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ROVEMA VPK Series - User Manual

ROVEMA VPK Series
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VPK Operations Manual

Table of Contents

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Summary

Introduction to Rovema VPK Bagmaker

Safety Instructions for Bagmaker Operation

Safety Devices

Details safety devices like guard doors and emergency stop buttons for machine protection.

Component Safety

Discusses the importance of using original spare parts and ensuring material compatibility for safe operation.

Operator Safety Guidelines

Outlines essential safety guidelines for operators to follow during bagmaker operation.

Lockout Procedures

Describes procedures for safely locking out air and electrical power before maintenance.

Parts and Functions of the VPK Bagmaker

Film Carriage

Explains the components responsible for managing and feeding the packaging film.

Film Spindle

Details the spindle that supports the packaging material on the film carriage.

Dancer Assembly

Describes the assembly that maintains tension on the film web during operation.

Film Unwind Brake

Covers the brake mechanism that controls the unwinding of the film roll.

Film Tracking Assembly

Explains the system that controls the film carriage's position relative to the forming collar.

Film Carriage Touchscreen Controls

Details the touchscreen interface for controlling film tracking position.

Out of Film Sensor Assembly

Describes the sensor that stops the bagmaker when the film roll is exhausted or tension is too high.

Guide Rollers

Explains the rollers that guide the film path and allow angle adjustments.

Film Feeding Device

Covers the device that pulls film and pushes it down the forming tube.

Film Feed Belts Assemblies

Describes the belt assemblies that suction and push the film tube.

Film Feeding Drive System

Details the system that powers the film feeding belts.

Film Feed Engage;Retract Device

Explains the device that moves film feeding belts and maintains belt pressure.

Forming Set

Describes the component that shapes the flat film into a tube.

Vertical Sealing Device

Covers the device that joins the film tube edges to create vertical seals.

Vertical Seal Band Unit

Details the unit that joins film edges using heat and pressure.

Vertical Seal Heating Bar

Explains the component that creates heat for melting the inner film layer.

Vertical Seal Band, Sensor, and Lever

Describes components involved in transferring heat and managing band tension.

Vertical Seal Drive System

Covers the system that synchronizes the sealing band with film feeding.

Vertical Seal Engage;Retract Device

Explains the device controlling seal band movement and pressure.

Vertical Seal Touchscreen Controls

Details touchscreen controls for vertical seal engage/retract timing.

Vertical Seal Band Support

Describes the support that holds and positions the seal band unit.

Horizontal Sealing Device

Covers the device that creates top and bottom seals and cuts the bag.

Horizontal Jaw Assemblies

Details the assemblies that create horizontal seals.

Horizontal Jaw Body

Explains the part of the jaw assembly that creates the seal.

Horizontal Jaw C-Frames, Carriers, and Springs

Describes components that work with jaw bodies to create seals.

Horizontal Seal Pressure

Discusses how jaw spring compression determines sealing pressure.

Horizontal Seal Drive System

Covers the system that drives the jaw opening and closing motion.

Horizontal Seal Touchscreen Controls

Details touchscreen controls for jaw profile and seal settings.

Horizontal Knife Assembly

Explains the assembly that cuts bags from the film tube.

Horizontal Temperature Controllers

Covers controllers that monitor and adjust horizontal sealing temperatures.

Registration Sensor

Explains the sensor that allows the bagmaker to use registered film.

Registration Sensor Touchscreen Controls

Details touchscreen controls for the registration sensor.

Pneumatics System

Covers the system controlling compressed air supply to various components.

Pneumatics Primary Manifold

Describes the manifold distributing compressed air to components.

Pneumatics Pressure Switch

Explains the switch monitoring air pressure in the primary manifold.

Pneumatics Cooling Devices

Details devices releasing compressed air for cooling seals.

Pneumatics Vacuum System

Covers the system creating suction for film feeding belt assemblies.

Pneumatics Solenoid Bank

Describes the bank supplying compressed air to pneumatic cylinders.

Optional Equipment

Lists optional components that enhance bagmaker capabilities.

Optional Bevel Plates, Grippers, and Deflators

Explains plates, grippers, and deflators for sealing and bag shaping.

Optional Splice Table

Covers the table used to attach new film rolls to exhausted ones.

Optional Automatic Film Tracking Sensors

Details sensors keeping film edges aligned with the vertical seal.

Bag Shaping Devices

Covers devices altering bag shape, like gusseting and STABILO seals.

Gusset Device

Explains the device adding folds to create gussets in the film tube.

STABILO SEAL Sealing System

Describes the system creating square corners on film tubes.

Theory of Operations for Bagmaking

Forming Cycle

Explains the 360-degree virtual encoder count basis for operations.

Heat Sealing Process

Details the process of bonding film layers using heat, time, and pressure.

Vertical Sealing Cycle

Describes the timing of the vertical seal engage/retract movements.

Horizontal Sealing Cycle

Covers the cycle where horizontal seals are formed, cut, and cooled.

Film Registration

Explains how the registration sensor aligns film for sealing based on printed marks.

Operator Controls and Interface

Operator Interface Overview

Describes the touchscreen, numeric keypad, function keys, and arrow keys for operation.

Touchscreen and Function Key Usage

Details the touchscreen and function keys used to select machine functions.

Numeric Keypad and Arrow Key Navigation

Explains how the numeric keypad and arrow keys are used for input and navigation.

Operations Screen

Identifies the screen displaying commonly used touchcells and switches.

Operations Screen Switches

Details switches on the operations screen for film, jogging, belts, and heat control.

Operations Screen Switches (cont.)

Details switches on the operations screen for feeder, length, speed, and settings.

Settings Screen Overview

Describes the screen containing controls for forming, recipe management, and data monitoring.

Settings Screen: Cam Settings

Details settings that determine cam positions for various operations.

Settings Screen: Jaw Seal Settings

Covers controls for jaw speed and seal time settings.

Settings Screen: Feeder Screen

Explains the screen that synchronizes the bagmaker and product feeder.

Settings Screen: Printer Screen

Details settings for the printing device on the film.

Settings Screen: Vertical Seal Screen

Covers controls for the vertical seal engage/retract movements.

Settings Screen: Photoeye Screen

Explains controls for the registration sensor operation.

Settings Screen: Stabilo Seal Screen

Details controls for the STABILO sealing system.

Settings Screen: Recipe Management

Covers functions for loading and saving product recipes.

Settings Screen: Alarms

Describes the screen that appears when an alarm or warning condition exists.

Temperature Controllers

Explains controllers that monitor and adjust sealing temperatures.

MAIN DISCONNECT Switch

Details the switch that turns electrical power on or off.

AIR DISCONNECT Lever

Covers the lever controlling the flow of air to the bagmaker.

Push-Buttons and Selector Switch

Describes various push-buttons and selector switches for machine operation.

Machine Setup Procedures

Powering the Bagmaker

Guides on activating electrical and pneumatic supplies for the bagmaker.

Loading a Product Recipe

Explains how to load machine parameters for specific product packaging.

Setting Machine Speed and Bag Length

Details how to adjust machine speed and bag length settings.

Installing the Forming Set

Provides instructions on how to install a specific forming set for a bag style.

Loading a Film Roll

Guides on how to place a new film roll onto the film carriage.

Threading a Film Roll

Describes the steps to thread the film through the bagmaker's components.

Vertical Seal Setup

Covers positioning the vertical sealing device relative to the forming tube.

Pneumatic Pressure Settings

Details setting pneumatic pressures for various devices based on production environment.

Setting the Film Tension

Explains how to adjust dancer arms for proper film tension.

Setting Film Tracking Position

Guides on aligning film edges with the vertical seal using film tracking.

Positioning Automatic Film Tracking Sensors

Describes how to position sensors for automatic film edge alignment.

Registration Sensor Setup

Covers setup of the registration sensor for registered or non-registered film.

Sensor Setup for Non-Registered Film

Details disabling the registration sensor for non-registered film use.

Sensor Setup for Registered Film

Guides on positioning the sensor for registered film.

Determining Photoeye Window Value

Explains how to set the photoeye window for continuous registration mark tracking.

Determining Photoeye Correction Value

Guides on setting photoeye correction to align seals with desired locations.

Operating Procedures

Start-Up Procedures

Outlines procedures for starting the bagmaker for operation.

Preparing the Bagmaker

Details steps to prepare the bagmaker for forming empty bags.

Making Empty Bags

Guides on producing a few empty bags to check settings.

Checking Empty Bags

Explains how to check the integrity and quality of empty bags.

Making Filled Bags

Guides on producing filled bags and identifying necessary adjustments.

Checking Filled Bags

Details how to check the quality of filled bags for product and air issues.

Starting a Production Run

Covers starting a normal production run of filled bags.

Shut Down the Bagmaker

Provides procedures for emergency, normal, and extended shutdown.

Restart Bagmaker After E-Stop

Guides on restarting the bagmaker after an emergency stop event.

Jogging the Bagmaker

Explains how to operate the bagmaker at a slow steady pace for adjustments.

Working with Components

Replacing Heater Cartridges and Temp. Probes

Details replacing heating elements and temperature sensors in jaw assemblies.

Replacing Film Feed Belts

Guides on replacing worn film feed belts to restore traction.

Replacing the Cutting Knife

Explains how to replace the knife for consistent bag cutting.

Aligning the Forming Set

Covers how to align the forming set for proper bag forming.

Aligning Belt Assemblies

Guides on aligning belt assemblies to the forming tube.

Changeover Procedure

Maintenance Procedures

Daily Cleaning

Outlines daily cleaning tasks for the bagmaker.

Daily Maintenance

Details daily checks and maintenance for the bagmaker.

Weekly Maintenance

Covers weekly maintenance tasks for the bagmaker.

Troubleshooting Guide

EMERGENCY STOP PUSH-BUTTON Issues

Lists causes and corrective actions for emergency stop issues.

SAFETY CIRCUIT LATCH Issues

Details causes and corrective actions for safety circuit latch faults.

LOW AIR PRESSURE Issues

Lists causes and corrective actions for low air pressure conditions.

REVERSE MODE Issues

Covers causes and corrective actions for issues related to reverse mode.

BELTS OPEN Issues

Lists causes and corrective actions for belts being in the open state.

JOGGING MODE Issues

Details causes and corrective actions for jogging mode issues.

TEMPERATURE CONTROL Issues

Lists causes and corrective actions for temperature control problems.

REGISTRATION FAILED Issues

Covers causes and corrective actions for film registration failures.

FILM CARRIAGE LEFT LIMIT Issues

Lists causes and corrective actions for film carriage hitting its left limit.

FILM SPLICE TABLE ACTIVATED Issues

Details causes and corrective actions when the film splice table is activated.

SCALE;FEEDER NOT READY Issues

Lists causes and corrective actions for scale or feeder not being ready.

PREMIUM FEEDER NOT READY Issues

Covers causes and corrective actions for premium feeder not ready status.

MOTION CONTROLLER RE-CALC Issues

Explains causes and corrective actions for motion controller recalibration.

OUT OF FILM Issues

Lists causes and corrective actions when the film roll is exhausted.

INVALID CALCULATION Issues

Details causes and corrective actions for invalid calculation errors.

FILM CARRIAGE RIGHT LIMIT Issues

Lists causes and corrective actions for film carriage hitting its right limit.

MOTION CONTROLLER;SERVO AXIS ERRORS

Lists specific error messages and corrective actions for motion control systems.

VERTICAL SEAL DRIVE ERRORS

Details error messages related to the vertical seal drive.

POWER UNWIND ERROR MESSAGES

Covers error messages related to the power unwind system.

ROVEMA VPK Series Specifications

General IconGeneral
Machine TypeVertical Form Fill Seal (VFFS)
ModelVPK Series
ApplicationPackaging of powders, granules
Bag StylesPillow bag, gusseted bag, block bottom bag, quad seal bag
Sealing TechnologyHeat sealing
Film MaterialLaminates
Control SystemPLC-based with touch screen interface
Power Supply380-480V, 50/60Hz, 3-phase

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