AGR-30SS Shrink Wrapping Machine Installation, Operation, & Service Manual

Table of
Contents
Safety
Introduction
AGR-30SS Installation
Shrink Wrapper
Operation
Installation, Operation & Service
Manual Periodic
Maintenance
Maintenance &
Testing
Trouble-
Shooting
Electrical
Schematics
Service
Information
Illustrated
Parts List
P/N 100003.11031
O.E.M.
Revision: A, January 22, 2009 Vendor Info
Copyright 2009, Arpac L.P. All rights reserved.
This document is the property of Arpac L.P. and contains confidential and proprietary information
owned by Arpac L.P. Any unauthorized copying, use or disclosure of it without the prior written
permission of Arpac L.P. is strictly prohibited.
Attention: Consult Accompanying Documents - As Applicable
This manual was originally written in English in the United States.
Arpac L.P.
9511 West River Street Phone:1-847-678-9034
Schiller Park, IL Fax:1-847-671-7006
60176 USA
www.arpac.com
Record of Revisions
i
Revision History
REV Date Reason for Change
A 1-22-09 Original
Table i-1. Revision History
List of Affected Pages

PPage Number Rev PPage Number Rev PPage Number Rev
Level Level Level
All A
Table i-2. List of Affected Pages
Revision History i-1

AGR-30SS Shrink Wrapper Installation, Operation & Service Manual
i-2
Warranty Information
ii
ARPAC-PMI warrants the Products of its manufacture to be free from defects in
material or workmanship for a period of one year from date of shipment from
ARPAC-PMI’s factory, provided that:
1 Such equipment is given normal and proper usage.
2 It is still owned by the original buyer.
3 The Products have been operated in accordance with generally approved
practice and in accordance with ARPAC-PMI’s specifications and
instructions.
4 No repairs, alterations, or replacements have been made by others without
ARPAC-PMI’s prior written approval.
5 Genuine ARPAC-PMI repair components are used during the warranty
period.
ARPAC-PMI’s liability under this warranty or in connection with any other claim
relating to the Products shall be limited to the repair or, at ARPAC-PMI’s option,
the replacement of any Products, parts or components thereof which are returned
to ARPAC-PMI freight prepaid and which are defective in material or
workmanship.
The Buyer shall notify ARPAC-PMI immediately of any defective parts and
ARPAC-PMI shall thereupon correct the defect or defects. If such correction
requires the replacement of a defective part or parts, ARPAC-PMI will supply
same F.O.B. its factory.
If warranty parts are required, ARPAC-PMI will, at its discretion, repair or
replace any defective parts with a charge to a valid purchase order number.
Defective parts, with a valid Return Material Authorization number obtained
from ARPAC-PMI’s service department, must be returned to ARPAC-PMI within
thirty (30) days of warranty part shipment, freight prepaid, to receive a credit to
this purchase order number. Failure to do so will result in zero credit being
applied to the original P.O. or may void this warranty. All returned parts are
subject to factory inspection. ARPAC-PMI reserves the right to determine the
cause of failure and the subsequent inclusion of the replacement part under this
warranty. Defective parts that have been disassembled or damaged during
removal or otherwise tampered with will not be covered under this warranty.
Damage caused during transport is the responsibility of the carrier and is not
covered under this warranty. All damages detected upon receipt of equipment
should be reported immediately to the carrier and ARPAC-PMI should be
notified.
ARPAC-PMI shall in no event be held liable for any direct, indirect, incidental or
consequential damage, losses, expenses or delay caused by defective parts and
will not accept any charges for work performed by Buyer in making adjustments
or repairs to the Products unless such work has been authorized in writing by
ARPAC-PMI. Except as stated herein, ARPAC-PMI makes no other warranty,
ii-1
expressed or implied, nor does it assume or authorize anyone else to assume for
it, any other obligation relating to our products or any products.
Any Product or component not of ARPAC-PMI’s own manufacture is not covered
by this warranty and is sold to Buyer only with such warranty, if any, as is
provided by such manufacturer, to the extent ARPAC-PMI and its assigns are
able or entitled to enforce such warranty. Such items are not warranted by
ARPAC-PMI in any way.
When components are sold to be assembled in combination of Buyer’s design, the
warranty shall be limited to each separate component and shall not apply to any
combinations or components.
EXCEPT AS EXPRESSLY STATED ABOVE, ARPAC-PMI MAKES NO
WARRANTY, EXPRESS OR IMPLIED, WHETHER OF MERCHANTABILITY OR
FITNESS FOR ANY PARTICULAR PURPOSE OR USE OR OTHERWISE, ON
THE PRODUCTS, OR ANY PARTS OR LABOR FURNISHED DURING THE
SALE, DELIVERY OR SERVICING OF THE PRODUCTS.
ARPAC-PMI factory trained, qualified technical services personnel are available
for start-up and instructional assistance. If the customer does not utilize ARPAC-
PMI personnel for this function, ARPAC-PMI is only liable for replacement of
defective parts, not for labor or expenses necessary to adjust any problems during
the start-up period.
ARPAC-PMI personnel are available for ARPAC-PMI equipment training, either
on-site/hands on or in classroom environment, supported by visual aids and
literature, to be contracted for by a separate purchase order.
ii-2
Table of Contents
1
Prelude i — Record of Revisions
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
List of Affected Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
Prelude ii — Warranty Information

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-1
Chapter 1 — Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Chapter 2 — Safety
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Personnel Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.1 Safety Goggles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.2 Disconnect Power Before Servicing . . . . . . . . . . . . . . . . . . . . 2-1
2.2.3 Proper Cleaning Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.4 Proper Removal of Product . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.5 Keep Hands and Other Body Parts Clear . . . . . . . . . . . . . . . 2-2
2.2.6 Ensure Safety Devices are Operational . . . . . . . . . . . . . . . . . 2-2
2.2.7 Never Reach Into Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.8 Energy Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.9 Guarding and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.10 Interfacing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Statement of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Safety Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.6 Lockout/Tagout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.7 EMERGENCY STOP Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.8 Guard Door Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
1-1
Chapter 3 — Introduction
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Machine Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.1 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.2 Tray Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.3 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.6 Mechanical Sub-Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6.1 Film Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6.2 Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.6.3 Infeed Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.6.4 Seal Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.6.5 Shrink Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.6 Turbo Cooling Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Chapter 4 — Installation
4.1 Machine Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Chapter 5 — Operation
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Main Disconnect Switch Description . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Main Control Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Miscellaneous Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.1 Pneumatic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.2 Stack Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5.1 Starting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5.2 Stopping the Machine in an Emergency . . . . . . . . . . . . . . . . 5-5
5.5.3 Stopping the Machine (Short Term) . . . . . . . . . . . . . . . . . . . 5-5
5.5.4 Stopping the Machine (Long Term) . . . . . . . . . . . . . . . . . . . . 5-5
5.6 Operator Interface Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.1 Security Levels: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.2 Logging Into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.6.3 Operator Interface Menu Group Descriptions . . . . . . . . . . . 5-9
5.6.4 Load/View Menu Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.6.5 Setpoint Modify Menu Group . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.6.6 Maintenance and Alarm History Menus . . . . . . . . . . . . . . 5-18
5.6.7 Production Data Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.7 Managing Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
1-2
5.7.1 Loading a Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5.7.2 Copying a Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.8 Product Load/Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.8.1 Interface Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.9 Replacing Lower Film Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.10 Replacing Upper Film Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Chapter 6— Periodic Maintenance

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Walk Around Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Cleaning External Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5 Check Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.6 Draining Air Filter Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.7 Checking Air Lubricator Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.7.1 Filling Air Lubricator With Oil . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.8 Cleaning Seal Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.9 Inspecting Shrink Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.10 Inspecting Film Feed Drive Rollers . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.11 Inspecting Conveyor Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.12 Cleaning Photo Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.13 Greasing Seal Bar Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.14 Greasing Zerk Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.15 Greasing Ram Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.16 Greasing Bridge Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.17 Lubricating Seal Bar Drive Chains . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.18 Lubricating Conveyor Drive Chains . . . . . . . . . . . . . . . . . . . . . 6-21
6.19 Checking Tunnel Curtains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.20 Replacing Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6.21 Changing Oil in Conveyor Gearboxes (3 Total) . . . . . . . . . . . . 6-26
Chapter 7 — Maintenance
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Adjusting Dancer Bar Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 Adjusting Dancer Bar Trigger Arm . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Adjusting Dancer Bar Counterweights . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Seal Bar Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.6 Seal Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.7 Seal Bar Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.8 Cold Bar Rebuilding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.9 Polyethylene Hot Bar Rebuilding . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.10 Seal Frame Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
1-3
7.11 Seal Frame Squaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Chapter 8 — Troubleshooting
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Fault Message Troubleshooting Index & Charts . . . . . . . . . . . . . . 8-2
8.3 General Troubleshooting Index & Charts . . . . . . . . . . . . . . . . . . . 8-7
Chapter 9 — Electrical Schematics

9.1 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Chapter 10 — Service Information

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 Field Service Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2.1 Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2.3 Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2.4 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2.5 ARPAC Commitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2.6 Scheduling Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3 Installation Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3.1 Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3.2 Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3.4 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3.5 ARPAC® Commitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.3.6 Customer On-Site Preparation . . . . . . . . . . . . . . . . . . . . . . 10-3
10.3.7 Scheduling Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
10.8 Service Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Chapter 11 — Illustrated Parts List

11.1 Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.2 How to Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.3 Commonly Ordered Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Chapter 12 — O.E.M. Information 1

12.1 O.E.M. Vendor Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Notes
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n-1
Distributor Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n-4
1-4
Safety Information
2
2.1 Introduction
Every effort has been made by ARPAC-PMI to provide you with a safe
machine. This section describes the safety precautions that should be
taken when working with, on or around the equipment. It is essential that
machine operators and maintenance personnel follow the safety
information.
2.2 Personnel Instructions

Read and understand the following personnel safety information before
operating the equipment:
2.2.1 Safety Goggles

Make sure that you wear safety goggles and other personal protective
equipment according to your company’s safety standards when operating
this machine. You may get injured if you do not.
2.2.2 Disconnect Power Before Servicing

Make sure that all power is disconnected from machine and machine has
cooled to room temperature before servicing it. You may get severely
injured if you do not.
2.2.3 Proper Cleaning Solvents

Only use non-flammable, non-aerosol cleaning solvents to clean heat
tunnel area. Also make sure that machine has cooled to room temperature
before cleaning it. You may get severely injured or burned if you do not.
2.1 Introduction 2-1

A-SIC-30-SS Tray Wrapper Installation, Operation & Service Manual
2.2.4 Proper Removal of Product

If machine stops with product in it, immediately push product out with a
stick, board, etc. Product may catch fire or explode if you do not. Do not
try to push product out with your hands. You may get injured or burned if
you do.
2.2.5 Keep Hands and Other Body Parts Clear

All personnel working around or coming in contact with the equipment
must be instructed to keep their hands and other parts of their person and
clothing clear of all moving parts.
2.2.6 Ensure Safety Devices are Operational

Equipment must not be operated if safety devices, including guards and
doors are removed, disconnected or damaged.
2.2.7 Never Reach Into Equipment

Personnel shall not reach into the equipment for any reason, including
maintenance, adjustment or clearing of jams, while the equipment is in the
cycle mode. The cycle mode stops when the guard doors are opened or
when the CYCLE STOP button is pressed. This process may take a couple
of seconds. Do not reach into the machine until the machine has stopped.
Before any person reaches into the equipment for maintenance or
adjustment, air and electrical power shall be turned off using lockable
shutoffs provided. The clearing of jams may be done while the machine is
turned on, but not while in the cycle mode.
Anyone entering the machine for maintenance, troubleshooting or any
procedure entailing the removal of guards or performing work at any
point of operation, shall be required to observe all applicable lockout-
tagout requirements.
NOTE: Because companies tend to tailor the lock/out program to their specific
needs, we advise all users to refer to their company’s procedure manual.
2-2 2.2 Personnel Instructions

2.2.8 Energy Hazards

Guard doors are equipped with electrical interlocks. When opened they
interrupt the air supply and de-energize all outputs to the motion control
devices on the wrapper. They do not shut off the main drive motor, the
seal bar temperature controller or any of the tunnel functions.
Before any person reaches into the equipment for maintenance or
adjustment, air and electrical power shall be turned off using lockable
shutoffs provided. The clearing of jams may be done while the machine is
tuned on, but not while in the cycle mode.
CYCLE STOP buttons do not de-energize any circuits.
EMERGENCY STOP push buttons shut off power to the control circuit,
the seal bar, all motors, the master air supply regulator and the tunnel.
They do not shut off power to the programmable controller.
Warning
Machine devices may move when the air is turned on or off, when
the electrical power is turned on or off or when the guard doors are
opened or closed.
Heat is used to seal and shrink the film and apply adhesives, including
heat seal type labels and glue. After shutting off the power, seal bar
components, the tunnel, label applicators and glue units may remain hot
to the touch for an hour or more.
Warning
Do not clean a hot tunnel!!! When cleaning the machine or any
components, use only non-flammable cleaning materials.
Flammable and/or aerosol cleaners may ignite or explode when
coming into contact with the hot tunnel. This is extremely
hazardous to your health.
2.2 Personnel Instructions 2-3

