Your machine is important to us, thats why we make our maintenance procedures public and easy to access.
Table of Contents
Standard Operating Procedure: Calibrating Front End Backstop
1. Purpose
How to properly calibrate the Front-End Backstop. This procedure will be used in the Feed Section in the front of the machine. This will help you put your backstop to the desired measurement and tell the machine exactly where the backstop is at. This should help going forward making all future set-ups easier.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to calibrate the Front-End Backstop.
3. Prerequisites
Tools Needed: Tape measure or known size of corrugated board. You do need the admin password to get into the front LCD and calibrate the machine.
Machine must have power and be operational to perform.
Password: 12345
4. Procedure
⦁ Stop the Machine and make sure there is nothing in the hopper of the front feed section.
⦁ On the Front Feed Section Panel, use the Backstop switch to move the Backstop to the desired position. Make sure this position is correct with your personal tape measure or a corrugated board that you know the measurements of.
⦁ On the LCD Panel on the Front Feed Section Panel got to L2.
⦁ Now click on the Orange written number for the Backstop. This will be the numbers above the yellow numbers. (the “set” numbers)
⦁ When you click on those numbers there will be a password screen pop up.
⦁ Enter in Password: 12345
⦁ This will take you back to the L2 screen however the Backstop numbers will be highlighted in blue. Click on this again.
⦁ Another numeric screen will pop up and this is where you put the actual dimension that you have the backstop at.
⦁ Hit enter and this will exit you back to the L2 screen once again with the backstop number being changed.
5. Definitions and Pictures
Front End Backstop:
The front-end backstop provides support for the corrugated material in the hopper. Making sure this section is correctly calibrated helps for faster and more accurate set ups and operation of the machine. Along with Housekeeping and keeping this area lubricated, Calibration is also very important
Backstop Switch and LCD:
On the Front Feed Section Panel there is a switch labeled BACKSTOP. (ENDSTOP)
From this picture you can also see the orange and yellow numbers. The orange being the “ACTUAL” measurement the part is at and the yellow being the number the machine was to “SET UP” at. The Backstop (ENDSTOP) is in the lower right corner.
PASSWORD SCREEN:
When you press onto the orange number for the Backstop (ENDSTOP) on L2 of the LCD panel, this is the password screen that will come up. Enter 12345.
Hit Enter and it will take you back to the L2 screen with the same drive side operator number being highlighted in blue
Standard Operating Procedure: Homing The New Counter Ejector Fork Up-Down, Fork In-Put, And Elevator Up-Down
1. Purpose
How to Zero out the counter ejectors MAIN 3 processes which are Fork UP/Down, Fork In/Out, and Elevator Up/Down. This procedure can be used on different errors you may get in the counter ejector along with Zeroing out this entire section. This will provide smooth movement in that area, extend your machine life, and decrease downtime for costly repairs.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to Zero out the counter ejectors MAIN 3 processes which are Fork UP/Down, Fork In/Out, and Elevator Up/Down.
3. Prerequisites
TTools Needed: There are a lot of moving parts in the counter ejector so you may need some tools beforehand if you are doing other work in this area such as tightening up the chains or adjusting the cylinders BUT for this step you do not need any actual tools. You can have some allen keys on hand in case you need to move any sensors.
4. Procedure
First the process on the Elevator up and down.
⦁ Turn the switch on the Counter Ejector to Manual so that you can move the controls on the HDI screen.
⦁ Hit F3 on the HDI screen and there you can press and raise the different things that are in the counter ejector.
⦁ Manually lower the table elevator to the proximity switch located inside the button of the counter ejector. Make sure you do not go past this switch and hit the limit switch. This will cause the machine to time out. You have to completely remove the limit switch, power off the machine with the Key located on the counter ejector section, and then manually move it out of the way. (this limit switch process applies to all three sections) make sure the sensor is close (almost touching) and secure. Ensure that your top height of the elevator is low enough that the belts take your corrugated out of the area.
⦁ Go to the HMI screen and touch the upper right tab next to the F1 location and this should open up a password screen. The password is 13572468
⦁ Next hit the Servo Position tab. This will take you to the 3 critical servo positions in the counter ejector. The fork up and down, fork in and out, and finally lifter (elevator) up and down which is the one we are adjusting now.
⦁ Hit the Wrench on a hard hat icon. Hit this button. This will now ask if you want to reset these locations with a push of the button to zero. Only hit okay on the lifter up and down. This will zero that location which is the lifter up and down.
⦁ Back out of this screen. You can manually move anything at this point or set it in automatic and it should go through and set itself back home.
The Fork Up and Down and Fork In and Out methods are both very similar to the above. Use the same screens and same password. Instead of moving the elevator like in the above notes, you move the forks up and down or in and out. You move them the same way as above, they have their own buttons but they are in the same screens and locations on F3 as listed above.
5. Definitions and Pictures
Proximity Sensor- The sensor that is located to detect when the forks reached its 0 limit back, 0 limit high, and the elevator 0 limit low. Those are the 3 Proximity sensors that we are speaking about in this section.
Limit Switch – Located just after the Proximity Sensors and will go off if fully engaged. You must remove the KEY located on the counter ejector operator side for 30 seconds after removing the switch physically. When you power the machine back on, you should be able to move the position manually again. Remember to reattach the limit switch if this happens.
This is where you need to touch in order to access the password screen that you need to get to the proper spot so you can zero out and home your counter ejector. Touch between the F1 tab and the empty tab space next to it. Right in the middle of them both will take you to the password screen.
The PASSWORD is 13572468
After putting in the password it will take you to this screen. This is the screen where you Hit the SERVO POSITION TAB.
NOTE this screen. When you get everything all set up and recalibrated, you can start the machine at any speed and come back here and hit the demo tab, this will cycle the counter ejector according to the speed automatically.
This servo position tab will take you to the picture above. From here you can Hit the Wrench on a hard hat icon. This will now ask if you want to reset these locations with a push of the button to zero or change those locations themselves. Most of the time we are setting it to zero and have our machine in position for this so we just ZERO it out here.
You must measure this location (COUNTER EJECTOR BACKSTOP) first when homing your counter ejector. This backstop position is also very important to the FORK IN AND OUT and its ERRORS. Always check the backstop dimension first and make sure it is correct on the HMI SCREEN. If it is not CALIBRATE IT correctly.
Next is measuring the distance from the pusher plate to the edge of the paper forks. This dimension is your forks in and out. If the backstop is set correctly and this number is entered correctly on the HMI SCREEN then you should not have any issues with FORK IN and OUT ERRORS.
This switch puts the counter ejector section in manual mode allowing you to move it with the other switches located on the left side of this picture. The BLUE button or home button is also the reset button. Hitting that several times when the switch is turned to manual will do a soft reset on the current function.
The bundle press is another location that needs to be exact when homing the counter ejector. Make sure that this number is correct and if not CALIBRATE it. If your forks are sticking up a little higher than the bundle press table, one of those dimensions could be off and it’s usually this one. Correct it on the HMI and it should go back to where you need it to be.
The pictures above and below are the Proximity switches that need to be aligned when homing to zero. Make sure that all of these connections are tight and secure on a regular basis. Note the limit switch located right below as well.
