Related Manuals for Sharp MAX-PRO 1182
Summary of Contents for Sharp MAX-PRO 1182
- Page 1 MAX-PRO Operator Manual Models 1182 Parts: +1 (262) 246-8815 ext. 1571 sharpparts@pregis.com Service: +1 (262) 246-8815 ext. 1572 sharpservice@pregis.com Original Printed English Copyright 2021 Rev. 2...
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Page 3: Table Of Contents
Front View Cleaning Seal Bar 3-13 Top View Cleaning Unwind Rollers 3-14 Side View © Sharp EZ-Bags SECTION 4 - FAULTS & ALERTS HMI Fault Management SECTION 2 - CONTROLS HMI Alert Management Security Home Screen Printer Fault Management Printer Troubleshooting... -
Page 4: Prefix
Print Resolution 203, 300 dpi Print Width (max.) 4.09” (104 mm) Your Sharp MAX-PRO is the result of extensive research and field testing with the following features: • Advanced diagnostics monitor individual machine components, notifying technicians of any potential prob- lems and allowing replacement parts to be ordered before a failure occurs. -
Page 5: General Information
GENERAL INFORMATION ABOUT THIS MANUAL This manual has been prepared for your use in operating model 1174-02 of the Sharp MAX-PRO Continuous Bagging System. Images and instructions may differ slightly for older models, but basic function is the same. Included in the manual are helpful facts on operating and basic troubleshooting information. -
Page 6: Safety Rules & Procedures
Any exposed electrical components should never come into contact with the ground-connector and any other electrically conductive objects such as tools. It is extremely important to follow all of the safety guidelines and warning detailed inside the Sharp Op- erator Manual before removing any guards or servicing the machine. -
Page 7: Equipment Safety Features
EQUIPMENT SAFETY FEATURES MACHINE GUARDS WARNING! The Sharp MAX-PRO is equipped with guards cover- ing the heated sealing area and the underside of the The Sharp MAX-PRO is equipped with Jaw Ob- Head Assembly. DO NOT operate the MAX-PRO with struction Detection Sensors. -
Page 8: Safety Labels
EQUIPMENT SAFETY FEATURES This label is placed onto removable shields, panels, or SAFETY LABELS guards near the Sealing Jaw of the Sharp MAX-PRO General Danger Label to warn of potential crush danger. Always disconnect electrical power from the machine prior to removing any guards and/or panels. - Page 9 SECTION 1 - INTRODUCTION EQUIPMENT SAFETY FEATURES This label on the Sharp MAX-PRO is placed where there is potential of injury due to pinch points or mov- ing parts. Make certain electrical power is disconnect- ed before removing any guards and/or panels.
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Page 10: Specifications
121.97 cm) size of product will cause rate to vary. TECHNICAL ASSISTANCE Assistance with your Sharp MAX-PRO can be ob- tained by contacting Sharp Packaging Systems Tech- nical Service Hotline by phone or e-mail. To help serve you better, Sharp Packaging requests that you provide the serial number of bagger and a brief de- scription of the problem. -
Page 11: Machine Dimensions
SECTION 1 - INTRODUCTION MACHINE DIMENSIONS FRONT VIEW Bagger dimensions viewed from front. Measurements are in inches. MAX-PRO Operator Manual Original Printed in English... -
Page 12: Top View
SECTION 1 - INTRODUCTION MACHINE DIMENSIONS TOP VIEW Bagger dimensions viewed from top. Measurements are in inches. MAX-PRO Operator Manual Original Printed in English... -
Page 13: Side View
SECTION 1 - INTRODUCTION MACHINE DIMENSIONS SIDE VIEW Bagger dimensions viewed from side. Measurements are in inches. MAX-PRO Operator Manual Original Printed in English... -
Page 14: Sharp Ez-Bags
SHARP EZ-BAGS & RIBBON The Sharp MAX-PRO uses thermal transfer ribbon to The Sharp MAX-PRO is designed to use a wide varie- print various information onto the bags as they pass © ty of bag sized and materials. Sharp EZ-Bags through the machine. -
Page 15: Section 2 - Controls
SECTION 2 - CONTROLS SECURITY The ‘Technician’, ‘Field Service’, and ‘Manufacturing’ icons are password protected. Pressing any of these icons will prompt user to type in a password. The ‘Operator’ and ‘Support’ icons are not password protected. NOTE: See Supervisor or Manager for correct password for each icon. MAX-PRO Operator Manual Original Printed in English... -
Page 16: Home Screen
SECTION 2 - CONTROLS SCREEN NAVIGATION HOME SCREEN This screen appears at machine start-up and by pressing the home button on bottom left corner of screen. Pressing any of the large buttons on this screen, opens new screen. MAX-PRO Operator Manual Original Printed in English... - Page 17 SECTION 2 - CONTROLS SCREEN NAVIGATION OPERATOR BUTTON Pressing the Operator Button from the Home Screen opens the Operator Dashboard Screen. This screen al- lows Operator to monitor bagger function. Access to this screen is not password protected. JOB DETAILS Pressing the Job Detail button opens a pop-up window with bag dimensions and bag feed speed.
