is issued.
Revision Record
1 Safety
Described safety information to operators, safety measure of
the machine, information of ensuring hygiene control on
products and management contents regarding work safety
which is required when operating the machine. This chapter
is also used for education and training of safety.
2 Overview of the Machine
Described machine specification of main equipment that
makes up this machine and preparation by customers. Pay
attention to contents of specification limits.
3 Operation
Described function of operation panel, preparation of
operation and operation procedure.
4 Cleaning
Described cleaning/washing after normal operation and
regularly.
5 Maintenance/Inspection
Described maintenance/inspection of oil filling, inspection,
adjustment and parts replacement for this machine. See each
instruction book for maintenance/inspection of accessory
equipment.
6 Troubleshooting
Described cause and measures for failure while operating
the machine.
7 Accessories/Consumable Parts List Described accessories/consumable parts of this machine.
8 Installation
Described installation procedure of this machine and
precaution.
vi
Revision Record
Revision Record
Manual Title
Packing Machine for
Rectangular Teabag
FP-80T Type
Rev. No.
Date
Revised
First
Rev.1
Dec, 2010
Jun, 2014
Doc. No.
FS-23T-TFCE11-ENG
Date Issued
Dec, 2010
Contents of Revision (Clause, Pages and Contents, etc. of Revision Contents)
Added “Standard Lifetime Based on the Design”
Added caution for oscillator wiring
vii
Revision Record
viii
Contents
Contents
Introduction................................................................................................................... i
Warranty ...................................................................................................................... ii
Standard Lifetime Based on the Design ...................................................................... ii
Disclaimer................................................................................................................... iii
Important Information ................................................................................................. iv
Intended Usage of Machine ................................................................................... iv
To Use the Machine Safely..................................................................................... iv
About this Instruction Manual .................................................................................. v
Contact Information ................................................................................................. v
Contents of this Instruction Manual ............................................................................ vi
Revision Record ........................................................................................................ vii
Contents .................................................................................................................... viii
1
Safety ................................................................................................................ 1-1
1.1
General Precautions ............................................................................................. 1-2
1.1.1
Observance ................................................................................................... 1-2
1.1.2
Prohibitions .................................................................................................... 1-2
1.2
Warnings ............................................................................................................... 1-3
1.2.1
Types of Warnings and Their Meanings ......................................................... 1-3
1.2.2
Safety Labels ................................................................................................. 1-3
1.2.3
Safety Labels and Their Locations ................................................................. 1-4
1.3
Remaining Risks and Hazardous Area .................................................................. 1-6
1.4
Safety Devices ...................................................................................................... 1-7
1.4.1
[EMERGENCY STOP] Button ........................................................................ 1-7
1.4.2
Electrical Safety Devices (Interlock) ............................................................... 1-8
1.4.3
Safety Cover .................................................................................................. 1-9
1.5
Lockout/Tagout .................................................................................................... 1-10
1.5.1
Procedures for Locking Out/Tagging Out the Main Power ............................ 1-10
1.5.2
Procedures for Releasing Lockout/Tagout of the Main Power ...................... 1-10
1.6
Safety and Hygiene Control................................................................................. 1-11
1.6.1
Safety/Hygiene Education and Training ....................................................... 1-11
1.6.2
Personal Protective Equipment .................................................................... 1-15
1.6.3
Janitorial Maintenance ................................................................................. 1-15
1.6.4
Disposal of Waste Oil, Waste Fluid and Waste Materials ............................. 1-15
1.7
Action and Countermeasures to Emergency Situation......................................... 1-16
ix
Contents
2
3
Overview of the Machine................................................................................... 2-1
2.1
Overview of the Machine ....................................................................................... 2-2
2.2
Configuration of the Machine ................................................................................. 2-3
2.2.1
Name of Each Part......................................................................................... 2-3
2.2.2
Vertical/Horizontal Sealing Unit ...................................................................... 2-5
2.2.3
Air Pressure Device Unit ................................................................................ 2-6
2.2.4
Operation Panel ............................................................................................. 2-7
2.3
Specification of the Machine .................................................................................. 2-8
2.4
Optional Device ..................................................................................................... 2-9
Operation .......................................................................................................... 3-1
3.1
Precautions for Operation...................................................................................... 3-2
3.2
Overview of the Operation ..................................................................................... 3-3
3.3
Function of the Operation Panel ............................................................................ 3-4
3.3.1
Description of the Operation Panel................................................................. 3-4
3.3.2
Description of the STOP Screen .................................................................... 3-6
3.3.3
Description of the SET Screen ....................................................................... 3-7
3.3.4
Description of the AUTO Screen .................................................................... 3-9
3.3.5
Description of the DATA SETTING Screen ................................................... 3-11
3.4
Preparing for Operation and Adjustment .............................................................. 3-13
3.4.1
Inspection before Work ................................................................................ 3-13
3.4.2
Air Source Supply and Turning the Power ON ............................................. 3-13
3.4.3
Operation Check for Electrical Safety Devices ............................................. 3-14
3.4.4
Setting the Filter ........................................................................................... 3-15
3.4.5
Adjusting the Vertical Sealing Unit ............................................................... 3-19
3.4.6
Specifying Filter Feed Pitch .......................................................................... 3-23
3.4.7
Adjusting the Horizontal Sealing Unit ........................................................... 3-24
3.4.8
Adjusting the Tag Detection Sensor ............................................................. 3-28
3.5
Starting Operation ............................................................................................... 3-31
3.5.1
Setting Counter ............................................................................................ 3-31
3.5.2
Feeding Material and Operation Procedure.................................................. 3-32
3.5.3
Stopping the Operation of the Machine ........................................................ 3-34
3.6
Finishing Operation ............................................................................................. 3-35
x
Contents
4
Cleaning ............................................................................................................ 4-1
4.1
Precautions for Cleaning ....................................................................................... 4-2
4.2
Cleaning List ......................................................................................................... 4-3
4.3
Cleaning the Hopper ............................................................................................. 4-4
4.4
Cleaning the Volumetric Doser .............................................................................. 4-6
4.5
Cleaning the Tag Detection Sensor/ Film Joint Detection Sensor (Option) ............ 4-8
4.6
Cleaning the Filter Chute....................................................................................... 4-9
4.7
Cleaning the Vertical/Horizontal Sealing Unit....................................................... 4-10
4.8
Cleaning the Static Eliminator Bar ....................................................................... 4-11
4.9
Cleaning the Control Box .................................................................................... 4-12
4.10 Removing the Vertical Seal and Cut Pieces ........................................................ 4-14
5
Maintenance/Inspection ..................................................................................... 5-1
5.1
Precautions for Maintenance/Inspection ................................................................ 5-2
5.2
Maintenance/Inspection List .................................................................................. 5-3
5.3
Inspecting the Volumetric Doser ............................................................................ 5-4
5.4
Inspecting the Ultrasonic Horn (Vertical Sealing Unit/Horizontal Sealing Unit) ....... 5-5
5.5
Inspecting the Disc (Vertical Sealing Unit/Horizontal Sealing Unit) ........................ 5-7
5.6
Replacing the Ultrasonic Horn (Vertical Sealing Unit) ............................................ 5-8
5.6.1
Removal ........................................................................................................ 5-9
5.6.2
Replacement.................................................................................................. 5-9
5.6.3
Attachment................................................................................................... 5-11
5.7
Replacing the Ultrasonic Horn (Horizontal Sealing Unit) ...................................... 5-13
5.7.1
Removal ...................................................................................................... 5-14
5.7.2
Replacement................................................................................................ 5-14
5.7.3
Attachment................................................................................................... 5-16
5.7.4
Adjusting the Sealing Intensity ..................................................................... 5-17
5.8
Replacing the Perforation Disc (Vertical Sealing Unit) ......................................... 5-19
5.8.1
Removal ...................................................................................................... 5-19
5.8.2
Attachment................................................................................................... 5-20
5.9
Replacing the Horizontal Disc (Horizontal Sealing Unit) ...................................... 5-21
5.9.1
Removal ...................................................................................................... 5-21
5.9.2
Replacement................................................................................................ 5-22
5.9.3
Attachment................................................................................................... 5-22
5.10 Replacing the Ultrasonic Generator Fuse ............................................................ 5-23
5.11 Replacing the PLC Battery .................................................................................. 5-24
5.12 Replacing the Silicon Rubber (Horizontal Sealing Unit) ....................................... 5-25
5.13 Adjusting the Volumetric Doser ........................................................................... 5-26
5.14 Adjusting the Ultrasonic Horn (Vertical Sealing Unit) ........................................... 5-28
xi
Contents
5.15 Adjusting the Ultrasonic Horn (Horizontal Sealing Unit) ....................................... 5-29
5.16 Adjusting the Perforation Disc (Vertical Sealing Unit) .......................................... 5-30
5.17 Adjusting the Disc (Horizontal Sealing Unit) ........................................................ 5-31
5.18 Adjusting the Jaws Speed ................................................................................... 5-32
5.19 Adjusting the Traverse Speed .............................................................................. 5-34
5.20 Teaching the Tag Detection Sensor ..................................................................... 5-36
5.20.1 Tag Detection Sensor Power Tuning ............................................................ 5-37
5.20.2 Teaching the Tag Detection Sensor (Setting the Threshold Value) ............... 5-38
5.21 Teaching the Film Joint Detection Sensor (Option) .............................................. 5-41
5.21.1 Film Joint Detection Sensor Power Tuning ................................................... 5-42
5.21.2 Teaching the Film Joint Detection Sensor (Setting the Threshold Value) ...... 5-43
5.22 Lubricating the Sliding Section ............................................................................ 5-46
6
7
8
Troubleshooting ................................................................................................ 6-1
6.1
Precautions on the Troubleshooting ...................................................................... 6-2
6.2
Error Alarm and its Releasing Method ................................................................... 6-3
6.3
Other Errors .......................................................................................................... 6-7
Accessories/Consumable Parts List .................................................................. 7-1
7.1
Accessories List .................................................................................................... 7-2
7.2
Consumable Parts List .......................................................................................... 7-4
Installation ......................................................................................................... 8-1
8.1
Overview for Installation ........................................................................................ 8-2
8.2
Preparation before Installation ............................................................................... 8-3
8.2.1
Base .............................................................................................................. 8-3
8.2.2
Machine Installation Circumstances ............................................................... 8-3
8.2.3
Utility .............................................................................................................. 8-3
8.2.4
Obtaining the Installation Area ....................................................................... 8-5
8.3
Carrying in the Machine ........................................................................................ 8-6
8.4
Machine Installation............................................................................................... 8-7
8.5
Operation Check ................................................................................................... 8-7
xii
1 Safety
1
Safety
Safety precautions in this chapter are to be a guideline for preventing physical injury of a person
engaged in the machine.
Items in this section can be used as regular safety education and training as well as a single reference.
This chapter describes the following contents.
•
General Precautions
•
Warnings
•
Remaining Risks and Hazardous Area
•
Safety Devices
•
Lockout/Tagout
•
Safety and Hygiene Control
•
Action and Countermeasures to Emergency Situation
1-1
1.1 General Precautions
1.1
General Precautions
General precautions are described as an observance and prohibitions.
1.1.1
1.1.2
Observance
•
Nobody can approach to the machine, except a person who is educated and trained for remaining
risk and preventing its risk.
•
The machine installation and remodeling should be requested to Fuso Industries Co., Ltd. or our
agent.
Remodeling that can lose safety of the operator and the machine and changes of operation
procedures and operation modes may cause serious injury and damage to the machine.
•
Perform periodical inspection to confirm that all functions of the safety devices work normally.
•
If safety devices do not activate correctly, stop operating the machine and inform person
responsible for the machine. Person responsible for the machine should inform us immediately.
•
Before turning the [MAIN POWER] switch "ON", verify that there are no personnel around the
machine.
•
If the machine stopped due to unknown causes, restart the machine after receiving permission of
the person responsible for the machine.
•
If there are failures in the switches, do not restart the machine on any terms before repairing the
switches.
•
If you find any signs during operation that may lose your safety, such as abnormal sound,
vibration, temperature, and excessive load, stop the machine immediately and inform the person
responsible for the machine. Then, follow his/her instruction.
•
After operation, always perform cleaning/washing following the instruction manual.
•
When cleaning the machine, always check for foreign objects.
•
Spilt product or cleaning solvent on the floor may cause slipping/tripping. Be sure to wipe them
off.
•
Put tools and others used for work away in a designated place after use. If any foreign objects such
as tools, bolts, or nuts remain in the container, quality defect of the product may occur as well as
breakage in the parts.
•
Follow the instruction manual for the replacement cycle of the machine parts.
•
If product requires treatment such as hot material, and materials for cleaning/disinfecting that are
dangerous to human body, always wear personal protective equipment such as heat-resistant
gloves, protective glasses, and protective masks designated in the instruction manual, and follow
the details in the MSDS (Material Safety Data Sheet) for usage.
Prohibitions
•
DO NOT remove safety devices and other parts.
•
DO NOT operate nor adjust the machine with functions such as interlock switches on the safety
cover disabled by taping/clasping.
•
DO NOT inspect nor adjust the machine during operation, except for designated sections.
•
DO NOT place anything on the machine.
•
DO NOT wear neckties or things as there is a possibility of being entangled.
•
Wear work outfits whose sleeves can be hooked. Otherwise, the sleeves may be entangled into the
machine.
•
DO NOT have anything in the pocket of your work outfit. Otherwise, objects may fall into the
machine and may cause problems on the product and the machine.
•
DO NOT perform any work with your hair exposed to prevent your hair from being entangled or
mixing into the product.
•
DO NOT work around the machine without wearing personal protective equipment.
•
DO NOT touch moving parts of the machine during operation.
1-2
1.2 Warnings
1.2
Warnings
To alert operators to danger, the following two measures are always provided with the machine.
1.2.1
•
Warnings described in this instruction manual
•
Safety labels affixed on the machine
Types of Warnings and Their Meanings
This manual includes the following four types of warnings to be used for expected hazards during
operation of the machine.
Neglecting such warnings may cause accidents, resulting in personal injury or even death.
Also this machine or its auxiliary equipment may be damaged seriously or may break.
Be sure to always observe the instructions of the warnings.
" DANGER" indicates an imminently hazardous situation which, if
not avoided, will result in serous injury or death.
" WARNING" indicates a potential hazardous situation which, if
not avoided, could result in serous injury or death.
" CAUTION" indicates a potential hazardous situation which, if not
avoided, may result in minor or moderate injury.
"CAUTION" used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may result in
property damage.
"NOTE" is used to emphasize important matters or useful information
for the machine operation or maintenance.
1.2.2
Safety Labels
Precautions to observe in order to prevent you and other workers from injury or to prevent properties
from damaging, are indicated by types and locations of the safety labels.
Always follow the warnings instructed on the safety label affixed on the machine, and descriptions in
this instruction manual.
 Be sure to follow the instructions of the safety labels.
Otherwise, danger resulting in personal injury, death, or property
damage may arise.
 Do not smear, cover, or peel off the safety labels.
If the safety labels on the machine are damaged or missing from the
machine, place a purchase order for new labels and affix them to their
proper positions.
If the safety labels on the machine are damaged or missing from the machine, place a
purchase order for new labels and affix them to their proper positions according to this
instruction manual.
1-3
1.2 Warnings
1.2.3
Safety Labels and Their Locations
Safety labels and their locations on the machine are described below.
1.2.3.1
Locations of Safety Labels
Locations of Safety Labels (Exterior of the Machine)
Locations of Safety Labels (Inside of the Machine)
1-4
1.2 Warnings
1.2.3.2
Types of Safety Labels
No.
1
Label
No.
5
2
6
3
7
4
8
1-5
Label
1.3 Remaining Risks and Hazardous Area
1.3
Remaining Risks and Hazardous Area
There are remaining risks and hazardous area while operating the machine.
 Keep your hands and fingers away from the filter roll section and material feed
section during operation.
There are no covers on it. Your fingers and hands can be caught resulting in injury.
Hazardous Area
No.
1
2
Description
Filter roll section
Material feed section
1-6
1.4 Safety Devices
1.4
Safety Devices
This machine is equipped with following safety devices.
•
Emergency button
•
Interlock switch for safety door
•
Lockout mechanism of [MAIN POWER] switch
Safety devices not only ensure safety of operators but also protect the machine and metals.
Therefore, before beginning the work, be sure to perform function test of the safety devices. If any
malfunction is found, inform your supervisor immediately. Do not operate the machine until functions
of the safety devices recover to normal status.
1.4.1
[EMERGENCY STOP] Button
Press [EMERGENCY STOP] button to stop the machine immediately.
Remove the cause of the abnormality, and then recover the machine from emergency stop.
[EMERGENCY STOP] Button
No.
1
■
Emergency Stop Procedures
1
■
Description
[EMERGENCY STOP] button
Press the [EMERGENCY STOP] button.
The machine stops immediately.
Recovery Procedures
1
Turn the [STOP/FILTER SET/AUTO] selector switch to "STOP" mode.
2
Turn the [MAIN POWER] switch "OFF".
3
Remove the cause of the abnormality.
4
Turn the [EMERGENCY STOP] button clockwise to release the lock.
5
Turn the [MAIN POWER] switch "ON".
6
Press the [SFC RESET] button.
7
Press the [ALARM RESET].
8
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
9
Press the [START] button.
