Damark Packaging Inc

OPERATIONS MANUAL

MAXIPAK SHRINK SYSTEM

PLEXPACK CORP. 2045 Midland Avenue, Toronto, ON, Canada M1P 3E2 Phone: 416-609-8011 Toll Free: 1-800-265-1775 Fax: 416-298-4328 [email protected] www.damarkpackaging.com

TABLE OF CONTENTS

SECTION PAGE #

1 Introduction 3

2 Initial Inspection 4

3 Safety and Warranty 5

4 Electrical Connections 7

5 Operation 8

6 Routine Maintenance 11

7 Trouble Shooting 14

8 Parts List 16

9 Electrical Schematics 17

SECTION 1

INTRODUCTION

SHRINK PACKAGING

Simply stated, shrink packaging is a method of combining, enhancing or protecting products in an attractive, economical way.

The most versatile and widely used equipment in shrink packaging is the L-Sealer/Shrink Tunnel combination. Used together, these two machines form the normal system but it is important to remember that they can be used alone quite effectively using specific techniques. These various other forms of shrink packaging are too complicated for this brief summary, but can be explained by your Damark distributor.

The L-Sealer utilizes a supply of centre folded film to form a loose fitting bag around a product. This process can be accomplished with an operator or, with more advanced Damark machines, completely automatically.

From the L-Sealer, the package is either pushed or conveyed onto the Shrink Tunnel conveyor. Even on the simplest and least expensive Damark system, the Shrink Tunnel is completely automatic. The purpose of the Shrink Tunnel is to expose the film around the package to a flow of heated air (at a pre-set temperature) for a specific period of time. The temperature in the Shrink Tunnel is thermostatically controlled so, once it has been set, there are no further heat adjustments required. The length of time a package spends within the heat chamber is determined by the speed of the Shrink Tunnel conveyor. This, too, can be set at whatever speed is required, and that speed will be maintained.

It can now be seen that the L-Sealer/Shrink Tunnel combination is extremely simple to use. The same system can be used for a wide variety of sizes or different products with minimal changeover time.

MAXIPAK

The Damark Maxipak series of sealer/tunnel combinations have been designed to offer the utmost in versatility and reliability.

This manual has been compiled to assist the purchaser in the operation and maintenance of this unit. Recommended maintenance will greatly improve the performance and reliability of your new machine. Any problems not covered by this manual can be referred to the factory service department.

Damark is continually striving to improve its products. It reserves the right to change or discontinue the specifications and designs shown in this manual without notice and without incurring obligation.

SECTION 2

INITIAL INSPECTION

Immediately after your receive your machine(s), inspect them closely for any obvious signs of damage.

Remember that the inside of the machines have sensitive electronic controls; damage on the outside of the machine, although minor, can sometimes be a indication of rough handling during shipment.

If any damage is noticed, contact your carrier immediately. Report it and if necessary, file a claim.

SECTION 3

SAFETY AND WARRANTY

SAFETY

Read this entire safety section before operating machines.

• Keep all extremities, jewelry, loose clothing and hair away from moving assemblies and conveyors.

• Conveyor belts that have become worn or frayed, can be hazardous and should be replaced promptly.

• Never operate this or any moving equipment without all covers and guards in place.

• Shrink tunnel openings on packaging machinery can get very warm after a period of use, keep hands away while in operation and use caution if the machine has been running recently.

• Never insert pressurized containers, flammable or explosive materials into or through a shrink tunnel.

• Proper voltage must be applied to machine.

WARRANTY

If any part of your new Damark equipment fails within twelve (12) months of shipment from the factory resulting from a manufacturing defect, Damark will furnish the required replacement part without charge, F.O.B. factory, upon receipt of the defective part. Related service, labour, and diagnostic calls are not included.

This warranty does not cover damage by accident, misuse, abuse, installation in abnormal conditions of moisture, dirt or corrosive matter, misapplication, or improper installations; and does not cover expendable items such as Teflon covers, sealing elements, pilot lights, etc.