- Page 18 SECTION 2 - CONTROLS SCREEN NAVIGATION Reverse and Forward: Buttons jog film. OPERATOR DASHBOARD - CONTINUED PERFORMANCE Last Cycle Time: Displays the actual time of last completed cycle, in seconds. Average Cycle Time: The average cycle time all cycles, in seconds. Reset Average Cycle Time: Reset or clears the average cycle time.
- Page 19 SECTION 2 - CONTROLS SCREEN NAVIGATION TECHNICIAN BUTTON Pressing the Technician Button from the Home Screen opens the Job Setup Screen. This screen allows a Us- er to configure Bag Dimensions and Feed Speed, Bag Opening, Package Eject, Pressure Bar and Seal Bar, Auxiliary Input/output and Printer.
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Page 20: Job Setup Screen
SECTION 2 - CONTROLS SCREEN NAVIGATION JOB SETUP SCREEN - BAG DIMENSIONS AND FEED SPEED Any changes made to this screen requires operator to press ‘Load Job’ button. BAG DIMENSIONS Length: This refers to the usable area inside the bag. This is measured from the bottom of the bag to the seal. - Page 21 SECTION 2 - CONTROLS SCREEN NAVIGATION JOB SETUP SCREEN - BAG OPENING Any changes made to this screen requires operator to press ‘Load Job’ button. BAG OPENING Bag Opening Retry Count: Display the number of attempts Bag Opening Fingers try open bag before feeding new bag out.
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Page 22: Package Eject
SECTION 2 - CONTROLS SCREEN NAVIGATION JOB SETUP SCREEN - PACKAGE EJECT Any changes made to this screen requires operator to press ‘Load Job’ button. Bag Drop Time: Time for bag to drop before feeding new bag out. LOW-PRESSURE AIR LPA Bag Eject Assist: Toggle switch turns LPA ON or OFF to assist the ejection of sealed bag. -
Page 23: Pressure Bar
SECTION 2 - CONTROLS SCREEN NAVIGATION JOB SETUP SCREEN - PRESSURE BAR AND SEAL BAR Any changes made to this screen requires operator to press ‘Load Job’ button. PRESSURE BAR Open Delay: Adjusts the delay, in seconds, that occurs prior to opening the Pressure Bar. Close Delay: Adjusts the delay, in seconds, that occurs prior to closing the Pressure Bar. - Page 24 SECTION 2 - CONTROLS SCREEN NAVIGATION JOB SETUP SCREEN - AUXILIARY INPUT/OUTPUT Any changes made to this screen requires operator to press ‘Load Job’ or ‘Save & Load’ button. INPUT Not Configured: No configuration. Bagger Inhibit: Will not allow bagger to cycle until input held low. Warning appears when this is active. OUTPUT 1 Not Configured: No configuration.
- Page 25 SECTION 2 - CONTROLS SCREEN NAVIGATION Any changes made to this screen requires operator to press ‘Load Job’ or ‘Save & Load’ button. OUTPUT 2 Not Configured: No configuration. Printer Data Ready: Output active when Printer is ready for a new label. Waiting For Printer: Machine is cycling and film is backed up and ready to print but printer needs label.