2.2.9 Guarding and Doors

Equipment must not be operated if any safety devices, including guards
and doors are removed, disconnected or damaged.
Guard doors are equipped with electrical interlocks. When opened they
interrupt the air supply and de-energize all outputs to the motion control
devices on the wrapper. They do not shut off the main drive motor, the
seal bar temperature controller or any other tunnel functions.
Personnel shall not reach into the equipment for any reason, including
maintenance, adjustment or clearing or jams, while the equipment is in the
cycle mode. The cycle mode stops when the guard doors are opened or
when the CYCLE MODE button is pressed. This process may take a
couple of seconds. Do not reach into the machine until the machine has
stopped.
All entering the machine for maintenance, troubleshooting or any
procedure entailing the removal of guards or performing work at any
point of operation, shall be required to observe all applicable lockout
requirements.
NOTE: Because companies tend to tailor the lockout/tagout program to their

specific needs, we advise all users to refer to their company’s procedure manual.
Warning
Machine devices may move when the air is turned on or off, when
the electrical power is turned on or off or when the guard doors are
opened or closed.
2.2.10 Interfacing Equipment

Observe all applicable codes when interfacing this equipment to other
equipment. Specific attention must be paid to any PINCH POINTS that
may be created and the prevention of an UNINTENDED RESTART of the
equipment when the electrical interlocks shut it down.
2-4 2.2 Personnel Instructions

2.3 Statement of Liability

While this machine has been designed for safe operation, improper
operation or carelessness may result in serious injury or damage to
equipment. The manufacturer or its agents and representatives assume no
responsibility for the following:
1 Injury or danger from improper use of the machine.
2 Problems or hazards resulting from failure to maintain the equipment
as specified in this manual.
3 Equipment which has been tampered with or modified. Arpac is not
liable for any damage or injury arising from failure to follow the
instructions and procedures provided within the manuals or
associated informational material, or from user failure to use caution
when installing, operating, adjusting, or servicing this machine. Arpac
is not liable for damage or injury arising from the use of this product
for any other use than that intended by the manufacturer.
2.4 Safety Conventions Used in this Manual

Specific safety information is listed in this manual in the form of
WARNING and CAUTION statements. Pay close attention to these
statements - they contain important information on avoiding potential
hazards to you or the equipment.
Warning Statements
• are used to indicate hazards or unsafe practices which COULD result
in severe personal injury or death.
• appear in bold type.
• have a triangular symbol with an exclamation point above the text.
• are preceded by the word Warning.
• are always found before the step or piece of information to which they
refer to.
• look like the following example:
Warning
Make sure that all power is disconnected from machine according
to Section 2.7 and machine has cooled to room temperature before
servicing it. You may get severely injured if you do not.
2.3 Statement of Liability 2-5

Caution Statements
• are used to indicate hazards or unsafe practices which could result in
minor personal injury or product or property damage.
• appear in bold type.
• have a triangular symbol with an exclamation point above the text.
• are preceded by the word Caution.
• are always found before the step or piece of information to which they
refer to.
• look like the following example:
Caution
Remove shipping bolts before operating machine. Machine may
get damaged if you do not.
2-6 2.4 Safety Conventions Used in this Manual

2.5 Safety Labels

The labels shown below are placed at various locations around the
machine. They are self explanatory.
Figure 2-1. Machine Safety Labels
2.5 Safety Labels 2-7

2.6 Lockout/Tagout Procedure

Before servicing the machine, make sure that it’s power is locked out and
tagged as follows:
1 Notify all affected employees that machine is going to be locked out.
2 Turn the main disconnect switch (1 in Figure 2-2) off.
Figure 2-2. Main Disconnect Switch
3 Place padlock (1 in Figure 2-3) though switch and lock it.

4 Place tag (2) on switch that includes the name of the person who
locked machine out.
5 After completing maintenance, remove lock and tag and notify all
affected employees that machine is back in service.
1
2
Figure 2-3. Lock & Tag
2-8 2.6 Lockout/Tagout Procedure

6 Press main air valve (1 in Figure 2-4.) down to turn it off.

7 Place padlock (2) though main air valve and lock it.
8 Place tag (3) on switch that includes the name of the person who
locked machine out.
Figure 2-4. Pneumatic Lock & Tag (Typical)
2.6 Lockout/Tagout Procedure 2-9

2.7 EMERGENCY STOP Buttons

There is at least one and maybe several EMERGENCY STOP buttons
located on the machine. Pressing any of these buttons will immediately
stop the machine and drop all electrical and pneumatic power to the
machine except the machine’s internal controls.
The machine cannot be restarted until all EMERGENCY BUTTONS are
pulled up and the CYCLE STOP RESET button on the main control panel
has been pressed.
Figure 2-5. Typical EMERGENCY STOP Button
2.8 Guard Door Switches

Each guard door on the machine is equipped with a safety interlock
switch. When a guard door is open, all moving components on the
machine will immediately stop. Power to the heating elements and seal
bars, however, will remain on and those components will remain hot.
The machine cannot be restarted until all guard doors are closed and the
CYCLE STOP RESET button on the main control panel has been pressed.
Typical Guard
Door Switch
Figure 2-6. Typical Guard Door Switch
2-10 2.7 EMERGENCY STOP Buttons

Introduction
3
3.1 Introduction
This manual provides installation, operation and service information for
the AGR-30SS shrink wrapper. This manual also includes a spare parts list
for the machine.
Figure 3-1. AGR-30SS Shrink Wrapper

3.2 Machine Features

ARPAC®-'-PMI’s Model AGR-30SS shrink wrapper is part of a dependable
line of shrink packaging systems designed to service a wide variety of
industries with around-the clock reliability. This compact and economical
single frame shrink wrapper is capable of wrapping up to 11 bundles per
minute, depending on product size.
The AGR-30SS is ideal for wrapping a wide range of trayed boxes, cans
and bottles in either a single tier or stacked arrangement. The AGR-30SS is
ideal for wrapping a wide range of trayed boxes, cans and bottles in either
a single tier or stacked arrangement.
The AGR-30SS Shrink Wrapper guarantees years of reliable service and is
ready to ship in as little as two weeks from order date.
3.2.1 Standard Features

• Heavy-duty rugged construction designed for high durability and
around-the-clock operation
• Laser cut and CNC machined components for maximum precision
• Digital controls for fast and accurate setup when changing product
size and film
• Single stage belt infeed conveyor for smooth and gentle product
handling
• Durable Intralox® conveyor belts eliminate tracking problems
• Simple film threading procedure
• Easy access heater elements
• Compact, single frame design (wrapper with integrated tunnel)
• Full guarding for operator safety
• NEMA 12 electrical cabinet and controls
• Low film alert warns that a film changeover will soon be necessary
• Central point lubrication simplifies preventive maintenance
3-2 3.2 Machine Features

3.2.2 Tray Applications

• Dairy
• Food
• Beverage
• Pharmaceutical
• Bakery
• Personal Care
3.2.3 Options
• Casters for easy machine portability
• Pacing conveyor
• Low tension film assist
• Jib crane to assist with film loading
• Alternate seal frame opening changes product height range to
2” - 10”
• Alternate voltages available: 208VAC, 230VAC, 575VAC
• Print registration - top film only
• Film on film modification
3.2 Machine Features 3-3

3.3 Dimensions
Figure 3-2. Dimensions
3-4 3.3 Dimensions

3.4 Specifications
Specifications
Power Requirements - Electrical: 460VAC, 3Ph, 60Hz, 35A, 28kW
- Pneumatic: 80 psi, 15 SCFM
Product Width 4.5”
Product Length 7.0”
Product Height 4.75”
Film - Max. Film width: 28” single-wound
- Clear or randomly printed
- Film roll diameter: up to 14” with a 3” core
- Film gauge: up to 6 mil. maximum
- Film type: low density polyethylene (L.D.P.E)
Conveyor Speed Up to 11 bundles per minute
No user serviceable parts
Table 3-1: Specifications
3.5 Abbreviations
% Percent
°C Degree Celsius
cm Centimeter
°F Degree Fahrenheit
Kg Kilogram
Lb Pound
M Meter
max. Maximum
min. Minimum
mm Millimeter
UL Underwriters Laboratories
3.4 Specifications 3-5

3.6 Mechanical Sub-Assemblies

This section gives a brief overview of the equipment and its functions
under normal production conditions.
3.6.1 Film Feed System

The film feed system consists of the following major components:
Film Cradles & Feed Rollers

There are two inline film cradles mounted on the machine. The purpose of
the cradles is to hold the film and feed the film into the dancer bars.
The cradles are fitted with DC gearmotor driven rollers. These rollers
periodically feed the film into the dancer bars when signaled by switches
on the dancer bars.
Figure 3-3. Film Cradles
Each cradle is also fitted with a photo detect eye that monitors the film
level. When a film roll starts to run low and the eye detects the presence of
the rolls spool, the detect eye will send a signal to the machine’s PLC
which will issue an alarm message on the machine’s display. The yellow
beacon will also light up to alert the operator of the problem.
Figure 3-4. Photo Detect Eye
3-6 3.6 Mechanical Sub-Assemblies

Film Feed
There are two film feed assemblies on this machine. The upper is located
in the top of the second frame upright. The lower is located in the bottom
of the second frame upright. Each assembly removes the film from the
corresponding film roll and then feeds it to the dancer assembly.
Film Feed Rollers
Figure 3-5. Film Feed Rollers
This is done by placing the film between the two spring loaded film feed
rollers. These rollers, driven by an electric clutch off the main drive, pull
the film off of the film roll at a calculated rate. The film then travels to the
dancer bar assembly.
NOTE: Only the lower roller of each pair of film feed rollers is driven. It is
provided with a replaceable rubber lagging or cork material.
Proximity switches on the dancer mechanism send signals to the PLC to

control the film feed clutches.
Warning
Do not put your body parts, clothing, rags or anything else near
these rollers when the machine is in cycle. You may get seriously
injured if you do.
3.6 Mechanical Sub-Assemblies 3-7

Dancer Bar
The dancer bar assembly is made up of a series of film guide rollers, a
stationary arm and a pivoting arm with counter weights and one or more
proximity switches. There are two dancer bar assemblies on this machine.
The upper dancer bar is located near the upper film feed rollers. The lower
dancer bar is located near the lower film feed rollers. Each was designed to
create a reservoir of film under constant light tension to immediately meet
the film requirements of the advancing product and closing seal bar.
Figure 3-6. Dancer Bar
The film is fed into the dancer bars by the film feed rollers when the
dancer trigger arm moves in front of the dancer proximity switch. When
enough film is fed the dancer arm will pivot down, thus moving the
dancer trigger arm away from the dancer proximity switch and stopping
the film feed rollers.
When another product moves through the seal frame, it will use more film
and cause the dancer arm to pivot up again. This will move the dancer
trigger arm in front of the dancer proximity switch again, which will again
begin the feeding of film.
If the film breaks or runs out, the dancer arm will drop to its lowest limit.
This will cause the film break trigger arm to move away from the film
break proximity switch, which will stop the machine from cycling. The
machine will not go into cycle again until the film break trigger arm is in
front of the film break proximity switch.
NOTE: Only the upper dancer bar assembly has a film break trigger arm.
The dancer arm has two counterweights. These are used to adjust the
amount of tension placed on the film If they are moved toward the pivot
point of the dancer arm, the film tension will increase. If they are moved

away from the pivot point of the dancer arm, the film tension will
decrease. The dancer weights were positioned during the testing process.
However, due to environment, product or film changes, they may need to
be readjusted by the customer.
NOTE: Increased film tension will not result in a tighter wrap on the product, but
will cause weak seals and broken film webs.
Each dancer switch plate has a dancer bar stop. These are used to adjust
the amount of swing the dancer arm has. They have been adjusted by the
manufacturer and under normal conditions will not need to be readjusted.
If however, there is a need to readjust the stops, adjust them so that the
dancer arm will pivot as far as possible without interference.

3.6.2 Seal Assembly

The seal assembly is one of the most important assemblies on the machine.
It is in this area that the product is wrapped or sealed in the film. The seal
bars cut and fuse the film before and after each product, thus creating a
film sleeve around the product. The cutting of the film must be complete
and accurate. If the film is not cut completely, then excessive film will be
pulled into the tunnel creating a possible major problem.
The film sleeve itself must not be too large or too small. If it is too large the
tunnel will not be able to shrink it properly. This will cause the film to
have wrinkles and not hold the product securely.
Seal Frame
The seal frame is the mechanical assembly on which the seal bars are
mounted. This assembly opens and closes the seal bars, thus sealing both
ends of the plastic sleeve that has been formed around the product.
Seal Bars
Figure 3-7. Seal Bar Assembly
The main ram moves the product through the seal frame and onto the seal
conveyor. When the product clears the seal frame photo eye, the PLC
sends a signal to the main ram, bridge and to the seal bar solenoid valve.
The main ram retracts, the bridge drops down, and the seal bars close.
When the seal bars close, they seal and cut the film simultaneously sealing
the product in the film and preparing the next section of film for the next
product. After the preset seal dwell timer times out, the PLC signals the
seal bars to open and the bridge to rise.

