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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 1 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 2 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. 3 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. 4 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. 5 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 #: 6 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. 7 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. 8 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).
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