Operation & Service Manual 65-43-2 Effective: December …partners.wexxar.com/assets/docs/manuals/BEL150SS... · Operation & Service Manual 65-43-2 Effective: December 20, 2011 Replaces:

Operation & Service Manual 65-43-2 Effective: December 20, 2011 Replaces: August 29, 2011

BEL 150 / 150X V.02 SERIES Semi-Automatic Uniform Case Tape Sealer

Wexxar Packaging Inc. Phone (604) 270-0811 • Fax (604) 270-7897

E-mail: [email protected]

BEL 150 V.02 Series of Semi-Automatic Uniform Case Tape Sealers 2

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BEL 150 V.02 The BEL 150 accepts uniform case sizes with the top flaps pre-folded by an operator before top and bottom tape sealing with either 2” or 3” wide tape. The power required is 120V single-phase for the conveyor drive, and it connects to an electrical outlet by a conventional cord and plug.

DEKKA

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Standard Specifications:

Length Width Height Case Size Range Minimum 8” / 203mm 5” / 127mm 4” / 102mm Maximum [no limit] 18” / 457mm 21” / 533mm Machine Dimensions 37.5” / 953mm 33” / 838mm 60” / 1524mm

In/Outfeed Height Frame 22” / 558mm

With adjustable leg extensions [foot pad]

Minimum

Maximum

23.5” / 597mm

32” / 813mm

Speed Up to 30 cases / min.

Shipping Weight Approx. 480 lbs. / 218 kg.

For further detail see Layout Drawing 75-924 in the Technical Reference publication 66-115


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BEL 150X V.02 The BEL 150X can handle uniform cases of a larger maximum size than a standard BEL 150.

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DEKKA

Standard Machine Specifications:

Length Width Height

Case Size Range Minimum 8” / 203mm 5” / 127mm 4” / 102mm* Maximum [no limit] 26” / 660mm 30” / 762mm *for cases wider than 7” /

178mm

Machine Dimensions 37.5” / 953mm 41” / 1041mm 65.5” / 1666mm



Minimum

Maximum

20.5” / 520mm**

29” / 737mm**

**full range requires exchange of leg extension screw length at conveyor drive corner



For further detail see Layout Drawing 75-952


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BEL 151 V.02 The BEL 151 accepts uniform case sizes for bottom-only tape sealing with either 2” or 3” wide tape.

151

Standard Machine Specifications:

Length Width Height

Case Size Range Minimum 8” / 203mm 5” / 127mm 4” / 102mm Maximum [no limit] 18” / 457mm [no limit] Machine Dimensions 37.5” / 953mm 33” / 838mm 39” / 988mm



Minimum

Maximum

23.5” / 597mm

32” / 813mm



For further detail see Layout Drawing 75-951


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TABLE OF CONTENTS

INSTALLING THE BEL 150 7

Transportation and Storage 7

Leveling the Machine 7

Power Connection 7

Installing the Tape Heads 8

CASE SIZE ADJUSTMENTS 9

Width Adjustment 9

Height Adjustment 10

STARTING THE MACHINE 11

FEEDING CASES 11

SERVICE AND MAINTENANCE PROCEDURES 12

Conveyor Side-Belt Replacement 12 Belt Tensioning and Tracking Adjustment 13 Uni-Drive Conveyor Chain Drive Tension 13

ARCH CROSS-MEMBER VERTICAL SLIDE ADJUSTMENT 16

TROUBLESHOOTING GUIDE 17

Section 1 - Corrugated Case Quality & Specifications 17

Section 3 - General Taping Conditions 20

TECHNICAL REFERENCE INFORMATION – SEE PUBLICATION 66-115. 21


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BEL 150 V.02 Semi-Automatic Case Taper

START / STOP Switch [Magnetic Motor Starter and Thermal Overload Protection]

Case Height Adjustment (both sides).