An air cylinder causes the seal bars to open and close. An electric solenoid
valve controls this air cylinder. Flow controls are used to control the speed
of opening and closing the cross seal bars. They are located at the air
cylinder, between the cylinder and its manifold base.
Hydraulic shock absorbers are provided for both seal closing and opening.
Both the upper and lower seal carriers are guided by double ball bearings
at the ends of each carrier. The air cylinder raises the lower seal carrier,
which through two chain linkages, lowers the upper carrier bar until the
seal bars meet. A squaring shaft interconnects the two chain linkages. This
ensures positive alignment of seal bars.
The operating cylinder of the seal frame attaches to the lower seal carrier
by a threaded connection on its rod end. This provides some adjustment of
the total seal opening.

Seal Bars
There are two seal bars in each machine. One is called the hot bar and the
other is called the cold bar. The hot bar has a thermocouple, two Teflon
coated inserts, a knife, a plug, two guards, and mounting brackets. The
cold bar has one silicon strip, one piece of Teflon cloth and two side plates.
Cold Bars
Hot Bars
Figure 3-8. Seal Bars
The purpose of this assembly is to seal and cut the film before and after
each product. This is accomplished by squeezing two pieces of film
together between the hot and cold bars. The hot bar heats the film until the
two pieces of film fuse together. Simultaneously, the knife, which is
mounted between the two Teflon coated plates, cuts the fused section of
the film into two pieces.
A panel-mounted temperature controller connected to a thermocouple
located within the seal bar accurately controls the temperature of the
heated surfaces. The temperature controller shows the actual temperature
of the seal bar.

3.6.3 Infeed Conveyor

The infeed conveyor is a clutch-driven rubber top Intralox®' belted
conveyor. The purpose of the infeed conveyor is to transfer the product
from the customer’s conveyor, through the seal frame area and onto the
seal conveyor.
Photo Eye
Infeed Conveyor
Figure 3-9. Infeed Conveyor
The infeed conveyor starts running when the machine is placed in the
cycle mode and will continue to run even while the seal frame is closed
unless another product blocks the infeed photo eye. This prevents a
product from trying to enter the seal frame area while the seal bars are
closed.
The infeed photo eye is located at the exit of the infeed conveyor just
before the seal frame. This photo eye will detect a product as it enters the
seal frame area from the infeed conveyor. The delay to start seal timer
starts when the product clears the photo eye. The seal frame closes and the
seal conveyor stops when the timer times out. This timer is adjustable
through the PLC.
When the seal bars open, the infeed conveyor will start again, transferring
the next product through the seal frame.

3.6.4 Seal Conveyor

The seal conveyor is a clutch-driven rubber top Intralox® belted conveyor.
After the product is wrapped in film, the seal conveyor transfers it from
the seal frame area onto the tunnel belt and into the shrink tunnel.
Seal Conveyor Tunnel Belt Shrink Tunnel
Figure 3-10. Seal Conveyor
The seal conveyor starts when the machine is placed into the cycle mode.
When the product pushes through the film and onto the seal conveyor, the
seal conveyor stops and the seal bars close. After the seal dwell timer
times out, the seal bars open, and the seal conveyor restarts.
A clutch connected to the main drive chain drives the seal conveyor. The
kick-out roller located at the exit of the conveyor functions as a transfer
roller. However, if something is forced between the conveyor belt and this
roller, the roller will lift up, preventing a pinch point. To re-install the
roller, simply place it back into the slots in the sides of the conveyor.

3.6.5 Shrink Tunnel

The tunnel has an Intralox® belted conveyor, one controlled heat zone, a
drive motor and a cooling section. The tunnel shrinks the film around the
product without adversely affecting the product in any way. the film must
not only properly contain the product, but it must be aesthetically
acceptable as well.
Stack Light
Tunnel Blower
Main Tunnel Body
Operator Controls
Cooling Section
Figure 3-11. Shrink Tunnel
The tunnel drive motor, located under the tunnel, drives the main tunnel
conveyor belt. Adjusting the frequency of the main tunnel drive motor
controller or by changing the sprocket ratios on the main drive chain will
change the speed of the conveyor belt.
The speed of this conveyor should be set slightly faster than the conveyor
feeding it. This prevents shingling and/or tipping of the products as well
as it keeps them spaced properly. It is important that the products are
spaced properly going through the tunnel for proper airflow around the
product and even shrinking of the film. It is also important that the
products are spaced after the tunnel, as the film will be somewhat tacky,
and if the products are allowed to touch each other, the film wrapped
around them may become damaged. When adjusting the speed of this
conveyor, the operator must also adjust the temperature of the tunnel. It is
important to operate this conveyor at the slowest acceptable speed to get
the job done, as the faster the conveyor runs the higher the tunnel
temperature must be kept.
The main tunnel conveyor belt is an intralox belt The drive shaft has a
series of sprockets that drive the belt.

These eliminate the need for special tracking. Another advantage to the
intralox belt is that no belt take-up is necessary.
Tunnels are heated in sections called heat zones. Depending on the
application some tunnels are equipped with more than one heat zone.
Each heat zone in the tunnel has its own heater element tray, radial blower
and thermocouple mounted inside for temperature feedback to the tunnel
temperature controller. The radial blower that moves the heated air is
mounted directly above the heater element trap. Each heater element tray
consists of a series of electrical thermal coils mounted in a stainless steel
frame. As electrical current is applied to the coils, they become hot. The air
drawn from the inside of the tunnel heat zone through the tunnel intake
vents by the radial blower, which passes through the heater element tray,
thus becoming hot. The hot air then returns to the inside of the tunnel heat
zone through the exhaust vents in the top and sides of that zone. A
thermocouple located in each heat zone near the heater element tray is
connected to the corresponding temperature controller allowing for
accurate temperature control of that zone.
The intake vents for each heat zone are located on the inside of the tunnel
walls in the center of the zone next to the deck. The exhaust vents are
located on the inside of the tunnel walls on the top and sides of the tunnel.
There are louvers located on both sides at the exit end of the tunnel. These
louvers control the velocity and direction of the airflow in the
corresponding areas.
At the exit end of the tunnel, a cooling section blows room temperature air
onto the product. This cools the film down as it moves onto the customer’s
conveyor.
Caution
It is important to clear any jams very quickly, as any product left
in the tunnel could be melted or damaged. the tunnel temperature
should never exceed 450° Fahrenheit.
Warning
The tunnel and some of its parts can become extremely hot. Do not
allow anything, with the exception of the product, to enter the
tunnel while it is turned on. This includes your body parts. Do not
clean a hot tunnel. When cleaning the machine or any components,
use only non-flammable cleaning material. Flammable and/or
aerosol cleaners may ignite or explode when coming into contact
with the hot tunnel.

Tunnel Blower
The tunnel blower is an electrically controlled radial blower located at the
top of the tunnel. The purpose of the blower is to circulate heated air
around the film wrapped bundles as they travel through the tunnel.
Some applications require a tunnel with more than one heat zone. Each
heat zone has its own blower. The blower draws air from the center of the
tunnel through an electric heater element tray. The heated air is then
returned to the tunnel through holes in the top and sides of the inside
tunnel walls.
3.6.6 Turbo Cooling Section

The turbo cooling section is mounted at the exit end of the tunnel. It is
designed to cool off the film immediately after the product exits the
tunnel.
Turbo Cooling Section
Figure 3-12. Turbo Cooling Section
The turbo cooling section directs ambient temperature air onto the top,
sides and ends of the product as it exits the tunnel. This cooling is
adequate to ensure that the film shrinks uniformly around the product.
However, even after the product passes the cooling section, the film
around the product may still be somewhat soft or tacky. Therefore, it is
recommended that the products not be allowed to touch each other
immediately after they exit the cooling section.


Installation
4
4.1 Machine Installation Instructions
The machine will be installed by an Arpac service technician.
4.1 Machine Installation Instructions 4-1

4-2 4.1 Machine Installation Instructions

Operation
5
5.1 Introduction
This chapter describes the following:
• What the controls of the machine do.
• How to run the machine.
• How to use the machine’s interface.
5.2 Main Disconnect Switch Description

The main disconnect switch (1 in Figure 5-1) turns off all power to the
machine.
.
Figure 5-1. Main Disconnect Switch

5.3 Main Control Panel Description

Figure 5-2 below shows the location of the main control panel. The
paragraphs that follow describe each control.
1 2
3 4
5 6
Figure 5-2. Main Control Panel
1 POWER ON Push Button - Pressing this button turns the machine

on.
2 EMERGENCY STOP PUSH-Pull Button - Pressing this button will
immediately shut down all electrical devices, with the exception of the
controller. The button must be pulled out before restarting the
machine.
3 CYCLE START Button - Pressing this push button starts the normal
cycle of the machine.
4 STOP/RESET Push Button - Pressing this button stops the machine
after the cycle in process is complete.
5 MANUAL SEAL - Pressing this button will make the seal bars close. It
is used when threading a new roll of film into the machine.
6 Machine interface - The machine interface allows the operator to
change recipes in order to run a different type of product. It also
displays fault and condition messages about the machine. The control
is described in depth in Section “5.6 Operator Interface Information”
on page 5-6.
5-2 5.3 Main Control Panel Description

5.4 Miscellaneous Controls

This section describes miscellaneous controls of the machine.
5.4.1 Pneumatic Controls

Lubricator - The lubricator adds drops of light machine oil to the airflow
of the machine. These drops of oil lubricate the air cylinders on the
machine. The rate at which oil is added can be changed by adjusting the
knob on top of the lubricator. The oil level in the lubricator should be
checked daily and oil added as required.
Main Air Valve - This valve turns all air to the machine on or off. Air is off
when the valve is pressed down.
Main Air Regulator - This sets the air pressure to the machine. It should
be set to 80 PSI.
Regulator &
Gage
Shut-Off Valve
Lubricator
Figure 5-3. Air Controls
5.4 Miscellaneous Controls 5-3

5.4.2 Stack Light

The stack light shows the status of the machine and warns the operator of
problems.
• Solid Red indicates an emergency stop button is tripped.
• Flashing Red indicates a fault or alarm situation.
• Solid Amber indicates the tray blanks are getting low.
• Flashing Amber indicates the machine is in the override or interlock
mode.
• Solid Green indicates the machine is in the cycle mode.
• Flashing Green indicates the machine is going into or coming out of
the cycle mode. It also indicates that machine is in standby mode
because it received an outside signal from an upstream or
downstream sensor to stop.
Figure 5-4. Light Stack
5-4 5.4 Miscellaneous Controls

5.5 Operating the Machine

The following sections describe how to start, stop and restart the machine.
5.5.1 Starting the Machine

1 Make sure the machine is loaded with film.
2 Turn the main disconnect switch on (refer Figure 5-1 on page 5-1 for
location).
3 Turn air shut off valve on - in up position (refer Figure 5-3 on page 5-3
for location).
4 Make sure the main air regulator is set to 80 P.S.I.
5 Pull all EMERGENCY STOP buttons up.
6 Press POWER ON button.
7 Press CYCLE STOP/RESET button to clear any error messages.
8 Wait for the tunnel and seal bar to heat up - it will take 10-20 minutes.
9 Press the CYCLE START button to start the machine.
5.5.2 Stopping the Machine in an Emergency

To stop the machine in an emergency, press the machine’s EMERGENCY
STOP button. This will make the machine stop immediately without
completing the cycle in progress.
After pressing an EMERGENCY STOP button, you must pull the button back
up, press the CYCLE STOP/RESET, and then press the CYCLE START button to
restart the machine.
5.5.3 Stopping the Machine (Short Term)

To stop the machine during normal operation, simply press the CYCLE
STOP/RESET button.
5.5.4 Stopping the Machine (Long Term)

To stop the machine on a long term basis, do the following.
1 Press the CYCLE SOP/RESET button.
2 Turn the main disconnect switch off (refer Figure 5-1 on page 5-1 for
location).
3 Turn air shut off valve off- in down position (refer Figure 5-3 on
page 5-3 for location).
5.5 Operating the Machine 5-5

5.6 Operator Interface Information

The operator interface displays information about the current status of the
machine and allows operators to changes timers, counters, conveyor
speeds, etc. This allows operators and maintenance personnel to set up,
adjust and troubleshoot the machine so that the machine will run their
products at its optimum performance level.
The Operator Interface allows the operator to monitor and change the
operation of the machine.
5.6.1 Security Levels:

There are three different security levels associated with the interface. Each
progressive level offers a deeper level of access to controlling and
monitoring the machine. The levels are as follows:
1 Basic: This level is available to all users and is active when the
machine is first turned on. This level does not allow anyone to change
anything. But it does allow the operator to view basic machine
messages.
2 Operator: This level is available to trained operators of the machine. It
allows the operator to load different recipes for different products into
the machine and to change setpoints in the machine’s operation. The
operator must login to the machine and enter a password to gain
access to this level.
3 Maintenance: This level is available to trained maintenance
technicians. It allows access to all functions of the machine. The
technician must login to the machine and enter a password to gain
access to this level.
5-6 5.6 Operator Interface Information

5.6.2 Logging Into Machine

In order to login into the machine, you must first have a four digit
numerical password to access the operator or maintenance levels. Each
level has a different password. If you do not know the password, you can
get it from your supervisor or by calling Arpac. The password was set
when the machine was built and it cannot be changed.
To login to the machine:
Caution
Do not use anything but your fingers to operate the interface’s
touch screen. Using pens or pencils to contact the touch screen can
easily damage it and it is very expensive to replace.
1 Turn the machine on. A bootup screen will appear for a moment and
then the OverView 1 menu shown below will appear. If the machine
was already on but the screen is blank, touch it to activate it.
Figure 5-1. OverView 1 Menu
5.6 Operator Interface Information 5-7

5.6.2 Logging Into Machine (cont.)

2 Press the LOGIN button in the lower right section of the OverView 1
menu. The Login menu shown below will appear.
Figure 5-2. Login Menu
3 Press the User button. A second menu will appear as shown below.
Figure 5-3. Login Keypad
4 If you want to login to the operator level, press the “o” button on the
second screen. If you want to login to the maintenance level, press the
“m” button.
5 Press the return key “↵“ on the second screen.
6 Press the Password button.
7 Enter the four-digit password on the second menu.
8 Press the return key “↵“ on the second menu.
9 Press the return key “↵“ on the first menu.
10 You are now logged in.