Same: Proximity sensors and limit switches on the operator side for the FORK IN and OUT
Standard Operating Procedure: Daily Clean Up Of Machine
1. Purpose
How to properly Clean the machine at the end of a shift or day. You can specific things you might want to do on specific days as well but this is a basic daily clean up of the machine. This will help prevent breakdown and unnecessary downtimes on the machine.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need to properly clean the machine daily and what should be looked at and maintained to help keep your SRPACK machine in top form.
3. Prerequisites
Tools Needed:
Rags or Paper towels to wipe down shafts and excess oils and grease.
Air Hose
Food Grade Silicone
Soap and water
an empty 5 gallon bucket for every print station
4. Procedure
⦁ First stop the machine from moving.
⦁ Go to the Die Cutter Section and open the Die Cutter Gap to max. You never want to leave your die cutter gap crushing. It will ruin your dies and your mats and your machine.
⦁ Open the machine up manually.
⦁ You should open the Die Cutter Section, the Slotter Section (if your machine has one), any print section that you have been using that day front and back, and the section between the feeder and the first print section.
⦁ One person can begin in the Feed Section of the machine while another can start at the rear of the machine in the Counter Ejector. There is no true order, just things that need to be done.
⦁ FEED SECTION:
⦁ Blow out area: pay special attention in the feed table between the rollers, the ball screw shafts and all of the linear bearings and slides that they roll on.
⦁ Lubricate table areas that are stainless, feed gates and sides, linears ball screws and slides, ball screws and any other area up front that may need FOOD GRADE SILICONE. DO NOT get this on the feed wheels, if you do, you can clean them with a little denatured alcohol.
⦁ Wipe excess silicone with RAGS or Paper towel so that there is not build up on these parts. This needs to be daily to ensure that there is no build up.
⦁ Lubricate the backstop and make sure the angle bolts are tightened and everything is secure
⦁ PRINTER SECTION:
⦁ Blow out area: pay special attention in the feed table between the rollers. Clean out any corrugated board caught in the table.
⦁ Clean Print Die and remove ink so that it does not dry on it overnight.
⦁ Clean any ink off the print cylinder.
⦁ Return your ink, do at least 1 washout on the machine, return back to the ink supply and let SOAP AND WATER run through the ink chamber for 5-10 mins (This is where you need the empty 5 Gallon buckets).
⦁ When this is done, go through the cycle again. Ink return, Washup, and then you can ink return and then STOP.
⦁ Clean any excess ink, grease, or oil in the machine.
⦁ Check ink pans to ensure they are being cleaned by the soap and water clean ups and if not you will need to remove these and clean them or clean them in place. Excessive build up causes low ink alarms and other issues to occur in the machine.
⦁ Turn off Anilox Roll.
⦁ Open Ink Chamber and wipe clean
⦁ Check the wiper blade, check end seals if your model has those
⦁ SLOTTER SECTION: (If your machine has one)
⦁ Blow out area: pay special attention to the ball screw shafts and all of the linear bearings and slides that they roll on.
⦁ Make sure the area is clear of debris and ink. (if there is ink on these shafts then you have other issues in the machine with your printers. Clean all of this off the shafts.
⦁ Lubricate stainless steel shafts, linears ball screws and slides, and ball screws. FOOD GRADE SILICONE. DO NOT get this on the crush wheels or creaser wheels, if you do, you can clean them with a little denatured alcohol.
⦁ Wipe excess silicone with RAGS or Paper towel so that there is not build up on these parts. This needs to be daily to ensure that there is no build up. Both lubricating and wiping down.
⦁ DIE CUTTER SECTION:
⦁ Blow out area: Clear all excess debris and material
⦁ Clean all the area, the die cutter floor and scrap conveyors.
⦁ Wipe the Pull Rolls Shafts, lubricate, and wipe excess.
⦁ RAIL SECTION: (If your machine is a FFG)
⦁ Blow out area: pay special attention between the gang rollers and all of the belts. The area after the die cutter and where all the excess scrap travels on the rails tracks need to be blown out and cleaned as well.
⦁ Make sure that all sensors are secure and in place. Sometimes during jam ups we may not see sensors that have moved out of place throughout the day or days.
⦁ Every other day you can take a rag with the silicone on it and wipe the rails that the boxes slide down.
⦁ Wipe and clean all shafts. Lubricate the stainless steel shafts with FOOD GRADE SILICONE.
⦁ Wipe excess silicone with RAGS or Paper towel so that there is not build up on these parts. This needs to be daily to ensure that there is no build up on these shafts and your rails will slide freely as they should.
⦁ Clean the glue : Shut it down (see SOP for cleaning the glue)
⦁ Check the machine counter and make sure it is in position and clean the lens.
⦁ COUNTER EJECTOR: (if your machine is a FFG)
⦁ Blow out area: Make sure the area is clear of bad boxes, torn paper or dirty sensors.
⦁ Clean excess glue off any rollers.
⦁ Check gearbox oil levels.
⦁ Check Chains for lubrication and to make sure they are tight. Lubricate if necessary. Ask maintenance to tighten chains if necessary.
5. Definitions and Pictures
Front End of SRPACK Machine:
The Feed Section is very important on this machine and must be well maintained. Check the gearbox oil levels regularly. Blow out and lubricate the machine daily. Keep the ball screws clean and your stainless well lubricated.
The Printer Section needs to be cleaned to keep working every day all day. Getting ink throughout the machine is never a good thing and we have to work daily in order to prevent the bigger problems from happening. Daily clean up and maintaining this area will ensure that you can have good set up times and minimal issues with your print sections.
The Slotter Section (if your machine has one) is very important to blow out, wipe down, and lubricant daily. This has 5 head sections with 4 main components on each one. Keeping these clean causes less binding in the shafts and allows for free movement of the slotter heads. Clean all shafts and ball screw shafts and lubricate with FOOD GRADE SILICONE and wipe
The Rail Section (FFG MACHINES)
This section’s shafts and other moving parts are very important to keep clean. Gears, shafts, and slides should be wiped down and lubricated daily. Excess corrugated needs to be removed and all ball screws should be cleaned. Make sure that all gang rollers are tight and in place as well. Machine vibration causes nuts to come free and these may move over time.
Check belts for wear and lacing.
Check belts and drives.
Counter Ejector Section (FFG)
Making sure this section is blown out, chains are tightened and lubricated, and all sensors are clean and clear are the main things for cleaning up daily in the counter ejector.
Clean any excess glue or ink off the counter ejector pull roll. Again, if you are getting these types of build ups then you should look at the glue and the ink situation and see what needs to be adjusted.
Clean all sensors and clear counter ejector bundle press of any boxes.
Double check the box counter position.
Standard Operating Procedure: Paralleling The Anilox Roll
1. Purpose
How to properly calibrate the Front-End Backstop. This procedure will be used in the Feed Section in the front of the machine. This will help you put your backstop to the desired measurement and tell the machine exactly where the backstop is at. This should help going forward making all future set-ups easier.