Top Tape Head and Mounting Bracket

Case Width [Conveyor] Adjustment (both sides)

Bottom Tape Head and Holder

Case Size Adjustment Instructions

Bottom tapehead Instructions

Machine Operation Instructions

Case Height Scale

Machine Maintenance Instructions

Case Height Adjustment Lock


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Installing the BEL 150

Transportation and Storage

The BEL 150 should not be stored or transported in extreme temperatures. Transport and store in a covered environment not directly exposed to the natural elements, such as rain, snow or wind. When transporting the machine it should be safely secured to prevent movement.

Remove the through-bolts that secure the machine to the shipping base. Use wooden dunnage blocks under the frame when using a forklift to lift the machine off its shipping base and to position it. If the machine is equipped with casters use the caster brakes when the machine is in the desired location to prevent movement.

Leveling the Machine

The machine should be installed in a level position to avoid frame stress and ensure optimum performance. The machine is equipped with adjustable leg-height and leveling pads as standard equipment and adjustable casters are available as an option. Once the infeed / outfeed height has been set, use a spirit level both along and across the frame side-rail members to level the machine.

Power Connection

The BEL 150 is equipped with single-phase 115 VAC / 60 HZ electrics and manufactured to NEMA 12 specifications. The drive system is powered by a 1/2 horsepower TEFC motor that draws eight amps. A 14 gauge (AWG) power extension cord with standard three pin connection must be used to connect the machine to the power source.

A dedicated electrical circuit is recommended for this machine. If any electrical connections are needed to install the machine, these must be handled by an electrician qualified in your jurisdiction.


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Installing the Tape Heads

Tape heads are mounted with pins on the sides of the heads that fit into corresponding slots in the tape head mounting bracket. Lower the tape head into the bracket aligning the pins with the slots. The upper tape head, when pushed firmly toward the rear of the machine in its mounting slots, is held in position by a thumb screw. Please consult the tape head manual for instructions on the mounting of tape rolls and the proper threading of tape through the applicator head.

TOP TAPEHEAD

BOTTOM TAPEHEAD


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SAFETY CAUTION

Make sure machine is disconnected from electrical power source before undertaking any adjustment or service procedures.

Case Size Adjustments

Width Adjustment

Use a sample case to adjust the width. With the conveyor belts just lightly touching the case sides, remove the case and close ½ turn more.


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Height Adjustment

Note: Depending on case fill, some minor adjustment may be further required in order to firmly tape down the top flaps.

Top tapehead holder rollers should contact the fully closed top flaps of the case.


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Starting the Machine

To start the machine, press the green START button on the switch. BEL machines are fitted with magnetic starter switches for added safety protection from accidental start- up in the event of a power outage or disconnection. The switch is positioned at the center of the frame arch for easy access from either side of the machine.

Use the red STOP button to stop the machine.

FEEDING CASES

First fold down the top flaps of the case by hand. Holding the top flaps closed, direct the case between the infeed guides until it contacts the side-belts. The belts grip the case and transport it through the tape heads that apply tape to the top and/or bottom flaps. Because of the BEL Uni-drive feature, cases presented squarely to the machine will retain this squareness throughout the sealing cycle, providing a stronger seal and better appearance.

Note: If the case sides are bulged by the product inside, the use of an optional side compression roller (Kit # 70-007 for the BEL 150, 70-185 for the BEL 150X) is recommended to draw the top major flaps together to effect a tighter seal. This option is also recommended when the case being sealed has a sealed length that is less than half of the case height.


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Service and Maintenance Procedures

Conveyor Side-Belt Replacement

1. Loosen the top and bottom belt tensioning bolts so that the belt is completely slack.

2. Remove the screws from the top plate and the top belt tensioning bolt from the idle pulley shaft.

Lift off the top plate.

3. Remove the stainless steel conveyor cover and then remove and replace the belt.

4. Reassembly is the reverse of disassembly. Replace all conveyor covers.

Loosen top belt tensioning bolt

Loosen bottom belt tensioning bolt

Remove top screws

Remove top belt tensioning bolt.

Remove the top plate.