5.6.3 Operator Interface Menu Group Descriptions

OverView Menu
The OverView menu is shown below.
The sections below describe the various functions of the menu.
Menu Title Clock
Machine Speed
Current Recipe
Temperature
Controllers
Purge On/Off
Menu Group Login

Buttons Button
Fault & Alarm Toggle
Messages Buttons
Figure 5-4. OverView Menus
Menu Title: Is the title of the menu currently displayed.

Clock: Shows the current time.
Login Button: Pressing the button makes the login menu appear and
allows you to login to the machine.
Machine Speed: This shows the machine’s speed in parts per minute.
Temperature Controllers: These displays show the actual and set
temperature of the tunnel and seal bar heaters.
Purge ON/Off: This buttons turns the purge feature on or off. When the
purge feature is on and the CYCLE START button is pressed, the machine
will cycle all remaining product out of the machine without accepting any
new product.
Toggle Buttons: When a menu group has more than one menu, the
toggle buttons allow you to toggle between menus in the group.
Menu Group Buttons: Pressing these buttons makes various menu
groups appear. Each of these menus will be described in sections that
follow.
Fault & Alarm Messages: Displays fault and alarm messages such as
“Low Film” or “Emergency Stop”.

Current Recipe: Shows the current recipe being used by the machine. A
recipe is a set of parameters (height, length, width, etc.) that is specific to
the type of product being run. These parameters are recorded and saved
in a named file (recipe) so that they can be easily loaded into the machine
when the product is run in the future.
Pop-Up Screens
Keypad
• When an action requires the entry of numeric data by an operator, a
pop-up keypad is displayed over the current screen.
Deletes last character

entered.
Aborts entry and closes Accepts entry and closes

keypad keypad.
Figure 5-5. Numerical Keypad
Pop-Up Screens (cont.)

Keyboard

• Similarly, when an action requires the entry of string (i.e. text) data by
an operator, a pop-up keyboard is displayed on top of the current
screen.
Deletes last character

entered.
Accepts entry and closes

keypad.
Aborts entry and closes

keypad
Figure 5-6. Numerical Keypad
Password Protection
• If an operator attempts to access a display under an account without
sufficient security level access, the following graphic banner appears
at the top of the display.
Figure 5-7. Password Banner

5.6.4 Load/View Menu Group

Pressing the LOAD/VIEW button will make the LOAD/VIEW menu
appear. The Load/View menu group is comprised of two menus.
The first menu is used to change the Current Recipe. The Next Recipe can
be selected with the Up/Down Arrows or by pressing the New Product #
numeric keypad.
Figure 5-8. LOAD/VIEW 1 Menu
5.6.4 Load/View Menu Group (Cont.)

The second display allow an operator to rename a recipe by pressing the
corresponding Product Name string (i.e. text) display and allows an
operator to copy the name of one recipe to another.
Figure 5-9. LOAD/VIEW 2 Menu

5.6.5 Setpoint Modify Menu Group

The Setpoint Modify menu is group is used to view and/or change five
parameters of the current recipe. There are eight menus in the group. The
are described starting below and on the following pages.
1 Seal BarTemp.: This sets the temperature of the seal bar.
2 Tunnel Temperature: This sets the temperature of the tunnel.
3 Delay to Detect Product at Main Ram: This sets the amount of time
the machine will wait for the product to move from the infeed photo
eye to the product detector at the main ram before issuing a fault
message - indicating a jam.
4 Delay to Detect Product Min. Accumulation: This sets the
maximum amount of time that the machine will wait for product to
arrive on the infeed conveyor and still be able to automatically restart.
5 Delay to Start Seal Bar: This sets the amount of time the seal bars
will wait to close after a product has been first detected at the opening
of the bars. This is basically used to set the length of film that is sealed
around the product - longer products require longer times.
Figure 5-10. Setpoint Modify 1 Menu

5.6.5 Setpoint Modify Menu Group (Cont.)

6 Seal Bar Dwell: This sets the amount of time the seal bar stays closed
on the film.
7 Delay to Return Main Ram: This sets the amount of time the main
ram will wait to return after fully extending.
8 Number of Main Ram Short Strokes: This sets the number of short
strokes the main ram will use when pushing product through the seal
bars.
9 Spare: Not used.
10 Spare: Not used.

11 Spare: Not used.

12 Spare: Not used.
13 Spare: Not used.
14 Spare: Not used.
15 Spare: Not used.
16 Spare: Not used.

17 Spare: Not used.
18 Spare: Not used.
19 Spare: Not used.
20 Spare: Not used.

5.6.5 Setpoint Modify Menu Group (Cont.)

21 Spare: Not used.
22 Spare: Not used.
23 Spare: Not used.
24 Spare: Not used.
25 Spare: Not used.
26 Spare: Not used.

27 Spare: Not used.
28 Spare: Not used.
29 Spare: Not used.
30 Spare: Not used.

31 Spare: Not used.

32 Spare: Not used.
33 Spare: Not used.
34 Spare: Not used.
35 Spare: Not used.
36 Spare: Not used.

37 Spare: Not used.
38 Spare: Not used.
39 Spare: Not used.
40 Spare: Not used.

5.6.6 Maintenance and Alarm History Menus

The Maintenance menu group consists of four menus. They are used to
control various maintenance functions of the machine and are only
accessible by using the maintenance password. Each menu is described in
the sections that follow.
The Maintenance 1 menu has the following features:
Config. Mode: This button is to be used only by Arpac service technicians
to set internal software functions of the machine. Do not press it. If you do,
you will not harm the machine but you will have to turn the machine’s
main disconnect switch off and restart the machine to reset it.
Figure 5-18. Maintenance 1 Menu

Pressing the NEXT button will lead you to the Maintenance 2 menu. This
menu is used only by service technicians to set internal software functions
of the machine. This menu is used with a laptop computer interfaced to
the machine.
Figure 5-5. Maintenance Menu 2
41 Low Temp. Deviation from Setpoint: This sets the minimum

temperature that the seal bars and tunnel will operate at before
issuing a fault message.
42 Seal Bar High Temp. This sets the maximum temperature that the
seal bar will operate at before issuing a overheat fault message.
43 Spare: Not used.
44 Tunnel High Temp.: This sets the maximum temperature that the
tunnel will operate at before issuing a overheat fault message.
45 Spare: Not used.

5.6.6 Maintenance and Alarm History Menus (cont.)

46 Spare: Not used.
47 Spare: Not used.
48 Spare: Not used.
49 Spare: Not used.
50 Spare: Not used.

Alarm History: Pressing the ALARMS HISTORY button will make the
ALARMS HISTORY menu appear. This displays the fault message history
of the machine since the last time the fault message history memory has
been cleared. The memory can be cleared by pressing the Clear Alarm
History button. The display also shows the time when the fault message
occurred and when the operator acknowledged the fault message. The
operator can acknowledge the fault message by pressing the Ack Alarm
button. The operator can also acknowledge all fault messages by pressing
the Ack All button. A fault message DOES NOT have to be acknowledged
to restart the machine after the machine has stopped due to a fault
condition.
Figure 5-19. Alarm History Menu

5.6.7 Production Data Menus

The Production Data menu group consists of 2 menus. They are used to
monitor production data. Each menu is described in the sections that
follow.
The Production Data 1 menu has the following features:
Run Time (In Cycle): This shows the number of minutes the machine has
been in cycle (producing product) on a per shift and per day basis. The
total tally from the previous day is also shown.
Idle Time (No Prod.): This shows the number of minutes the machine has
been idle (not producing product) on a per shift and per day basis. The
total tally from the previous day is also shown.
Product Count: This shows the number products the machine has
produced on a per shift and per day basis. The total tally from the
previous day is also shown.
Values can be reset by pressing the Reset Current Shift or Reset All
buttons.
Figure 5-20. Production 1 Data Menu

The Production Data 2 Menu:

This shows the start and stop times of the three daily shifts. The times are
shown in 24-hour format. The start and stop times can be changed by
pressing the number values and reentering new time in the pop-up menu
that appears.
Figure 5-21. Production Data 2 Menu
Figure 5-22. Changing Start and Stop Times

5.7 Managing Recipes

Recipes are data files that hold data about a specific type of product. This
data instructs the machine on how to process the product. If the machine
is first designed to run 10 different kinds of products, then the machine
will have 10 different recipes - one for each product.
5.7.1 Loading a Recipe

When running a specific of product, the recipe for that product must be
loaded into the machine’s computer. This can be done as follows:
1 After logging in as an operator, press the Load/View button (1 in
Figure 5-23).
1
Figure 5-23. Load/View Button
2 Press the up or down buttons (2 in Figure 5-24) until the desired

recipe name and number (3) appears.
2
3
Figure 5-24. Load/View 1 Menu
5-24 5.7 Managing Recipes

3 Press Load button (4 in Figure 5-25) to load new recipe.
Figure 5-25. Load Button
4 After loading new recipe, it will appear in Curr. Prod. Name and
Curr. Prod. # as shown below. Procedure is complete.
Figure 5-26. New Recipe Loaded
5.7 Managing Recipes 5-25

5.7.2 Copying a Recipe

New types of products require new recipes. But sometimes products are
very similar. In such cases, the easiest way to create a new recipe is to copy
a recipe from a similar product and make the required changes to the
copied file. The procedure below describes how to copy a file.
1 After logging in as an operator, press the Load/View button (1 in
Figure 5-27).
1
Figure 5-27. Load/View Button
2 Press the next button (2 in Figure 5-28). The second Load/View menu
will appear.
Figure 5-28. Load/View 1 Menu

3 Press number button (3 in Figure 5-29) of recipe that you want to

copy. For this example, the number will be 4.
4 Press the Copy From button (4).
4
Figure 5-29. Product Number Buttons
5 Press number button (5 in Figure 5-30) of blank recipe that you want
to copy recipe into. For this example, the number will be 14.
6 Press the Copy To button (6) and go to the next step on the next page.
6
Figure 5-30. Copy To Button

5.7.2 Copying a Recipe (Cont.)

7 Press the OK To Copy button (7 in Figure 5-30).
7
Figure 5-31. OK To Copy
8 After pressing the OK To Copy button, the selected recipe will be

copied into the selected blank position. In this example, file 4 was
copied to blank position 14 as shown below.
9 Press the title button (8 in Figure 5-32) of the copied file. This will
open a separate pop-up menu that will allow you to rename the newly
copied file.
Figure 5-32. Copied File

10 Type in the copied file’s new name and press the return “↵“ key.
Procedure is complete.
Figure 5-33. Copied File

5.8 Product Load/Setup Parameters

5.8.1 Interface Parameters
Parameter
Description
Recipe 1
Recipe 2
Recipe 3
Recipe 3
Recipe 4
Recipe 5
Recipe 6
Recipe 7
Recipe 8
1 Seal Bar Temp. 360
2 Tunnel Temp 380
3 Delay to Detect Prod. At Main Ram 10
4 Delay to Detect Prod. Min. Accumula- 30

tion
5 Delay to Start Seal Bar 15
6 Seal Bar Dwell 15
7 Delay to Return Main Ram 10
8 Number of Main Ram Short Strokes 0
41 Low Temp. Deviation From Setpoint 30
42 Seal Bar High Temp. 450
44 Tunnel High Temp 500
Table 5-1: Setup Parameters
5-30 5.8 Product Load/Setup Parameters

5.9 Replacing Lower Film Roll

This procedure describes how to change the left film roll when the film
runs out or when changing to a different type or different width film.
Tools Required:
• Utility Knife
Warning
Press EMERGENCY STOP button on machine before doing this
procedure. You can get severely injured if you do not.
1 Press EMERGENCY STOP button.