The machine starts running.
1-7
1.4 Safety Devices
1.4.2
Electrical Safety Devices (Interlock)
If the safety door is opened during automatic operation, an interlock activates and stops the machine.
Close the safety door and recover the machine.
The interlock switch is furnished at the following position.
•
Safety door on the operation side
Interlock Switch
No.
1
■
Description
Interlock switch
Activation Check
1
Open the safety door on the operation side during automatic operation.
Interlock switch is activated and the machine stops.
When interlock switch is activated, alarm buzzer sounds and [DOOR OPEN] is indicated on the
LCD touch panel.
■
Recovery Procedures
1
Close the safety door.
2
Press the [SFC RESET] button.
3
Press the [ALARM RESET].
4
Select operating motions.
5
Press the [START] button.
The machine starts running.
1-8
1.4 Safety Devices
1.4.3
Safety Cover
The ultrasonic generator is equipped with a safety cover secured by bolts.
 Do not remove the safety cover during operation.
It may result in injury.
Safety Cover
No.
1
2
Description
Safety cover
Bolt
1-9
1.5 Lockout/Tagout
1.5
Lockout/Tagout
1.5.1
Procedures for Locking Out/Tagging Out the Main
Power
1
Inform all the workers involved with the machine that the main breaker of the main power will
be locked out.
2
Check that the [START] button is turned OFF.
3
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
4
Turn the peripheral devices (such as weigher and elevating machine) OFF.
5
Turn [US POWER] OFF.
6
Turn the [MAIN POWER] switch "OFF".
7
Insert a padlock into the [MAIN POWER] switch. Lock the padlock with a key so that the
[MAIN POWER] switch is fixed to OFF position.
The worker should keep the key during work, or the person responsible for the machine should
keep it.
Locking Out the Main Power
No.
1
2
8
1.5.2
Description
[MAIN POWER] switch
Padlock
Attach a label indicating that the power supply is locked out, on or near the main breaker.
Following information is indicated on the label.
•
Contact information of the person responsible for the machine
•
Date of lockout
•
Brief description on the purpose of lockout
Procedures for Releasing Lockout/Tagout of the Main
Power
1
After completion of tasks required for lockout, confirm that there is no danger to all workers in
the area.
2
Remove the label.
3
Remove the padlock
4
Inform all the workers involved with the machine that lockout for the main breaker of the main
power will be released.
1-10
1.6 Safety and Hygiene Control
1.6
Safety and Hygiene Control
This section provides information (for reference) from the manufacturer about the work safety and
hygiene control of the product implemented by your company.
Utilize this information to prevent physical injury in conjunction with the requirements from local,
state or federal acts and regulations and your company's own safety management rules.
1.6.1
Safety/Hygiene Education and Training
Safety/hygiene related skills can be improved by education, as well as other work techniques.
Safety/hygiene related items must be included in the education and training carried out by your
company. Specific safety/hygiene instructions related to the operation of the machine can be explained
during training for the machine operation by us, though, this is not enough.
All users in your company must be trained to raise awareness of safety/hygiene in order to recognize
the potential hazards, develop a mental attitude of alertness, and quickly respond to hazards. Also, it is
necessary to always observe the established procedures.
By raising awareness of safety/hygiene, workers can judge the situation, avoid dangerous action, keep
away from dangerous area, have a prevision of potential hazards, and take action to protect themselves.
The following shows the items considered to be least required for safety/hygiene education and
training.
1.6.1.1
Understanding and Observance of the Description in this
Instruction Manual
Make workers fully understand the following descriptions in this instruction manual and also train
them how to avoid the dangers involved in the actual machine.
−
Fuso Industries Co., Ltd. will not be liable for any damage or injury arising from an individual's
failure to follow the instructions or warnings included in this "Packaging Machine for Rectangular
Teabag FP-80T Type" instruction manual.
−
The copyright by which the drawings and technical references, including this instruction manual,
shall not, in whole or part, be copied, photocopied, or reproduced to any electronic medium or
machine-readable form without any prior permission from Fuso Industries Co., Ltd. as stated in
"Important Information".
−
Details described in "1.1 General Precautions" and "1.2 Warnings".
−
Precautions described in "3 Operation", "4 Cleaning", and "5 Maintenance/Inspection" in this
instruction manual.
If any worker whose native language is not English is involved in any work on the
machine, you shall give him or her through safety training of the machine on your
company's responsibility.
1.6.1.2
Precautions after Power Supply is Shut Off
−
If there are possibilities for the workers to get injured (especially when cleaning, performing
maintenace/inspection, or troubleshooting), turn the [MAIN POWER] switch "OFF".
−
In the following situations, workers may neglect to turn the power off. Clearly inform workers and
its necessity of turning the power off.
•
Turning the [MAIN POWER] switch "OFF" before performing work is troublesome for
workers. Therefore, they may neglect to turn the power off.
1-11
1.6 Safety and Hygiene Control
•
1.6.1.3
Workers may judge that there is no danger and do not turn the [MAIN POWER] switch
"OFF".
Handling of Hazardous Materials
Manage information such as distributed information and education/training contents since the workers
must handle hazardous materials. Especially, take caution on the following points.
−
Make sure to furnish the proper ventilation system in the area where hazardous materials are used,
and perform maintenance and inspection of the ventilation system periodically.
−
Follow all manufacturer recommendations for handling and storing hazardous materials.
−
Apply labels on all containers of hazardous materials in the workplace; then instruct workers how
to handle such hazardous materials observing the instructions of JIS Z7250 (established in
February 2000).
−
Check the Material Safety Data Sheet (MSDS) before handling any hazardous material.
−
The Material Safety Data Sheet (MSDS) gives specific details on physical and health hazards,
safety procedures, and emergency plans as shown on an example MSDS form on the following
pages.
−
Ensure workers to wear personal protective equipment (such as gloves, apron, and protective
glasses) when handling hazardous materials, following the manufacturer recommendations on
handling the hazardous materials.
−
Inform workers of the location and appropriate usage of an eye wash station in case of exposure to
hazardous materials.
−
Workers who handle hazardous materials must wash his/her hand before eating, drinking, or
smoking.
−
Call the worker responsible for hazardous materials in case of an emergency. Such worker shall be
educated and trained as to the handling of hazardous materials in case of an emergency.
1-12
1.6 Safety and Hygiene Control
1.6.1.4
Material Safety Data Sheet (MSDS)
The following is an example of the Material Safety Data Sheet (MSDS) standard form.
1-13
1.6 Safety and Hygiene Control
1-14
1.6 Safety and Hygiene Control
1.6.2
Personal Protective Equipment
Wear protective equipments specified in your company's safety standard when working.
1.6.3
Janitorial Maintenance
Poor janitorial maintenance results in tripping hazards, lack of room, and the possibility of slipping and
falling. Janitorial maintenance has a great influence on working environment. It has been found that
when when janitorial maintenance is good, work attitude becomes better, efficiency of the work
improves, and there are fewer injuries.
Though the following items may be already practiced by your company, some methods to improve
janitorial maintenance are:
1.6.3.1
1.6.4
−
Have a definite place for everything.
−
Keep everything in its place and return it when moved.
−
Put scrap and waste in proper containers.
−
Put cans, bottles, wrappers, etc., in the proper waste or recycling receptacles.
Examples of Poor Janitorial Maintenance that may Cause
Accidents
−
Objects left over on the floor: may result in tripping hazards
−
Slippery materials on the floor: may result in slipping hazards
−
Objects left overhead: may fall on someone
−
Objects out of its place: worker may accidentally bump or strike against
−
Insecurely piled objects: may shift or fall on worker unexpectedly
−
Improperly stored tools: may cause cuts and bruises
−
Trash and disorderly surroundings: foster bad attitudes and work habits
Disposal of Waste Oil, Waste Fluid and Waste
Materials
Disposing of materials and filters used for this machine, or the machine main body are subject to a
number of regulations for the environmental protection purposes. Follow the local, state, federal acts
and regulations and your company's rules when disposing of such materials.
1-15
1.7 Action and Countermeasures to Emergency Situation
1.7
Action and Countermeasures to Emergency
Situation
An emergency plan shall be established to rescue and provide aid to a worker who may be involved in
an accident while working with or on the machine. The emergency plan may include:
−
names of individuals to be contacted to assist in the rescue;
−
a procedure to be followed for releasing an entrapped hand, finger, or a part of body;
−
training of at least one person per work party in rescue procedures; and
−
appropriate tools and equipment to achieve rescue.
1-16
2 Overview of the Machine
2
Overview of the Machine
This chapter describes the following contents.
•
Overview of the Machine
•
Configuration of the Machine
•
Specification of the Machine
•
Optional Device
2-1
2.1 Overview of the Machine
2.1
Overview of the Machine
This section describes overview of the machine.
Packaging Machine for Rectangular Teabag (FP-80T Type) of Fuso Industries Co., Ltd. is a machine
that feeds raw material for the extraction of beverage use to a tea bag filter and seals the tea bag by seal
and cut packing with three-dimensional ultrasonic system.
2-2
2.2 Configuration of the Machine
2.2
Configuration of the Machine
This section describes configuration of the machine.
This machine is composed of filter roll section, filter chute tower, material feed section, bag outlet
section, vertical sealing unit, horizontal sealing unit, air pressure device unit, and operation panel.
2.2.1
Name of Each Part
Names and locations of each component which comprise the machine are as follows.
Name of the Component
2-3
2.2 Configuration of the Machine
No.
1
Section Name
Description
Feed roll holding lever
2
Filter feed motor
3
Filter grip roller
4
5
Filter roll section
Filter intermediate roller
Filter roll fixing lever
6
Filter roll
7
Filter roll fixing spring
8
Filter dancer roller
9
Safety door on the operation side
10
Filter chute roller
11
Tag detection sensor stay
12
Filter chute tower
13
Filter chute angle adjusting knob
14
15
Tag detection sensor
Filter chute
Operation panel
Operation panel
16
Waste filter air purge pipe
17
Hopper
18
Material feed section
Volumetric doser
19
Material volume adjusting handle
20
Safety door on the right side
21
Bag outlet section
Bag outlet chute
22
[MAIN POWER] switch
23
Control box
A
B
Vertical/horizontal
sealing unit
Air pressure device unit
See "2.2.2 Vertical/Horizontal Sealing Unit".
Air pressure device
2-4
2.2 Configuration of the Machine
2.2.2
Vertical/Horizontal Sealing Unit
This machine incorporate ultrasonic generator, which seals and cuts the filter vertically and
horizontally by its ultrasonic wave.
Names and locations of each component which comprise the horizontal sealing unit are as follows.
Vertical/Horizontal Sealing Unit
No.
1
Description
Traverse section
2
Jaws
3
Horizontal disc
4
Horizontal disc air cylinder
5
Horizontal ultrasonic horn
6
Static eliminator bar
7
Vertical ultrasonic horn
8
Filter vertical feed roller
9
Perforation disc
10
Vertical disc contact pressure adjusting knob
2-5
2.2 Configuration of the Machine
2.2.3
Air Pressure Device Unit
Names and locations of each component which comprise the air pressure device unit are as follows.
Opposite Side of the Lower Part of the Operation Side
Lower Part of the Right Side
No.
1
Description
Jaws air cylinder solenoid valve (SV1)
2
Traverse air cylinder solenoid valve (SV2)
3
Poker solenoid valve (SV4) (option)
4
Knocker solenoid valve (SV5) (option)
5
Spare (SV6) (option)
6
Bagging section main air regulator (RG1)
7
Horn cooling regulator (RG2)
2-6
2.2 Configuration of the Machine
2.2.4
Operation Panel
Names and locations of each operation button and indicator which comprise the operation panel are as
follows.
See "3.3.1 Description of Operation Panel" for usage of each operation button on the
operation panel and explanation of the alarm lamp.
See "6.2 Error Alarm and its Canceling Method" for the cause of the error alarm on the
operation panel and how to cancel the alarm.
Operation Panel
No.
1
Alarm lamp
Description
2
Power lamp
3
LCD touch panel
4
[STOP/FILTER SET/AUTO] selector switch
5
[EMERGENCY STOP] button
6
Alarm buzzer
7
[START] button
8
[STOP] button
9
[SFC RESET] button
2-7
2.3 Specification of the Machine
2.3
Specification of the Machine
Specification of this machine is as follows.
Description
Item
Specification
Packaging Machine for Rectangular Teabag
Type
FP-80T type
Bag sealing system
Three-dimensional ultrasonic seal and cut system
Dimension
820 (W) × 970 (D) × 2255 (H) mm
Weight
450 kg
Electric power
Main unit : 3-Phase 200V, 3.0 kW
Compressor : 3-Phase 200 V, 3.7 kW
Air dryer : 100 VAC, 0.4 kW
Amount of air used
0.6 MPa/280 L/min (Dry air)
Air outlet
Steel hose nipple 3/8 × 12φ
Packing item
Raw material for the extraction of beverage use such as tea and
coffee
2 to 8 g max. 17 cc (for volumetric doser only)
Option filter chute is available (depending on packing amount)
Filter chute: There is a choice among 120, 140, 160, and 180 mm
To install weigher (option), see the instruction manual "Automatic
weigher for small quantity (FW-100SA (N) Type)" seperately issued.
Nylon
Polyester gauze
Non-woven fabric
Others (material that can be sealed and cut by ultrasonic wave)
Non-tagged filter
Tagged filter (determined in the arrangement in advance)
Max. 100 bags/min.
Packing amount
Material of filter
Type of filter
Packing capacity
Tea bag size
Width of filter in use: 120 to 180 mm
Rectangular tea bag: 60 to 80 (W) × 40 to 80 (L) mm
Weighing method
Hopper
Volume weighing by volumetric doser
Weighing by load cell by a weigher (option)
15 mm width pulling strength approx. 200 g
May have an error by wear of ultrasonic horn disc
18 L
Usage environment
Air-conditioned factory
Safety measure
Safety cover on the vertical/horizontal sealing unit
[EMERGENCY STOP] button (operation panel)
Interlock switch (safety door)
when safety cover is opened during operation, the machine will stop
and alarm occurs.
Ultrasonic seal cut
2-8
2.4 Optional Device
2.4
Optional Device
See documents attached to each optional device for detailed usage.
Description
Automatic weigher for small
quantity (FW-100SA (N)
Type)
Sub-hopper poker
Performance
Capable of high accuracy weighing by load cell
Material chute knocker
Prevents clogging of the material in material chute.
Doser vibrator
Prevents clogging of the material in volumetric doser
Filter joint alarm device
Detects the seam of the filter.
Prevents clogging of the material in sub hopper.
2-9
2.4 Optional Device
2-10
3 Operation
3
Operation
This chapter describes the following contents.

Precautions for Operation

Overview of the Operation

Function of the Operation Panel

Preparing for Operation and Adjustment

Starting Operation

Finishing Operation
3-1
3.1 Precautions for Operation
3.1
Precautions for Operation
This section describes precautions to be observed when operating the machine.
Read the precautions carefully and fully understand it before operating the machine.
 Do not put hands or body into part without a cover including the top of main unit
during operation.
It may cause injury.
 When running the filter between the filter grip roller and the filter intermediate roller,
be careful not to get your hand caught.
 When running the filter through tea bag filter vertical feed roller, be careful not to get
your hand caught.
 Do not touch tea bag filter horizontal traverse section during operation.
Otherwise, your hands can be caught or hit.
 As the machine starts operating, make sure for your safety when working on the
machine.
 After stopping the machine, make sure for your safety when working on the
machine.
 During operation or immediately after stopping the operation, do not directly touch
on ultrasonic oscillator device section.
It may cause burn injury due to temperature rise.
 If there is any danger during operation, press the [EMERGENCY STOP] button
immediately.
 Do not manually operate solenoid valve (operation check) during automatic
operation.
It may cause damage.
 Close the drain cock for compressor without fail.
Otherwise, air pressure decreases, cooling power to cool the ultrasonic device
decreases, and the machine may not work correctly.
 Too much air pressure may cause excessive contact strength between the
ultrasonic horn and the disc.
It may cause wear-out failure.
3-2
3.2 Overview of the Operation
3.2
Overview of the Operation
This section describes overview of the operation.
Operation procedure from preparation to finishing is as follows.
Operation preparation procedure varies depending on the specification.
Inspection before Work
See section 3.4.1
Supply power source
Supply air source
See section 3.4.2
Supply electric source
(Main unit power-on)
(Peripheral device power-on)
Operation preparation
Operation Check for Electrical Safety Devices
Setting the Filter
Adjusting the Vertical Sealing Unit
Specifying Filter Feed Pitch
Adjusting the Horizontal Sealing Unit
Adjusting the Tag Detection Sensor
See section 3.4.3
See section 3.4.4
See section 3.4.5
See section 3.4.6
See section 3.4.7
See section 3.4.8
Starting Operation
Setting Counter
Feeding Material and Operation Procedure
See section 3.5.1
See section 3.5.2
Finishing Operation
See section 3.6
3-3
3.3 Function of the Operation Panel
3.3
Function of the Operation Panel
This section describes how to operate the operation panel, LCD touch panel, and their display contents,
which are required to operate the machine. Main functions of the operation panel and the LCD touch
panel are as follows.
3.3.1

Operation of automatic operation

Operation of manual operation

Operation of machine element

Operation in error occurrence
Description of the Operation Panel
Functions of switches and buttons on the operation panel are as follows.