Remove conveyor cover

Remove and replace belt

Make belt completely slack


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Belt Tensioning and Tracking Adjustment

Tension the belt by tightening the top and bottom tensioning bolts. The tension of the belt should be just enough to prevent belt slippage or so that approximately one inch of play is available when the belt is pulled sideways by hand in the center of the machine. With the conveyor running, tighten the upper and lower bolts to position the belt so that it is running true and not trying to ride up or down on the idler pulley.

Uni-Drive Conveyor Chain Drive Tension

The Uni-Drive side-belt conveyor is designed to keep the case square during sealing, which results in a technically stronger seal and a better-finished appearance. This is achieved by linking the drives of both conveyor belts to a single motor and gear-reducer that inherently synchronizes belt speeds better than other belt drive systems on the market. Uniform chain tension is maintained automatically during case width adjustments through a self-compensating serpentine configuration.

Belt tension adjustment

Belt tracking adjustment


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Chain tension is preset at the factory but if the drive becomes noisy or needs adjustment then adjust as shown below. Proper tension is achieved when the horizontal sag in the chain measures between 1/8 inch and 1/4 inch with drive belts in a fully opened position.

1. At the conveyor drive motor corner of the machine, loosen the idle sprocket mounting bolt enough to allow it move in its slot.

2. Unfasten the flexible plastic bellows on top of the stainless steel safety cover and remove the

cover.

3. Loosen the locknut and adjust the tension chain tensioning bolt

Chain idle sprocket mounting bolt

Adjustment locknut

Tension adjustment


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4. Re tighten the idle sprocket mounting bolt

SAFETY: The safety covers must be replaced before operating the machine.

The optional BEL 150 Spare Parts Maintenance Kit contains all of the parts necessary for maintaining the Uni-Drive conveyor. See the Technical Reference manual 66- for details, and contact the factory or your local Belcor distributor for the kit’s price and availability.

Replace the stainless steel safety covers before operating the machine.


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ARCH CROSS-MEMBER VERTICAL SLIDE ADJUSTMENT

The machine arch cross-member supports the upper tape head holder on the BEL 150. It mounts to the arch assembly with vertical slide bar bearings that ride inside the arch columns, allowing the cross member to move smoothly up and down for case height adjustment.

The bearings are made of a special hardwearing plastic material but may need periodic adjustment to compensate for wear or for loosening due to frequent adjustment or operating vibration. If worn or loose, the bearings allow excessive movement of the upper tape head holder and may affect taping performance.

There are wedge-shaped spacers between the bearing bars at the top and bottom with a threaded rod adjustment between them. Tightening the nuts on the rod will reduce the bearing clearance.

Vertical slide bar bearings

If the bearings are loose or worn they may allow excessive movement of the top tapehead holder.

Top slider bearing adjustment nut

Bottom slider bearing adjustment nut


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Troubleshooting Guide

Section 1 - Corrugated Case Quality & Specifications

Corrugated case quality is a major factor in smooth running and quality sealing. The following points will help determine if you have a case size or quality problem:

1. Case dimensions: Ensure that the products fill the case efficiently and do not bulge, over-fill, or under-fill the case. Re-sizing of cases can often result in cost savings by using the correct case size and material weight. Consult your corrugated case supplier, for help to achieve this. A correctly filled case will help the automatic process by supporting the case body during flap folding and the top flap sealing.

2. Score (fold) Lines: Ensure that the scores in the cases are as well defined as possible to help with the automatic folding process. Your corrugated case supplier can help with this by making sure that correct scoring pressure is used for your case specification. This is one of the most common causes of poor case- closing performance

3. Corrugated case weakness: The case manufacturing process can damage the fluted construction of corrugated board. Points to watch for:

a. Crushed corrugate: Ensure that the flutes have not been crushed overall, causing the case to have a soft and limp feeling. This causes poor case rigidity during machining and also does not give your product the protection it deserves.

b. Bands of crushed corrugate flutes: Selective bands of crushing, usually parallel to the case flutes, can cause failure lines down the case and result in poor machine-handling performance.

c. Case storage: Flat cases should be stored in dry conditions and on a flat surface. Be careful not to stack excessive weight on to the cases, as crushing can result.