2. Scope
How to properly parallel the Anilox roller in a print section. This procedure can be used on any print section on the machine. This will help you parallel the Anilox roll and make sure that you are getting pressure evenly across the entire section.
3. Prerequisites
Tools Needed: 7.2 MM Gauge, 24MM Wrench or Crescent Wrench. (Some printers use a .250 print plate or smaller, use this number as a gauge)
Machine must be opened and not currently running. Machine must have power and air in order for the Anilox roller to engage.
4. Procedure
⦁ Open the machine to the desired print section and open it with the side that has access to the Anilox roll. On a bottom printer section unit, the is usually located on the backside of the section.
⦁ Release the two latches on either side of the Anilox Roll guard and open this guard.
⦁ Make sure that the cylinder is clean across the portion that you will be gauging so that your gauge sits flat against the surface.
⦁ Go to the operator side LCD screen and MANUALLY ENGAGE the Anilox Roll. This will push the Anilox Roll up towards the Print Cylinder.
⦁ Take your gauge and push it between the Anilox Roll and the Print Cylinder. Go to the operator side LCD screen and use the Anilox Gap Switch to raise or lower the gap until you bring the Anilox Roll and Print Cylinder flat against the 7.2mm Gauge. Make sure that you check at least 5 locations across the Anilox Roll and the Print Cylinder gap.
⦁ There are 2 screws that control this parallel. You must unscrew the nut on the screw to loosen it and then either move it upward or downward if needed to parallel the gap or to allow for more room to get to ZERO if need be. These are your Parallel Adjustment Screws.
⦁ Once all 5 locations that you have gauged are flat and squeezing between the Anilox Roll and the Print Cylinder firmly Go to the Operator side LCD screen and tap on the Anilox Gap on the touchscreen itself, this will trigger the PASSWORD screen. PASSWORD is 12345.
⦁ The Anilox Gap will show again but it will be highlighted in BLUE this time. Touch it again. This will trigger the screen where you can input your gap now.
⦁ Enter in 0.000 and hit enter. This should change your Anilox Gap to ZERO. It will still be highlighted in Blue.
⦁ Hit F1 on the Touchscreen, this takes you to the main page of the LCD touchscreen and out of the password protected area. You are done.
5. Definitions and Pictures
Anilox Roll- An anilox roll is a hard cylinder, usually constructed of a steel or aluminum core which is coated by an industrial ceramic, typically chromium (III) oxide powder, whose surface is engraved with millions of very fine dimples, known as anilox cells. In the printing process, the anilox roll is coated in a precise layer of ink that is then transferred to the raised portions of the printing plate. The number, size, and geometry of the anilox cells vary and will determine the amount of ink that the anilox roll delivers to the plate
Print Plate Cylinder- the cylinder of a rotary printing press that carries the print plate and impresses it by counterrotation against the inked printing surface on the plate cylinder
Anilox Gap- The gap between the Anilox Roll and the Print Plate Cylinder
See Above Picture – The gauge being used is place between the Anilox Gap
Anilox Engage – When you engage the Anilox you are telling the print station that you want to use that printer to print and you are engaging the Anilox roll to come forward towards the Print Plate Cylinder.
Anilox Roll Parallel Screws- These screws control the parallel of the Anilox Roll. There is 1 located on each side of the anilox roll.
Standard Operating Procedure: Putting Oil In The Gearboxes In The Feeder Section
1. Purpose
How to properly put oil into the gearbox sections of the feeder section. This will show you where both locations are that you need to pay attention to. Fill spot and sight glasses. This will help prevent breakdown and other issues that occur in the feed section.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to put oil into both sections of the gearbox in the feeder section.
3. Prerequisites
Tools Needed: A 10mm Allen Key, and a 5mm Allen Key. The 10mm is for the bolt you need to remove at the top of Box A and the 5mm is for the cover on Box B.
Heavy Duty Gear oil
4. Procedure
⦁ When looking directly at the SRPACK machine, go to the operator side front and remove the front and top panel to reveal the feeder section gearboxes and other portions of the feed section.
⦁ When the machine is new, sometimes the sight glass on Box A will be covered with tape or other material. Remove this so the sight glass can be seen.
⦁ On the Top of Gearbox A, there is a bolt that needs to be removed in order to fill this section. Once you remove this bolt with the 10mm Allen Key, you should be able to begin filling this section with a heavy-duty gear oil.
⦁ Fill until you see the sight glass full. Put the bolt back into the top.
⦁ The second gearbox or Gearbox B is located right next to it. Some have a cover over a small opening that you can just pour the oil into. Use your 5mm Allen Key here. There is a sight glass on the inside of the machine between the feed section and the first print section. When you fill this gearbox up, you will be able to view this sight glass.
⦁ Pour oil directly into the area in front of that gearbox and let it drop into it. Once this side is full as indicated by the sight glass, you can cover it back up if your machine has this.
⦁ It is very important that both of these gearboxes get oil in them. They need to be checked regularly and maintained.
5. Definitions and Pictures
Front End of SRPACK Machine:
The operator side panel is located right below the safety bellows. Be careful when removing this stainless-steel section. Keep all bolts together and do not bend the steel plates.
⦁ This is where the bolt needs to be removed from the top and you put oil into Gearbox A from here.
⦁ This location is open and allows oil to drip into Gearbox B. You can fill right from here.
⦁ This is the sight glass for Gearbox A. On new machines it is usually covered with tape or paper, remove that so you can use it.
This is the Sight glass that is located between the feed section and the first printer section. This gearbox is low and needs more oil. You can also see the release hole below the sight glass. You should change this oil out at least once a year, but it should be checked regularly.
SOP For Cleaning The Ball Shaft
1. Purpose
How to properly clean and care for the ball screw shafts and bushings in your machine. This procedure can be used on any location in your machine that has ball screw shafts in them. This will provide smooth movement in that area, extend your machine life, and decrease downtime for costly repairs.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to clean and maintain the ball screw shafts and bushings or bearings on their machine.
3. Prerequisites
Tools Needed: Wire brush, 6mm or 8mm allen key, small headed flat screwdriver, rags or paper towel, WD-40 LPS1 or whatever lubricating spray you are using for your machine.
Put your slotter heads IN-SLOT before opening the machine so that your heads will move side to side when you have the machine open, follow all safety procedures for going into the machine.
4. Procedure
⦁ Before opening your machine, you MUST put your slotter heads IN-SLOT. This is required in order to allow the heads to move side to side when the machine is opened. This will prevent damage to the upper and lower heads if they become misaligned.
⦁ Open the machine in the desired section (slotter mostly) and enter it according to safety procedures (Remove the travel lock key and keep this on your person)
⦁ Take an air hose and clean away any loose dust and dirt that you can in the beginning. Get whatever will just come out.
⦁ Now start with Head #1 and begin to move it in the operator direction. Notice what shafts are moving when you are doing this. In the Slotter section there are usually 4 shafts that this head uses. 2 you can see from one side and 2 more if you enter the section from the other side. Choose one of these shafts and as you are moving the head in the operator direction, place the METAL WIRE BRUSH against the shaft and hold firmly getting in between the slots and getting all of the build up out of that area. Use your RAGS and CLEANERS to get rid of excess dust and scrap.