Operation Panel
1.
Alarm lamp
This alarm lamp illuminates when an error occurred on the
machine.
2.
Power lamp
This lamp illuminates by turning the [MAIN POWER] switch
"ON".
3-4
3.3 Function of the Operation Panel
3.
LCD touch panel
Displays the operation screen.
Screens that are displayed differ depending on the mode of
[STOP/FILTER SET/AUTO] selector switch.
In [STOP] mode: STOP screen
In [FILTER SET] mode: SET (preparation for operation) screen
In [AUTO] mode: AUTO (automatic operation) screen
4.
[STOP/FILTER SET/AUTO] selector switch
This is a selector switch to select the machine motion.
Screens displayed on the LCD touch panel switch over by turning
this selector switch.
Select "STOP", "FILTER SET", or "AUTO" depending on the
situation.
5.
[EMERGENCY STOP] button
This button is to stop the machine immediately in an emergency.
By pressing this button, the machine stops immediately and the
power to the PLC is turned OFF.
In the case of danger during machine operation, press this button
immediately.
6.
Alarm buzzer
This is a buzzer device to generate warning sound in error
occurrence.
7.
[START] button
This button is to start/stop automatic operation.
Pressing this button after turning the [STOP/FILTER SET/AUTO]
selector switch to "AUTO" mode, the machine starts automatic
operation continuously.
Pressing this button after turning the [STOP/FILTER SET/AUTO]
selector switch to "FILTER SET" mode, the machine operates for
one cycle and stops.
This also indicates the status of the machine by illuminating,
flashing, or turning off.
Illuminating: the machine is operating
Flashing: the machine is stopped with it not in the origin point
Light turned off: machine is stopped
8.
[STOP] button
This button is to stop the machine.
Pressing this button during automatic operation stops the machine.
3-5
3.3 Function of the Operation Panel
9.
3.3.2
[SFC RESET] button
This button is to reset the control section.
Pressing this button when "RESET SFC" is displayed on the
message indicator will reset the control section.
Description of the STOP Screen
The STOP screen is displayed when the [STOP/FILTER SET/AUTO] selector switch is turned to
"STOP" mode.
STOP Screen
1.
ZERO
Indicates the angle of the main motor axis of the machine.
2.
[FILTER]
This button selects the operation of the filter.
Press this button to select the operation mode of the filter ("BY
BAG" or "BY PITCH").
Indicates the current operation mode of a filter.
3-6
3.3 Function of the Operation Panel
3.
FEED
Indicates the dimension of the current filter.
Indicates the value set at [FILTER FEED PITCH] on the DATA
SETTING screen.
(See "3.3.5 Description of the DATA SETTING Screen")
4.
CPTY
B/M
Indicates the current operation capacity (speed).
Indicates the value set at [CAPACITY] on the DATA SETTING
screen.
(See "3.3.5 Description of the DATA SETTING Screen")
3.3.3
Description of the SET Screen
The SET screen is displayed when the [STOP/FILTER SET/AUTO] selector switch is turned to
"FILTER SET" mode.
SET Screen
1.
[FILTER SLOW FEED]
This button is to operate filter vertical feed roller.
While pressing this button, the filter vertical feed roller is operated.
It is used when setting the filter.
3-7
3.3 Function of the Operation Panel
2.
[US POWER]
This button is to operate vertical/horizontal sealing unit.
By turning this button ON, the ultrasonic generator for ultrasonic
vertical/horizontal seal and cut will turn ON.
When the button is OFF, manual operation and automatic operation
is not available.
3.
[DOSER]/[WEIGHER] (option)
This button is to operate volumetric doser or a weigher (option).
By turning this button ON, the material fed into the hopper will be
discharged in the set amount.
4.
[ALARM RESET]
This button is to reset alarm displayed on the message indicator.
3-8
3.3 Function of the Operation Panel
3.3.4
Description of the AUTO Screen
The AUTO screen is displayed when the [STOP/FILTER SET/AUTO] selector switch is turned to
"AUTO" mode.
AUTO Screen
1.
[JAWS]
This button is to operate jaws. By turning this button ON, jaws
becomes operable. Pressing the [START] button operates the jaws.
2.
TRAVERSE
This button is to operate traverse section.
By turning this button ON, traverse section becomes operable.
[TRAVERESE] can be operated when the [JAWS] is turned ON.
Pressing the [START] button operates the traverse section.
3.
[NWF AIR]
This button is to operate non-woven fabric adapter set.
Turning this button ON operates the non-woven fabric adapter set.
4.
[FALL ASSIST] (option)
This button allows the material fall assist device (sub-hopper
poker, material chute knocker, and doser vibrator) to become
operable.
By turning this button ON, material fall assist device becomes
operable.
3-9
3.3 Function of the Operation Panel
5.
[US POWER]
See "3.3.3 Description of the SET Screen".
6.
[DOSER]/[WEIGHER] (option)
See "3.3.3 Description of the SET Screen".
7.
[COUNT]
This button allows the CURRENT counter to become operable.
By turning this button ON, CURRENT counter becomes operable.
8.
[RESET]
This button is to reset the current quantity of production.
By pressing this button, CURRENT counter becomes 0.
9.
[DATA SETTING]
This button is to display DATA SETTING screen.
Pressing this button displays the DATA SETTING screen.
10.
[ALARM RESET]
This button is to reset alarm displayed on the message indicator.
3-10
3.3 Function of the Operation Panel
3.3.5
Description of the DATA SETTING Screen
The DATA SETTING screen is displayed when the [DATA SETTING] is pressed on the AUTO screen
or PASSWORD screen.
DATA SETTING Screen
1.
[FILTER FEED PITCH] <40-80> mm
Sets the filter size.
The filter size is applied by pressing [ENT] after entering the
values with the numerical keypad.
2.
[TARGET] <1-999999> BAGS
Sets scheduled quantity of products to be produced.
The filter size is applied by pressing [ENT] after entering the
values with the numerical keypad.
3.
[CAPACITY] <60-80> B/M
It is used when changing the production capacity according to the
change of material.
The filter size is applied by pressing [ENT] after entering the
values with the numerical keypad.
4.
[TOTAL RESET]
This button is to reset the total quantity of production on the
AUTO screen.
Total count number on the AUTO screen is reset to 0 by pressing
this button.
3-11
3.3 Function of the Operation Panel
5.
Up/down arrow key
It is used when moving the cursor to each item on the DATA
SETTING screen.
6.
Numerical key pad
It is used when entering the values to each item on the DATA
SETTING screen.
7.
[ENT] key
It is used when determining the entered values to each item on the
DATA SETTING screen.
8.
[CL] key
It is used when clearing the values entered to each item on the
DATA SETTING screen.
9.
[AUTO]
This button is to display AUTO screen.
Pressing this button displays the AUTO screen.
10.
[PASSWORD]
This button is to display PASSWORD screen.
The PASSWORD screen will be operated by our service person.
You do not need to perform operation on this screen.
3-12
3.4 Preparing for Operation and Adjustment
3.4
Preparing for Operation and Adjustment
This section describes precautions to be observed for operating the machine, and performing
adjustment work.
Prepare for operation and adjust the machine before operating the machine.
3.4.1
Inspection before Work
Check followings before turning the machine ON.
3.4.2

If the safety cover is not loose

If no foreign object are in the material

If the machine and the peripherals are organized
Air Source Supply and Turning the Power ON
Method for air source supply and turning the power ON are as follows.
1
Turn the compressor ON.
2
Open the main air valve.
Send air to the machine.
Supply Air Source
No.
1
Section main air regulator
Description
2
Horn cooling air regulator
 Close the drain cock for compressor without fail.
Otherwise, air pressure decreases, cooling power to cool the ultrasonic device
decreases, and the machine may not work correctly.
3-13
3.4 Preparing for Operation and Adjustment
3
Turn the [MAIN POWER] switch "ON".
[MAIN POWER] Switch
No.
1
3.4.3
Description
[MAIN POWER] switch
4
Press the [SFC RESET] button.
5
Press [ALARM RESET] to reset the alarm.
6
Check the sound of cooling air for cooling the ultrasonic device.
7
Turn [US POWER] ON.
8
Turn the peripheral devices (such as weigher and elevating machine) ON.
Operation Check for Electrical Safety Devices
After turning the [MAIN POWER] switch "ON", make sure that [EMERGENCY STOP] button and
interlock switch for safety door operates normally. If not, immediately request inspection of safety
related devices to person in charge of maintenance.
For operation method of the electrical safety devices, see "1.4.1 [EMERGENCY STOP]
Button" and "1.4.2 Electrical Safety Devices (Interlock)".
3-14
3.4 Preparing for Operation and Adjustment
3.4.4
Setting the Filter
Filter setting procedure is as follows.
Setting the Filter
No.
1
Description
Filter feed motor
2
Feed roll holding lever
3
Filter grip roller
4
Filter intermediate roller
5
Filter roll fixing spring
6
Filter roll fixing lever
7
Paper air purge pipe
8
Filter chute roller
9
Tag detection sensor stay
10
Tag detection sensor
11
Filter chute angle adjusting knob
12
Filter chute
13
Filter dancer roller
1
Check that the safety door is closed.
2
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
3
Loosen the filter roll fixing lever, and remove the filter roll fixing spring.
4
Insert the filter roll into filter roll section to set the filter.
5
Attach the filter roll fixing spring and tighten the filter roll fixing lever.
6
When using tagged filter, insert the liner paper into the paper air purge pipe being careful so that
the liner paper will not be caught in the filter.
7
Lower the filter grip lever to open the filter grip roller.
8
Run the filter into the filter intermediate roller.
 When running the filter between the filter grip roller and the filter intermediate roller,
be careful not to get your hand caught.
9
Raise the filter grip lever to close the filter grip roller.
3-15
3.4 Preparing for Operation and Adjustment
10
Press [FILTER] and set to "BY PITCH" mode.
When adjusting filter edge, set [FILTER] to "BY PITCH" mode even though when using a
tagged filter.
11
Turn the [STOP/FILTER SET/AUTO] selector switch to "FILTER SET" mode.
12
Run the filter between the filter dancer roller and the filter chute roller.
13
Turn the filter chute angle adjusting knob and adjust chute angle.
Standard memory position is 0.
Filter Chute Angle Adjusting Knob
No.
1
Description
Filter chute
2
Filter chute angle adjusting knob
3
Scale
14
Turn the [STOP/FILTER SET/AUTO] selector switch to "STOP" mode.
15
Open the safety door on the operation side.
 If the safety door is opened when the [STOP/FILTER SET/AUTO] selector switch is
not set to "FILTER SET", air pressure and the power to the machine is shut off and
the [DOOR OPEN] alarm lamp displays.
16
Loosen the filter vertical feed roller dial.
Filter vertical feed roller dial
No.
1
Description
Filter vertical feed roller dial
3-16
3.4 Preparing for Operation and Adjustment
17
Run the filter through ditch of filter chute along with the filter chute.
18
Holding the filter, take it to the upper filter vertical feed roller with hand.
 When running the filter through tea bag filter vertical feed roller, be careful not to get
your hand caught.
Filter Vertical Feed Roller
No.
1
Description
Filter vertical feed roller
19
Tighten the filter vertical feed roller dial.
20
Close the safety door on the operation side.
21
Turn the [STOP/FILTER SET/AUTO] selector switch to "FILTER SET" mode.
22
Press the [SFC RESET] button.
23
Press [FILTER SLOW FEED] to run the filter as far as the position where the cut filter edge can
be seen.
24
Turn the [STOP/FILTER SET/AUTO] selector switch to "STOP" mode.
25
Open the safety door on the operation side.
26
Cut the end of the filter that is vertically seal-cut.
27
Put the cut end of the filter into the waste filter air purge pipe.
Waste Filter Air Purge Pipe (Insertion Slot)
No.
1
2
28
Description
End of the filter
Waste filter air purge pipe (Insertion Slot)
Adjust the filter adjusting guide in order to prevent meandering of the filter due to loosening.
3-17
3.4 Preparing for Operation and Adjustment
Filter Adjusting Guide
No.
1
Description
Filter adjusting guide
28-1
Loosen the attachment screw.
28-2
Hold the filter adjusting guide against the back of the filter.
28-3
Tighten the attachment screw.
29
Close the safety door on the operation side.
30
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
31
Press the [SFC RESET] button.
32
Turn [JAWS] ON.
33
Turn [TRAVERSE] ON.
34
Turn [US POWER] ON.
35
Press the [START] button.
Waste filter air purge pipe begins inhaling the end of the filter by air pressure.
36
Adjust the filter edge by adjusting the filter roll position with a filter roll positioning screw.
When adjusting the filter edge, it is required to feed the filter for about 50-60 cm until
the filter edge is adjusted properly. Make fine adjustment when operating the machine.
Adjustment of Filter Edge Misalignment
No.
1
Description
Filter
2
Filter roll fixing spring
3
Filter roll positioning screw
3-18
3.4 Preparing for Operation and Adjustment
3.4.5
Adjusting the Vertical Sealing Unit
Adjustment procedure of vertical sealing unit is as follows.
Vertical Sealing Unit
No.
1
Description
Filter vertical feed roller
2
Urethane belt
3
Perforation disc
4
Vertical disc contact pressure adjusting knob
5
Waste filter air purge pipe
6
Holding plate
7
Ultrasonic horn bracket
8
Oscillator
9
Oscillator screw
10
Ultrasonic horn (wear resistant)
1
Check that the safety door is closed.
2
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
3
Open the safety door on the operation side.
4
Turn and adjust the vertical disc contact pressure adjusting knob so that the perforation disc
slightly contacts with the ultrasonic horn.
 Be careful of the contact strength between the ultrasonic horn and the perforation
disc.
It may cause wear-out failure.
Turning the vertical disc contact pressure adjusting knob clockwise moves the
perforation disc to the back of operation side.
Turning the vertical disc contact pressure adjusting knob counterclockwise moves the
perforation disc to the front of operation side.
3-19
3.4 Preparing for Operation and Adjustment
Contact Position of Ultrasonic Horn and Perforation Disc
No.
1
Description
Ultrasonic horn
2
Perforation disc
5
Close the safety door on the operation side.
6
Turn the [STOP/FILTER SET/AUTO] selector switch to "FILTER SET" mode.
7
Turn [US POWER] ON.
8
Press [FILTER SLOW FEED] to feed the filter.
Ultrasonic wave seals and cuts the filter vertically.
 As the machine starts operating, make sure for your safety when working on the
machine.
While pressing [FILTER SLOW FEED], the filter vertical feed roller is operated.
9
Turn the [STOP/FILTER SET/AUTO] selector switch to "STOP" mode.
10
Open the safety door on the operation side.
11
Check that the ultrasonic wave vertically sealed and cut the filter.
If the filter is not vertically sealed and cut by ultrasonic wave, close the safety door and
perform adjustment again from step 1.
12
Close the safety door on the operation side.
13
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
14
Press the [SFC RESET] button.
15
Press the [ALARM RESET].
16
17
Turn [JAWS] ON.
Press the [START] button.
Filter vertical feed roller operates and feeds the filter.
 As the machine starts operating, make sure for your safety when working on the
machine.
18
Check that the end of the filter which is vertically sealed and cut is discharged from the waste
filter air purge pipe.
3-20
3.4 Preparing for Operation and Adjustment
Waste Filter Air Purge Pipe (Discharge Slot)
No.
1
2
Description
Waste filter air purge pipe
End of the filter
If the end of the filter is not discharged from the waste filter air purge pipe, press the
[STOP] button to stop the machine, turn the [STOP/FILTER SET/AUTO] selector switch
to "FILTER SET" mode, and perform adjustment again from Step 6.
19 From the bag outlet chute, pull out the vertically sealed and cut filter for approx. 30 cm, and then
press the [STOP] button.
Bag Outlet Chute
No.
1
20
Description
Bag outlet chute
Turn the [STOP/FILTER SET/AUTO] selector switch to "STOP" mode.
If the cut status of the vertical seal part is insufficient, see "5 Maintenance/Inspection"
and adjust or replace the ultrasonic horn and perforation disc.
21
Open the safety door on the operation side.
22
Turn the lock nut and fix the position of vertical disc contact pressure adjusting knob.
3-21
3.4 Preparing for Operation and Adjustment
Vertical Disc Contact Pressure Adjusting Knob
No.
1
2
23
Description
Lock nut
Vertical disc contact pressure adjusting knob
Close the safety door on the operation side.
3-22
3.4 Preparing for Operation and Adjustment
3.4.6
Specifying Filter Feed Pitch
Procedure for specifying filter feeding pitch is as follows.
Procedures for specifying filter feeding pitch vary between non-tagged filter and tagged filter.
Specify the feeding pitch depending on the filter type.
3.4.6.1
Specifying Feeding Pitch for Non-Tagged Filter
1
Check that the safety door is closed.
2
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
3
Press [FILTER] and set to "BY PITCH" mode.
4
Specify dimension of the product to produce on [FILTER FEED PITCH] on the DATA
SETTING screen.
4-1
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
4-2
Press [DATA SETTING] to display the DATA SETTING screen.
4-3
Press the up/down arrow key and set the cursor on "FILTER FEED PITCH".
4-4
Enter the dimension of the product to produce with the numerical keypad and press
[ENT].