2 Cut the film at the red dashed line shown below.
Figure 5-8. Film Cut Point
3 Remove empty film roll from lower film rack.
5.9 Replacing Lower Film Roll 5-31

4 Place loaded film shaft onto rack as shown below. Make sure roll is
oriented so that film unreels from the bottom of the roll.
Figure 5-9. Loading Film
5 Thread film through rollers as shown in Figure 5-10.
Figure 5-10. Film Threading Diagram
5-32 5.9 Replacing Lower Film Roll

6 Place the upper roll film over lower roll film and secure in place with
a weight (1 in Figure 5-11).
Figure 5-11. Upper and Lower Film Overlapping and Secured with Weight
7 Close all guard doors.

8 Pull up all EMERGENCY STOP buttons.
9 Press CYCLE STOP RESET button.
10 Press MANUAL SEAL button. The seal bars will close and seal the
upper and lower film together.
11 Open guard door and remove weight and scrap film.
12 Close door.
14 Restart machine.
5.9 Replacing Lower Film Roll 5-33

5.10 Replacing Upper Film Roll

This procedure describes how to change the left film roll when the film
runs out or when changing to a different type or different width film.
Tools Required:
• Utility Knife
Warning
Press EMERGENCY STOP button on machine before doing this
procedure. You can get severely injured if you do not.
1 Press EMERGENCY STOP button.

2 Cut the film at the red dashed line shown below.
Figure 5-12. Film Cut Point
5-34 5.10 Replacing Upper Film Roll

3 Remove empty film roll from upper film rack.

4 Place loaded film shaft onto rack as shown below. Make sure roll is
oriented so that film unreels from the bottom of the roll.
Figure 5-13. Loading Film
5 Thread film through rollers as shown in Figure 5-14.
Figure 5-14. Film Threading Diagram
5.10 Replacing Upper Film Roll 5-35

6 Place the upper roll film over lower roll film and secure in place with
a weight (1 in Figure 5-15).
Figure 5-15. Upper and Lower Film Overlapping and Secured with Weight
7 Close all guard doors.

8 Pull up all EMERGENCY STOP buttons.
10 Press MANUAL SEAL button. The seal bars will close and seal the
upper and lower film together.
11 Open guard door and remove weight and scrap film.
12 Close door.
14 Restart machine.
5-36 5.10 Replacing Upper Film Roll

Periodic Maintenance
6
6.1 Introduction
This chapter covers the periodic maintenance procedures for the machine.
Warning
The following procedures should only be done after the machine
has been turned off, allowed to cool down and the air pressure has
been released. Always follow Lockout/Tagout procedures. Always
wear safety glasses and all required personal protective
equipment.

6.2 Preventive Maintenance Schedule

Refer to the schedule below for information on when to perform periodic
maintenance on the machine.
Note: Due to varying operating conditions, the procedures listed below

may have to be performed at greater or lesser intervals. You may have to
adjust intervals according to your machine’s performance.
When To Do It:
Every 6 Months*
Monthly
Weekly
Daily
What To Do: Refer to Section:
Perform Walk Around Safety Inspection X 6.3

Clean External Surfaces X 6.4
Check EMERGENCY STOP Button For Proper X 6.5
Operation
Drain Air Filter Bowl X 6.6
Check Air Lubricator Oil Level X 6.7
Clean Seal Bar X 6.8
Inspect Shrink Tunnel X 6.9
Inspect Film Feed Drive Rollers X 6.10
Inspect Conveyor Belts X 6.11
Clean Photo Eyes X 6.12
Grease Seal Bar Bushings X 6.13
Grease Zerk Fittings X 6.14
Grease Ram Fittings X 6.15
Grease Bridge Fittings X 6.16
Lubricate Seal Bar Drive Chains X 6.17
Lubricate Conveyor Drive Chains X 6.18
Inspect Tunnel Curtains for Damage X 6.19
Replace Air Filter Element X 6.20
Change Oil in Conveyor Gearboxes* X X 6.21
Table 6-1: Preventive Maintenance Schedule
*Change oil in gearbox after first 500 hours of operation and then every
six months afterwards.
6-2 6.2 Preventive Maintenance Schedule

6.3 Walk Around Safety Inspection
Tools Required:
• None
Warning
Turn off machine’s main disconnect switch before servicing
machine. You can get severely injured if you do not.
At the beginning of each day, do a daily safety inspection of the machine

and its surrounding area. Pick up any trash or obstacles around the
machine. Wipe up any grease or spills.
Figure 6-1. Inspecting the Machine
6.3 Walk Around Safety Inspection 6-3

6.4 Cleaning External Surfaces
Tools & Materials Required:

• cleaning wipes
• warm, soapy water
Warning
Use cleaning wipes and warm soapy water to clean external surfaces of
the machine.
6-4 6.4 Cleaning External Surfaces

6.5 Check Emergency Stop Button

With the machine cycling, press the EMERGENCY STOP button. The
machine should stop immediately. Pull button back up and press CYCLE
STOP/RESET button to reset.
Figure 6-2. EMERGENCY STOP Button
6.5 Check Emergency Stop Button 6-5

6.6 Draining Air Filter Bowl

Tools Required:
• Cleaning Wipes
1 Make sure that air is connected to machine and machine is turned on
but not running.
2 Turn drain plug (1 in Figure 6-3) 1/4 turn and let water drain out.
3 Turn drain plug back 1/4 turn to stop air flow.
4 Wipe up expelled water.
1
Figure 6-3. Air Filter Drain Plug
6-6 6.6 Draining Air Filter Bowl

6.7 Checking Air Lubricator Oil Level

Tools Required: None
1 Visually check the level of the oil in the lubricator. It should be
between the levels shown in Figure 6-4. If oil level is below minimum
level, add oil according to the steps starting on the following page.
Max. Level
Min. Level
Figure 6-4. Air Lubricator Oil Levels
6.7 Checking Air Lubricator Oil Level 6-7

6.7.1 Filling Air Lubricator With Oil

• Cleaning Wipes
• SAE 10 Air Lubricator Oil
Warning
Turn off main air valve before adding oil to lubricator. You may
get seriously injured if you do not.
1 Turn off main air valve (1 in Figure 6-5) by pressing it all the way
down.
Figure 6-5. Main Air Valve Shutoff Valve
6-8 6.7 Checking Air Lubricator Oil Level

2 Unscrew lubricator fill plug (1 in Figure 6-6).
Figure 6-6. Lubricator Fill Plug
3 Fill lubricator to maximum level shown below.

4 Screw fill plug back in.
6.7 Checking Air Lubricator Oil Level 6-9

5 Turn main air valve back on.
Max. Level
Figure 6-7. Maximum Fill Level
6-10 6.7 Checking Air Lubricator Oil Level

6.8 Cleaning Seal Bars

• Cleaning Wipes
• Warm, Soapy Water
Warning
1 Turn off machine’s main disconnect switch.

2 Manually move seal bars (1 in Figure 6-8) to position shown.
3 Clean seal bars with cleaning wipes and warm soapy water.
Thoroughly dry seal bars.
4 Turn main disconnect switch back on.
Figure 6-8. Seal Bars
6.8 Cleaning Seal Bars 6-11

6.9 Inspecting Shrink Tunnel

• Cleaning Wipes
• Fine Wire Brush
Warning
Turn off machine’s main disconnect switch before servicing it.
Also, let shrink tunnel cool to room temperature before servicing
machine. You can get severely injured or burned if you do not.
1 Turn off machine’s main disconnect switch and let shrink tunnel cool
to room temperature.
2 Inspect inside of shrink tunnel as shown below. Remove any foreign
objects or melted film.
Figure 6-9. Shrink Tunnel
6-12 6.9 Inspecting Shrink Tunnel

6.10 Inspecting Film Feed Drive Rollers

• Cleaning Wipes
• Fine Wire Brush
Warning

2 Inspect drive rollers (1 in Figure 6-10). Remove any dirt, objects or
melted film.
Figure 6-10. Drive Rollers
6.10 Inspecting Film Feed Drive Rollers 6-13

6.11 Inspecting Conveyor Belts

• Cleaning Wipes
• Fine Wire Brush
Warning

2 Inspect conveyor belts (1 in Figure 6-11). Remove any dirt, objects or
melted film.
Figure 6-11. Conveyor Belts
6-14 6.11 Inspecting Conveyor Belts

6.12 Cleaning Photo Eyes

• Cleaning Wipes
• Window Cleaning Solution
Warning

2 Spray a small amount of window cleaning solution to the face of each
photo eye (The red dots in Figure 6-12 show the location of photo-
eyes).
3 Dry photoeye with cleaning wipe.
Figure 6-12. Photo Eyes
6.12 Cleaning Photo Eyes 6-15

6.13 Greasing Seal Bar Bushings

• Clean Rag
• No. 2 General Purpose Lithium Grease
• Standard Size Grease Gun with Standard Nozzle
Warning

2 Apply one pump of grease to each fitting (1 in Figure 6-13).
3 Wipe up excess grease.
4 Close guard doors.
Figure 6-13. Seal Bar Bushings’ Grease Fittings
6-16 6.13 Greasing Seal Bar Bushings

6.14 Greasing Zerk Fittings

• Clean Rag
1 Apply one pump of grease to each fitting (1 and 2 in Figure 6-14).
Figure 6-14. Zerk Fittings
6.14 Greasing Zerk Fittings 6-17

6.15 Greasing Ram Fittings

• Clean Rag
1 Apply one pump of grease to each fitting on ram manifold (1 and 2 in
Figure 6-15).
2
Figure 6-15. Ram Fittings
6-18 6.15 Greasing Ram Fittings

6.16 Greasing Bridge Fittings

• Clean Rag
1 Apply one pump of grease to each fitting on ram manifold (1 in
Figure 6-16).
1
Figure 6-16. Bridge Fittings
6.16 Greasing Bridge Fittings 6-19

6.17 Lubricating Seal Bar Drive Chains

• Clean Rag
• Food Grade Lubricating Oil
• Small Paint Brush
Warning

2 Lightly but thoroughly apply oil to chains (1 in Figure 6-17) with
brush.
3 Wipe up excess or spilled oil.
Figure 6-17. Seal Bar Drive Chains
6-20 6.17 Lubricating Seal Bar Drive Chains

6.18 Lubricating Conveyor Drive Chains

• 5/32” Hex Wrench
• Clean Rag
• Food Grade Lubricating Oil
• Small Paint Brush
Warning

2 Remove covers over drive chains.
3 Lightly but thoroughly apply oil to chains (1 in Figure 6-17) with
brush.
Figure 6-18. Conveyor Drive Chain (Typical)
4 Wipe up excess or spilled oil.

5 Reattach covers.
6.18 Lubricating Conveyor Drive Chains 6-21

6.19 Checking Tunnel Curtains

Warning
Turn off machine’s main disconnect switch and let machine cool to
room temperature before servicing it. You can be severely injured
if you do not.
1 Turn main disconnect switch off.

2 Check tunnel curtains (1 in Figure 6-19) for any damage or tearing.
Replace as required.
1
Figure 6-19. Tunnel Curtains
6-22 6.19 Checking Tunnel Curtains

6.20 Replacing Air Filter Element

Part Required:
• Numatics EKF32B 5 Micron Filter Element
Warning
Turn off main air valve before adding oil to lubricator. You may
get seriously injured if you do not.
1 Turn off main air valve (1 in Figure 6-5) by pressing it all the way
down.
Figure 6-20. Main Air Valve Shutoff Valve
2 Press down on tab (1 in Figure 6-21).
Figure 6-21. Tab
6.20 Replacing Air Filter Element 6-23

3 While still pressing on tab, turn bowl so that tab aligns with mark (1 in
Figure 6-22).
Figure 6-22. Turning Bowl
4 Pull bowl off of filter body.
Figure 6-23. Removing Bowl
6-24 6.20 Replacing Air Filter Element

5 Unscrew baffle (1 in Figure 6-24) and pull filter element (2) off of filter
body.
6 Reverse step to reassmble.
Figure 6-24. Removing Filter Element
6.20 Replacing Air Filter Element 6-25

6.21 Changing Oil in Conveyor Gearboxes (3 Total)

• 1/4” Hex Wrench
• AGMA #8C Gearbox Oil (Mobil 600 Cylinder Oil or Equivalent)
• Clean Rag
• Container for Waste Oil (1 Quart [1 L] Min.)
• Pump Type Oil Can
Warning

2 Place container under drain plug (1 in Figure 6-25).
3 Remove drain plug (1) and let oil drain out.
4 Screw drain plug back in.
5 Remove fill plug (2).
6 Fill gear box up with oil can until oil level is up to fill plug hole.
7 Screw fill plug back in.
Figure 6-25. Conveyor Gearbox (Typical)
6-26 6.21 Changing Oil in Conveyor Gearboxes (3 Total)

Maintenance & Testing
7
7.1 Introduction
This chapter covers various maintenance and testing procedures for the
machine.

7.2 Adjusting Dancer Bar Stops

Tools Required:
• 1/2” Open-End Wrench
Warning
Turn off machine’s main disconnect switch before doing this
procedure. You may get seriously injured if you do not.
1 Loosen both of the dancer bar stops using a 1/2” wrench.

2 Allow the dancer arm to swing downward as far as possible without
contacting any other parts of the machine, the product or the floor.
3 Retighten the dancer bar stops.
4 After adjusting the dancer bar stops, adjust the dancer bar trigger
arms. See Dancer Bar Trigger Bar on the next page.
Figure 7-1. Dancer Bar Stops
7-2 7.2 Adjusting Dancer Bar Stops

7.3 Adjusting Dancer Bar Trigger Arm

Tools Required:
• Set of Hex Wrenches
Warning
Turn off main disconnect switch before doing this procedure. You
may get seriously injured if you do not.
1 Prior to adjusting the dancer bar trigger arms, adjust the dancer bar
stops. See Dancer Bar Stops on previous page.
2 Loosen the dancer trigger arm shaft collars using a 9/64” hex wrench.
Loosen only one of the screws for each trigger arm.
Figure 7-2. Dancer Bar Trigger Arm
NOTE: If you are having trouble distinguishing between the trigger arms,
remember that the lower dancer bar will not have a film break trigger arm. Also,
the film feed trigger arms are on the opposite side of the machine as the film break
trigger arm.
7.3 Adjusting Dancer Bar Trigger Arm 7-3

3 Adjust the film break trigger arm so that it moves away from the film
break proximity switch when the dancer arm is just above its lowest
point.
Figure 7-3. Film Break Trigger Arm
4 Retighten the film break trigger arm shaft collar.

5 Adjust the film feed trigger arm so that it moves in front of the film
feed proximity switch when the dancer arm is at the horizontal
position.
Figure 7-4. Retighten Film Feed Trigger Arm
6 Retighten the film feed trigger arm shaft collars.
NOTE: Be sure that the dancer bar trigger arms pass within 1/8” of the
corresponding proximity switch.
7-4 7.3 Adjusting Dancer Bar Trigger Arm

7.4 Adjusting Dancer Bar Counterweights

Tools Required:
Warning
Film tension is set by the counterweights on the dancers. The tension

should always be set close to the minimum, but not too tight. The dancer
bar must have enough tension on it to pull the film down. This will allow
the dancer to respond quickly to the film that is being fed by the film feed
rollers.
1 Loosen the bolts that hold in both counterweights using a 7/16”
wrench.
2 Slide the counterweight to the desired position. Moving the
counterweight toward the pivot point of the dancer arm will increase
film tension. Conversely, moving the counterweight away from the
pivot point will decrease film tension.
NOTE: Increased film tension will not result in a tighter wrap on the product, but
will cause weak seals and broken film webs.
3 Retighten the bolts that hold in both counterweights.
Figure 7-5. Dancer Bar Counterweights
7.4 Adjusting Dancer Bar Counterweights 7-5

7.5 Seal Bar Removal

Tools Required:
Warning
Turn off machine’s main disconnect switch and let seal bar cool to
room temperature before doing this procedure. You may get
seriously injured or burned if you do not.
1 If removing the hot bar, disconnect the electrical disconnect.

2 Using the 9/16” wrench, remove the mounting bolts from the seal bar
being removed.
3 Remove the seal bar.
Cold Bar
Mounting Bolts
Cold Bar
Electrical
Disconnect
Hot Bar
Hot Bar
Mounting Bolts
Figure 7-6. Seal Bar Removal
7-6 7.5 Seal Bar Removal

7.6 Seal Bar Installation

Tools Required:
Warning
1 Position the seal bar on the carrier bar. When installing the hot bar, the
electrical disconnect must be positioned near the electrical cable.
2 Install the seal bar mounting bolts. Do not tighten yet.
.
Cold Bar
Mounting Bolts
Cold Bar
Electrical
Disconnect
Hot Bar
Hot Bar
Mounting Bolts
Figure 7-7. Seal Bar Installation
7.6 Seal Bar Installation 7-7

Caution
Bolts which mount seal bars into wrapper must not extend more
than one-half inch into expansion mount or the mount will be
irreparably damaged. Be sure to use all washers originally
supplied with these bolts. Replacement bolts should be of
identical lengths. Manually close the seal frame and make sure the
bars line up. The mounting holes are intentionally oversized to
allow precise alignment.
3 Using a 9/16” wrench, tighten the mounting bolts.
Caution
Do not operate the seal bar with the thermocouple wires connected
in reverse. The machine will get damaged if you do.
4 Connect the main power disconnect. Immediately after turning on the

electric power, observe the temperature controller.
If the display shows “FFF” or other unexpected temperature readout,
the thermocouple may be open or not connected. Check and correct. If
the display shows ”---” or other unexpected temperature readout, or if
the displayed temperature drops after power is applied, the polarity
may be reversed.
Reconnect the leads. The display will show the actual temperature of
the seal bar.
5 Test the strength of the seal by trying to pull it apart after the seal has
cooled. If the film separates at the seal without tearing when pulled,
more heat or dwell time is required. If the film tears along seal line,
the temperature setting or dwell time may be excessive.
7-8 7.6 Seal Bar Installation

7.7 Seal Bar Alignment

Tools Required:
Warning
NOTE: This procedure may be done the opposite way (by centering the cold bar to
the hot bar).
The seal bar alignment procedure is used to align the hot and cold bars in
order to get the best possible seal.
1 Manually close the seal bars.
2 Loosen the two mounting bolts on the cold bar. Do not remove the
bolts.
3 Set the hot and cold bar in line. The knife of the hot bar should be
centered to the cold bar.
4 Retighten the mounting bolts.
7.7 Seal Bar Alignment 7-9

7.8 Cold Bar Rebuilding

• Acetone
• Clean Rag
• Exacto Knife
Warning
1 Remove cold bar according to Section “7.5 Seal Bar Removal” on

page 7-6.
1 Remove the screws (1 in Figure 7-8) from the sides of the cold bar.
2 Remove the side plates (2) from the bar.
1
2
Figure 7-8. Side Plate Removal
7-10 7.8 Cold Bar Rebuilding

3 Remove the tape and silicone pad (1 in Figure 7-9) from the center bar
(2).
Figure 7-9. Silicone Pad Removal
4 Clean the center bar with acetone and a soft cloth.
Figure 7-10. Cleaning Center Bar
7.8 Cold Bar Rebuilding 7-11

5 Apply a thin layer of adhesive to the center bar. Smooth any ridges or
bubbles in the adhesive by using an Exacto knife. There should be a
layer of adhesive approximately 1/32 to 1/16” thick on the center bar.
Figure 7-11. Applying Adhesive

6 Carefully position the silicone strip on the adhesive on the bar.
Figure 7-12. Reattaching Silicone Strip
7 Invert the bar onto a flat surface and place a weight on it for at least six
hours.
Figure 7-13. Applying Weight

8 Using a razor blade, carefully trim any excess adhesive off of the sides
of the center bar.
Figure 7-14. Trimming Adhesive
9 Place the Teflon cloth over the silicone strip, draping it down on both
sides of the center bar. Do not use tape to hold the Teflon cloth.
Figure 7-15. Applying Teflon Cloth

10 Use a razor blade to cut holes in the Teflon to correspond with the
holes in the center bar. Do not pull the Teflon tape tight over the
silicone foam strip. Be sure that the tape has not wrinkled.
Figure 7-16. Punching Holes in Cloth
11 Reinstall the side plates and the screws.

12 Reinstall Cold bar on machine according to Section “7.6 Seal Bar
Installation” on page 7-7.
Figure 7-17. Reassembly

7.9 Polyethylene Hot Bar Rebuilding

• Acetone
• Clean Rag
• Exacto Knife
• Medium Flat-Tip Screwdriver
• Seal Bar Compound
• Steel Wool Pad
Warning
1 Remove cold bar according to Section “7.5 Seal Bar Removal” on

page 7-6.
2 Remove retaining screws (1 in Figure 7-18) and stripper plates (2).
2
1
Figure 7-18. Removing Stripper Plates
7-16 7.9 Polyethylene Hot Bar Rebuilding

3 Remove the screws (1 in Figure 7-19) of any spacers (2) that have
melted.
1
2
Figure 7-19. Spacer Buttons
4 Remove all of the seal bar mounting screws (1 in Figure 7-20).
Figure 7-20. Seal Bar Mounting Screws
7.9 Polyethylene Hot Bar Rebuilding 7-17

5 Remove the seal bar inserts (1 in Figure 7-21) by sliding them out from
between seal bar halves.
Figure 7-21. Seal Bar Insert Removal
6 Remove the knife blade (1 in Figure 7-22) from between seal bar
inserts (2).
1
Figure 7-22. Blade Removal

7 If heater element does not require replacement, skip ahead to step 13

on page 7-22. If the heater element requires replacement, unscrew
nuts (1 in Figure 7-23) and disconnect the wires (2) at each end of the
heater element rod (3).
1
2
2
3
1
Figure 7-23. Heater Element
8 Loosen the insulator screws (1 in Figure 7-24).
Figure 7-24. Insulator Screws

9 Spread the seal bar halves (1 in Figure 7-25) apart and remove the
heater element (2).
Figure 7-25. Heater Element Removal
10 Remove all old seal bar compound (1 in Figure 7-26) from seal bar
halves. Use acetone and a steel wool pad or a cloth to remove the
compound.
Figure 7-26. Seal Bar Compound

11 Add seal bar compound into the groove of one of the seal bar halves,
which the heater element sits in.
Figure 7-27. Adding Seal Bar Compound
12 Place the new heater element into the groove of one of the seal bar
halves, and rotate the heater element rod within. Do this until there is
a uniform layer of compound on the rod.
Figure 7-28. Rotating Element Rod in Compound

13 Place the second seal bar half onto the first half.
14 Screw the seal bar halves together with the mounting screws (1 in
Figure 7-29). Do not tighten the mounting screws yet.
Figure 7-29. Seal Bar Halves Together
15 Place the new blade (1 in “Blade Between Inserts” on page 7-22)

between the seal bar inserts (2).
Figure 7-30. Blade Between Inserts

16 Slide the inserts and blade back into the seal bar halves.
Figure 7-31. Inserting Inserts and Blade
17 Tighten the seal bar halve screws (1 in Figure 7-32) and the insulator
screws (2).
Figure 7-32. Tightening Screws

18 If the element was removed, place the heater element wire eyelets (1
in Figure 7-33) back into the ends of the rod, and tighten the two
heater element nuts (2).
2 2
Figure 7-33. Element Wire Hookup
19 Replace all spacer buttons (1 in Figure 7-34) and screws (2) that are
needed.
2 1
Figure 7-34. Adding Spacer Buttons

20 Reinstall the stripper plate (1 in Figure 7-35) with the retainer screws
(2).
21 Reinstall the hot bar according to Section “7.6 Seal Bar Installation” on
page 7-7.
NOTE: Make sure that the thermocouple and heater element wires are routed
correctly before tightening the retainer screws.
Figure 7-35. Reinstalling Stripper Plate

7.10 Seal Frame Shock Absorbers

The MA600 is the standard adjustable shock absorber used on ARPAC
seal frames. These units are intended to slow, but not stop, moving
objects.
Figure 7-36. Seal Frame Shock Absorber
It is very important that the seal frame shock absorbers are adjusted
properly. Improper settings will result in poor sealing action. If the shock
absorber is set too stiff, the seal bars either will not fully close or will just
barely close by the time the seal dwell timer times out. People in the field
tend to compensate for this by increasing the seal temperature or the seal
dwell time.
Check the setting on the shock absorber. It should be about “5” on the
scale around the end of the shock. It can be slightly less for small high-
speed seal frames and slightly more for large low speed seal frames.
Use the softest shock setting that does not allow the seal head to “bang” on
closing. Test the shock setting by placing a coin on the upper seal bar
carrier. Use the softest setting that keeps the coin in place when the seal
head closes. The coin may be tossed on opening.
The shock absorbers have a threaded exterior allowing them to be
positioned to suit. A lock nut is provided which must be securely
retightened whenever a shock is repositioned. Shocks must not be allowed
to bottom out. Check with a feeler gauge.
The positioning of the shock absorbers is very important! The seal closing
shock absorber must eliminate any and all bounding of the seal bars on
closure. The single-element seal bar will immediately cut the lower film on
first contact.
Any bouncing of the seal bars will result in the lower film pulling partially
or completely out of the seal jaws, resulting in poor closure or lack of
closure on the back end of the product.
7-26 7.10 Seal Frame Shock Absorbers

7.11 Seal Frame Squaring

NOTE: Only qualified maintenance personnel should perform this procedure.

Warning
Turn off machine’s main disconnect switch and let seal bar cool to
room temperature before doing this procedure. You may get
seriously injured or burned if you do not.
1 Before squaring the seal frame, make sure the seal bars are aligned
according to Section “7.7 Seal Bar Alignment” on page 7-9.
2 Remove the hot and cold seal bars according to Section “7.5 Seal Bar
Removal” on page 7-6. Using an 1-1/4” wrench, loosen the
transtorque bushing on the seal frame squaring shaft.
3 Using a 9/16” wrench, loosen the chain tensioners.
4 Using a 9/16” wrench, loosen the carrier bar mounting bolts in the
bushing blocks.
Figure 7-37. Seal Frame Squaring
7.11 Seal Frame Squaring 7-27

5 Place two identical, evenly milled spacers vertically between the seal
carrier bars.
NOTE: For proper squaring, it is important that the spacers are identical.
6 Secure the spacers in place by placing two threaded rods through the
clearance holes in the seal bar carriers. Tighten the rods down using
four nuts.
7 Using a 9/16” wrench on the chain tensioners, retighten the chain
evenly.
NOTE: When pulled at its midpoint, the chain should deflect approximately 1/2”
8 With a 9/16” wrench, retighten the carrier bar mounting bolts in the
bushing blocks.
Figure 7-38. Seal Frame Squaring
9 Retighten the transtorque bushing, using a 1 -1/4” wrench.

10 Remove the spacers, threaded rods and nuts from the seal bar carriers.
11 Replace the hot and cold seal bars.
12 Connect a jumper to the wrapper door interlock. See Chapter 9,
Electrical Schematics.
7-28 7.11 Seal Frame Squaring

Warning
Be sure that the only thing in the path of the seal bars is the paper.
Be careful to keep your hands clear. We recommend using a large
piece of paper.
13 Hold a piece of paper between the seal bars at one end, and press the
manual seal button. The paper should be held tight by the seal bars.
Figure 7-39. Correct Seal Frame Squaring
Figure 7-40. Incorrect Seal Frame Squaring
14 Repeat step 13 on the other side of the bars. Hold the paper tightly
again.
7.11 Seal Frame Squaring 7-29

15 If the paper is loose on either side of the seal bar, repeat the entire
procedure. If the paper is equally tight on both sides, the seal frame is
squared properly.
16 Remove the jumper from the wrapper door interlock.
7-30 7.11 Seal Frame Squaring

Troubleshooting
8
8.1 Introduction
This chapter is divided into two sections.
The first section is an index of fault messages that appear on the machine’s
display. This index is cross referenced to a group of troubleshooting charts
that will guide you through how to resolve fault message issues.
The second section is an index of generic machine problems not indicated
by fault messages. This index is cross referenced to a second group of
troubleshooting charts that will guide you through how to resolve the
problem.

8.2 Fault Message Troubleshooting Index & Charts

Use the following troubleshooting index and troubleshooting charts as an
aid in solving your problems associated with fault messages that appear
on the machine’s display.
Problem Refer to Page:

Note: After solving problem that caused message to occur, press the CYCLE/
STOP RESET button on the main control panel to clear message from display.
DC Power Is Off 8-3
Discharge Drive Not Ready 8-3
E-Stop Engaged 8-3
Excessive Run Time for Lower Film Feed 8-3
Excessive Run Time for Upper Film Feed 8-3
Infeed Drive Not Ready 8-4
Main Ram Jammed 8-4
Seal Bar Blocked While Closing 8-4
Seal Bar High Temp. Alarm 8-4
Seal Bar Jammed 8-4
Seal Bar Temp. Too Low 8-4
Tunnel Blower Motor Overload Tripped 8-4
Tunnel Drive Not Ready 8-5
Tunnel High Temp Alarm 8-5
Tunnel Temp. Too Low 8-5
Web Broken 8-6
Wrapper Door #1, #2,#3, #4 Open 8-6
Table 8-1: Troubleshooting Index
8-2 8.2 Fault Message Troubleshooting Index & Charts

Fault Message Possible Cause Remedy

Discharge Drive Not Drive controller fault Shut down the machine
Ready for a minimum of 1
minute and restart the
machine.
(The PLC received a fault
If problem immediately
message from the
reoccurs, refer to Allen-
discharge conveyor’s
Bradley Powerflex
adjustable frequency
documentation included
drive.)
on the CD in Chapter 12
of this manual for further
guidance.
E-Stop Engaged Emergency Stop button Pull out all Emergency
pressed in. stop buttons, press Cycle
Stop/Reset button and
restart machine
EXCESSIVE RUN TIME Incorrect film tension Adjust the dancer bar
UPPER/LOWER FILM counterweights.
FEED
(The PLC has detected
that the film feed has run
continuously longer than
the preset timer allows.
Film may accumulate in
the dancer bar area.)
Improper film threading. Inspect the film threading.
Re-thread as necessary.
One or more film dancer Inspect dancer bar rollers
rollers not turning freely. and bearings. Clean or
replace as necessary.
Incorrect dancer bar Adjust the dancer bar
trigger arm adjustment. trigger arm.
Film feed rollers slip on Check to see that the hold
the film. down springs at the end
of the film feed roller are
compressed to a height
between 1” and 1-1/4”.
Correct or replace as
necessary.
8.2 Fault Message Troubleshooting Index & Charts 8-3


Infeed Drive Not Ready Drive controller fault Shut down the machine
for a minimum of 1
(The PLC received a fault machine.
message from the infeed
conveyor’s adjustable
frequency drive.)
Bradley Powerflex
guidance.
Main Ram Jammed Main ram jammed by an Check for and remove any
obstruction. obstruction.
Seal Bar Blocked Obstruction in the path of Remove the obstruction.
the seal bars
Dirty, defective or Inspect the photo eye and
misaligned photo eye wiring. Clean, replace or
correct as necessary.
Tunnel High Temp. Tunnel thermocouple is Test for an open circuit
Alarm bad. across thermocouple.
Replace if open.
Seal Bar Jam Obstruction in the path of Remove the obstruction.
seal bars
Seal Bar Temp. Too Low Seal bar has not had Wait 10-20 minutes for
enough time to warm up. seal bars to warm up.
Seal bar circuit breaker is Make sure that circuit
blown. breaker is turned on.
Seal bar heater element is Test for short and open
bad. circuits on seal bar heater
element. Replace as
necessary.
Tunnel Blower Motor Blower motor overload Reset switch.
Overload Tripped switch tripped.
Blower fan jammed. Check for obstructions
Blower motor bad. Check and, if necessary,
replace motor


Tunnel Drive Not Ready Drive controller fault Shut down the machine
for a minimum of 1
(The PLC received a fault machine.
message from the tunnel’s
adjustable frequency
drive.)
Bradley Powerflex
guidance.
Seal bar thermocouple is Test for an open circuit
bad. across thermocouple.
Replace if open.
Tunnel High Temp. Tunnel thermocouple is Test for an open circuit
Alarm bad. across thermocouple.
Replace if open.
Tunnel blower motor Make sure that circuit
circuit breaker has blown. breaker is turned on.
Tunnel blower motor Inspect and, if necessary,
drive belt is broken. replace belt.
Tunnel blower motor is Test and, if necessary,
bad. replace motor.
Tunnel Temp. Too Low Tunnel has not had Wait 10-20 minutes for
enough time to warm up. tunnel to warm up.
Tunnel blower motor Make sure that circuit
circuit breaker has blown. breaker CB2 is turned on.
Tunnel blower motor Inspect and, if necessary,
drive belt is broken. replace belt.
Tunnel blower motor is Test and, if necessary,
bad. replace motor.
Tunnel heater fuse or Make sure that circuit
circuit breaker is blown. breaker is turned on.
Tunnel heater element is Test for short and open
bad. circuits on tunnel heater
element. Replace as
necessary.
Tunnel thermocouple is Test for an open circuit
bad. across thermocouple 2T/
C. Replace if open.
8.2 Fault Message Troubleshooting Index & Charts 8-5


WEB BROKEN Film web broken Remove film from
machine. Reinstall the
film roll.
Improper trigger arm Adjust the film break
adjustment trigger arm as necessary.
Defective or misaligned Inspect the proximity
proximity switch switch and wiring.
necessary.
Wrapper Door #1, #2, #3, Wrapper door opened Close the wrapper door.
#4 Open
(Connection between the

wrapper door
microswitch and magnet
has been interrupted.)
Door interlock damaged Inspect the guard door
or defective interlock and wiring.
Replace if necessary.

8.3 General Troubleshooting Index & Charts

Use the following troubleshooting index and troubleshooting charts as an
aid in solving general problems with the machine not indicated by fault
messages...
Problem Refer to Page:

Excessive Film Feed 8-8
Film Builds Up on Seal Bars 8-8
Film Does Not Cut Completely 8-8
Film is Not Feeding and Film Feed Rollers Do Not Turn 8-9
Film is Not Feeding and Film Feed Rollers Turn 8-9
Machine is “Ready to Run” but Will Not Start 8-9
Poor Shrink or No Shrink 8-10
Poor Temperature Uniformity 8-11
Seal on Back of Product Opens 8-11
Tunnel Slow to Reach Temperature 8-12
Weak Seal Line 8-13
Table 8-2: Troubleshooting Index
8.3 General Troubleshooting Index & Charts 8-7

Problem Possible Cause Remedy

Excessive Film Feed Incorrect film tension Adjust the dancer bar
counterweights.
(More film than required

is fed to the machine
possibly accumulating in
the dancer bar area.)
One or more film dancer Inspect dancer bar rollers

rollers not turning freely and bearings. Clean or
replace as necessary.
Incorrect dancer bar Adjust the dancer bar
trigger arm adjustment trigger arm.
Film Builds up on Seal Dirty seal bars Clean seal bars.
Bars
(Film residue forms on the
hot and/or cold bars,
causing poor seals.)
Temperature too high Adjust temperature on

temperature control.
Check thermocouple
connection to temperature
controller.
Defective cold bar Inspect Teflon tape on
cold bar and replace if
necessary.
Film Does Not Cut Seal frame chain Check that the seal frame
Completely tensioners incorrectly chain tensioners are
tightened adjusted equally and not
(Seal bars close on the film
over-tightened.
but do not cut the film
into two pieces)
Knife blade improperly Check that the knife blade
installed is sharp and installed
properly.
Low air pressure Make sure that air is
turned on and set to at
least 80 psi.
8-8 8.3 General Troubleshooting Index & Charts


Film is Not Feeding and Incorrect dancer bar Adjust the film feed
Film Feed Rollers Do Not trigger arm adjustment trigger arms.
Turn
(The film feed rollers do

not turn and no film is fed
to the product.)
Film feed clutch not Inspect connection
engaging between PLC and clutch.
Correct as necessary.
Inspect the clutch. Replace
as necessary.
Film Feed clutch engages, Inspect the clutch. Clean
but slips or replace as necessary.
Film is Not Feeding and Film feed rollers turn, but Check that the pinch
Film Feed Rollers Turn slip on the film roller moves freely on its
shaft.
(The film feed rollers are
turning but no film is fed
to the product.)
Check to see that the hold
down springs at the end
of the film feed roller are
compressed to a height
between 1 and 1-1/4”.
necessary.
Improper film threading Inspect the film threading.
Machine is “Ready to Latch or counter locked in Press EMERGENCY
Run” but Will Not Start STOP push-pull button.
Wait at least 30 seconds.
This gives the machine’s
(Machine will not begin PLC time to reset. Pull out
cycle as indicated.) the EMERGENCY STOP
push-pull button. Press
the POWER ON push
button to reset the latches
and counters.


Poor Shrink or No Shrink Temperature too low Increase temperature
preset on temperature
(The film does not shrink
controller.
to the product as desired
or does not shrink at all.)
Incorrect air flow in Adjust the tunnel louvers.
tunnel
Air intakes on side of Clean air intake openings
tunnel blocked by film in the tunnel.
Wrong rotation tunnel Inspect tunnel blower(s)
blower(s) motor wiring. Disconnect
two of the three power
leads and reconnect to the
opposite leads.
Tunnel blower(s) not Check blower bearings.
running Replace as necessary.
Check for overload.
Correct problem or reset
as necessary.
Check for loose
connections. Replace as
necessary.
Inspect tunnel blower
motor(s). Replace as
necessary.
Defective tunnel blower Inspect blower fan belt.

fan belt Adjust or replace as
necessary.
Cooling blower or other Reposition blowers or

fan in plant blowing fans.
cooled air into tunnel


Poor Temperature Incorrect temperature Adjust temperature on
Uniformity settings in multi-zone temperature control.
tunnels.
(Poor temperature
uniformity causes the film
to shrink inconsistently on
the package.)
Loose connection Check connection
between thermocouple
and temperature
controller. Correct as
necessary.
Loose or open circuit on Inspect heater element
heater element tray tray. Check for open
circuit or loose wires.
Tighten wires or replace
coils as necessary.
Defective tunnel blower Inspect blower fan belt.
fan belt Adjust or replace as
necessary.
Incorrect air flow in Adjust the tunnel louvers.
tunnel
Air intakes on side of Clean air intake openings
tunnel blocked by film in the tunnel.
Seal on Back of Product Too much air trapped Check to see that the
Opens with the sealed product performers are positioned
correctly.
(Film is cut, but the seal at
the back of the package
opens on the wrapper or
in the tunnel.)
Consider the use of pre-

punched or perforated
film.
Seal line not in the center Readjust the seal head if
of the product needed.
Seal bars closing too close Adjust product spacing.
to the back of the product
Continued on next page...


Seal on Back of Product Seal bar edge damaged Inspect the seal bar and
Opens (Cont.) replace if necessary.
Defective film Inspect film for unusual
sags or curls, and replace
film if necessary. If
problem persists, contact
your film supplier.
Low air pressure See the “Low Air
Pressure” error message.
Defective air cylinder Inspect the air cylinder.
Replace as necessary.
Tunnel Slow to Reach Blown circuit breaker Inspect circuit breaker.
Temperature Correct as necessary.
(Tunnel takes longer than

usual to reach desired
temperature.)
and temperature
necessary.
. Loose or open circuit on Inspect heater element
heater element tray tray. Check for open
circuit or loose wires.
Tighten wires or replace
coils as necessary.
Defective tunnel blower Inspect fan belt. Adjust or
fan belt replace as necessary.
Tunnel blower not Inspect circuit breakers
running and connections. Correct
or replace as necessary.
Cooling blower or other Reposition blowers or
fan in plant blowing fans.
cooled air into tunnel.


Weak Seal Line Dirty seal bars Inspect seal bars. Clean as
necessary.
(The seal on the front,
back or sides of the
product pulls apart
easily.)
Defective cold bar Inspect Teflon tape on
cold bar. Replace as
necessary.
Inspect the cold bar seal
pad. Replace seal pads
that are too hard or too
soft.
Film not relaxed Adjust product spacing
and/or speed of
conveyors.
Defective temperature Inspect temperature
controller controller. Replace as
necessary.
Incorrect temperature Adjust temperature on
setting (too high or low) temperature control.
Blown circuit breaker Inspect circuit breaker.
Correct as necessary.
and temperature
necessary.
Seal dwell timer incorrect Change seal dwell time
from the set point modify
screen.
Incorrect seal bar Inspect seal bar
alignment alignment. Correct as
necessary.
Incorrect air pressure Check balance for equal
pressure units with two
air cylinders.
Continued on next page...


Weak Seal Line (Cont.) Incorrect air pressure Check and adjust the air
pressure if necessary. Air
pressure should be 80 psi
minimum.
Check airflow adjustment
(solenoid/cylinder).
Check for air leakage.
Incorrect data (auto preset Check presets: film
option) thickness and speed/
minute.
Hot bar knife dull or Check that the knife blade
misaligned is sharp and installed
properly.
Improper film threading Inspect the film threading.

Electrical Schematics
9
9.1 Electrical Schematics
This chapter contains the electrical schematics for the AGR-30SS Tray
Wrapper.
9.1 Electrical Schematics 9-1

9-2 9.1 Electrical Schematics

Service Information
10
10.1 Introduction
This section contains an overview of ARPAC-PMI®’s field service policies.
10.2 Field Service Policy

10.2.1 Objective
To furnish our customer with prompt, competent, and complete service so
they can operate at optimum efficiency.
10.2.3 Service Personnel

ARPAC-PMI®’s field technicians are experienced in the servicing of
ARPAC-PMI® equipment, are qualified to instruct customer’s personnel
in correct operation and maintenance procedures of ARPAC-PMI®
equipment. ARPAC-PMI® Field Service Technicians are fully supported
by factory and all Engineering Departments.
10.2.4 Training
The ARPAC-PMI® Group is pleased to provide free lifetime access to
ARPAC-PMI® University’s regularly scheduled technical training courses
for customers purchasing a packaging machine from ARPAC-PMI® or its
distributors.
These technical training courses will focus on theory of operation,
machine setup and operation, preventive maintenance and long-term care.
Many specific machine courses are available on ARPAC-PMI® bundler,
horizontal, corrugated, and stretch wrapping machines. These regularly
scheduled 1 day or 2 day courses are held approximately every 12 weeks
at the ARPAC-PMI® University and Demo Room located near O’Hare
airport in Chicago. Class demand will influence the frequency of these
class offerings.
For further information or a current technical training calendar and
agenda, contact ARPAC-PMI®’s training department at 847-678-9034 ext
4088.

Custom machine specific training courses can be developed for delivery at

your location or at ARPAC-PMI®. For further information and a
quotation, contact ARPAC-PMI®’s training department.
10.2.5 ARPAC-PMI Commitment

• Be readily available to communicate with the customer(s).
• Service Technicians available for supervision and instruction of
personnel at prevailing rates and expenses.
• Upon arrival of the ARPAC-PMI® Service Technician, he should be

able to commence immediately, minimize “downtime” of your
production facilities and commence training of your personnel.
10.2.6 Scheduling Service

At least 10-days advance notice is required for scheduling personnel.
Emergencies will be handled as quickly as possible. If assistance is
required during installation or operation of the system or if you need
information pertaining to system-related problems not covered by this
manual, please contact ARPAC-PMI® Service Dept. (telephone (847) 678-
9034.
10.3 Installation Policy

10.3.1 Objective
To furnish our customer with prompt, competent, and complete service so
they can operate at optimum efficiency. Failure to use factory trained
personnel for initial machine start-up may void the warranty.
10.3.2 Service Personnel

ARPAC-PMI®’s field technicians are experienced in the servicing of
ARPAC-PMI® equipment, and are qualified to instruct customer’s
personnel in the correct operation and maintenance procedures of
ARPAC-PMI® equipment. ARPAC-PMI® Field Service Technicians are
fully supported by factory and all Engineering Departments.
10.3.3 Training
ARPAC-PMI® personnel are available for ARPAC-PMI® equipment
training, either on site hands-on, or in a classroom environment supported
by visual aids and literature to be administered under separate purchase
order.
10-2 10.3 Installation Policy

The ARPAC-PMI® Group is also pleased to provide free lifetime access to

ARPAC-PMI® University’s regularly scheduled technical training courses
for customers purchasing a packaging machine from ARPAC-PMI® or its
distributors.
These technical training courses will focus on theory of operation,
machine setup and operation, preventive maintenance and long-term care.
Many specific machine courses are available on ARPAC-PMI® bundler,
horizontal, corrugated, and stretch wrapping machines.
These regularly scheduled 1 day or 2 day courses are held approximately
every 12 weeks at the ARPAC-PMI® University and Demo Room located
near O’Hare airport in Chicago. Class demand will influence the
frequency of these class offerings.
For further information or a current technical training calendar and
agenda, contact ARPAC-PMI®’s training department at 847-678-9034 ext
4088.
Custom machine specific training courses can be developed for delivery at
your location or at ARPAC-PMI®. For further information and a
quotation, contact ARPAC-PMI®’s training department.
10.3.4 ARPAC-PMI® Commitment

• To furnish equipment per quotation.
• Be readily available to communicate with the customer(s) to facilitate
start-up.
• Service Technicians available for start-up supervision and instruction
of personnel at prevailing rates and expenses.
• Upon arrival of the ARPAC-PMI® Service Technician, he should be

able to commence immediately, minimize “downtime” of your
production facilities and commence training of your personnel.
10.3.5 Customer On-Site Preparation

• Unload, unpack, and inspect the equipment for any freight damage
(apparent or hidden). If there is any damage, the Bill of Lading will
need to be signed, noting the damage. You will then need to file all the
necessary freight claims with the appropriate carrier. All shipments
are freight collect and you are responsible for any damages in transit.
• Remove all interfering equipment and clear area where equipment is
to be installed.
• Assemble/erect subject equipment.
10.3 Installation Policy 10-3

• Lag system to floor.

• Furnish all electrical wiring and connections per system requirements.
• Furnish any air and/or gas lines and connections if required.
• Integrate with any existing up and/or down stream equipment.
• Provide qualified technicians, operators, and maintenance personnel
to start-up system.
10.3.6 Scheduling Service

If assistance is required during installation or operation of the system or if
you need information pertaining to system-related problems not covered
by this manual, please contact ARPAC-PMI® Service Dept. (telephone
(847) 678-9034).
10.3.7 Aftermarket Contact Information

Contact information for parts and service is listed below. Please have your
machine’s model number and serial number ready when calling. Also
have a Purchase Order number when calling.
ARPAC-PMI® Parts Contact Information

Phone: (847) 678-9034
Fax: (847) 678-2109
parts@ARPAC-PMI.com
Hours of operation Monday through Friday,

7:30 AM to 6:00 PM (Central Time)
ARPAC-PMI® Service Contact Information

Phone (847) 678-9034
Fax: (866) 365-4131
Hours of Operation Monday through Friday,
After Hour Emergency Service: (847) 678-9034
10-4 10.3 Installation Policy

Illustrated Parts List
11
11.1 Ordering Parts
For your convenience, replacement parts and accessories can be ordered
from ARPAC-PMI® by fax 24 hours a day. Please have the following
information available to ensure quick, easy, and accurate service.
• Your name and telephone number
• Your P.O. (Purchase Order) number
• Your preferred method of delivery
Replacement Parts Policy & Contact Information

Should a replacement part be needed, ARPAC-PMI®’s return material
authorization policy must be adhered to. ARPAC-PMI® will not distribute
equipment or parts without a purchase order from an authorized ARPAC-
PMI® distributor. This procedure includes warranty and non-warranty
replacement parts. A return authorization will be issued at that time, and
credit will not be issued until the suspect part has been received and
inspected. Call ARPAC-PMI® sales for the distributor in your area at (847)
678-9034.
ARPAC-PMI® Parts Contact Information

Phone: (847) 678-9034
Fax: (847) 678-2109
parts@ARPAC-PMI.com
Hours of operation Monday through Friday,

11.1 Ordering Parts 11-1

11.2 How to Use This Parts List

General Part Numbers
This chapter contains all part numbers necessary to order AGR-30SS
Shrink Wrapper replacement parts and assemblies.
This illustrated parts breakdown is presented in disassembled order.
Detail parts are shown below their respective upper level assemblies
whenever possible.
The parts lists follow the illustration for a particular assembly and
represent components of that assembly. The number listed in the quantity
column is the number of the specific part required to complete the
assembly and may not reflect the quantity needed for the entire system.
The lists are divided into four columns. The item/index numbers refer to
the identification number located on the drawing. The part number is the
ARPAC-PMI part number, used to identify the part for ordering. The part
description column lists each part name, and the quantity column lists the
quantity of that part used in that particular assembly.
Illustrations are shown before the parts list for each assembly.
11-2 11.2 How to Use This Parts List

O.E.M. Information
12
12.1 O.E.M. Vendor Information
The CD on the next page contains original equipment manufacturer
information for the machine. This information includes service and
operation instructions for such items as the machine’s temperature
controller, motor drives, sensors, etc. The information is organized in
alphabetical order according to each vendor’s brand name.
12.1 O.E.M. Vendor Information 12-1

12-2 12.1 O.E.M. Vendor Information

Notes
n-1
Notes
n-2
Notes
n-3
Distributor Information
This product was manufactured by:
Arpac L.P.
9511 West River Street
Schiller Park, IL 60176 U.S.A.
(847) 678-9034
www.arpac.com
And is distributed by:
n-4

AGR-30SS Shrink Wrapping Machine Installation, Operation, & Service Manual

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Table of

Attention: Consult Accompanying Documents - As Applicable

This manual was originally written in English in the United States.

REV Date Reason for Change

Table i-1. Revision History

List of Affected Pages

Table i-2. List of Affected Pages

Revision History i-1

Prelude ii — Warranty Information

Chapter 1 — Table of Contents

5.7.1 Loading a Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Chapter 6— Periodic Maintenance

7.11 Seal Frame Squaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Chapter 9 — Electrical Schematics

Chapter 10 — Service Information

Chapter 11 — Illustrated Parts List

Chapter 12 — O.E.M. Information 1

Distributor Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n-4

2.2 Personnel Instructions

2.2.1 Safety Goggles

2.2.2 Disconnect Power Before Servicing

2.2.3 Proper Cleaning Solvents

2.1 Introduction 2-1

2.2.4 Proper Removal of Product

2.2.5 Keep Hands and Other Body Parts Clear

2.2.6 Ensure Safety Devices are Operational

2.2.7 Never Reach Into Equipment

2-2 2.2 Personnel Instructions

2.2.8 Energy Hazards

2.2 Personnel Instructions 2-3

2.2.9 Guarding and Doors

NOTE: Because companies tend to tailor the lockout/tagout program to their

2.2.10 Interfacing Equipment

2-4 2.2 Personnel Instructions

2.3 Statement of Liability

2.4 Safety Conventions Used in this Manual

2.3 Statement of Liability 2-5

2-6 2.4 Safety Conventions Used in this Manual

2.5 Safety Labels

Figure 2-1. Machine Safety Labels

2.5 Safety Labels 2-7

2.6 Lockout/Tagout Procedure

Figure 2-2. Main Disconnect Switch

3 Place padlock (1 in Figure 2-3) though switch and lock it.

Figure 2-3. Lock & Tag

2-8 2.6 Lockout/Tagout Procedure

6 Press main air valve (1 in Figure 2-4.) down to turn it off.

Figure 2-4. Pneumatic Lock & Tag (Typical)

2.6 Lockout/Tagout Procedure 2-9

2.7 EMERGENCY STOP Buttons

Figure 2-5. Typical EMERGENCY STOP Button

2.8 Guard Door Switches

Figure 2-6. Typical Guard Door Switch

2-10 2.7 EMERGENCY STOP Buttons

Figure 3-1. AGR-30SS Shrink Wrapper

3.1 Introduction 3-1

3.2 Machine Features

3.2.1 Standard Features

3-2 3.2 Machine Features

3.2.2 Tray Applications

3.2 Machine Features 3-3

Figure 3-2. Dimensions

3-4 3.3 Dimensions