⦁ You can move the head back to the drive side and do this same process in reverse as well. It is okay to use lubricant at this time to help with movement. Go back and forth until you get everything out of the slots of the ball screw. If there is still build up, take your SMALL HEADED FLAT SCREWDRIVER and place it in the slot and move the head in either direction. You should be able to apply enough pressure as to not ruin the ball screw appearance and still be able to get everything out of the slots.
⦁ Do this for each of the 4 shafts.
⦁ Each shaft has a Bronze/Brass Bushing or a linear type ball screw bearing. IF you are having difficulties with these then see the “SOP procedure for CLEARING or REPLACING your SLOTTING SECTION BALL SCREW BUSHINGS”. For cleaning, you should be able to use an air hose and blow, remove the dust and dirt and lubricate with WD40, LPS1, or whatever your company’s lubricate of choice is. You may be able to use your 6mm or 8mm ALLEN KEY (depending on your machine’s screw sizes) to loosen the dust covers on the bushings in order to get debris cleaned out of them possibly.
⦁ After cleaning the shafts and the bushings and/or bearings, lubricate the shafts, make sure that there is no hang up or hesitation in movement when operating. Dry all excess oils or lubricants.
⦁ Repeat these steps for the other heads and shafts in the section. Moving the slot heads back and forth on the shafts and making sure you have lubricated and cleaned any spots still catching.
5. Definitions and Pictures
Ball Screw Shaft – A cylindrical shaft that has a helical raceway for the bushing or bearings to ride on or in.
Ball Screw Bushing – The bushing that rides in on the ball screw, it is usually brass or bronze.
Ball Screw Bearing – The linear bearing that has balls that ride inside the helical raceway of the shaft.
Proper movement of your ball screws whether it be in your slotting area or other areas of your machine rely on good housekeeping and parts being able to move where they need to go. Excessive dust and dirt can cause binding in your shafts and prevent poor movement or cause major damage in the affected area.
The wire brush will get all of the build up off the shaft that tends to get between the shaft and the bushing that causes bindingThe Ball screw bushings should be cleaned out. Remove the plastic dust cover and loosen bolts if need be
The Ball Screw Bushing can be loosened and the plastic dust cover removed in order to get the dust and dirt released from that area. Blow this out and lubricate with WD40 or LPS1. This will allow your heads to move freely in the slotter section causing less issues with set ups.
Calibrating Front Feed Guides
1. Purpose
How to properly calibrate the Front Drive Side and Operator Side Guides. This procedure will be used in the Feed Section in the front of the machine. This will help you put your side guides to the desired measurement and tell the machine exactly where that guide is at. This should help going forward making all future set-ups easier.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to calibrate the front guides in the feed section of the machine.
3. Prerequisites
Tools Needed: Measuring tape. You do need the admin password to get into the front LCD and calibrate the machine.
Machine must have power and be operational to perform.
Password: 12345
4. Procedure
⦁ Stop the Machine and make sure there is nothing in the hopper of the front feed section.
⦁ On the Front Feed Section Panel, use the Drive Side Guide switch to move the drive side guide to the desired position. Make sure this position is correct with either the tape measure provided on the machine or your personal tape measure. Measuring from the center of the machine, out to the drive side.
⦁ On the LCD Panel on the Front Feed Section Panel got to L2.
⦁ Now click on the Orange written number for the drive side guide. This will be the numbers above the yellow numbers. (the “set” numbers)
⦁ When you click on those numbers there will be a password screen pop up.
⦁ Enter in Password: 12345
⦁ This will take you back to the L2 screen however the Drive side numbers will be highlighted in blue. Click on this again.
⦁ Another numeric screen will pop up and this is where you put the actual dimension that you have the drive side guide at.
⦁ Hit enter and this will exit you back to the L2 screen once again with the drive side guide number being changed.
⦁ Repeat these same steps for the Operator Side Guide as well.
5. Definitions and Pictures
Drive Side and Operator Side Guides –
These guides set up automatically to the dimensions of your corrugated board. Making sure this section is correctly calibrated helps for faster and more accurate set ups and operation of the machine. Along with Housekeeping and keeping this area lubricated, Calibration is also very important.
Side Guide Switches and LCD:
On the Front Feed Section Panel there are 2 switches labeled Side Guide OP and DS. These are for the Drive side and the operator side controls of the front end section. This moves the guides in and out from the center of the machine.
From this picture you can also see the orange and yellow numbers. The orange being the “ACTUAL” measurement the part is at and the yellow being the number the machine was to “SET UP” at.
PASSWORD SCREEN:
When you press onto the orange number for the Drive Side Guide on L2 of the LCD panel, this is the password screen that will come up. Enter 12345.
Hit Enter and it will take you back to the L2 screen with the same drive side operator number being highlighted in blue.
Cleaning Out The Counter Ejector When A Jam Occurs
1. Purpose
How to properly clean out the counter ejector when a jam up occurs. This procedure will cover the Counter Ejector portion of the machine at the exit and how to clear it when boxes jam inside of it. This will help you remove waste and keep the integrity of all the working pieces of the counter ejector.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to clean out the counter ejector when a jam up occurs.
3. Prerequisites
Tools Needed: No tools needed.
4. Procedure
⦁ First stop the machine completely.
⦁ Change the switch on the Counter ejector from Automatic to Manual.
⦁ Hit F3 on the HDI screen taking you where you can now move the internal parts of the counter ejector.
⦁ Most likely you will need to lower the elevator, maybe move the forks out or up and any other things you can move to make removing the jammed boxes easier to remove from the machine.
⦁ Open the Counter Ejector Window on the operator side to go into the machine to remove the boxes. (This window has a safety shut off and should not start when opened. Since the employee will be between the window and the sensor it is up to the company to determine additional safety measures)
⦁ Once all of the boxes are removed in this area, you can back out and close the window making sure the sensor clicks into place when shutting it.
⦁ Now hit the switch on the Counter Ejector operator side that turns it from Auto to Manual and turn it back to Automatic. Press the blue or green button to cycle the counter ejector as you normally would to start the machine. This should cycle the counter ejector in whatever position you have it currently in and take it back to the home position and ready to start a new bundle.
5. Definitions and Pictures
Counter Ejector :
The counter ejector provides support for the corrugated material as it stacks folded boxes in it. Making sure this section is correctly calibrated helps for faster and more accurate set ups and operation of the machine. When Jam up occurs this could be moved out of position, causing additional errors to occur.
To clear these jam ups, it must be done Manually so that all of these working pieces stay in the positions that they are supposed to be in. If you have a jam up and just cycle the boxes out of the machine, you are moving several components out of their positions and causing damage to the counter ejector area. This will cause multiple error codes and motor overloads.
L3 on the Counter Ejector screen is where you can move the internal parts of the counter ejector. The Forks in and out / up and down, elevator up and down, actuators in and out, and box hold down up and down.
Use these buttons to move these parts when you have a jam up. The machine must be cleared out before trying to cycle the counter ejector. You should never cycle the counter ejector to clear the jam up.
L3 on the Counter Ejector screen is where you can move the internal parts of the counter ejector. The Forks in and out / up and down, elevator up and down, actuators in and out, and box hold down up and down.
Use these buttons to move these parts when you have a jam up. The machine must be cleared out before trying to cycle the counter ejector. You should never cycle the counter ejector to clear the jam up.
PASSWORD SCREEN:
When you press onto the BLUE number for the Backstop (ENDSTOP) on L2 of the LCD panel, this is the password screen that will come up. Enter 12345.
Hit Enter and it will take you back to the L2 screen with the same drive side operator number being highlighted in blue
Starting Your Anilox Roll And Ink Supply
1. Purpose
How to properly start your Anilox Roll and start your Ink Supply. This procedure will help you start your Anilox Roll and get it moving which allows the ink supply system to be able to then function. You MUST start the Anilox Roll in motion for the ink supply to work.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to start your anilox roll on any print section and then use the ink supply system to provide ink to the chambers, rolls, wipers, and dies.
3. Prerequisites
Tools Needed: You do not need any tools to perform these tasks. Please use safety guidelines when performing all tasks around your machine to prevent injury.
4. Procedure
⦁ Go to the Print Section that you would like to start the Anilox on and run ink into.
⦁ There is a green switch on the left side labeled ANILOX RUN. This is the switch we will be hitting. BEFORE HITTING THIS SWITCH make sure that you have something that you are going to be running through the printer section itself. Ink, Soap Water, Machine wash-up, etc.
⦁ Flip this from the ZERO or O which indicated OFF to the single line position which indicates ON. The Switch should light up green and the Anilox inside the machine will start spinning.
⦁ You do not want this to ever run dry. Running this dry would cause the plastic from the wiper blades to be melted into the anilox roll and cause damage. This is why you want to start the next step immediately.
⦁ Look at the INK SYSTEM section of the Printer Section Panel. There is a switch and an okay button there.
⦁ To start ink running through the system, place a bucket of ink under the unit and put the hoses into the bucket and if it has a vertical return system, make sure the bucket is under the hose coming from the top. Flip the switch inside the INK SYSTEM section to INK SUPPLY. This will start pumping ink into the ink chamber and across the anilox roll.
⦁ As the ink returns there are two different ways it may be returning to the bucket. Either by gravity or by pump. You can change the number of seconds the pumps remain on to pump more ink in and you can also control some units that have return pumps and how many seconds they stay on to return more ink or to return it faster.
⦁ If you were to Switch to INK RETURN and hit the OKAY button it will return all of the ink in the printer section by pumping the ink back into the ink bucket.
⦁ Once all the ink is returned to the ink bucket, remove that bucket and place something around the bottom section or into another bucket with holes beneath it to release waste water from the next step which is the WASH-UP. This is to try to maintain a clean work area.
⦁ Flip the switch to Wash-Up and press okay. This will start the Wash-up process which is timed on the machine. It will pump water into the machine for a number of seconds and then do a small ink supply when you place some soap and water under the hoses again.
⦁ flip the switch again to INK RETURN and let the wash down water all return out of the machine.
⦁ Now flip the ship to Ink Supply and place a bucket of water and soap in position with the supply hose placed in the bucket. Hit okay on the ink supply and run until you see soapy water coming out of the return hose and place this inside the bucket. Let this run for a few minutes to allow the chamber to get the foam and soap to the upper levels of the ink chamber and return bins. The more excess ink you can get cleaned out the better.
⦁ Then repeat steps 8-12 until your chamber is clean and you get clean water coming from the ink chambers and through the hoses.
⦁ Your chamber is now clean and you can flip the switch to INK SUPPLY once again and start your new color ink if ready. IF your water is still ink colored then repeat the above steps on Wash-ups and return the waste water ink. and then start your new color ink.
5. Definitions and Pictures
Every Printer Section on the SRPACK is very similar when it comes to starting the Anilox Roll and getting the Ink Supply System to start working. In order for the Ink Supply System to work, the Anilox Roll must be in the run position and working. Usually the green switch is lit up when you turn the anilox roll on.
The Ink System Switch allows you to switch from INK SUPPLY (Runs ink), Return (Returns the ink), Wash-up (when water is turned on the machine it allows water to run through the chamber for the allotted time washing the ink in the chamber out of the system.
The L2 screen on the LCD of the Print Section shows you the amount of seconds that the pumps remain on and off, how long the ink return runs for, and how long the Wash-up runs for (also how long water goes into the chamber for)
Calibrating The Slotter Section
1. Purpose
How to properly calibrate the slotter section heads. This procedure will help you calibrate the slotter section heads so that your panel lengths are accurate. Making sure that all the heads are in the starting position when setting up an order is key and thus should help all future set ups to be more accurate.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to calibrate slotter section heads.
3. Prerequisites
Tools Needed: Tape measure or enter in an order that you know the dimensions to be correct. You do need the admin password to get into the slotter section LCD and calibrate the machine.
Machine must have power and be operational to perform.
Password: 12345
4. Procedure
⦁ Stop the Machine and make sure there is nothing in the machine. if you are using a board size, make sure this order has been put into the system and you’ve hit setup and the slot heads are now where they think they need to be.
⦁ Open the machine between the slotter section and the die cutter section. You can look inside and see the tape measure running along top of the section. The arrows above each head shows where the head actually thinks it is.
⦁ On the slotter section LCD Panel go to L2. This will display your slot heads’ locations in a column on the left hand side of the LCD.
⦁ Now click on the Orange written number for the slot head that you want to change.
⦁ When you click on those numbers there will be a password screen pop up.
⦁ Enter in Password: 12345
⦁ This will take you back to the L2 screen however the slot head number will be highlighted in blue. Click on this again.
⦁ Another numeric screen will pop up and this is where you put the actual dimension that you have the slot head at. Use your Tape measure of the length of the panel and input this as the number you want the slot head to be at.
⦁ Hit enter and this will exit you back to the L2 screen once again with the slot head location number being changed.
5. Definitions and Pictures
Slotter Section and Slot Heads:
The Slotter Section of your machine cuts out the slots in order to form panels and allow the box to be creased and possibly folded to make a box. Housekeeping in this section is crucial and should be done daily.
Slotter Section LCD L2 Screen:
This screen shows you the location of all of your slot heads as well as the gaps and register of the lead and trail knives. You will click on the slot head numbers to the left hand column to change that dimension to the correctly calibrated number.
Slotter Section LCD Screen L3:
This screen shows where your slotter heads should be set up at (yellow numbers) and where the actual slotter head is. (Blue numbers.
PASSWORD SCREEN:
When you press onto the orange number for the slotter head location on L2 of the LCD panel, this is the password screen that will come up. Enter 12345.
Hit Enter and it will take you back to the L2 screen with the same drive side operator number being highlighted in blue.
Safety
1. Purpose
How to properly maintain safety and focus on your SRPACK Machine at all times. These procedures will be used throughout the machine and at all times. This will help you and your coworkers operate in a safe workspace. The goal is always for zero accidents.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper safety functions and operations of an SRPACK Machine.
3. Prerequisites
Tools Needed: You do not need any tools to do this. You do need to walk around the entire machine and understand your lock outs and tag outs for your specific machine. This includes water and air lock outs as well the power lock outs. or ZES locations (Zero Energy State)
4. Procedure
⦁ Start at the rear Drive side location and start to identify the electrical power lock outs and emergency stops in the area.
⦁ Locate the Water and Air main lock outs. When working on your machine at least the AIR should be entirely locked out to ZES state when possible.
⦁ As you head towards the front of the machine make sure the bellows on each side of the feed front side guides are attached and across the front of the machine. This restricts the access personnel have to the front feed roll so items or body parts do not get caught in between the pinch points.
⦁ When Feeding, the machine does NOT have a last sheet indicator and will continue to feed. NEVER have your hands on top of the feed section sheets.
⦁ There are lots of emergency stops throughout the machine. Start making yourself aware of all of these locations. Note there are pull cords as emergency stops as well located in between each section of the machine.
⦁ There are a lot of pinch points between rollers throughout the machine. Keep your fingers clear of these areas and pay extra attention when in the machine with your IMS key and performing tasks. This Key allows you to be in the machine and changing a print or performing other tasks and will still allow the machine to move. A Travel Lock Key is an IMS type of key that you must take out when entering inside the machine for ANY purpose.
⦁ Inside the printer section, you will see the emergency pull cord and some other safety items you should be aware of. When lowering and raising the ink chamber, your unit may have a level with a red knob attached that allows you to set the distance for your ink chamber to open. You must be careful with your hands when in this section.
⦁ Also in the ink section when putting on a print plate, this should always be done by one person that is controlling the rotating print cylinder.
⦁ As you go through the machine you may have a Slotter Section. Keep your hands and fingers away from moving parts in this section when open. When touching the knives you must have gloves and your arms must be covered to prevent injuries.
⦁ If your SRPACK Machine has a dryer section, know that it is hot and everything you touch in there will be hot.
⦁ The die cutter section is mostly pinch points to be aware of but still has the emergency stops and pull cords like the other units.
⦁ There are 2 types of lockout procedures used on RDCs (Rotary Die Cutters) and FFGs (Flexo Folder Gluers) One is used to place the machine in “Set-up Mode” (Intermediate Mechanical State, IMS), and the other procedure is used to placed the machine in ZES (Zero Energy State)
⦁ “Set-up Mode” is a state (IMS) where certain functions of the machine are disabled, but it allows the operator to set up the equipment or make adjustments (machine run, open/close, and scrap conveyor inhibited, etc)
⦁ “ZES” is a state where all the power and air sources for the machine are de-energized. This allows for operators, maintenance personnel or service personnel to repair or service the equipment.
5. Definitions and Pictures
The front end section of the machine should have some type of bellow across the front end to prevent employees access to the feed roll. There are also emergency stops located throughout the outside and insides of the machines. The ZES key is located on the front panel of every SRPACK machine. Turning this key will turn the power off to the entire FRONT section of the machine (from die cutter to the feed section)
Inside between each section of the machine there are emergency pull cords. There are a lot of pinch points throughout the machine and employees need to make themselves aware of these locations and keep their hands and fingers away.
Locating Pinch Points, keeping your hands free from moving gears, and always paying attention to where you are stepping always helps prevent on the job accidents. Pay attention and always focus when operating your machine.
If your SRPACK machine has a dryer unit, everything inside there will be hot to the touch. Protective gear must be worn when dealing with anything in this area to prevent injury.
Set Up
1. Purpose
How to properly set up your SRPACK machine. These procedures will be used throughout the machine and at all times. This will help you and your coworkers operate in a safe workspace and set up the machine accordingly. The goal is to set the machine up with as little downtime as possible.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to set up an SRPACK machine properly.
3. Prerequisites
Tools Needed: A front guide stopper measuring tool (approx. .060-.100), Tape or tie downs for print dies in the printer section, die cutter section bolts, print die, die cutter die, air or power tool for die cutter section bolts
4. Procedure
⦁ You must have the order specs that you would like to put into the machine. Put these dimensions into the machine. (See SOP for Entering and Order on the CNC) External
⦁ Locate the material that you need to complete the order as indicated from the order sheet. External
⦁ Get die cutter dies/and printer plate dies if this applies, the number of the dies should be indicated on the order sheet, if you do not have a die cut die, set up the pull rolls in this position. External
⦁ Get ink for the job, again this should be indicated on the order sheet what inks are to be used with this order. External
⦁ Open the machine at the needed locations. (See SOP for Opening Your Machine) If there is a die cut die then you may have to open it up at the die cutter section to put on the new die or pull rolls. If it is more than a 1 color order then you may have to open the machine in different sections so that the new dies can be placed in the machine. Internal
⦁ Put on the Print Die(s), and/or the die cutter die(s) in the sections they pertain to. Follow all safety rules when putting on a die cutter die, entering the machine, and when moving parts on the machine. Internal
⦁ Start the new ink in all printer sections that you will be using for this job. (See SOP for Starting your Anilox and Print Ink Supply). ENGAGE the PRINTER SECTION that you will be using. External/Internal
⦁ Close the machine entirely and lock it. Internal
⦁ Go to the CNC of the machine. Hit MAIN on the bottom of the screen which takes you to the page that shows you the current orders listed to run, current run speed, and the dimensions of the current order you are running. In the middle of the screen there will be a start set up button that will be lit in green. (IF it is gray, then the machine is not in a position to be set up currently, find the issues and the set up will light in green when ready. Hit that button.
⦁ This will start the machine in AUTOMATIC SETUP and will change the LCD screen on the CNC to MONITOR which shows you all the movement of the machine. The numbers indicated on the screen show where the machine wants to set up at and where the parts of the machine are actually at currently as it sets up. IF there is a RED X mark on any of the numbers then this dimension has not been set up correctly and must be checked and perhaps manually put into position after whatever issue is discovered. Set up is complete when all areas that have double boxes have check marks next to them indicating they are in the said location.
⦁ Once all of the numbers are check marked in green, the machine is in all set up locations and ready for a test box. (See SOP for Starting the Machine and Running a Box).
⦁ FIRST start at the feed section and make sure your gaps and sections are set up correctly according to Flute size. Walk from the front of the machine to the rear and check all of these locations.
⦁ Go to the CNC, Counter ejector, or front of the machine and Start your machine and run a single test box!
5. Definitions and Pictures
Get your ORDER that will be running on the machine. This will usually have the print layout for the current corrugated box. It should also contain information such as the type of board to be used, the print die numbers, colors, the die cutter board number, and any special notes for the customer.
When opening the machine, try to open it in all the sections that you will be using. Allowing access to these sections so that employees can get in, get there job done, and get out with as little downtime as possible is the goal. Have your tape or whatever you will be using for your print dies ready when you enter the machine safely with your IMS key. Getting External items in your set up done anytime the machine is currently running another job is a plus and will reduce downtime
Always be Safe when working inside the Machines. Take your IMS key before entering the machine and remember there are pull cords and safety e-stop buttons throughout the machine to keep you safe. Keep your hands and fingers free from all pinch points and pay attention when putting on dies. This is always a 1 person operation and only that person should control the moving parts when in that section of the machine.