Standard pitch of this machine is 40 mm to 80 mm.
3.4.6.2
Specifying Feeding Pitch for Tagged Filter
1
Check that the safety door is closed.
2
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
3
Press [FILTER] and set to "BY BAG" mode.
4
Measure distance between filter tags.
Measurement of Distance between Tags
5
Set the measured distance between the tags on the DATA SETTING screen.
5-1
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
5-2
Press [DATA SETTING] to display the DATA SETTING screen.
5-3
Press the up/down arrow key and set the cursor on "FILTER FEED PITCH".
5-4
Enter the dimension of the product to produce with the numerical keypad and press
[ENT].
If the distance between tags is 60 mm, the value to specify will be 60 mm.
3-23
3.4 Preparing for Operation and Adjustment
3.4.7
Adjusting the Horizontal Sealing Unit
Adjustment procedure of the horizontal sealing unit is as follows.
Horizontal Sealing Unit
No.
1
Description
Ultrasonic horn bracket
2
Horizontal disc
3
Horizontal disc air cylinder
4
Gasket
5
Oscillator
6
Oscillator screw
7
Ultrasonic horn (wear resistant)
1
Check that the safety door is closed.
2
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
Horizontal Disc Contact Pressure Adjuster
No.
1
Description
Pressure gauge
2
Lock nut
3
Horizontal disc contact pressure adjusting knob
3
Loosen the lock nut of the horizontal disc contact pressure adjuster.
4
Turn the horizontal disc contact pressure adjusting knob to set the air pressure to 0.2 to 0.3 MPa.
3-24
3.4 Preparing for Operation and Adjustment
 Be careful of the contact strength between the ultrasonic horn and the horizontal
disc.
It may cause wear-out failure.
Turning the horizontal disc contact pressure adjusting knob clockwise increases the air
pressure.
Turning the horizontal disc contact pressure adjusting knob counterclockwise
decreases the air pressure.
Contact Position of Ultrasonic Horn and Horizontal Disc
No.
1
Ultrasonic horn
Description
2
Horizontal disc
5
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
6
Turn [US POWER] ON.
7
Turn [JAWS] ON.
8
Turn [TRAVERSE] ON.
9
Press the [START] button.
Check that the filter vertical feed roller, jaws, horizontal seal and cut section, and horizontal disc
operates. Also, check that the filter is fed, and then sealed and cut horizontally by ultrasonic
wave.
 As the machine starts operating, make sure for your safety when working on the
machine.
10
Press the [STOP] button.
11
Turn the [STOP/FILTER SET/AUTO] selector switch to "STOP" mode.
12
Open the safety door on the operation side.
13
Check that the ultrasonic wave horizontally sealed and cut the filter.
If the filter is not horizontally sealed and cut by ultrasonic wave, close the safety door
and perform adjustment again from step 1.
14
Close the safety door on the operation side.
3-25
3.4 Preparing for Operation and Adjustment
15
When using tagged filter, adjust the tag detection sensor position.
For adjusting the tag detection sensor, see "3.4.8 Adjusting the Tag Detection Sensor".
16
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
17
Press the [SFC RESET] button.
18
Press the [START] button.
Check that the filter vertical feed roller, jaws, horizontal seal and cut section, and horizontal disc
operates. Also, check that the filter is fed, and then sealed and cut horizontally by ultrasonic
wave.
 As the machine starts operating, make sure for your safety when working on the
machine.
19
Press the [STOP] button.
20
Turn the [STOP/FILTER SET/AUTO] selector switch to "STOP" mode.
21
Check the strength of the horizontal seal of the product, which is discharged from the bag outlet
chute.
If the strength of the horizontal seal is insufficient, see "5 Maintenance/Inspection" and
adjust or replace the ultrasonic horn and vertical disc.
22
Turn the lock nut and maintain the air pressure of the horizontal disc contact pressure adjuster.
23
Check that the dimension of the product discharged from bag outlet chute is as specified on the
[FILTER FEED PITCH].
If the dimension of the product discharged from bag outlet chute is not as specified on
the [FILTER FEED PITCH], see "6 Troubleshooting".
3-26
3.4 Preparing for Operation and Adjustment
24
When using tagged filter, check that the tag on the product discharged from the bag outlet chute
is positioned at the center.
If the tag position is not in the center of the product, see "3.4.8 Adjusting the Tag
Detection Sensor" and adjust the tag detection sensor again.
If the tag detection sensor cannot be adjusted properly, see "3.4.6.2 Specifying Feeding
Pitch for Tagged Filter" and review the specified filter feeding pitch.
If the feeding pitch is smaller than the tag dimension, the tag detection sensor cannot
detect the tag properly.
The tag detection sensor cannot detect the tag properly also when the sensitivity
adjustment of the tag detection sensor signal amplifier is insufficient. For adjusting the
sensitivity of the tag detection sensor signal amplifier, see "5.20 Teaching the Tag
Detection Sensor".
3-27
3.4 Preparing for Operation and Adjustment
3.4.8
Adjusting the Tag Detection Sensor
When using tagged filter, it is required to adjust the tag detection sensor.
Adjustment procedure of the tag detection sensor is as follows.
Adjusting the Tag Detection Sensor
No.
1
Description
Tag detection sensor
2
Tag detection sensor position adjusting thumbscrew
3
Tag detection sensor stay
4
Tag detection sensor stay position adjusting thumbscrew
1
Check that the safety door is closed.
2
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
3
Check that the [FILTER] is set to [BY PITCH] mode.
4
Adjust the tag detection sensor and the tag detection sensor stay position so that the tag detection
sensor can detect the center of the tag.
 Make sure for your safety and adjust the tag detection sensor, after stopping the
machine.
Detection Position of Tag Detection Sensor
No.
1
5
Description
Filter
2
Tag detection sensor
3
Tag
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
3-28
3.4 Preparing for Operation and Adjustment
6
Press the [START] button.
Filter vertical feed roller and jaws operate and feeds the filter.
 As the machine starts operating, make sure for your safety when working on the
machine.
7
Press the [STOP] button.
8
Check that the intermediate position between the tags is positioned at the intermediate position
of the jaws section.
Jaws Section
9
No.
1
Tag
Description
2
Jaws
If the intermediate position between the tags is not positioned at the intermediate position of the
jaws section, visually check the misaligned amount.
Amount of Tag Position Misaligned
10
Deleting or adding the misaligned amount (visually checked on step 9), adjust the tag detection
sensor position again.
3-29
3.4 Preparing for Operation and Adjustment
If hanging tag is used, adjustment is required for the tag detection sensor not to detect
the hole at the center of the tag.
Hanging Tag
No.
1
Description
Hanging tag
3-30
3.5 Starting Operation
3.5
Starting Operation
This section describes operation procedure of the machine.
After operation preparation procedure is completed, start the operation.
For operation preparation procedures, see "3.4 Preparing for Operation and
Adjustment".
3.5.1
Setting Counter
Counter setting procedure is as follows.
1
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode and display the AUTO
screen.
2
Press [DATA SETTING] to display the DATA SETTING screen.
3
Press the up/down arrow key and set the cursor on "TARGET".
4
Enter the number of the product to produce with the numerical keypad and press [ENT].
5
Press [AUTO].
DATA SETTING Screen
No.
1
Description
[TARGET]
2
Up/down arrow key
3
Numerical key pad
4
[ENT]
5
[AUTO]
The machine will automatically stop when production of the tea bags has reached the
value set on the counter.
If the quantities to produce tea bags are set to "0", the machine will be in "stop" status.
3-31
3.5 Starting Operation
3.5.2
Feeding Material and Operation Procedure
Feeding material and operation procedure is as follows.
For feeding material and operation procedure, procedures vary depending on whether to use
volumetric doser or weigher (option).
3.5.2.1
Feeding Material and Operation Procedure by Volumetric
Doser
1
Check that the safety door is closed.
2
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
3
Feed materials into the hopper.
4
Adjust the material discharge volume with the material volume adjusting dial.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
Though there may be a slight difference depending on the material, discharge volume
changes by approx. 0.1 g, by turning the material volume adjusting dial for 1 scale.
The material discharge volume decreases by turning the material volume adjusting dial
clockwise.
The material discharge volume increases by turning the material volume adjusting dial
counterclockwise.
Material Volume Adjusting Dial
No.
1
Description
Material volume adjusting dial
5
Set the scheduled quantity of products to be produced on the DATA SETTING screen. (See
"3.5.1 Setting Counter".)
6
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
7
When using non-woven fabric, turn [NWF AIR] ON.
8
If there is material fall assist device (option), turn [FALL ASSIST] (option) ON.
9
Turn [DOSER] ON.
3-32
3.5 Starting Operation
10
Press the [START] button.
Materials are discharged from the volumetric doser, and the machine starts production in
automatic operation.
 If there is any danger during operation, press the [EMERGENCY STOP] button
immediately.
3.5.2.2
Feeding Material and Operation Procedure by Weigher
Weigher (FW-100SA (N) Type)
1
Check that the safety door is closed.
2
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
3
Feed materials into the weigher (option).
4
Check that the power of the weigher is turned ON.
5
With the weigher, set the weigh volume.
For operating the weigher, see instruction manual "Automatic weigher for small
quantity (FW-100SA (N) Type)".
6
Set the scheduled quantity of products to be produced on the DATA SETTING screen. (See
"3.5.1 Setting Counter".)
7
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
8
When using non-woven fabric, turn [NWF AIR] ON.
9
If there is material fall assist device (option), turn [FALL ASSIST] (option) ON.
10
Turn [WEIGHER] ON.
11
Press the [START] button.
Materials are discharged from the weigher, and the machine starts production in automatic
operation.
 If there is any danger during operation, press the [EMERGENCY STOP] button
immediately.
3-33
3.5 Starting Operation
3.5.3
Stopping the Operation of the Machine
Stopping the operation of this machine is as follows.
1
Press the [STOP] button.
2
Turn the [STOP/FILTER SET/AUTO] selector switch to "STOP" mode.
3
Check that the machine has stopped.
3-34
3.6 Finishing Operation
3.6
Finishing Operation
Finishing operation of the machine is as follows.
1
Check that the [START] button is turned OFF.
2
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
3
Turn the peripheral devices (such as weigher and elevating machine) OFF.
4
Turn the [MAIN POWER] switch "OFF".
5
Close the main air valve.
6
Turn the compressor OFF.
Drain moisture from the compressor.
7
Perform cleaning and maintenance/inspection of the machine.
For cleaning and maintanance/inspection of the machine, see "4. Cleaning" and "5
Maintenance/Inspection".
3-35
3.6 Finishing Operation
3-36
4 Cleaning
4
Cleaning
This chapter describes the following contents.
•
Precautions for Cleaning
•
Cleaning List
•
Cleaning the Hopper
•
Cleaning the Volumetric Doser
•
Cleaning the Tag Detection Sensor/Film Joint Detection Sensor (Option)
•
Cleaning the Filter Chute
•
Cleaning the Vertical/Horizontal Sealing Unit
•
Cleaning the Static Eliminator Bar
•
Cleaning the Control Box
•
Removing the Vertical Seal and Cut Pieces
4-1
4.1 Precautions for Cleaning
4.1
Precautions for Cleaning
This section describes precautions to be observed when cleaning the machine.
Read the precautions carefully and fully understand it before working.
 Before opening the control box cover for the purpose of cleaning or
maintenance/inspection, always turn off the primary power source.
Otherwise it may cause electrical shock.
 If there are dusts in the control box, make sure to remove them.
If dusts accumulate in the control box, electrical leakage or fire may
result.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 Always work with at least one other person when handling heavy objects.
You may injure your lower-back or foot injury may result if the object is dropped on
your foot.
 Dry the parts soon after cleaning with water.
Leaving the parts wet may generate/multiply microbes, depending on the properties
of water or environment.
 Always clean the static eliminator bar after work.
It may damage the static eliminator bar if you neglect to clean it.
4-2
4.2 Cleaning List
4.2
Cleaning List
Cleaning items on each part of the machine are as follows.
Hopper
Item
Cycle
Daily
Reference
Section 4.3
Volumetric doser
Daily
Section 4.4
Tag detection sensor/film joint detection sensor
(option)
Daily
Section 4.5
Filter chute
Daily
Section 4.6
Vertical/horizontal sealing unit
Daily
Section 4.7
Static eliminator bar
Daily
Section 4.8
Control box
Removing the vertical seal and cut pieces
Daily
Section 4.9
As needed
Section 4.10
Make sure to clean the machine from the top to the bottom.
4-3
4.3 Cleaning the Hopper
4.3
Cleaning the Hopper
This section describes cleaning procedure of the hopper.
 Dry the parts soon after cleaning with water.
Leaving the parts wet may generate/multiply microbes, depending on the properties
of water or environment.
When using materials that are difficult to be removed by normal cleaning procedures,
clean the parts with water.
Hopper
No.
1
2
3
1
Description
Hopper
Hopper fixing screw
Shutter
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Close the shutter of the hopper.
4
Loosen the hopper fixing screws and remove the hopper from the machine.
 Always work with at least one other person when handling heavy objects.
You may injure your lower-back or foot injury may result if the object is dropped on
your foot.
5
Remove materials inside the hopper.
4-4
4.3 Cleaning the Hopper
6
Using an air gun (accessory), blow with air from top to bottom.
Air Gun
No.
1
Description
Air gun
When blowing with air, prevent filter roll section from covering with dust.
7
Disinfect inside the hopper with alcohol.
8
Attach the hopper on the machine and tighten the hopper fixing screws.
9
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
4-5
4.4 Cleaning the Volumetric Doser
4.4
Cleaning the Volumetric Doser
This section describes cleaning procedure of the volumetric doser.
 Dry the parts soon after cleaning with water.
Leaving the parts wet may generate/multiply microbes, depending on the properties
of water or environment.
When using a weigher, see the instruction manual "Automatic weigher for small
quantity (FW-100SA (N) Type)".
When using materials that are difficult to be removed by normal cleaning procedures,
remove the volumetric doser and clean it with water.
Volumetric Doser
No.
1
2
1
Description
Volumetric doser
Sub-hopper
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Remove materials inside the volumetric doser/sub hopper.
2-1
Turn the [MAIN POWER] switch "ON".
2-2
Turn the [STOP/FILTER SET/AUTO] selector switch to "AUTO" mode.
2-3
Turn [US POWER] ON.
2-4
Turn [JAWS] ON.
2-5
Turn [TRAVERSE] ON.
2-6
Press the [START] button.
Filter is sealed and cut.
2-7
Press the [STOP] button.
4-6
4.4 Cleaning the Volumetric Doser
2-8
Turn [TRAVERSE] OFF.
2-9
Turn [DOSER] ON.
2-10
Press the [START] button.
Materials in the volumetric doser go into the filter through filter chute.
2-11
Press the [STOP] button after materials in the volumetric doser are all gone.
2-12
Turn [DOSER] OFF.
2-13
Turn [TRAVERSE] ON.
2-14
Press the [START] button.
Sealed and cut horizontally by ultrasonic wave, material fed into the filter is discharged.
2-15
Press the [STOP] button.
2-16
Turn the [STOP/FILTER SET/AUTO] selector switch to "STOP" mode.
2-17
Turn the [MAIN POWER] switch "OFF".
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
3
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
4
Remove the hopper.
(See "4.3 Cleaning the Hopper".)
5
Using an air gun (accessory), blow with air from top to bottom.
Before blowing with air, make sure to remove the filter roll from the filter roll section.
Dusts may adhere to the parts.
6
Disinfect inside the volumetric doser/sub hopper with alcohol.
7
Attach the hopper.
(See "4.3 Cleaning the Hopper".)
8
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
4-7
4.5 Cleaning the Tag Detection Sensor/Film Joint Detection Sensor (Option)
4.5
Cleaning the Tag Detection Sensor/Film Joint
Detection Sensor (Option)
This section describes cleaning procedure of the tag detection sensor and film joint detection sensor.
Tag Detection Sensor/Film Joint Detection Sensor
No.
1
2
1
Description
Tag detection sensor
Film joint detection sensor
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Using an air gun (accessory), blow with air to clear dusts away.
Before blowing with air, make sure to remove the filter roll from the filter roll section.
Dusts may adhere to the parts.
4
Using soft fabric, gently wipe the tag detection sensor and film joint detection sensor head.
5
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
4-8
4.6 Cleaning the Filter Chute
4.6
Cleaning the Filter Chute
This section describes cleaning procedure of the filter chute.
Filter Chute
No.
1
1
Description
Filter chute
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Remove the filter roll from the filter roll section.
4
Loosen the four thumbscrews fixing the filter chute and remove the filter chute.
Before blowing with air, make sure to remove the filter roll from the filter roll section.
Dusts may adhere to the parts.
5
Using an air gun (accessory), blow with air.
6
Using soft fabric, gently wipe the inside of the filter chute.
7
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
4-9
4.7 Cleaning the Vertical/Horizontal Sealing Unit
4.7
Cleaning the Vertical/Horizontal Sealing Unit
This section describes cleaning procedure of the vertical/horizontal sealing unit.
Vertical/Horizontal Sealing Unit
No.
1
2
1
Description
Safety door
Vertical/horizontal sealing unit
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Using an air gun (accessory), blow with air from top to bottom.
Before blowing with air, make sure to remove the filter roll from the filter roll section.