4. Case squareness: The glue joint where the manufacturer glues the flat case together often can present a quality problem if they are misaligned. This causes the case to be wider at one end than the other or to be twisted from end to end. Both conditions can cause case jams and poor sealing quality.

5. Flap corner slots: If the corner slots are wide, cases can be automatically folded with a minimum of interference between major and minor flaps.

6. Overlapped or gapped case flaps: These conditions can be caused by incorrect flap lengths. Fold the case by hand to see that flaps meet neatly in the case center.

Use your corrugated case supplier’s expertise to help you achieve the correct specifications for your automatic sealing line.


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Section 2 - Conveyor Belt System The Uni-drive side-belt conveyor system is designed to keep the case square during sealing to produce a technically stronger seal and a better looking appearance.

Problem: Case Is Not Sealing Squarely.

Despite the parallel drive nature of the Uni-Drive conveyor, the cases exit the machine not square after sealing. Be sure that:

• the case is square before it engages in the side-belt conveyor belts.

• the side belts are correctly adjusted to case width by the following method: 1. Adjust the belts in until they lightly contact case sides, but so that the case can still slide

through belts if pushed firmly. 2. Remove the case and adjust the belts inwards one-half turn.

• neither of the conveyor belts is slipping on its drive pulley. See the section on belt tensioning procedure in the Service and Maintenance Procedures section.

• in the case of round can or bottle products, check that belts are set to grip lightly but firmly on case sides. Excessive side pressure can cause round objects to roll ‘over-center’ and push the case out of square.

Problem: Depressed or Crushed Band on Lower Case. If the cases exit the machine with a band of crushed corrugation at the level of the conveyor belts, it is likely that the case is gripped too tightly in the belts.

Problem: Rubber ‘Dust’ Being Shed by Belt.

A dark gray or almost black dust appears beneath the conveyor belts, particularly at the case exit end of the machine

• Ensure that the case is clearing the belts as it exits the machine and that outfeed conditions do not cause cases to back up into the machine.

• Ensure that belt tensioning and tracking adjustments are correct, as described under Service and Maintenance Procedures. Incorrect settings can cause premature belt wear and possible belt breakage. (See section on Uni-drive in machine manual.)

Problem: Rattling Noise from the Conveyor Drive.

Although pre-stretched chain is used in the machine drive, the chain over time may loosen and rattle on the drive cover. Tighten the idler sprocket, as described in the Service and Maintenance Procedures section.


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Problem: Frequent Belt Breakage.

Belt life will depend on the conditions of machine use, but frequent breakage may be due to one or more of the following conditions:

• Belt tracking. Ensure that the idler pulley has its camber set so that the belt does not try to ride up or down on the pulleys. See belt tensioning and tracking adjustment under Service and Maintenance Procedures

• Belt Tension. The belts may be over-tensioned. The correct setting allows approximately one inch of slack at center point of conveyor.

• Idler and drive pulley rotation. Ensure that pulleys rotate freely and that bearings are not seized or excessively worn.

Problem: Machine Jams Frequently.

Turn OFF the machine as soon as the jam occurs and before clearing the jam. Open the belts and raise the top tape head. Remove the jammed case and debris. Check for the following causes of case jams:

• The top tape head is adjusted too low.

• The product is overfilled or inconsistent, causing intermittent jams.

• The belts are set too tight, causing machine overloading.

• Check the position of the top ski.


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Section 3 - General Taping Conditions

Problem: Tape Does Not Stick To Case Surface. The tape is not bonding to the corrugated board of the flaps or ends of the case to provide a secure seal. Look for the following conditions:

• Under-filled Case. Ensure that the product provides support under the top flaps so that they are not simply pushed down or away from the tape head rather than having the tape rolled onto the surface.