After hitting SET UP on the CNC machine it will take you to the MONITOR. This screen shows you in gray where the machine would like to set up and then in white where the actual machine part that is setting up is. IF there is a RED X on the screen then this item did not set up. You can let the machine continue to set up the other portions of the machine and then stop it when all other locations have green check marks. Find out what the issue is and either hit set up again and let it set up or just move the machine part to the set up location.
Always check your gaps throughout the machine before running your first box. Start at the beginning of the machine and make sure your feed section is set up to the flute standards. Making sure that the gaps that were not set up in the machine, you have changed according to the size prints that you have in the machine. SRPACK machines run .280 inch prints. If you have a folding section then check these gaps as well as the box comes out of the die cutter section and into the rails. Follow this up to the stacker or the die cutter section and make sure your gaps are set according to the box exit.
The Exit Roll Gap along with the Counter Ejector section if you have a FFG machine should be double checked on set up as well. You have several areas here that get set up such as the exit roll gap, the back stopper length, and the bundle press height. The side guides inside the counter ejector allow for the bundles to be stacked neatly together from side to side. Adjust these after a box has entered the counter ejector section. When you reach your desired stack height you can also readjust your bundle press if needed as the stacked boxes exit your machine.
If your SRPACK is a RDC then you will have a stacker unit and much like the counter ejector, you will have to set up a couple of things on the stacker to make sure that the corrugated board is traveling through the section and stacking according to the orders needs. Make as many adjustments as you can with the arm, gaps, and belt speeds as you can before running a box through the machine. Once you run a box through the machine you can make the back end adjustments to catch the board.
Entering orders and preparing all external parts of a set up will help improve your setup downtime dramatically. By taking the opportunities to do some of the tasks while the machine is still running the previous order is a plus on so many levels. The employees know what their days consist of and get to be proactive in their daily tasks instead of being reactive.
Opening Your SRPACK Machine
1. Purpose
How to properly Open an SRPACK Machine. This procedure will help open the machine in sections or every section automatically with the push of a couple of buttons.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to open an SRPACK Machine in sections or fully.
3. Prerequisites
Tools Needed: You do not need any tools to perform these tasks. You do need the admin password to get into the Front end section LCD if you need to change the section opening timing. You will need the password to perform this task.
Machine must have power and be operational to perform.
Password: 13572468
4. Procedure
⦁ Stop the Machine and make sure there is nothing in the machine. Go to the operator side of the machine and locate the machine lock switch in green. ALL UNITS with a picture of the machine underneath it. It is usually lit in green when locked
⦁ Unlock the machine. There is another switch (Hand/Auto) in this panel that works directly with open and closing the machine. If you have this switch in AUTOMATIC then you can not manually open and close sections of the machine. It will only Automatically open when you flip the switch to auto and press the okay button.
⦁ With this switch in manual you can go to each section of the machine and click the machine CLOSE/OPEN switch to open while holding in the light blue unlock button at the same time. There will be a slight pause and then an alarm will sound, continuing to hold both the switch and the button in position. The section will start to open.
⦁ You can release the light blue button after the desired section you are opening is several inches away from the other section and it will continue to open as long as you are pushing the open switch.
⦁ Continue to do this process for any other sections you desire to open, you must start at the die cutter section and move forward to release sections since this is a motor driven feature driven from the feed.
⦁ If you want to open the entire machine every section you can flip the HAND/AUTO switch to Auto and hit the OKAY button. This will start the machine opening up every section to a predetermined number of seconds allowing the customer space between each unit to perform whatever tasks they need to do.
⦁ You can change this number by clicking the upper right corner of the Front LCD screen when in L1. It is located between the machine speed and the L1 and L2 on the touch screen. You press right between the speed and these two icons and you will get a password pop up screen.
⦁ Enter in Password: 13572468
⦁ This will take you the tamper speed on and off and the open time for each section. Only change these numbers if you know it will not damage the machine and run it off the track. Change this number and hit back.
5. Definitions and Pictures
The Operator Side Panel on the feed section is some of the most important buttons and switches. Each unit will have a CLOSE/OPEN Switch along with a light blue machine unlock button.
This section will also have the main machine UNLOCK ALL UNITS switch in green (lit up when locked) and it will also have the Manual-Automatic Open and Start buttons on it as well. You will need to unlock the machine to move it and put the switch on manual to open the machine by section.
You are able to open the machine all at once in Automatic mode. The open time indicated on the screen to the left shows how many seconds each section will open up when put in automatic mode. Only change this number if you know the machine will not run off the tracks and cause damage.
PASSWORD SCREEN:
When you press onto location as indicated in the procedures, this is the password screen that will come up. Enter 13572468.
Hit Enter and it will take you to the above screen where you can change the open timing.
Common Alarms And Faults
1. Purpose
How to properly view and clear some of the more common faults and alarms on your machine. This procedure will help you view the Status of the machine in 2 different locations (Front Feed Section LCD Screen and the separate CNC Machine.) to recognize common alarms and fix common faults.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to view and fix common alarms and faults.
3. Prerequisites
Tools Needed: You do not need any tools to perform these tasks. Please use safety guidelines when performing all tasks around your machine to prevent injury.
4. Procedure
⦁ There are 2 places to view the ALARMS and FAULTS on your machine.
⦁ The FRONT END FEED LCD SCREEN is one place that will display all current faults on the L1 screen.
⦁ The CNC Machine under STATUS. Click on Status and this screen will give you the current Alarms or Faults on the machine.
⦁ You can also view your ALARM HISTORY on the CNC under STATUS top right corner is ALARM HISTORY and click there.
⦁ When viewing the faults note that the section that the alarm or fault is for, is usually called out letting you know where to check for that alarm or fault. i.e. FEEDER – Frame Mode Move – This fault indicates that there is a fault in the FEEDER section. This particular one indicates that the key is either not turned in the working position or not there all together. IF these two things are not the issue, that is when maintenance needs to take the next steps and backtrack for loose wires and connections.
⦁ When viewing the alarms and faults, notice that they will try to give you as much information as possible. i.e. PRINTER 2 – Emergency Stop Enabled. This means that someone has pulled the emergency stop cord in that section and it must be released and the machine reset to start again.
⦁ Restarting after an emergency stop pull cord. Once that cord has been pulled, the small box at the end will show a yellow marking on the inside indicating that it has been pulled. You must push in the light blue plunger next to this and it will change the yellow marking to green again, meaning that it is now reset and ready to go. You now MUST GO BACK TO THE FRONT OF THE MACHINE and hit the orange OKAY button that starts the entire machine’s communications.
⦁ When a fault is highlighted in light pink that usually means the machine is inoperable. When highlighted in light blue, you can usually still move the machine parts and ink pumps and other things that are working on the machine still.
⦁ Another common Fault is when the machine will not feed after starting, so the machine is running but it will not feed. There could be several reasons for this happening so you go to your CNC portion of your machine and view the STATUS SCREEN on your machine to see what faults you may have. A lot of times it’s something simple like your front feed section air suction is not turned on. Simply turning this on and clearing this fault will allow you to now push feed and your machine to be working again.