- Page 26 SECTION 2 - CONTROLS SCREEN NAVIGATION JOB SETUP SCREEN - PRINTER Any changes made to this screen requires operator to press ‘Load Job’ or ‘Save & Load’ button. PRINTER SETTINGS Speed: This numeric setting determines the web feed speed during the print cycle. It is adjustable from 2.00 to 12.00 Inches/Sec.
- Page 27 SECTION 2 - CONTROLS SCREEN NAVIGATION APPLICATION SCREEN Pressing the Settings Button icon on Left Menu Bar (When in password protected screen) will open the Appli- cations Settings page. Any changes made to this screen requires operator to press ‘Load Job’ or ‘Save & Load’ button. Application - This allows a User to select HMI Language and to activate Demo Mode.
- Page 28 SECTION 2 - CONTROLS SCREEN NAVIGATION FIELD SERVICE BUTTON Pressing the FIELD SERVICE button from the Home Screen opens the Service Screen. This screen display the Inputs and Outputs that are active (Highlighted Green) on PLC. This screen allows a User to manually trigger Bag Position, Bag Open Fingers, Integrated Exit Conveyor, Load Plate, Low-Pressure Air, High-Pressure Air, Pass-Thru, Pressure Bar, Printer, Seal Bar, Seal Flatteners and Vacuum.
- Page 29 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - BAG BAGGER HEAD Raise: Pressing button will raise the head of bagger. Lower: Pressing button will lower the head of bagger. Photo-Eye Covered: Green light indicates the Photo-eye detects bag. Reverse: Pressing Reverse button will reverse the web as long as button is pressed. Forward: Pressing Forward button will advance the web as long as button is pressed.
- Page 30 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - BAG OPEN FINGERS FINGERS Grab: Activates the Bag Open Fingers. Fingers will Rotate down. Release: Fingers will Rotate up to release the bag. CYCLES Total: The total number of cycle the Bag Open Fingers have completed since last reset. OPEN RETRIES Total: The total number of times the Bag Open Fingers have attempted to open fed bag.
- Page 31 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - INTEGRATED/EXTERNAL EXIT CONVEYOR. Start: Pressing this button will turn the Conveyor ON. Press button again to stop. JOG DWELL Dwell: Time that conveyor will run. Jog Sec.: Press and hold to run exit conveyor until released. This will changed the Dwell. Apply To Settings: Time that jog was pressed can be set to job dwell setting.
- Page 32 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - LOAD PLATE LOAD SHELF To Discharge: Moves the Load Shelf to the ‘Discharge’ position. To Load: Moves the Load Shelf to the ‘Load’ Position. FRONT PLATE To Discharge: Moves the Front Plate to the ‘Discharge’ position. To Load: Moves the Front Plate to the ‘Load’...
- Page 33 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - LOW/HIGH PRESSURE AIR LOW PRESSURE AIR Start: Pressing this button turns Low Pressure Air ON. Press again to turn OFF. Dwell: The amount of time the Low Pressure Air will be ON according to setting in loaded job. Current: The actual setting of Low Pressure Air blast.
- Page 34 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - PASS-THRU Distance: The current Pass-thru distance. Jog IN: Moves Jaw inward as long as button is pushed or until it reaches Face Plate. Jog OUT: Moves Jaw outward as long as button is pushed or until it reaches end of travel. MANUAL POSITION Current: The actual width of Jaw.
- Page 35 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - PRESSURE BAR Move IN: Pressing this button will retract or close the Pressure Bar. Pressure Bar will remained closed until Move OUT is pushed. Move OUT: Pressing this button will extend or open the Pressure Bar. CYCLES Total: Total number of Cycles the Pressure Jaw has completed since last reset.
- Page 36 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - PRINTER Online: When lit, printer is on and ready for label. Pause: The Pause key temporarily suspends printing. Pressing the key again will return the printer to normal operation. Reset: Clears printer faults. Raise Printhead: Press to raise Printhead.
- Page 37 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - SEAL BAR Move IN: Pressing button will retract Seal Bar. Move OUT: Pressing button will extend Seal Bar. Seal Bar will remain out until Move IN button is pressed. CYCLE Current: Displays the length of time Seal Bar is active. Pulse Sec.: Cycles the Seal Bar.