The warranty is limited on electric motors to the warranty offered by our suppliers.

This warranty constitutes the exclusive remedy of any purchaser of Damark equipment and is in lieu of all other warranties expressed, implied, including without limitation any implied warranty of merchantability or fitness and Damark shall have no other obligations of liability. In no event shall Damark be liable for special or consequential damages.

Damark will not be responsible for repairs by anyone other than Damark.

SECTION 3

SAFETY AND WARRANTY

WARRANTY (continued)

This warranty is void if any modifications or alterations are made to the equipment by anyone other than Damark Packaging Inc.

Installation and operation of the equipment in compliance with all applicable electrical and safety standards is the sole responsibility of the purchaser.

This manual has been prepared specifically for the following machine:

Serial #:

SECTION 4

ELECTRICAL CONNECTIONS

Connection of your machine (except 110 volt machines) should be carried out only by a qualified electrician. The correct voltage and amperage is displayed on the identification label located on each machine.

In the case of 110 volt machines, they can be plugged directly into the electrical supply. The use of extension cords is not recommended.

For machines connected by an electrician, prior to his leaving, check that each function of the machine is operating correctly. Turn all control knobs to the ‘zero’ setting. Then, with the power turned on, try each function by turning the knob a little at a time until a response is noted.

SECTION 5

OPERATION

CONTROLS ON THE MAIN PANEL - FROM LEFT TO RIGHT

POWER ON The ‘power on’ light will illuminate when the main switch is in the ‘on’ position.

HEAT ON The ‘heat on’ light is illuminated whenever the heaters are in operation. When the shrink tunnel heat control is first turned on, this light will illuminate, and will remain that way until the temperature within the chamber reaches the desired level. From then on, it will only come on as the thermostat calls for more heat. In this way, the heaters constantly fluctuate between on and off.

SEALING TEMPERATURE Adjusts sealing temperature of sealing wire. Clockwise increases heat.

DWELL TIME Controls the magnet down time.

HEAT The heat control can be set to a maximum of 200° C (400° F). The working range of most films is 130-160° C (270-320° F).

CONVEYOR The conveyor control is used to set the desired speed of the shrink tunnel conveyor.

LOADING FILM With the folded edge of the film towards the rear of the machine the roll of film is placed on top of the two rollers, which form the film cradle.

The rubber collars can be adjusted to the edges of the roll of film to hold the film in the desired position. The loose end of the film is pulled towards the sealing area with the lower half of film feeding under the loading table and the upper half of film feeding on top of the loading table.

LOADING FILM The loading table can be adjusted for different widths of film by loosening the screw under the front of the table, moving the table to the correct position and re-tightening the screw.

SECTION 5

OPERATION (continued)

SEAL TEMPERATURE The sealing temperature control is used to set the temperature on the sealing wire in order to achieve the strongest possible seal with the particular type of film you are using.

To set this control correctly, we first turn it counter-clockwise to its minimum setting. Then, after inserting the loose edge of the film into the sealing area, pull down the sealing head to the closed position and observe the film. Is it sealed? Has it cut and separated?

The effect we are seeking initially is a clean cut in the shape of the sealing wires. If the film will not separate at the point where the seal has been made, turn the dwell dial a little at a time, operating the machine each time, until the film separates cleanly. The temperature is now set at its most efficient point.

CONVEYOR The conveyor dial is used to set the speed of the conveyor or, more importantly, the length of time a package will spend in the shrink chamber exposed to the heat. When the unit is first switched on, slowly turn the conveyor dial clockwise and counter-clockwise, and observe the conveyor belt speeding up and slowing down. Once you are ready to start, set the conveyor dial about half way around, and leave the conveyor running as we set the heat controls.

SHRINK TUNNEL CONTROLS

TUNNEL TEMPERATURE The first time your system is to be used, it is advisable to check the functions of the heaters and temperature controller. To do this, turn the heat control to 50° C (120° F), the ‘heat on’ light is illuminated. This tells you that the controller has switched the heaters on. Wait a few minutes and you will notice the ‘heat on’ light go off. Feel inside the tunnel to ascertain if the chamber has warmed up slightly. If it has, then the heaters and heat controller are working correctly and we can begin to set up the machine to produce packages.