⦁ Another common alarm or fault comes with FFGs. The counter ejector will not allow you to start feeding until it has been reset and homed. There is a blue or green button that will blink when the counter ejector is not in position to run. You will be able to start the machine but it will not feed. You must go to the counter ejector and clear this fault by homing it.
⦁ When the counter ejector is blinking blue or green it needs to be reset. There is a switch on the back panel of the counter ejector that goes from HAND to the box with the arrows around it which indicates AUTOMATIC. Flip this switch to hand and then back to automatic and hit the blue or green button. This should start your counter ejector moving and clearing out whatever is inside of it and finding its home to begin catching boxes again.
⦁ There are many faults and alarms on the machine and these were just a couple of the common ones. Remember to view all faults at the feed section or the STATUS screen on the CNC to see where and what might be going on with your machine. They will try to point you in the right direction.
5. Definitions and Pictures
The SRPACK alarms and faults can be seen on the front LCD screen as well as the CNC for the machine. The machine is full of safety features with e-stops, pull cords, door and gate sensors, and other items to keep the employees safe. Please do not change or remove these items.
As you can see from the Printer Section LCD Panel there is an E-stop and also a LOW INK Alarm. All print units are the same so this will be on every unit that has a printer. The E-stop would stop the entire machine running and shut down the power. You must release the E-stop and go to the front of the machine and hit the orange OKAY button to start the machine’s communications again.
In between the sections of your machine there are cord emergency stops. If pulled, you must push in the light blue button so that the unit shows its green signal meaning it is ready to use again. Once you have pushed that button, you must go to the front of the machine and push the orange OKAY button that starts the communications on the machine
You can view all of your Alarms and Faults from the CNC on your machine. Click on the STATUS button on the bottom section of the LCD when powered on and this will show you all current alarms and faults.
This is the view from the front end feeder lcd screen. As you see there is a list of different errors on the machine with different highlighted colors
This is the view from the CNC machine. This list has a list of alarms and faults that are currently on this machine.
Gaps-Speeds You Need To Adjust EVERY Order
1. Purpose
How to properly check which gaps/ speeds need to be checked and/or adjusted every time you set up a new order on your machine. This procedure will help you check the right gaps on every order that do not change automatically but might be necessary to change due to print plate thickness, setting your trail and lead knives gap, die board thickness, (1025 model) rail gap, and folding belt speeds.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to set your Anilox gap, your Leading and Trail knife gap, the die board gap, (1025 model) your rail gap, and your folding belt speeds.
3. Prerequisites
Tools Needed: You do not need any tools to perform these tasks. Please use safety guidelines when performing all tasks around your machine to prevent injury.
4. Procedure
⦁ Everytime you set up a new order on your machine, there are several gaps that DO NOT SET UP Automatically and must be checked in order to make sure we are not damaging the print plates,slot knives, die boards, or the machine.
⦁ Anilox Gap
⦁ Lead and Trail Knives in the Slotter Section
⦁ The Die Cutter Impression Gap
⦁ (1025 Model) Single or Double Wall Switch
⦁ Counter ejector area – Folding Belt Speeds
⦁ After your set up is complete and your monitor screen has all green check marks next to the appropriate boxes you are ready to go through your checklist
⦁ Anilox Gap – This gap is .280 and a Print Plate at .280 should be .0000 on your LCD screen. If your print is worn, you would go down from there. If thicker, then higher.
⦁ Lead and Trail Knives in the Slotter Section – These raise up every order to allow the knives to go into slot and move side to side. They must be set every order. You should know what this number is as it varies by machine. If you do not then view SOP on setting up your lead and trail knives. These numbers need to be set every order.
⦁ The Die Cutter Impression Gap- This is the impression gap in the die cutter section and it DOES NOT CHANGE AUTOMATICALLY. When going from single wall to double wall you need to know what your settings need to be according to your pull roll that you have on the die cylinder. Adjust to the flute of the corrugated board.
⦁ (1025 Model) Single or Double Wall Switch – This switch is located near the glue section on the machine. You will need to manually move this switch from single to double wall corrugated when needed.
⦁ Folding Belts Speeds in the Rails- This is located in the counter ejector LCD screen. This allows you to speed up and slow down the folding belts on the inside of your rails. If you change these speeds, they DO NOT CHANGE BACK TO 100 and 100. You need to start each order at 100 and 100 on the folding belt speed.
5. Definitions and Pictures
Anilox Gap -The Gap between your Anilox and the print cylinder. This gap is .280
Lead and Trail Knife Gaps – These gaps need to set on every order. As your knives wear, this gap will change
Die Cutter Impression Gap – This gap is determined by the pull roll that you have on the die cylinder and the flute of the corrugated board.
(1025 Model) Single and Double Wall Switch – Use this switch when the machine is not running and it will change your gang rollers in the rails from single to double wall or vise versa
Folding Belts Speeds – You can change the speed of your folding belts in the rails to help provide a better quality box
Calibrating The Gang ROllers In The Rails
1. Purpose
How to properly Calibrate the Gang Rollers in the rails of your 1025 SRPACK machine. This will provide the correct gap for your corrugated to travel through the machine smoothly.
2. Scope
This is to be used by Thacker Machinery/SRPACK employees and/or any personnel that need the proper way to calibrate your gang rollers in your rails on your machine. If your corrugated board is moving in the rail section then this SOP will help with that..
3. Prerequisites
Tools Needed: You need 2 10MM wrenches. Please use safety guidelines when performing all tasks around your machine to prevent injury.
4. Procedure
⦁ Open your rails wide enough to be able to work between them.
⦁ Hit the SINGLE WALL switch on the Gluer Section and make sure it is on SINGLE WALL.
⦁ When adjusting the rollers we need to start at the rollers that first come in by the die cutter. These 4 rollers do not change and have spring and stop bolts that set the gaps. This gap should be tight enough to grab single wall and double wall board. Make sure these rollers are straight across and grabbing the corrugated evenly as it enters into the rails. Use a piece of C-Flute Corrugated for reference.
⦁ With a C-flute piece of corrugated, now start to calibrate the other rollers. Each roller has a stop bolt, crew and nut set up that sets the height of the roller. Slide the piece of corrugated between the belts and under the roller. The rollers should be touching on the top belt lightly. Go through all of the rollers both drive side and operator side and adjust each roller.
5. Definitions and Pictures
These front rollers are very important as they first grab your board from the die cutter section, into the rails. They are adjusted with a stop bolt, screw and nut set up that you adjust according to your board. Make sure that these are grabbing your board as it glides it smoothly through your belts.
Adjusting the Stop Bolt, screw and nut, and spring set up helps set the height of the rollers. If they are not even, check the bushings and the washers to adjust if necessary as well.
Use a piece of C-Flute Corrugated board to adjust every roller in the rails, both drive side and operator side.
Each Roller has a Stop Bolt and a Nut that tightens to set the rollers height. Adjusting this screw in and out with the Stop Bolt, adjusts your rollers height.
Set your switch on the Gluer Section to Single wall Corrugated when calibrating and set all rollers first to single wall