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Page 38: Seal Flatteners
SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - SEAL FLATTENERS Raise: Pressing button raised the Seal Flattener Fingers. Lower: Pressing button lowers the Seal Flattener Fingers. DISTANCE FROM CENTER The distance that fingers are from the center of sealing area. Jog IN: Moves fingers IN as long as button is pressed or until fingers reach center. - Page 39 SECTION 2 - CONTROLS SCREEN NAVIGATION SERVICE SCREEN - VACUUM Start: Turns on Vacuum. Vacuum will stay on until button is pressed again. DWELL Current: The actual setting of the Vacuum ON. Pulse Sec.: Pressing the button will turn Vacuum ON for length of Dwell Setting. Setting: The actual length of Vacuum on when button is pushed.
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Page 40: Support Screen
SECTION 2 - CONTROLS SCREEN NAVIGATION SUPPORT SCREEN SUPPORT CONTACT - Provides the contact information for Sharp Service and Sharp Parts. Also provides Sharp Packaging Systems mailing address. SOFTWARE VERSIONS - Displays current Software. Upgrade From File: Allows for mapping to saved HMI program file used to upgrade program. -
Page 41: Section 3 - Set-Up & Operation
MACHINE PLACEMENT inspect and test all the electrical components to en- Your Sharp Bagger has been shipped to you well crat- sure they are functioning properly. To avoid short- ed in order to prevent any damage to the machine. It... - Page 42 5. Plug the Male End of second Power Cord into a POWER CONNECTION properly grounded wall outlet or electrical drop. The Sharp MAX-PRO is equipped with a 3-prong elec- 6. Insert the Female end into Power Entry Module on trical cord for standard, properly grounded, 115 VAC, top of the Printer Control Box.
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Page 43: Air Supply
SECTION 3 - SET-UP & OPERATION MACHINE ADJUSTMENTS AIR SUPPLY HEIGHT ADJUSTMENT The Sharp MAX-PRO has a filter/regulator equipped Machine height can be adjusted to allow manual load- with a male end 1/4” nominal flow NPT air quick dis- ing at a convenient height. -
Page 44: Load Plate
SECTION 3 - SET-UP & OPERATION MACHINE ADJUSTMENTS HEAD ROTATION - CONTINUED LOAD SHELF The Load Shelf can be moved up or down to accom- modate different sized bags. 1. Loosen the Locking Handles on back of Load Plate, 1. Loosen the Rotating Clamp Screws. 2. -
Page 45: Loading Bag Film
SECTION 3 - SET-UP & OPERATION LOADING BAG FILM Then under-over Unwind Drag Tubes, then under A decal showing the film threading path through the Idler Roller, finally over the Unwind Drive Roller. machine is located on the Frame Cover. Close Unwind Cradle Latch. - Page 46 SECTION 3 - SET-UP & OPERATION LOADING BAG FILM Pull the film Under the Printer Carriage until edge drapes over the Platen and Drive Rollers and down past the Front Finger Plate. 5. Lower and lock the Drive Roller Cradle Latch. MAX-PRO Operator Manual Original Printed in English...
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Page 47: Loading Ribbon
SECTION 3 - SET-UP & OPERATION LOADING RIBBON A decal showing the ribbon threading path is located on the inside of Carriage Cover. 1. Raise the Carriage Cradle and Open Carriage 6. Place empty cardboard roll onto Ribbon Rewind Cover. Hub. -
Page 48: Operation
SECTION 3 - SET-UP & OPERATION OPERATION 9. Press the ‘Operator’ button to open Operator Before attempting to operate the machine, read all Screen. information under Equipment Safety Features, page 1- 2 and Controls, page 3-1. 10. Press the ‘Job Search’ and select job to be load- Load film material as illustrated in Web Threading Dia- gram on machine. -
Page 49: Cleaning Guidelines
It is extremely important to follow all of the safety guidelines and warning detailed inside the Sharp Operator Manual before removing any guards or servicing the machine. MAX-PRO Operator Manual... -
Page 50: Cleaning / Maintenance Intervals
SECTION 3 - SET-UP & OPERATION CLEANING / MAINTENANCE INTERVALS • Inspect the Air Filter for debris and replace as DAILY CLEANING / MAINTENANCE necessary. • Inspect the Bag Edge Present Sensor. Clean • Inspect all external wiring for loose connec- as needed. - Page 51 SECTION 3 - SET-UP & OPERATION CLEANING BAG EDGE PRESENT SENSOR 1. Remove Power from bagger. PRINTHEAD 2. Clean with a cotton swab if dirty. Do not use any 1. Turn the Printer Control Box OFF. solvents or cleaning solutions on the sensing por- 2.
- Page 52 DRIVE & PLATEN ROLLERS 6. Repeat for Platen Roller (Shown in yellow). Regular cleaning of the Drive & Platen Rollers will keep the Sharp MAX-PRO running at optimum perfor- 7. When rollers are clean, close the Cradle Latch. mance. 8. Return power and air to bagger.
- Page 53 In order to do this, the machine needs power and air. This will cause the Seal Bar to heat 7. NEVER use any metallic utensils on the surface of Seal Bar. Use the Cleaning Wand (Sharp P/N 704173-01) to remove any residue accumulated •...
- Page 54 CLEANING UNWIND DRIVE ROLLER PINCH ROLLER Regular cleaning of the Unwind Drive & Pinch Rollers will keep the Sharp MAX-PRO running at optimum After Cleaning the Unwind Drive Roller, clean the Un- performance. wind Pinch Roller in the Latch Assembly.
- Page 55 FAULT & ALERT MANAGEMENT BAGGER FAULTS Faults are defined as an error condition that will stop the bagger and prevent subsequent cycles from occurring as long as the fault persists. All faults must be cleared before resetting bagger. Fault Cause Possible Solution (S) Pressure Bar Obstruction The Pressure Bar attempted to...
- Page 56 FAULT & ALERT MANAGEMENT BAGGER FAULTS Fault Cause Possible Solution (S) Bag Failed To Open The Bag Opened Sensor failed to This fault is usually the result of a make as the Bag Open Fingers problem with the Pressure Bar Pass were attempting to open the bag.
- Page 57 FAULT & ALERT MANAGEMENT BAGGER/PRINTER WARNINGS Fault Cause Possible Solution (S) Seal Bar not at Temperature - Seal Bar is not at the required tem- Bagger will not cycle until required Bagger inhibited from cycling perature for sealing. temperature has been reached. Low Pressure Air Timed Out Low Pressure Air Timed Out No intervention required by opera-...
- Page 58 FAULT & ALERT MANAGEMENT PRINTER FAULTS All printer functions are internally monitored. When a problem (Fault) or a potential problem (Warning) is detect- ed, a corresponding message will appear in the display. Fault messages receive the highest display priority. If more the one fault is detected the display will cycle between messages.
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Page 59: Printer Troubleshooting
FAULT & ALERT MANAGEMENT PRINTER TROUBLESHOOTING Barcode Does Not Scan Issue Possible Cause Possible Solution (s) The barcode printed on label 1. Print a test label. The barcode is not within specifi- does not scan. 2. If necessary, manually adjust cations because the printer is set the darkness or print speed at an incorrect darkness level. - Page 60 FAULT & ALERT MANAGEMENT PRINTER TROUBLESHOOTING Angled Gray Lines on Blank Labels Issue Possible Cause Possible Solution (s) Fine, angular gray lines on Wrinkled ribbon Verify the ribbon is loaded properly, blank labels smooth out ribbon Missing Print Issue Possible Cause Possible Solution (s) Long tracks of missing print on Print element damaged...
- Page 61 ITY TO USE THE MACHINE, EVEN IF SHARP HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, OR FOR ANY CLAIM AGAINST BUYER BY ANY OTHER PARTY. Buyer shall give written notice to Sharp of any alleged failure or refusal of Sharp to repair or replace as promised by this warranty within fifteen (15) days after Buyer learns of the alleged failure or refusal.
- Page 62 APPENDIX - A MAX-PRO Operator Manual Original Printed in English...
- Page 63 APPENDIX - A MAX-PRO Operator Manual Original Printed in English...