Set the heat to 150° C (310° F). This is the recommended starting point. Wait approximately 10 to 15 minutes for the tunnel to come up to temperature. When the ‘heat on’ light goes off again, it indicates that the tunnel is up to the desired temperature.

We are now ready to use the Maxipak Shrink System.

SECTION 5

OPERATION (continued)

OPERATING THE COMPLETE SYSTEM

We have described in an earlier paragraph how to set up the sealing section. Now we are ready to use it.

Mount a roll of film on the machine and feed it as we described earlier across the loading table and into the sealing area. It is necessary each time a new roll of film is started to make an initial seal. This is done by operating the machine once the empty piece of film is within the sealing area.

Now take a product to be packaged and insert it into the film, pull it into the seal area and complete another seal. Once completed, we should be left with a fairly loose bag around your product. Place this on the shrink tunnel conveyor and let it go through the chamber. Observe the package as it comes out of the shrink chamber.

If the package is too loose or wrinkled, it is usually an indication of too little heat or too little time in the shrink tunnel. If holes are burned in the film, it is a result of too much heat or too much time in the shrink tunnel. If either of these situations occurs, the easiest course of action is to either increase or decrease the conveyor speed. This should produce an attractive tight package. If it does not, then an adjustment to the temperature, either up or down, would be necessary.

SECTION 6

ROUTINE MAINTENANCE

There are only three routine maintenance procedures on the Maxipak Shrink System. These are changing the Teflon tape on the sealing bed, changing the sealing wire when it breaks, and maintaining correct conveyor belt tracking.

CHANGING TEFLON TAPE

The purpose of the Teflon tape is to protect the silicone sponge rubber sealing base. It should be replaced whenever it starts to show signs of extreme wear. The life of the tape is entirely dependent on the amount of use of the machine, and the temperature at which the sealing wires are set.

CHANGING SEALING WIRES

Sealing wires only need to be changed when the old one breaks. However, when a breakage might result in a loss of production affecting other machines, it is sometimes advisable to change the wires at two to four week intervals.

To change the wire, first remove the old one from the wire pin and retaining screw on the sealing head. Cut a piece of wire from the roll about three inches longer that the required length.

First, insert the wire into the wire pin and secure with the locking screw. Next, depress the wire pin spring, loop the other end of the wire around the retaining screw at the opposite end of the sealing head. Pull the wire tight and tighten the retaining screw. Cut any excess wire.

CONVEYOR BELT ALIGNMENT

Prior to shipping from the factory, your Maxipak was operated for a minimum of four hours to check the tracking of the conveyor belt. It is advisable, particularly when you have just installed your new unit, to carefully watch the conveyor belt to make sure the tracking is maintained.

If you find the belt is wandering slightly one way or the other, it should be adjusted. There are two adjusting screws located at the exit end of the shrink tunnel. If the belt is tracking to the right, tighten the screw on the right: if the belt is tracking to the left, tighten the screw on the left.

CAUTION: When tightening these adjusting screws, tighten no more than 1/8th turn each time, then check to see if you have the desired result.

SECTION 6

ROUTINE MAINTENANCE (continued)

SEAL PRESSURE SET UP

The seal process is a combination of three elements: heat, dwell and pressure, the latter being the most common source of seal problems. The normal reaction when seal problems occur is to increase the heat. Usually the opposite is true and lowering the heat and resolving the pressure problem will improve seal strength. Most L Sealers use an electro magnet to create pressure against a rubber surface. Heat resistant tape is used to protect the rubber surface. Pressure can be increased by adjusting the gap between the magnet surface and the seal pad. The following procedure should be used for seal set up:

1. Replace the rubber on the lower seal pad. 2. Turn the heat control to “0” and the dwell control to “2”. Place a one inch strip of paper on the lower seal pad and close the seal head. With the head closed, pull the paper. Some resistance should be felt. Move the paper around the seal area checking the pressure. It is desirable to have slightly less pressure towards the pivot point of the side sealing pad. 3. Pressure for the side pad can be adjusted by moving the bearing up or down. 4. Pressure for the front pad can be adjusted by moving the magnet pad. 5. Once the overall pressure has improved, any low points on the pad should be shimmed from underneath the rubber using adhesive Teflon tape, in short strips, locating them in the pad retainer. This will provide a level seal surface. 6. Place new Teflon tape on the seal pad. 7. Seal wires should be straight and the wire pin spring should be fully compressed.

SEAL SOLUTIONS

Generally the components surrounding the hot wire sealing system will have an extended life if the heat is kept to a minimum. The strongest seals are usually achieved at the point where the film just separates.

SEAL WIRES BREAKING AT THE WIRE PIN Usually indicates the seal temperature is too high and excessive heat at the hop spot in front of the wire pin will cause the wire to over heat. The pressure should be checked.

SEAL WIRES BREAKING AT THE CROSSOVER POINT The point where the two wires cross will be subjected to excessive voltage if one of the ground locations is corroded. Clean the two wire ground screws and the head surface behind them.

SECTION 6

ROUTINE MAINTENANCE

SEAL SOLUTIONS (continued)

SEAL WIRES SNAKING The wire pin spring permits the wire to expand under tension as it heats up. It is imperative that the spring is completely compressed when replacing wires. The other cause for wire snaking is a lack of pressure in that area (see pressure setup) or too much pressure at the pivot point towards the rear of the side seal.

THIN, WEAK SEALS There is an insulator underneath the sealing wire that will wear with heat and time. If a groove is evident, this should be replaced. Remove the insulator and clean the head section. Use RTW sealant and attach the new insulator to the head ensuring the new surface is level. Replace the sealing wires.

SECTION 7

TROUBLE SHOOTING

SEALER SECTION

BAD SEALS check: Sealing wires to see if one is broken. Worn Teflon tape: replace if necessary. Worn silicone rubber: replace if necessary. Melamine insulation. Even pressure all around sealing head. To check pressure, turn heat to minimum setting, dwell to maximum. Operate machine holding a piece of paper between sealing head and base. Trying to pull out the paper should be met with resistance. The holding power of sealing head should be even all around.

NO HEAT ON SEALING WIRES check: Timer: replace if necessary.

TUNNEL SECTION

BELT NOT TRACKING check: See section on routine maintenance.

CONVEYOR NOT RUNNING check: Fuse: replace if necessary. Motor brushes: replace if necessary. D.C. supply to motor. Speed control unit. NO AIR FLOW check: Blockage on intake. Blower motor. Motor overheating . Fuse.

SECTION 7

TROUBLE SHOOTING

TUNNEL SECTION (continued)

HEAT ZONE WON’T COME TO TEMPERATURE check: Blower (see above). Supply fuses. Heaters.

HEAT STAYS ON check: Supply voltage with serial plate. Supply fuses. Heaters. Thermostat.

SECTION 8

PARTS LIST

VOLTAGE - 220/110 VOLT SINGLE PHASE Part Number Description M001563 Head return device PEB0033 Heat control (timer) PEB0036 Heat control (tunnel) PEB0071 Speed control conveyor PEE0022 1600 watt heater PEF0004 1 amp fuse PEF0013 15 amp fuse PEK0002 Indicator lamp PEM0026 Conveyor motor PES0001 Micro switch PES0103 220 volts on-off switch 20 amp PET0002 Transformer - 220 volts PHP0001 Wire pin PRE0100 Heat insulator PRR0007 Sealing rubber PYW0025 Pin holder

SUGGESTED SPARE PARTS Part Number Description PEE0061 Sealing wire PEF0004 1 amp fuse PEF0013 15 amp fuse PRR0007 Sealing rubber PRT0001 ½” Teflon tape

SECTION 9

SCHEMATIC

L1 N L2 ISWB 15 WA

20 AMP A1 1M A2 20 AMP 1SC F2 1 AMP L1 L2 TEMPERATURE CONTROL F3 2CR HEAT CONTATCOR 1HC

HEAT ON 1LT

POWER ON 2LT

1 AMP F4 1 AMP F5 BLOWER 1

1 AMP F6 1 AMP F7 BLOWER 2 3M

ELEMENT 1HC 1HC

SEAL TRANSFORMER IT

SIDE WIRE 2CR

OPTIONAL CONVEYOR N FRONT WIRE 1CR A1 4M A2 1 AMP F8 MOTOR L1 L2

1CR 2CR

ITC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2P EM 1P 3P 1L5 20V OV

2L5 M C D H C S A O W E L E G N E A E A N V L T A L E L N T

MAXI PAK 220/110 20 A

SECTION 9 SCHEMATIC L1 L2 ISWA N ISWB TUNNEL CONVEYOR

F1 20 AMP A1 1M A2 F2 20 AMP

1 AMP ISC L1 L2 F3 HEAT ON OFF

L1 L2 ITC 2CR 1HC

POWER ON 2LT

1 AMP F4 BLOWER 1 1 AMP F5 2M

1 AMP F6 BLOWER 2 1 AMP F7 3M

1 HC ELEMENT 1 HC

15 AMP F8 SEAL TRANSFORMER IT 15 AMP F9

30 AMP F10

SIDE WIRE 30 AMP F11 2 CR FRONT WIRE

A1 4M A2 N OPTIONAL 1 AMP F12 1 CR CONVEYOR MOTOR L1 2SC L2

1CR 2CR

1TC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

EM 20W OV 100 1P 2P 3P 1L5 2L5 1 W M C D H C S A O W E L E G N E A E A N V L T A L E L N T MAXI - PAK TEMPERATURE CONTROL 220/110 20 A

L1 L2

F1 20 AMP F2 20 AMP F3 4 AMP F4 4 AMP

F5 2 AMP

TUNNEL CONVEYOR A1 1M A2 1 SC L1 L2 TEMPERATURE CONTROL HEAT CONTACTOR 2CR 1HC HEAT ON 1LT POWER ON C1 2LT 1 AMP F6 BLOWER 1 1 AMP F7 2M

3M 1 AMP F8 1HC 1 AMP F9 ELEMENT 1HC 1HC 1HC ELEMENT

F10 15 AMP SEAL TRANSFORMER IT F11 15AMP

F12 30 AMP SIDE WIRE 2CR F13 30 AMP OPTIONAL CONVEYOR FRONT WIRE MOTOR C1 A1 4M A2 N .

F14 1AMP 1CR L1 25C L2

1CR 2CR

1TC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

EM 1P 2P 3P 1LS 20V OV

2LS 100 M C D H C S 1W A 0 - 1 O W E L E G 200V N E A E A N V L T A L E L N T MAXI - PAK 220 VAC 20 A

L1 L2

F1 20 AMP F2 20 AMP F3 4 AMP F4 4 AMP

F5 2 AMP

TUNNEL CONVEYOR A1 1M A2

L1 L2 HEAT ON OFF TEMP CONTROL L1 1TC L2 1TC 2CR 1HC POWER ON C1 2LT

F6 1 AMP BLOWER 1 F7 1 AMP 2M BLOWER 2 F8 1 AMP F9 1 AMP 3M 1 HC ELEMENT 1HC

ELEMENT 1 HC 1HC

F10 15 AMP SEAL TRANSFORMER IT F11 15 AMP

F12 30 AMP SIDE WIRE 2CR F13 30 AMP FRONT WIRE

OPTIONAL CONVEYOR MOTOR C1 A1 4M AZ N F14 1 AMP 1CR L1 L2

1CR 2CR

1TC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

EM 1P 2P 3P 1LS 20V 0V 100 2LS 1W M C D H C S A 0 - 1 O W E L E G 200V N E A E A MAXI - PAK N V L T A L TEMP CONTROL E L N 220 VAC 20 A T