Dusts may adhere to the parts.
5
Using a toothbrush (accessory), remove dusts and others adhered to the static eliminator bar.
(See "4.8 Cleaning the Static Eliminator Bar".)
 Always clean the static eliminator bar after work.
It may damage the static eliminator bar if you neglect to clean it.
6
Close the safety door on the operation side.
7
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
4-10
4.8 Cleaning the Static Eliminator Bar
4.8
Cleaning the Static Eliminator Bar
This section describes cleaning procedure of the static eliminator bar.
Static Eliminator Bar
No.
1
1
Description
Static eliminator bar
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Remove the filter roll from the filter roll section.
4
Using a toothbrush (accessory), remove dusts and others adhered to the static eliminator bar.
5
Using an air gun (accessory), blow with air.
6
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
4-11
4.9 Cleaning the Control Box
4.9
Cleaning the Control Box
This section describes cleaning procedure of inside of the control box.
Control Box
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 Before opening the control box cover for the purpose of cleaning or
maintenance/inspection, always turn off the primary power source.
Otherwise it may cause electrical shock.
2
Open the control box cover.
2-1
Turn the [MAIN POWER] switch to "OPEN/RESET" and hold the switch at that
position with your hand.
The switch will return to OFF position if you release your hand.
[MAIN POWER] Switch
No.
1
Description
[MAIN POWER] switch
4-12
4.9 Cleaning the Control Box
2-2
Pull the lever and open the control box cover.
Lever
No.
1
3
Description
Lever
Using a vacuum cleaner or an equivalent tool, vacuum dusts in the control box.
 If there are dusts in the control box, make sure to remove them.
If dusts accumulate in the control box, electrical leakage or fire may
result.
 Do not use the air gun.
Dusts may spread within the control box due to air pressure, and
electrical leakage or fire may result.
4
Check that the connectors in the control box are fully inserted.
5
Close the control box cover.
4-13
4.10 Removing the Vertical Seal and Cut Pieces
4.10
Removing the Vertical Seal and Cut Pieces
This section describes removal procedure of vertical seal and cut pieces.
Remove vertical seal and cut pieces as necessary during operation or after operation is finished.
Waste Filter Air Purge Pipe
No.
1
2
1
Description
Waste filter air purge pipe
Vertical seal cut pieces
Cut and remove vertical seal and cut pieces from waste filter air purge pipe with scissors or
equivalent tool.
4-14
5 Maintenance/Inspection
5
Maintenance/Inspection
This chapter describes the following contents.
•
Precautions for Maintenance/Inspection
•
Maintenance/Inspection List
•
Inspecting the Volumetric Doser
•
Inspecting the Ultrasonic Horn (Vertical Sealing Unit/Horizontal Sealing Unit)
•
Inspecting the Disc (Vertical Sealing Unit/Horizontal Sealing Unit)
•
Replacing the Ultrasonic Horn (Vertical Sealing Unit)
•
Replacing the Ultrasonic Horn (Horizontal Sealing Unit)
•
Replacing the Perforation Disc (Vertical Sealing Unit)
•
Replacing the Horizontal Disc (Horizontal Sealing Unit)
•
Replacing the Ultrasonic Generator Fuse
•
Replacing the PLC Battery
•
Replacing the Silicon Rubber (Horizontal Sealing Unit)
•
Adjusting the Volumetric Doser
•
Adjusting the Ultrasonic Horn (Vertical Sealing Unit)
•
Adjusting the Ultrasonic Horn (Horizontal Sealing Unit)
•
Adjusting the Perforation Disc (Vertical Sealing Unit)
•
Adjusting the Disc (Horizontal Sealing Unit)
•
Adjusting the Jaws Speed
•
Adjusting the Traverse Speed
•
Teaching the Tag Detection Sensor
•
Teaching the Film Joint Detection Sensor (Option)
•
Lubricating the Sliding Section
5-1
5.1 Precautions for Maintenance/Inspection
5.1
Precautions for Maintenance/Inspection
This section describes the precautions to be observed when performing maintenance/inspection works.
Read the precautions carefully and fully understand it before working.
 Before opening the control box cover for the purpose of cleaning or
maintenance/inspection, always turn off the primary power source.
Otherwise it may cause electrical shock.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
 Before starting the work, always check that the machine is not in the operation
status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 Before turning the machine on, always check around the machine.
 Always use bio-adneel spray which is an accessory for this machine, or lubricant for
food product machine.
Otherwise, hazardous lubricant may enter your body though the product.
 After adjustment, make sure to tighten the lock nut securely.
Otherwise, the adjusted position may be displaced due to vibrations.
 Before adjusting the position of the ultrasonic horn tip, always remove the horn
from the machine.
If you adjust the horn while it is installed in the machine, the gasket may be
damaged.
 Before adjusting the position of the disc, always remove the disc from the machine.
If you adjust the disc while it is installed in the machine, the disc may be damaged.
 Attach the ultrasonic horn not to kink the oscillator cable. If the cable is kinked,
disconnection or spark may occur.
5-2
5.2 Maintenance/Inspection List
5.2
Maintenance/Inspection List
The maintenance/inspection items on each part of the machine are as follows.
■
■
■
Inspection
Item
Inspecting the Volumetric Doser
Cycle
Daily
Reference
Section 5.3
Inspecting the Ultrasonic Horn
(Vertical Sealing Unit/Horizontal Sealing Unit)
Daily
Section 5.4
Inspecting the Disc
(Vertical Sealing Unit/Horizontal Sealing Unit)
Daily
Section 5.5
Item
Replacing the ultrasonic horn
(vertical sealing unit/horizontal sealing unit)
Cycle
Every 100000
products
Replacing the Perforation Disc (Vertical Sealing Unit)
Every 200000
products
Reference
Section 5.6
Section 5.7
Section 5.8
Replacing the Horizontal Disc
(Horizontal Sealing Unit)
Every 20000
products
Section 5.9
Replacing the Ultrasonic Generator Fuse
－
Section 5.10
Replacing the PLC Battery
－
Section 5.11
Replacing the Silicon Rubber (Horizontal Sealing Unit)
－
Section 5.12
Cycle
－
Reference
Section 5.13
Adjusting the Ultrasonic Horn (Vertical Sealing Unit)
－
Section 5.14
Adjusting the Ultrasonic Horn
(Horizontal Sealing Unit)
－
Section 5.15
Adjusting the Perforation Disc (Vertical Sealing Unit)
－
Section 5.16
Adjusting the Disc (Horizontal Sealing Unit)
－
Section 5.17
Adjusting the Jaws Speed
－
Section 5.18
Adjusting the Traverse Speed
－
Section 5.19
Teaching the Tag Detection Sensor
－
Section 5.20
Teaching the Film Joint Detection Sensor (Option)
－
Section 5.21
Cycle
Daily
Reference
Section 5.22
Replacement
Adjustment
Item
Adjusting the Volumetric Doser
■
Lubricating
Item
Lubricating the Sliding Section
5-3
5.3 Inspecting the Volumetric Doser
5.3
Inspecting the Volumetric Doser
This section describes how to inspect the volumetric doser.
When using a weigher, refer to the instruction manual "Automatic weigher for small
quantity (FW-100SA (N) Type)".
1
Check that the [US POWER] and the [MAIN POWER] switch, and the compressor power are all
turned OFF.
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 Before starting the work, always check that the machine is not in the operation
status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout for the main power.
(Refer to "1.5.1 procedures for Locking out/Tagging out the Main Power".)
3
Pull out the volumetric doser and inspect it for any scratches.
If the volumetric doser is scratched, remove the volumetric doser and adjust it.
(Refer to "5.13 Adjusting the Volumetric Doser".)
Volumetric Doser
No.
1
2
4
Description
Volumetric doser
Scratch
Release lockout for the main power.
(Refer to "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-4
5.4 Inspecting the Ultrasonic Horn
(Vertical Sealing Unit/Horizontal Sealing Unit)
5.4
Inspecting the Ultrasonic Horn
(Vertical Sealing Unit/Horizontal Sealing Unit)
This section describes how to inspect the ultrasonic horn.
Vertical/Horizontal Sealing Unit
No.
1
Description
Ultrasonic horn (horizontal sealing unit)
2
Horizontal disc (horizontal sealing unit)
3
Ultrasonic horn (vertical sealing unit)
4
Perforation disc(vertical sealing unit)
5-5
5.4 Inspecting the Ultrasonic Horn
(Vertical Sealing Unit/Horizontal Sealing Unit)
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Loosen the four thumbscrews at the filter chute and remove the filter chute.
5
Inspect each part of the ultrasonic horn. Inspection items are as follows.
Ultrasonic Horn Tip
•
Check if ultrasonic horn tip is not worn
•
Check if oscillator and ultrasonic horn are not loose
If any abnormal condition is found for the above point, replace or adjust the necessary parts.
See "5.6 Replacing the Ultrasonic Horn (Vertical Sealing Unit)", "5.7 Replacing the
Ultrasonic Horn (Horizontal Sealing Unit)", "5.14 Adjusting the Ultrasonic Horn (Vertical
Sealing Unit)", and "5.15 Adjusting the Ultrasonic Horn (Horizontal Sealing Unit)".
6
Install the filter chute and tighten the four thumbscrews.
7
Close the safety door on the operation side.
8
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-6
5.5 Inspecting the Disc (Vertical Sealing Unit/Horizontal Sealing Unit)
5.5
Inspecting the Disc (Vertical Sealing
Unit/Horizontal Sealing Unit)
This section describes how to inspect the disc.
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Loosen the four thumbscrews at the filter chute and remove the filter chute.
5
Inspect the disc. Inspection items are as follows.
Disc
•
Check if disc is not worn
If any abnormal condition is found for the above point, replace or adjust the necessary parts.
See "5.8 Replacing the Perforation Disc (Vertical Sealing Unit)", "5.9 Replacing the
Horizontal Disc (Horizontal Sealing Unit)", "5.16 Adjusting the Perforation Disc (Vertical
Sealing Unit)", and "5.17 Adjusting the Disc (Horizontal Sealing Unit)".
6
Install the filter chute and tighten the four thumbscrews.
7
Close the safety door on the operation side.
8
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-7
5.6 Replacing the Ultrasonic Horn (Vertical Sealing Unit)
5.6
Replacing the Ultrasonic Horn (Vertical Sealing
Unit)
This section describes how to replace the ultrasonic horn (vertical sealing unit).
If the horn does not cut well even after adjustment, or the replacement timing has come, replace the
ultrasonic horn and oscillator with new ones. When ordering the replacement parts, see "7.2
Consumable Parts List" and send the order to us.
Ultrasonic Horn
No.
1
Description
Oscillator lead connector
2
Oscillator
3
Vertical ultrasonic horn fixing screw (4 mm cap bolt)
4
Holding plate
5
Ultrasonic horn (wear resistant)
6
Vertical ultrasonic horn bracket fixing screw (5 mm cap bolt)
7
Vertical ultrasonic horn bracket
8
Vertical ultrasonic horn bracket gasket
5-8
5.6 Replacing the Ultrasonic Horn (Vertical Sealing Unit)
5.6.1
Removal
Ultrasonic horn removing procedure is as follows.
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Loosen the four thumbscrews at the filter chute and remove the filter chute.
5
Remove the oscillator lead connector.
6
Loosen the two vertical ultrasonic horn bracket fixing screws (5 mm cap bolts) and remove the
ultrasonic horn assembly together with the vertical ultrasonic horn bracket from the machine.
When removing the ultrasonic horn assembly, always support it by hand so that it will
not drop.
5.6.2
Replacement
Ultrasonic horn replacement procedure is as follows.
5.6.2.1
Disassembly
1
Loosen the ultrasonic horn fixing screws (4 mm cap bolts) at both sides of the oscillator and
remove the ultrasonic horn with the holding plate.
Removing the Ultrasonic Horn
No.
1
2
Description
Hexagonal wrench (for 4 mm cap bolt)
2
Ultrasonic horn fixing screw (4 mm cap bolt)
3
Holding plate
Remove the ultrasonic horn from the vertical ultrasonic horn bracket.
5-9
5.6 Replacing the Ultrasonic Horn (Vertical Sealing Unit)
3
Loosen the ultrasonic horn and oscillator by using two wrenches on their flats and separate the
ultrasonic horn and oscillator.
Flats on the Horn
No.
1
5.6.2.2
Description
Oscillator
2
Wrench
3
Ultrasonic horn
Assembly
1
Attach the oscillator to the ultrasonic horn by turning it.
2
Tighten the oscillator securely by using two wrenches on the flats of the ultrasonic horn and
oscillator.
3
From the tip of the ultrasonic horn, attach the ultrasonic horn bracket gasket. Then install the
ultrasonic horn bracket.
4
Fix the holding plate on the ultrasonic horn bracket and tighten the ultrasonic horn fixing screws
with a hexagon wrench.
Attaching the Ultrasonic Horn
No.
1
Description
Hexagon wrench
2
Ultrasonic horn bracket fixing screw (4 mm cap bolt)
3
Holding plate
4
Ultrasonic horn
5-10
5.6 Replacing the Ultrasonic Horn (Vertical Sealing Unit)
5.6.3
Attachment
Ultrasonic horn attachment procedure to the machine is as follows.
1
Adjust the vertical position by aligning the concave on the back side of the vertical ultrasonic
horn bracket with the locating pin on the machine.
Vertical Positioning
No.
1
2
2
Description
Vertical ultrasonic horn bracket (back side)
Locating pin
Attach the vertical ultrasonic horn bracket to the machine and temporarily tighten the two
vertical ultrasonic horn bracket fixing screws (5 mm cap bolts) with a hexagon wrench.
3
Determine the horizontal position of the ultrasonic horn. Loosen the filter vertical feed roller
adjusting knob.
4
Apply the ruler (accessory) from top to down of the filter vertical feed roller and tighten and fix
the filter vertical feed roller adjusting knob.
5
Move the vertical ultrasonic horn bracket by hand to find a position where the tip of the
ultrasonic horn contacts the ruler. At that position, fully tighten the vertical ultrasonic horn
bracket fixing screws (5 mm cap bolts).
Positioning the Ultrasonic Horn
No.
1
Description
Filter vertical feed roller
2
Ruler (accessory)
3
Filter vertical feed roller adjusting knob
6
Connect the oscillator lead connector.
7
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
8
Turn the [MAIN POWER] switch "ON".
9
Turn [US POWER] ON.
5-11
5.6 Replacing the Ultrasonic Horn (Vertical Sealing Unit)
Turning [US POWER] ON causes the oscillator to operate for approx. two minutes.
10
After verifying that the ultrasonic horn is oscillating, turn [US POWER] OFF.
11
Turn the [MAIN POWER] switch "OFF".
12
Install the filter chute and tighten the four thumbscrews.
13
Close the safety door on the operation side.
 Attach the ultrasonic horn not to kink the oscillator cable. If the cable is kinked,
disconnection or spark may occur.
Correct
Incorrect (kinked cables)
5-12
5.7 Replacing the Ultrasonic Horn (Horizontal Sealing Unit)
5.7
Replacing the Ultrasonic Horn (Horizontal
Sealing Unit)
This section describes how to replace the ultrasonic horn (horizontal sealing unit).
If the horn does not cut well even after adjustment, or the replacement timing has come, replace the
ultrasonic horn and oscillator with new ones. When ordering the replacement parts, see "7.2
Consumable Parts List" and send the order to us.
Ultrasonic Horn
No.
1
Description
Oscillator lead connector
2
Holding plate gasket
3
Holding plate
4
Oscillator
5
Oscillator screw
6
Horizontal ultrasonic horn bracket fixing screw (6 mm cap bolt)
7
Lock nut (6 mm)
8
Horizontal ultrasonic horn bracket
9
Horizontal ultrasonic horn bracket gasket
10
Ultrasonic horn (wear resistant)
11
Lock nut (4 mm)
12
Washer
13
Horizontal ultrasonic horn fixing screw (4 mm cap bolt)
14
Fixing spring
5-13
5.7 Replacing the Ultrasonic Horn (Horizontal Sealing Unit)
5.7.1
Removal
Ultrasonic horn removing procedure is as follows.
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Remove the oscillator lead connector.
5
Loosen the lock nut (6 mm).
6
Loosen the two horizontal ultrasonic horn bracket fixing screws (6 mm cap bolts) with a
hexagonal wrench, and remove the ultrasonic horn assembly together with the horizontal
ultrasonic horn bracket from the machine.
5.7.2
Replacement
Ultrasonic horn replacement procedure is as follows.
5.7.2.1
Disassembly
1
Loosen the lock nuts (4 mm) located at both sides of the ultrasonic horn tip and remove them
with the washers.
Removing Lock Nuts and Washers
No.
1
2
Description
Wrench
2
Lock nut (4 mm), washer
3
Hexagonal wrench (for 4 mm cap bolt)
4
Ultrasonic horn
A
11 mm
Loosen the two horizontal ultrasonic horn fixing screws (4 mm cap bolts) and remove the
holding plate.
5-14
5.7 Replacing the Ultrasonic Horn (Horizontal Sealing Unit)
3
Remove the ultrasonic horn assembly from the horizontal ultrasonic horn bracket.
4
Loosen the ultrasonic horn and oscillator by using two 22 mm wrenches on their flats and
separate the ultrasonic horn and oscillator.
Flats on the Horn
No.
1
5
5.7.2.2
Description
22 mm wrench
2
Oscillator
3
Ultrasonic horn
Remove the oscillator screw by hand from inside the ultrasonic horn.
Assembly
1
Attach the oscillator screw to a new ultrasonic horn by hand.
Insert the perforated end of the oscillator screw to the ultrasonic horn.
After the oscillator screw bottoms out, loosen the screw by 1 mm and retain it at that
position.
2
From the oscillator side of the ultrasonic horn, attach the holding plate gasket. Then install the
holding plate.
3
Attach the oscillator to the ultrasonic horn by turning it.
4
Tighten the oscillator securely by using two 22 mm wrenches on the flats of the ultrasonic horn
and oscillator.
5
From the tip of the ultrasonic horn, attach the horizontal ultrasonic horn bracket gasket. Then
install the horizontal ultrasonic horn bracket.
6
Attach the fixing spring to the horizontal ultrasonic horn fixing screw (4 mm cap bolt) and install
the assembly to the horizontal ultrasonic horn bracket.
Tighten the horizontal ultrasonic horn fixing screw (4 mm cap bolt) until the fixing
spring comes to a length of 11 mm.
5-15
5.7 Replacing the Ultrasonic Horn (Horizontal Sealing Unit)
7
While fixing the fixing screw with a hexagonal wrench, insert the lock nut (4 mm) and washer to
the tip of the fixing screw and tighten it with a wrench.
Tightening Nut
No.
1
5.7.3
Description
Wrench
2
Lock nut (4 mm), washer
3
Hexagonal wrench (for 4 mm cap bolt)
4
Ultrasonic horn
A
11 mm
Attachment
Ultrasonic horn attachment procedure to the machine is as follows.
1
Fit the horizontal ultrasonic horn bracket to the machine.
2
Position the ultrasonic horn to a point 1.5 mm from the disc and tighten the two horizontal
ultrasonic horn bracket fixing screws (6 mm cap bolt).
Positioning the Ultrasonic Horn
No.
1
A
3
Description
Horizontal ultrasonic horn bracket fixing screw (6 mm cap bolt)
1.5 mm
Tighten the lock nut (6 mm).
5-16
5.7 Replacing the Ultrasonic Horn (Horizontal Sealing Unit)
4
Fix the oscillator lead connector at the position shown in the figure and connect it.
Positioning the Oscillator Lead Connector
No.
1
Description
Oscillator lead connector
5
Connect the oscillator lead connector.
6
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
7
Turn the [MAIN POWER] switch "ON".
8
Turn [US POWER] ON.
Turning [US POWER] ON causes the oscillator to operate for approx. two minutes.
9
Turn [US POWER] OFF.
10
Turn the [MAIN POWER] switch "OFF".
11
Close the safety door on the operation side.
 Attach the ultrasonic horn not to kink the oscillator cable. If the cable is kinked,
disconnection or spark may occur.
Correct
5.7.4
Incorrect (kinked cables)
Adjusting the Sealing Intensity
The set position specified in section 5.7.3 is for a normal filter.
Depending on the material of the filter in use, it may be inappropriate to insure sufficient intensity for
horizontal ultrasonic seal and cut. In such a case, move the horizontal disc toward the center of the
ultrasonic horn to increase the sealing intensity.
5-17
5.7 Replacing the Ultrasonic Horn (Horizontal Sealing Unit)
Horizontal Sealing Unit
No.
1
1
Description
4 mm cap bolt
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Loosen the four 4 mm cap bolts.
5
Adjust the horizontal disc position by sliding it.
Adjusting the Sealing Intensity
6
Tighten the four 4 mm cap bolts.
7
Close the safety door on the operation side.
8
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-18
5.8 Replacing the Perforation Disc (Vertical Sealing Unit)
5.8
Replacing the Perforation Disc (Vertical Sealing
Unit)
When performing perforation sealing, the ultrasonic horn must be replaced with the
one of manual feed type for φ15.
This section describes how to replace the perforation disc and urethane belt.
When ordering the replacement parts, see "7.2 Consumable Parts List" and send the order to us.
Perforation Disc
No.
1
5.8.1
Description
Perforation disc fixing screw (5 mm cap bolt)
2
Perforation disc
3
E ring
4
Urethane belt
5
Filter vertical feed roller adjusting knob
6
Vertical disc bracket fixing screw (6 mm cap bolt)
7
Vertical disc bracket
8
Ultrasonic horn (15φ)
Removal
Perforation disc removing procedure is as follows.
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Loosen the four thumbscrews at the filter chute and remove the filter chute.
5-19
5.8 Replacing the Perforation Disc (Vertical Sealing Unit)
5.8.2
5
Remove the urethane belt from the machine.
6
Loosen the two vertical disc bracket fixing screws (6 mm cap bolts) and remove the vertical disc
bracket.
7
Using a flat-blade screwdriver, remove the E ring.
8
Remove the perforation disc from the vertical disc bracket.
Attachment
Perforation disc and urethane belt attachment procedure is as follows.
1
Attach the perforation disc to the vertical disc bracket.
2
Using pliers, attach the E ring by pinching the E ring.
Attaching E Ring
No.
1
E ring
Description
2
Pliers
3
Attach the vertical disc bracket to the machine and tighten the two vertical disc bracket fixing
screws (6 mm cap bolts).
4
Attach the urethane belt to the machine.
5
Install the filter chute and tighten the four thumbscrews.
6
Close the safety door on the operation side.
7
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-20
5.9 Replacing the Horizontal Disc (Horizontal Sealing Unit)
5.9
Replacing the Horizontal Disc (Horizontal
Sealing Unit)
This section describes how to replace the horizontal disc (horizontal sealing unit).
If the horn does not cut well even after adjustment, or the replacement timing has come, replace the
horizontal disc with a new one. When ordering the replacement parts, see "7.2 Consumable Parts List"
and send the order to us.
Horizontal Disc (Horizontal Sealing Unit)
No.
1
5.9.1
Description
Horizontal disc air cylinder
2
Horizontal disc bracket fixing screw
3
Horizontal disc fixing screw
4
Horizontal disc
Removal
Horizontal disc removing procedure is as follows.
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
5-21
5.9 Replacing the Horizontal Disc (Horizontal Sealing Unit)
4
Loosen the horizontal disc bracket fixing screws and remove the horizontal disc bracket.
Positions of Horizontal Disc Fixing Screws
No.
1
2
5.9.2
Description
Horizontal disc air cylinder
Horizontal disc bracket fixing screw
Replacement
Horizontal disc replacement procedure is as follows.
1
Loosen the horizontal disc fixing screws and remove the horizontal disc.
2
Attach a new horizontal disc and tighten the horizontal disc fixing screws securely.
When attaching the horizontal disc, face the marking side up.
If attached reversely, the sealing intensity will decrease.
5.9.3
Attachment
Horizontal disc bracket attachment procedure to the machine is as follows.
1
Align the hole on the horizontal disc bracket with the locating pin of the machine side and attach
it.
2
Tighten the horizontal disc bracket fixing screws.
3
Set the contact pressure of the horizontal disc to 0.2 to 0.3 MPa.
(See "3.4.7 Adjusting the Horizontal Sealing Unit".)
4
Close the safety door on the operation side.
5
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-22
5.10 Replacing the Ultrasonic Generator Fuse
5.10
Replacing the Ultrasonic Generator Fuse
This section describes how to replace the ultrasonic generator fuse.
Fuse Replacement Point (Inside Control Box)
No.
1
Description
Fuse (2A)
2
Fuse holder
3
Vertical ultrasonic generator
4
Horizontal ultrasonic generator
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 Before opening the control box cover for the purpose of cleaning or
maintenance/inspection, always turn off the machine power.
Otherwise it may cause electrical shock.
2
Open the control box cover.
(See "4.9 Cleaning the Control Box".)
3
Using a flat-blade screwdriver, remove the fuse holder from each ultrasonic generator.
Removing Fuse
No.
1
2
Description
Fuse holder
Flat-blade screwdriver
4
Remove the old fuse from the fuse holder and install a new fuse.
5
Using a flat-blade screwdriver, install the fuse holder to each ultrasonic generator.
6
Close the control box cover.
5-23
5.11 Replacing the PLC Battery
5.11
Replacing the PLC Battery
This section describes how to replace the PLC battery.
Replace it when [PLC BATTERY ERROR] is displayed on the screen.
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 Before opening the control box cover for the purpose of cleaning or
maintenance/inspection, always turn off the primary power source.
Otherwise it may cause electrical shock.
2
Open the control box cover.
(See "4.9 Cleaning the Control Box".)
3
Open the PLC battery box cover upwards.
Removing the PLC Battery
No.
1
Description
Control box
2
Cover
3
Battery
4
Connector
4
Remove the battery connector.
5
Pull out and remove the battery.
6
Insert and attach a new battery.
7
Connect the battery connector.
8
Close the battery box cover.
9
Close the control box cover.
5-24
5.12 Replacing the Silicon Rubber (Horizontal Sealing Unit)
5.12
Replacing the Silicon Rubber (Horizontal
Sealing Unit)
This section describes how to replace the silicon rubber for jaws.
When ordering the replacement parts, see "7.2 Consumable Parts List" and send the order to us.
Position of Silicon Rubber
No.
1
1
Description
Jaws
2
Teflon tape
3
Silicon rubber
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Loosen the four thumbscrews at the filter chute and remove the filter chute.
5
Remove the Teflon tape fixing the silicon rubber and the jaws.
6
Remove the silicon rubber from the jaws.
7
Attach a new silicon rubber to the jaws.
8
Fix the silicon rubber and the jaws with a new Teflon tape.
9
Install the filter chute and tighten the four thumbscrews.
10
Close the safety door on the operation side.
11
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-25
5.13 Adjusting the Volumetric Doser
5.13
Adjusting the Volumetric Doser
This section describes how to adjust the volumetric doser.
The volumetric doser is usable on both sides. The following paragraphs describe how to reuse the
volumetric doser by reversing it.
When using a weigher, refer to the instruction manual "Automatic weigher for small
quantity (FW-100SA (N) Type)".
If either side of the volumetric doser is scratched, grind it by using a file.
We are willing to undertake the grinding work if the customer requests it.
1
Check that the [US POWER] and the [MAIN POWER] switch, and the compressor power are all
turned OFF.
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 Before starting the work, always check that the machine is not in the operation
status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout for the main power.
(Refer to "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Remove the hopper from the machine.
(Refer to "4.3 Cleaning the Hopper".)
4
Loosen the four hopper supporter attachment screws and remove the hopper supporter.
Hopper Supporter
No.
1
Volumetric doser
Description
2
Hopper supporter
3
Hopper supporter attachment screw
5-26
5.13 Adjusting the Volumetric Doser
5
Loosen the four volumetric doser driving section cover attachment screws and remove the
volumetric doser driving section cover.
Volumetric Doser Driving Section Cover
No.
1
2
Description
Volumetric doser driving section cover
Volumetric doser driving section cover attachment screw
6
Loosen the four sub hopper attachment screws and remove the sub hopper.
7
Loosen the eight volumetric doser cover attachment screws and remove the volumetric doser
cover.
Positions of Volumetric Doser Volts
No.
1
2
Description
Volumetric doser cover attachment screw
Volumetric doser fixing screw
8
Loosen the two volumetric doser fixing screws and remove the volumetric doser.
9
Reverse the volumetric doser.
10
Attach the volumetric doser on the machine and tighten the two volumetric doser fixing screws.
11
Attach the volumetric doser cover on the machine and tighten the eight volumetric doser cover
attachment screws.
12
Attach the sub hopper and tighten the four sub hopper attachment screws.
13
Attach the hopper supporter and tighten the four hopper supporter attachment screws.
14
Attach the volumetric doser driving section cover on the machine and tighten the four volumetric
doser driving section cover attachment screws.
15
Attach the hopper to the machine.
(Refer to "4.3 Cleaning the Hopper".)
16
Release lockout for the main power.
(Refer to "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-27
5.14 Adjusting the Ultrasonic Horn (Vertical Sealing Unit)
5.14
Adjusting the Ultrasonic Horn (Vertical Sealing
Unit)
This section describes how to adjust the ultrasonic horn.
When the tip of the ultrasonic horn is worn, grind the horn with a sanding sponge (accessory). By
doing so, you can reuse the horn.
1
Remove the ultrasonic horn from the machine.
(Refer to "5.6.1 Removal".)
 Before adjusting the ultrasonic horn tip, always remove the horn from the machine.
If you adjust the horn while it is installed in the machine, the gasket may be
damaged.
2
Using a sanding sponge (accessory), grind the ultrasonic horn tip.
Grinding the Horn Tip
No.
1
2
Description
Sanding sponge (accessory)
Ultrasonic horn
 Sealing intensity differs depending on the angle of the ultrasonic horn tip.
Adjust the angle depending on the material.
Ultrasonic Horn Tip
3
Attach the ultrasonic horn to the machine.
(Refer to "5.6.3 Attachment".)
5-28
5.15 Adjusting the Ultrasonic Horn (Horizontal Sealing Unit)
 Attach the ultrasonic horn not to kink the oscillator cable. If the cable is kinked,
disconnection or spark may occur.
5.15
Adjusting the Ultrasonic Horn (Horizontal
Sealing Unit)
This section describes how to adjust the ultrasonic horn.
When the tip of the ultrasonic horn is worn, turn the horn and find a point that is not worn yet. By
doing so, you can reuse the horn.
If there is no more unworn face, replace the ultrasonic horn even before the
recommended replacement timing.
1
Remove the ultrasonic horn assembly from the machine.
(See "5.7.1 Removal".)
 Before adjusting the position of the ultrasonic horn tip, always remove the horn
from the machine.
If you adjust the horn while it is installed in the machine, the gasket may be
damaged.
2
Adjust the ultrasonic horn position so that its unworn point comes to the contact point with the disc.
Adjusting the Position of the Horn
No.
1
3
Description
Ultrasonic horn (wear resistant)
Attach the ultrasonic horn assembly to the machine.
(See "5.7.3 Attachment".)
 Attach the ultrasonic horn not to kink the oscillator cable. If the cable is kinked,
disconnection or spark may occur.
5-29
5.16 Adjusting the Perforation Disc (Vertical Sealing Unit)
5.16
Adjusting the Perforation Disc (Vertical Sealing
Unit)
Adjustment procedure of the perforation disc is as follows.
1
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the vertical/horizontal sealing unit, always check that the machine
is not in the operation status.
If the vertical/horizontal sealing unit is operating, it may cause electrical shock or
burn.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Loosen the four thumbscrews at the filter chute and remove the filter chute.
5
Remove the urethane belt.
6
Loosen the two vertical disc bracket fixing screws (6 mm cap bolts) and remove the vertical disc
bracket from the machine.
7
Slide the perforation disc with your hand by loosening the perforation disc fixing screw (5 mm
cap bolt) so that an unworn point of the perforation disc comes to the contact point with the
ultrasonic horn.
Perforation Disc
No.
1
2
Description
Perforation disc fixing screw (5 mm cap bolt)
Perforation disc
8
Tighten the perforation disc fixing screw (5 mm cap bolt).
9
Attach the vertical disc bracket to the machine and tighten the two vertical disc bracket fixing
screws (6 mm cap bolts).
10
Attach the urethane belt.
11
Install the filter chute and tighten the four thumbscrews.
12
Close the safety door on the operation side.
13
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-30
5.17 Adjusting the Disc (Horizontal Sealing Unit)
5.17
Adjusting the Disc (Horizontal Sealing Unit)
This section describes how to adjust the disc.
When the disc is worn, turn the disc and find a face that is not worn yet. By doing so, you can reuse
the disc.
If there is no more unworn face, replace the disc even before the recommended
replacement timing.
1
Remove the disc bracket from the machine.
(See "5.9.1 Removal".)
 Before adjusting the position of the disc, always remove the disc from the machine.
If you adjust the disc while it is installed in the machine, the disc may be damaged.
2
With your hands, adjust the disc position so that its unworn face comes to the contact point with
the ultrasonic horn.
Adjusting the Position of the Disc
No.
1
3
Description
Disc
Attach the disc bracket to the machine.
(See "5.9.3 Attachment".)
5-31
5.18 Adjusting the Jaws Speed
5.18
Adjusting the Jaws Speed
This section describes how to adjust the jaws speed.
Adjust the jaws speed so that the jaws close before the traverse section starts moving.
After adjustment, make sure to check the actual operation.
Position of Speed Control Knob
1
No.
1
Jaws open speed control knob
Description
2
Jaws close speed control knob
3
Lock nut
4
Safety door on the operation side
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Loosen the lock nut using needle-nose pliers and adjust the jaws speed by using the jaws open
speed control knob and jaws close speed control knob.
Turning the speed control knob clockwise decreases the speed.
Turning the speed control knob counterclockwise increases the speed.
5-32
5.18 Adjusting the Jaws Speed
5
After adjustment, tighten the lock nut using needle-nose pliers.
 After adjustment, make sure to tighten the lock nut securely.
Otherwise, the adjusted position may be displaced due to vibrations.
6
Close the safety door on the operation side.
7
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
8
Check that the jaws are closed before the traverse section starts moving.
If the adjustment is insufficient, readjust as necessary.
5-33
5.19 Adjusting the Traverse Speed
5.19
Adjusting the Traverse Speed
This section describes how to adjust the traverse speed.
Adjust the traverse speed so that the traverse section reciprocates while the jaws are
closed.
After adjustment, make sure to check the actual operation.
Position of Speed Control Knob
1
No.
1
Left traverse speed control knob
Description
2
Right traverse speed control knob
3
Lock nut
4
Safety door on the operation side
Check that the [MAIN POWER] switch is turned "OFF".
Check that the [STOP/FILTER SET/AUTO] selector switch is turned to "STOP" mode.
 When working on the driving section, always check that the machine is not in the
operation status.
Otherwise, your fingers and hands can be caught resulting in serious injury.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
2
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3
Open the safety door on the operation side.
4
Loosen the lock nut by using needle-nose pliers and adjust the traverse speed by using the left
traverse speed control knob and right traverse speed control knob.
Turning the speed control knob clockwise decreases the speed.
Turning the speed control knob counterclockwise increases the speed.
5-34
5.19 Adjusting the Traverse Speed
5
After adjustment, tighten the lock nut using needle-nose pliers.
 After adjustment, make sure to tighten the lock nut securely.
Otherwise, the adjusted position may be displaced due to vibrations.
6
Close the safety door on the operation side.
7
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
8
Check that the traverse section reciprocates while the jaws are closed.
If the adjustment is insufficient, readjust as necessary.
5-35
5.20 Teaching the Tag Detection Sensor
5.20
Teaching the Tag Detection Sensor
This section describes the teaching procedure for the tag detection sensor.
The tag detection sensor detects the presence or absence of a tag from a change in the amount of light
received.
The tag position may change as the machine is operated repeatedly. Make sure to conduct cleaning
(see "4.5 Cleaning the Tag Detection Sensor/Filter Joint Detection Sensor (Option)") and adjustment
periodically.
The tag position adjustment is required also when the filter roll is changed.
Tag Detection Sensor
No.
1
Description
Tag detection sensor signal amplifier
2
Tag detection sensor
3
Tag detection sensor position adjusting thumbscrew
5-36
5.20 Teaching the Tag Detection Sensor
Tag Detection Sensor Signal Amplifier (E3X-DA41-S)
No.
1
5.20.1
Description
[UP] button
2
[DOWN] button
3
[MODE] button
4
Operation mode selector switch
L: Select this when the color of the tag is lighter compared to the filter.
D: Select this when the color of the tag is darker compared to the filter.
5
6
SET/RUN selector switch
SET: Select this when performing setting.
RUN: Select this when operating.
Display section of threshold value
7
Display section of amount of light received
8
Power tuning indicating lamp
Tag Detection Sensor Power Tuning
To conduct a tag detection sensor power tuning, follow the procedure below.
1
Run the filter between the tag detection sensor.
2
Make sure that no tag is present between the light emitting head and the light receiving head of
the tag detection sensor.
3
Set the operation mode selector switch to the "D (dark)" mode.
4
Set the SET/RUN selector switch to the "RUN" mode.
5
Press and hold the [MODE] button for 3 seconds.
"Ptun" is displayed in the display section of amount of light received and a progress bar appears
in the display section of threshold value.
After a while, the progress bar in the display section of the threshold value reaches to its full length.
Then, the power tuning indicating lamp illuminates and a new amount of received light and threshold
value are displayed.
5-37
5.20 Teaching the Tag Detection Sensor
The power tuning is completed.
If the following result is displayed at the end of the step 4, the power tuning has failed. Retry the
power tuning.
5.20.2
•
If "ovEr" is displayed in the display section of threshold value,
a fiber error may have occurred or the optic axis may be deviated.
•
If "botm" is displayed in the display section of threshold value,
the power tuning is set to the minimum level (1/25 of standard value).
Teaching the Tag Detection Sensor (Setting the
Threshold Value)
To conduct a tag detection sensor teaching, follow the procedure below.
1
Set the operation mode selector switch to the "D (dark)" mode.
2
Change the SET/RUN selector switch from the "RUN" mode to the "SET" mode.
3
Loosen the tag detection sensor position adjusting thumbscrew and relocate and fix the tag
detection sensor to a position where the sensor light hits the tag.
Position where the Light Hits the Tag
4
Press the [UP] button once.
"tEch" is displayed in the display section of amount of light received.
5-38
5.20 Teaching the Tag Detection Sensor
5
Loosen the tag detection sensor position adjusting thumbscrew and relocate and fix the tag
detection sensor to a position where the sensor light hits the area where there is no tag.
Position Where the Light Hits Where there is No Tag
6
Press the [UP] button once.
"2Pht" is displayed in the display section of amount of light received.
7
Change the SET/RUN selector switch from the "SET" mode to the "RUN" mode.
A new amount of received light is displayed in the display section of amount of light received
and a new threshold value is displayed in the display section of threshold value.
If the following result is displayed at the end of the step 7, teaching has failed. Retry the power tuning.
(See "5.20.1 Tag Detection Sensor Power Tuning".)
•
If "ovEr" is displayed in the display section of threshold value:
•
If "Lo" is displayed in the display section of threshold value:
If the filter in use contains several shades, the teaching may not finish normally. In such a case,
manually adjust the threshold value.
To adjust the threshold value manually, follow the procedure below.
8
Press the [UP]/[DOWN] button to enter the threshold value.
Determine the threshold value by using the formula below.
5-39
5.20 Teaching the Tag Detection Sensor
([Amount of received light of the area where there is no tag] - [Amount of received light of the
area where there is a tag]) ÷ 2 + [Amount of received light of the tag]
(Example) If the value of Amount of received light of the area where there is no tag = 2000, and
Amount of received light of the area where there is a tag = 500, the formula will be as
follows.
(2000-500) ÷2 + 500 = 1250
0
500
Position
of the tag
No.
1
2
Threshold value
Between 500 and
2000
＝1250
2000
4000
Filter
Description
Amount of light received
Threshold value
If the tag cannot be detected proplery during actual operation, adjust the threshold
value.
5-40
5.21 Teaching the Film Joint Detection Sensor (Option)
5.21
Teaching the Film Joint Detection Sensor
(Option)
This section describes the teaching procedure for the film joint detection sensor.
The film joint detection sensor detects the presence or absence of a joint tape from a change in the
amount of light received.
The tag position adjustment is required also when the filter roll is changed.
Film joint detection sensor
No.
1
Description
Film joint detection sensor
2
Film joint detection sensor position adjusting thumbscrew
3
Film joint detection sensor signal amplifier
Film Joint Detection Sensor Signal Amplifier (E3X-DA41-S)
No.
1
Description
[UP] button
2
[DOWN] button
3
[MODE] button
4
Operation mode selector switch
L: Select this when the color of the joint tape is lighter compared to the filter.
D: Select this when the color of the joint tape is darker compared to the filter.
5
6
SET/RUN selector switch
SET: Select this when performing setting.
RUN: Select this when operating.
Display section of threshold value
7
Display section of amount of light received
8
Power tuning indicating lamp
5-41
5.21 Teaching the Film Joint Detection Sensor (Option)
5.21.1
Film Joint Detection Sensor Power Tuning
To conduct a film joint detection sensor power tuning, follow the procedure below.
This section describes the situation when the color of the joint tape is darker than the other positions.
1
Run the filter between the film joint detection sensor.
2
Make sure that no joint tape is present between the light emitting head and the light receiving
head of the film joint detection sensor.
3
Set the operation mode selector switch to the "D (dark)" mode.
Set the operation mode selector switch to the "L (light)" mode if the color of the joint
tape is ligher than the other positions. Also, perform power tuning with the joint tape
aligned to the film joint detection sensor.
4
Set the SET/RUN selector switch to the "RUN" mode.
5
Press and hold the [MODE] button for 3 seconds.
"Ptun" is displayed in the display section of amount of light received and a progress bar appears
in the display section of threshold value.
After a while, the progress bar in the display section of the threshold value reaches to its full length.
Then, the power tuning indicating lamp illuminates and a new amount of received light and threshold
value are displayed.
The power tuning is completed.
If the following result is displayed at the end of the step 5, the power tuning has failed. Retry the
power tuning.
•
If "ovEr" is displayed in the display section of threshold value,
a fiber error may have occurred or the optic axis may be deviated.
5-42
5.21 Teaching the Film Joint Detection Sensor (Option)
•
5.21.2
If "botm" is displayed in the display section of threshold value,
the power tuning is set to the minimum level (1/25 of standard value).
Teaching the Film Joint Detection Sensor (Setting the
Threshold Value)
To conduct a film joint detection sensor teaching, follow the procedure below.
1
Set the operation mode selector switch to a mode described below.
•
When the color of the joint tape is darker compared to the other positions: "D (dark)" mode
•
When the color of the joint tape is lighter compared to the other positions: "L (light)" mode
2
Change the SET/RUN selector switch from the "RUN" mode to the "SET" mode.
3
Loosen the film joint detection sensor position adjusting thumbscrew and relocate and fix the
film joint detection sensor to a position where the sensor light hits the following.
•
When the color of the joint tape is darker compared to the other positions: position of the light
where there is no joint tape
•
When the color of the joint tape is lighter compared to the other positions: position of the light
where there is joint tape
Position to Hit the Area Where there is No Joint Position where the Light Hits the Joint Tape
Tape
4
Press the [UP] button once.
"tEch" is displayed in the display section of amount of light received.
5
Loosen the film joint detection sensor position adjusting thumbscrew and relocate and fix the
film joint detection sensor to a position where the sensor light hits the following.
•
When the color of the joint tape is darker compared to the other positions: position of the light
where there is joint tape
•
When the color of the joint tape is lighter compared to the other positions: position of the light
where there is no joint tape
5-43
5.21 Teaching the Film Joint Detection Sensor (Option)
6
Press the [UP] button once.
"2Pht" is displayed in the display section of amount of light received.
7
Change the SET/RUN selector switch from the "SET" mode to the "RUN" mode.
A new amount of received light is displayed in the display section of amount of light received
and a new threshold value is displayed in the display section of threshold value.
If the following result is displayed at the end of the step 7, teaching has failed. Retry the power tuning.
(See "5.21.1 Film Joint Detection Sensor Power Tuning".)
•
If "ovEr" is displayed in the display section of threshold value:
•
If "Lo" is displayed in the display section of threshold value:
If the filter in use contains several shades, the teaching may not finish normally. In such a case,
manually adjust the threshold value.
To adjust the threshold value manually, follow the procedure below.
8
Press the [UP]/[DOWN] button to enter the threshold value.
Determine the threshold value by using the formula below.
([Amount of received light of the area where there is no joint tape] - [Amount of received light
of the area where there is a joint tape]) ÷ 2 + [Amount of received light of the joint tape]
(Example) If the value of Amount of received light of the area where there is no joint tape =
2000, and Amount of received light of the area where there is a joint tape = 500, the
formula will be as follows.
(2000-500) ÷2 + 500 = 1250
0
500
Position of the
joint tape
Threshold value
Between 500 and
2000
＝1250
2000
Filter
5-44
4000
5.21 Teaching the Film Joint Detection Sensor (Option)
No.
1
2
Description
Amount of light received
Threshold value
If the tag cannot be detected proplery during actual operation, adjust the threshold
value.
5-45
5.22 Lubricating the Sliding Section
5.22
Lubricating the Sliding Section
This section describes how to lubricate the sliding parts.
The lubricating points are shown below.
 Before starting the work, always turn the main power and the compressor power
OFF, and press the [EMERGENCY] button.
Jaws Section
No.
1
Description
Jaws section shaft/bearing
Horizontal Traverse Section
No.
2
Description
Horizontal traverse section shaft/bearing
5-46
5.22 Lubricating the Sliding Section
Traverse Section
No.
3
Description
Jaws section cylinder
Horizontal Traverse Section
No.
4
Description
Horizontal traverse section cylinder
Material Feed Section
No.
5
Description
Chain
5-47
5.22 Lubricating the Sliding Section
■
Lubricating Procedure
1
Perform the finishing operation.
(See "3.6 Finishing Operation".)
2
Clean the machine.
(See "4 Cleaning".)
3
Lubricate the specified greasing points of the machine.
 When cleaning or performing maintenance/inspection, always perform
lockout/tagout as well as turning the [MAIN POWER] switch "OFF".
Otherwise, your fingers and hands can be caught resulting in serious injury.
3-1
Perform lockout/tagout for the main power.
(See "1.5.1 Procedures for Locking Out/Tagging Out the Main Power".)
3-2
Apply bio-adneel spray (accessory) on the specified greasing points of the machine.
 Always use bio-adneel spray which is an accessory for this machine, or lubricant for
food product machine.
Otherwise, hazardous lubricant may enter your body though the product.
3-3
Release lockout/tagout for the main power.
(See "1.5.2 Procedures for Releasing Lockout/Tagout of the Main Power".)
5-48
6 Troubleshooting
6
Troubleshooting
This chapter describes the following contents.
•
Precautions on the Troubleshooting
•
Error Alarm and its Releasing Method
•
Other Errors
6-1
6.1 Precautions on the Troubleshooting
6.1
Precautions on the Troubleshooting
This section describes the precautions to be observed when performing troubleshooting.
Read the precautions carefully and fully understand it before working.
•
For replacing and adjusting
Maintenance/Inspection".
•
If customers perform troubleshooting, operators need to be trained for fully understanding the
operation and safety for this machine. Only the maintenance operator permitted by the company
can perform troubleshooting.
the
components,
follow
the
instructions
in
"5
Always perform the following procedures before starting the work.
•
Turn the [MAIN POWER] switch "OFF".
•
Turn the compressor OFF.
•
Perform lockout/tagout for the main power.
Follow the instructions in "1 Safety" during work.
If foreign object remains in the machine, breakage of the machine or quality problems of the products
may result.
6-2
6.2 Error Alarm and its Releasing Method
6.2
Error Alarm and its Releasing Method
This section describes error alarms and how to cancel them.
AUTO Screen
No.
1
Message indicator
Description
2
[ALARM RESET]
When an error occurs on the machine, error cause will be displayed in the message indicator on the
operation panel.
See the releasing method to remove the cause of the error.
1
Press [ALARM RESET].
2
Remove the cause of the error.
3
If it is necessary to inspect inside the machine, turn the [MAIN POWER] switch "OFF".
4
After inspecting, turn the [MAIN POWER] switch "ON".
No.
1
Error
EMERGENCY
STOP
Cause
[EMERGENCY STOP]
button has been pressed.
2
OVER TIME
This alarm occurs if the
Inspect the main motor for error or
turning speed of the main axis the torque limiter for slipping.
is abnormally slow.
4
AIR SHOTAGE
The air supply pressure has
decreased.
Inspect the compressor.
Inspect the primary pressure of air.
9
HOPPER LOW
LEVEL
This alarm is displayed when
the hopper level decrease
signal is received.
Reset the alarm and restart the
machine.
17
DOOR OPEN
The safety cover in the
bagging section is opened.
Close the safety cover in the bagging
section to cancel this alarm. (See
"1.4.2 Electrical Safety Devices
(Interlock)".)
6-3
How to Cancel
Turn the [EMERGENCY STOP]
button to the arrow direction to
cancel the lock.
(See "1.4.1 [EMERGENCY STOP]
Button".)
6.2 Error Alarm and its Releasing Method
No.
18
Error
DOSER MOTOR
ERROR
Cause
Materials cannot be fed
normally due to overload of
the volumetric doser.
How to Cancel
Inspect and replace the doser motor.
Contact Fuso Industries Co., Ltd. for
details on inspecting, adjusting, and
replacing the volumetric doser
section.
19
FILTER FEED
MOTOR ERROR
Filter feed motor is
overloaded.
Inspect and replace the filter feed
motor.
20
FILTER END
Filter has ran out.
Set a new filter. (See "3.4.4 Setting
the Filter".)
21
DOSER ERROR
Foreign objects are stuck in
the volumetric doser.
Clean and inspect the volumetric
doser.
[DOSER] is not turned ON.
Turn [DOSER] ON.
22
WEIGHER ERROR Failure occurred in the
weigher, or no material is
(Option)
discharged from the weigher
for 10 seconds or more.
Feed the material in the weigher.
Inspect the weigher.
23
WEIGHER
DISCHAGE
ERROR
(Option)
Check the weigher.
24
V.SEAL US ERROR Ultrasonic vertical sealing is
overloaded.
25
H.SEAL US
ERROR
Discharge completion signal
is not returned from the
weigher.
Inspect the vertical sealing unit.
Foreign objects are stuck in
the ultrasonic section
Open circuit has occurred at
the sealing unit
Remove the foreign object. Check
the connection of the oscillator lead
connector.
Ultrasonic generator fuse is
burned out.
Replace the fuse.
(See "5.10 Replacing the Ultrasonic
Generator Fuse".)
Inspect the horizontal sealing unit.
Ultrasonic horizontal sealing
is overloaded.
Foreign objects are stuck in
the ultrasonic section Open
circuit has occurred at the
sealing unit
Remove the foreign object. Check
the connection of the oscillator lead
connector.
Ultrasonic generator fuse is
burned out.
Replace the fuse. (See "5.10
Replacing the Ultrasonic Generator
Fuse".)
26
TAG LACK
The tag on the filter could not Remove the faulty section of the
be detected.
filter and restart the operation.
Clean the tag detection sensor.
Adjust the sensitivity of the tag
detection sensor signal amplifier.
(See "5.20 Teaching the Tag
Detection Sensor".)
28
FILTER JOINT
DETECT
(Option)
The joint on the filter has
been detected.
Remove the joit on the filter and
restart the operation.
29
VERT DISC
PRESSURE
ERROR
Vertical disc pressure
decrease has been detected.
Adjust the regulator so that the
pressure becomes appropriate.
(See "3.4.5 Adjusting the Vertical
Sealing Unit".)
6-4
6.2 Error Alarm and its Releasing Method
30
HORIZ DISC
PRESSURE
ERROR
Horizontal disc pressure
decrease has been detected.
Adjust the regulator so that the
pressure becomes appropriate.
(See "3.4.7 Adjusting the Horizontal
Sealing Unit".)
33
H.UNIT CW.OT
When turning to the CW
direction, an over traveling
limit has been activated due
to excessive action.
It is necessary to set the ZSET.
Contact Fuso Industries Co., Ltd.
34
H.UNIT CCW.OT
When turning to the CCW
direction, an over traveling
limit has been activated due
to excessive action.
It is necessary to set the ZSET.
Contact Fuso Industries Co., Ltd.
44
DOSER INV
COMM ERROR
An error occurred in
Inspect the connector for
communication with the doser disconnection or breakage.
motor.
45
FILTER FEED INV
COMM ERROR
An error occurred in
Inspect the connector for
communication with the filter disconnection or breakage.
feed motor.
65
2ch OVER
CURRENT
Overcurrent has been detected Turn the machine OFF, remove the
in the solenoid valve output. cause, and turn the machine ON
again.
66
3ch OVER
CURRENT
Overcurrent has been detected Turn the machine OFF, remove the
in the solenoid valve output. cause, and turn the machine ON
again.
67
4ch OVER
CURRENT
Overcurrent has been detected Turn the machine OFF, remove the
in the solenoid valve output. cause, and turn the machine ON
again.
68
5ch OVER
CURRENT
Overcurrent has been detected Turn the machine OFF, remove the
in the solenoid valve output. cause, and turn the machine ON
again.
69
6ch OVER
CURRENT
81
PLC BATTERY
ERROR
Overcurrent has been detected Turn the machine OFF, remove the
in the solenoid valve output. cause, and turn the machine ON
again.
PLC battery is weak.
Replace the PLC battery
It is recommended to supply immediately.
power to the PLC battery
(See "5.11 Replacing the PLC
once a day to check if "PLC
Battery".)
BATTERY ERROR" occurs.
82
WAITING FOR
WEIGHER
(Option)
Weighing speed of the
weigher is slow.
Inspect the weigher for weighing
speed.
84
HOPPER LOW
LEVEL
This alarm occurs when the
HOPPER LOW LEVEL
alarm is reset.
Visually check the volume of the
material.
85
SERV BATTERY
ERROR
Servo battery is low.
Replace the servo battery.
87
DOOR OPEN
The machine was attempted
to be started with the safety
door open.
Close the safety door.
88
COUNT UP
Quantity of the product has
When continuing production, press
reached the number set on the [RESET] to reset the counter and
counter.
start operation again.
89
COUNT UP
FINISHED
Quantity of the product has
When continuing production, press
reached the number set on the [RESET] to reset the counter and
counter.
start operation again.
6-5
6.2 Error Alarm and its Releasing Method
90
WEIGHER
PREPARATION
ERROR
(Option)
Weigher is not turned ON.
Check the weigher.
91
US POWER OFF
Ultrasonic generator is not
turned ON.
Turn [US POWER] ON.
92
MAIN AXIS ZERO
SEARCHING
The machine is searching the
zero-point of the main axis.
Wait until the zero-point search
completes.
93
FILTER GRIP OFF
[FILTER GRIP] is not turned
ON.
Turn [FILTER GRIP] ON.
100
RESET SFC
This message is displayed
when recovering from
EMERGENCY STOP or
DOOR OPEN error.
Press the [SFC RESET] button.
101
SERVO BATTERY
ERROR
Servo driver battery is weak.
Replace the servo driver battery.
6-6
6.3 Other Errors
6.3
Other Errors
This section describes other errors and how to release them.
No.
1
2
3
4
5
Error
Machine
does not
operate
Cause
Primary power is not
turned ON
How to Cancel
Turn the primary power ON
[MAIN POWER] switch is
not turned "ON".
Turn the [MAIN POWER] switch
"ON".
Malfunction of [START]
button
Replace the [START] button
Alarm occurs and the
machine stops
Remove the cause of the abnormality,
and cancel the alarm
Current quantity of
production number has
reached the scheduled
quantity of production
number.
Reset the current quantity of
production number and set the
quantity of production number.
(See "3.5.1 Setting Counter".)
Traverse
section does
not move
Low air pressure
Set the air pressure to the proper
pressure
Malfunction of
[TRAVERSE]
Replace the TRAVERSE
The traverse
section does
not move
smoothly
Inadequate speed of the
traverse air cylinder
Adjust the right traverse speed control
knob and the left traverse speed
control knob
(See "5.19 Adjusting the Traverse
Speed".)
Air leakage from the
traverse air cylinder
Inspect the traverse air cylinder for air
leaks
If air is leaking, replace the traverse
air cylinder
Malfunction of traverse air
cylinder solenoid valve
Replace the traverse air cylinder
solenoid valve
Filter vertical feed roller
pressure is low
Readjust the gripping pressure of the
filter grip roller
Machine
stops
Malfunction
of vertical
feed roller
Check or replace the magnet switch
Inspect the looseness of the filter
vertical feed roller bolt
Malfunction of vertical
stepping motor
Inspect the vertical stepping motor
and replace the parts
Clean and inspect the tag detection
sensor
(See "5.20 Teaching the Tag Detection
Sensor".)
Check the feed pitch
6-7
6.3 Other Errors
No.
6
7
Error
Feed and cut
error for
tagged filter
Filter tends
to be
misaligned
Cause
Check the vertical feed
dimension
How to Cancel
Readjust the vertical feed dimension
Readjust the feed pitch
Detection malfunction in
tag detection sensor
Clean the tag detection sensor and
adjust the tag detection sensor signal
amplifier
(See "5.20 Teaching the Tag Detection
Sensor".)
Position of the tag
detection sensor
Adjust the position of the tag
detection sensor
(See "5.22 3.4.8 Adjusting the Tag
Detection Sensor".)
Poor quality of the filter
Replace the filter
Position of the filter is
incorrect
Adjusting the filter roll section:
Move the adjustment screw to the left
when the filter shifts to the right
Adjusting the filter roll section:
Move the adjustment screw to the
right when the filter shifts to the left
Position of the filter roll
section is incorrect
Adjust the position of the filter chute
by loosening the fixing thumbscrew.
Adjust the filter roll position adjusting
dial
Turn it counterclockwise when the
front side protrudes
Turn it clockwise when the depth side
protrudes
Wear of ultrasonic horn and
perforation disc (vertical
sealing unit)
Adjust or replace the ultrasonic horn
(See "5.6 Replacing the Ultrasonic
Horn (Vertical Sealing Unit)".)
Adjust or replace the perforation disc
(See "5.8 Replacing the Perforation
Disc (Vertical Sealing Unit)".)
8
9
Wrinkles
tends to
occur during
traverse cut
The traverse
cut line of the
filter is not
level
Attachment position of the
ultrasonic horn is deviated
(vertical sealing unit)
(See "5.6 Replacing the Ultrasonic
Horn (Vertical Sealing Unit)".)
The perforation disc
urethane belt becomes long
(Option)
Replace the vertical disc urethane belt
(See "5.8 Replacing the Perforation
Disc (Option)".)
There is resistance in the
filter
Poor quality of the filter
Adjust the filter roll position adjusting
dial at the filter roll section
Replace the filter
Position of the filter chute
tower is deviated
Adjust the filter chute angle adjusting
knob
Attachment position of the
filter chute is not vertical
Adjust the position of the filter chute
tower
6-8
6.3 Other Errors
No.
10
Error
Malfunction
of traverse
cut
Cause
Wear of ultrasonic horn and
horizontal disc (horizontal
sealing unit)
Malfunction of the
oscillator (horizontal
sealing unit)
Open circuit at the
ultrasonic output cable
11
Finished
quality of
non-woven
fabric filter is
insufficient
(Option)
How to Cancel
Adjust or replace the ultrasonic horn
(See "5.7 Replacing the Ultrasonic
Horn (Horizontal Sealing Unit)".)
Adjust or replace the horizontal disc
(See "5.9 Replacing the Horizontal
Disc (Horizontal Sealing Unit)".)
Replace the oscillator
(See "5.7 Replacing the Ultrasonic
Horn (Horizontal Sealing Unit)".)
Replace the ultrasonic output cable
Filter cannot be fixed by
jaws
Replace the Teflon tape
Malfunction of jaws air
cylinder solenoid valve
Replace the jaws air cylinder solenoid
valve
Turn [NWF AIR] ON.
[NWF AIR] is not turned
ON.
Replace the silicon rubber
Low non-woven fabric air
pressure
Adjust the air pressure
Pipes at the lower filter
chute are bent
Readjust the filter chute lower pipe
6-9
6.3 Other Errors
6-10
7 Accessories/Consumable Parts List
7
Accessories/Consumable Parts List
This chapter describes the following contents.
•
Accessories List
•
Consumable Parts List
7-1
7.1 Accessories List
7.1
Accessories List
This section describes the accessories.
Accessories List
No.
1
Description
Ultrasonic horn (wear resistant, 25φ)
Quantity
1
2
Oscillator 25φ
1
3
Ultrasonic horn (15φ)
1
4
Oscillator 15φ
1
5
Oscillator screw 8×13 mm
1
6
Oscillator gasket 25φ
2
7
Oscillator gasket 15φ
2
8
Horizontal disc
2
9
Perforation disc
1
10
E ring
1
11
Hhorizontal disc attachment screw
4
12
Wrench 22 mm
2
13
Filter chute section thumbscrew
5×8 mm
4
14
Air gun
1
15
INSULOK-tie 100 mm
5
16
Fuse 1A
2
17
Fuse 2A
2
18
Teflon tape 50 mm×10 m
1
7-2
Type
R0.75
ASF-110
Remarks
7.1 Accessories List
No.
19
Description
Sanding sponge
Quantity
1
20
Tooth brush
1
21
Urethane belt
1
22
Tool box/tools
1
23
Fiber cutter
1
24
Cap bolt M5×20
2
25
Spring M5
2
26
Flat washer M5
2
27
Ultrasonic cable (for traverse)
1
28
Ultrasonic generator 25φ
1
Stepladder (For the interlocking machine
only)
1
Instruction manual (this manual)
1
Amplifier instruction manual
1
7-3
Type
USC-008
Remarks
7.2 Consumable Parts List
7.2
Consumable Parts List
This section describes the consumable parts.
The parts described below are the consumable parts. They are not covered by the
warranty.
No.
1
Description
Ultrasonic horn (15φ)
(wear resistant, 25φ)
(vertical/horizontal)
Quantity
1 for each
2
Oscillator (15φ) (25φ)
(vertical/horizontal)
1 for each
3
Perforation disc
1
4
Urethane belt
1
5
Jaws section silicon rubber
1
6
Teflon tape
1
7
Horizontal disc
1
7-4
Type
Remarks
8 Installation
8
Installation
This chapter describes the following contents.
•
Overview for Installation
•
Preparation before Installation
•
Carrying in the Machine
•
Machine Installation
•
Operation Check
8-1
8.1 Overview for Installation
8.1
Overview for Installation
This section describes the installation overview.
The procedures from installation preparation to installation completion are shown below.
Preparation before Installation
See section 8.2
Carrying in the Machine
See section 8.3
Machine Installation
See section 8.4
Operation Check
See section 8.5
8-2
8.2 Preparation before Installation
8.2
Preparation before Installation
8.2.1
•
Check that the height and width of the door are enough for carrying in the machine.
•
Make sure there are no obstacles on the carrying-in passage.
•
Determine the carrying-in sequence of the machines.
•
Store the machine indoors when it is temporarily placed before installation.
Base
8.2.2
•
Select the installation place having sufficient rigidity withstanding the total weight of the machine.
•
The machine installation height adjustment amount is 120 mm.
Machine Installation Circumstances
■
Temperature and Humidity
This machine is manufactured conforming to the following criteria.
•
Machine operation ambient temperature: +0 ºC to +40 ºC
•
Machine operation ambient humidity: 85 %
Some functions may be adversely affected if the temperature exceeds the
specified temperature described above.
■
Lighting (Recommended)
We recommend that the machine is placed under the following illumination.
•
Operation place: 650 lux or more
•
Machine ambient: 350 lux or more
8.2.3
Utility
8.2.3.1
Electricity
■
Primary Side Power
•
For wiring, follow "Electric Facility Criteria", "Internal Wiring Regulations", and "Power
Company Regulations". Attention is needed because the voltage largely drops especially when the
wiring distance becomes longer. In this case, allowable voltage drop is within 2 %.
•
The power cut protection circuit is not included in the machine control circuit. The machine may
stop due to an instant power cut. Install an uninterruptible power supply on the power side as
necessary in a region where instant power cut frequently occurs.
•
Please connect the power so that the S-phase becomes the ground phase.
•
Machine operation malfunction may occur due to that the wiring is heated or the power voltage
drops during operation when the primary side incoming line size is not proper. Be sure to consult
the construction worker to determine the incoming line size.
•
Loose screws may cause accidents. Completely tighten the screws at the connecting terminals, and
prevent them from being loose. Periodically check for loose screws, and tighten them to the
specified torque.
8-3
8.2 Preparation before Installation
■
Capacity of Electric Facility and Incoming Line Size on Primary Side
Unit
Body
Capacity of
Electric Facility
Approx. 3.0 KW
600V (IV)
Incoming Line
Size
2.0 mm 2
Input Power
Voltage
Breaker Capacity
3 phases 200 VAC 15AT
The incoming line size and the main breaker capacity are for the standard
specifications.
The line size is determined assuming three 600 V insulation lines (IV), ambient
temperature 30 ºC, and metal tube construction. The line size varies depending on the
ambient temperature and the construction method for routing line. Please consult the
construction worker for details.
2
For 100 V for the peripheral devices, adopt wires coping with IV 2 mm .
Please use the earth leading breaker with sensitivity setting current at 100 mA or more
considering ground resistance for grounding.
■
Grounding
For the machine grounding, D type grounding (see the following) is required if the machine supply
voltage is 200 V or 220 V. Be sure to conduct the grounding without fail in order to prevent electrical
shock accident.
D type grounding -> Voltage; 300 V or less, Ground resistance: 100Ωor less
For correct operation of the machine, provide 1 ground pole for each device as a
principle. Do not use 1 ground pole for several devices.
■
Installation of the Earth Leakage Breaker
The installation place of the earth leakage breaker is described in the internal wiring regulations as
following. "The earth leakage breaker has to be installed on the distribution panel power side or inside
the distribution panel excepting the case that it is built in the equipment as a principle". We recommend
that the earth leakage breaker is disposed in the customer's distribution panel.
8-4
8.2 Preparation before Installation
8.2.4
Obtaining the Installation Area
•
Obtain sufficient space for safely operating the machine.
•
Obtain sufficient space for performing cleaning/washing/maintenance/inspection for the machine.
•
Obtain sufficient space for disposing other accessories as necessary.
Dimension and Gravity Center of the Machine
Dimension
Item
Specification
820 (W) × 970 (D) × 2255 (H) mm
Installation area
1106 (W) × 1610 (D) mm
Required working area
(recommended)
Weight
1106 + 1000 (W) × 1610 + 1000 (D) mm × 1790 + 1000 (H) mm
450 kg
8-5
8.3 Carrying in the Machine
8.3
Carrying in the Machine
This section describes the procedure of carrying in the machine.
 Persons who obtain the license can be engaged in slinging work and
crane operation.
There exists a hazard that may result in death or serious personal
injury if the lifting load drops.
1
Remove the safety door (operation side).
2
Remove the waste filter air purge pipe.
3
Remove the hopper.
4
Insert the wire rope into the legs on the machine operation side and non-operation side to attach it
to the hook.
Lifting the Machine
5
Check that the hook is positioned over the machine gravity center prior to lifting the machine.
6
Make sure all operators are apart from the lifting site.
 Do not go under the lifting load.
There exists a hazard that may result in death or serious personal
injury if the lifting load drops.
7
Slowly lift up the machine.
8
Slowly lower the machine so as not to apply shock after moving it to the prescribed position.
8-6
8.4 Machine Installation
8.4
Machine Installation
This section describes installation procedure of the machine.
Machine Legs
No.
1
2
1
Description
Height adjustment nut
Fixing nut
Adjust the levels of the machine legs using the level gauge.
1-1
1-2
Adjust the length of machine legs by turning the height adjustment nut so that the
machine becomes horizontal.
Fix the machine legs by turning the fixing nuts after level adjustment completes.
2
Attach the hopper.
3
Attach the waste filter air purge pipe.
4
Attach the safety door (operation side).
8-7
8.5 Operation Check
8.5
Operation Check
Check that the machine correctly operates after installing the machine (See "3 Operation").
8-8
Issued Dec, 2010
FS-23T-TFCE1-1-ENG 2014.6.30.