• Overlapping flaps. If the outside (major) flaps are allowed to overlap, the ‘step’ created results in an uneven taping surface, causing poor tape adhesion that can release during shipping and handling. See comments on flaps (Troubleshooting Section 1, Corrugated Case Quality & Specifications)

• Tape-head roller contact. Ensure that the tape-head contact or wipe-down rollers are making good contact with the case and that the roller spring tension is correct.

• Dust or dirt. Large amounts of dust or dirt gathering on the casees or in the air will impair adhesive effectiveness.

• Temperature. Extremely hot or cold temperature may require tapes with appropriate adhesive formulations for good initial bond and permanent sealing performance.

• Tape adhesive. Ensure the presence and quality of tape adhesive. We recommend the ‘hot melt’ type of adhesive over Acrylic adhesive.

Problem: Tape is not cut uniformly. The tape is not cut properly every time. In the worst situations, several cases may be taped together. Check the following conditions:

• Tape head position. If the top tape head is set too high, the cut-off knife will not be fully activated resulting in poor cut off. The tape-head side plates should be within 1/16 to 1/8” of the case. Ensure also that cases ride fully down between the conveyor belts to provide proper contact with the bottom head cut off knife.

• Knife extension. Ensure that the knife extends enough to fully contact the tape during the cutting stroke.

• Tape tension. Unroll tension should be smooth and not too tight, as a ‘snap back’ caused by stretched tape can cause a jagged cut-off and cause tape pieces to be stuck to the blade.

• Clean knife. Clean the blade and apply a little silicon or oil to avoid adhesive build-up on the sharp points.

• Knife blade wear or damage. Blades must be very sharp to work well. The points are easily damaged if contacted by any hard material. Replace the blade if it seems dull.

• Cut-off spring tension. Ensure that the spring that provides power to cut-off arm has enough tension to cut through the tape. Replace the spring if it is too weak.

SAFETY CAUTION – Tape head knife is very sharp

!


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Problem: Tape tail does not stick down properly. The end of the tape on the back side of the case as it leaves the machine has not adhered well to the case. Check these conditions:

• Tape tension. Tension should be is smooth and not too tight. Tape tension ‘snap back’ will cause tape tail to recoil and not stick well on the back of the case.

• Tape head roller contact. Ensure that the wipe-down roller is actively pushing the tape down and that the spring is in good condition and set to the right tension.

Problem: Tape is off-center. The line of tape is not centered over the gap between flaps on the top or bottom of the case. Look for the following conditions:

• Tape roll position. Ensure that the tape roll is fully pushed onto spool. • Tape head straight. Ensure that the tape head sits straight in its bracket and is not tilted to one side. • Obstructions. Look for obstructions that could be pushing the tape off center. Problem: Tape Falls Forward on Bottom Tape Head. The beginning end of the tape must stand vertically in front of the tape head front roller in order to contact the leading end of the next case. A bow made across the tape by the tape head guides helps to stiffen it, and a static electric charge on the tape head rollers attracts the tape and helps to keep it in place. If the bottom tape will not stand vertically, look for the following conditions:

• Contamination. The tape may be wound around the roller, or there may be dirt on the roller. • No static charge. Dust roller surfaces with talcum powder to the increase static charge on the roller. • Incorrect tape head guide settings. Ensure that the tape holder or finger is set correctly. See the

Dekka tape head manual. • Inappropriate environment. A strong breeze in the vicinity of the tape sealer can cause the tape to

blow down. High temperature or humidity may affect the tape characteristics. • Inappropriate tape. Some brands and types of tape have more ‘body’ than others, so a change of

tape may be needed, particularly in difficult ambient conditions. We recommend that the tape have minimum thickness of at least 1.7 mil.

TECHNICAL REFERENCE INFORMATION – See Publication 66-115.

Documents

Operation & Service Manual 65-43-2 Effective: December …partners.wexxar.com/assets/docs/manuals/BEL150SS... · Operation & Service Manual 65-43-2 Effective: December 20, 2011 Replaces: