Maxpack e Manual

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INSTALLATION
AND
MAINTENANCE MANUAL
MAXPACK
Vertical Form, Fill and Seal

Serial No: Year :
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MACHINE INFORMATION
MODEL :
CLIENT :
SERIAL NO. :
TYPE OF PRODUCT :
PACKING MATERIAL :
BAG SIZE :
Table of Contents
GENERAL INFORMATION ................................................................................................................
1.1 CLAUSES ....................................................................................................................................... 1
1.2 FOREWORD .................................................................................................................................. 1
1.3 MACHINE AND MANUFACTURERS IDENTIFICATION ................................................................ 2
1.4 PLAN AND ELEVATION ............................................................................................................... 3
1.5 MACHINE DESCRIPTION ............................................................................................................. 4
SECURITY MEASURES ...................................................................................................................

2.1 INTRODUCTION ........................................................................................................................... 6
2.2 MACHINE SAFETY SYSTEMS ...................................................................................................... 7
2.3 MOVING AND LIFT SECURITY .................................................................................................... 8
2.4 ADJUSTMENT AND MAINTENANCE SECURITY ......................................................................... 8
SETTING UP ...................................................................................................................................
3.1 PACKING AND UNPACKING ..................................................................................................... 11
3.2 LOADING AND UNLOADING INSTRUCTIONS ......................................................................... 12
3.2.1 FORBIDDEN LIFTING MEANS ........................................................................................... 13
3.3 LEVELLING ................................................................................................................................. 14
3.4 CONNECTION ............................................................................................................................ 15
3.4.1 ELECTRICAL CONNECTION ................................................................................................. 15
3.4.2 SERVICE CONNECTION (PNEUMATIC) .............................................................................. 15
OPERATION PROCEDURE ..............................................................................................................

4.1 PRINCIPLE OF OPERATION ...................................................................................................... 16
4.2 INTENDED USE OF MACHINE ................................................................................................. 16
4.3 VERTICAL ROLLER ..................................................................................................................... 17
4.4 FILM UNWINDING UNIT ......................................................................................................... 18
4.5 PHOTOELECTRIC SENSOR FOR BAG LENGTH ........................................................................ 19
4.6 ENCODER UNIT FOR BAG LENGTH SETTING ........................................................................ 20
4.7 HORIZONTAL HOT BAR SEALER .............................................................................................. 21
4.8 VERTICAL HOT BAR SEALER ................................................................................................... 22
4.9 BAG DISCHARGE CHUTE ......................................................................................................... 23
MACHINE CONTROL .....................................................................................................................
5.1 INTRODUCTION ......................................................................................................................... 24
5.2 MAIN SWITCH .......................................................................................................................... 24
5.3 CONTROL PANEL ...................................................................................................................... 25
5.4 TOUCH SCREEN - OPERATION INTERFACE ............................................................................... 26
5.5 MACHINE CONTROL - MANUAL MODE ................................................................................... 27
5.6 MACHINE CONTROL - AUTOMATIC MODE ............................................................................. 28
5.7 MACHINE STATUS .................................................................................................................... 29
5.8 SUPERVISOR MODE ................................................................................................................. 30
5.9 FILLING STATUS ....................................................................................................................... 31
5.10 TIMER SETTING ....................................................................................................................... 32
5.11 ALARM SUMMARY PAGE ....................................................................................................... 33
5.12 ALARM POP-UP MESSAGE ..................................................................................................... 34
PRELIMINARY OPERATIONS ........................................................................................................

6.1 INTRODUCTION ........................................................................................................................ 36
6.2 FITTING AND REMOVING THE FORMING TUBE .................................................................... 37
6.3 FITTING OF FILM REEL ............................................................................................................ 38
6.4 FITTING OF FILM ..................................................................................................................... 39
6.5 CENTERING OF FILM ............................................................................................................... 39
6.6 STARTING OF MACHINE .......................................................................................................... 40
6.7 ADJUSTING THE TEMPERATURE OF SEALING BARS ............................................................. 40
6.8 ADJUSTMENT OF PHOTOELECTRIC SENSOR .......................................................................... 41
6.9 REPLACING THE FILM REEL ..................................................................................................... 42
MAINTENANCE .............................................................................................................................
7.1 INTRODUCTION ........................................................................................................................ 43
7.2 ROUTINE MAINTENANCE ......................................................................................................... 43
7.2.1 AFTER EVERY WORK SHIFT ............................................................................................. 43
7.2.2 AFTER EVERY 40 HOURS ................................................................................................. 44
TROUBLESHOOTING ......................................................................................................................
8.1 INTRODUCTION ........................................................................................................................ 46
SPARE PARTS REFERENCE ................................................................................................. 49 - 72

MAXPACK 1 - GENERAL INFORMATION
GENERAL INFORMATION
1.1 CLAUSES
This operation and maintenance instruction manual is an integral part of the machine supply
and shall follow it in any company transfer or moving and it contains information necessary
for its operation and maintenance.
JETPACK reserves the right, at any times, suspend production of any models, and to alter the
specifications and the design, without being obliged to give any notice.
JETPACK shall carry out, at any time, any modifications that they shall consider necessary
for technical or marketing requirements, without undertaking to immediately revised this
publication.
The accessories and the systems described in this publication generally relate to standard
production models and therefore may differ from that installed on your machine.
A copy of this manual has kept in our archives for a maximum period of 5 years. If you need
another copy, you may address to JETPACK within our period of preservation. For this
operation a charge will be imposed according to the manufacturing year and the structure of
the machine.
1.2 FOREWORD
Operation instructions aim at the right use of the machine to safeguard the physical integrity
of the machine users.
The constant observance of instructions will assure the maximum efficiency, operational
economy, long duration of the machine, and it will avoid dangerous situations during the
setting, the use and the maintenance of the machine.
Therefore, the purpose of this manual is that of giving information :

 on safety
 on the operation manner
 on maintenance
 on assistance.
1
1.3 MACHINE AND MANUFACTURERS IDENTIFICATION
The physical identification mean is a plate which must remain unaltered with time reporting
the necessary data to be supplied to the company JETPACK when the need arises.
This plate is the machine identification recognized by the manufacturer.
The customer may avail himself of assistance supplied by JETPACK.
However, we recommend a careful reference to the manual since many inconveniences can
be removed with minor interventions.
At all events, the customer may apply directly to the manufacturer:
JETPACK TECHNOLOGIES SDN BHD

No.1-G-20, Jalan Pinggiran Putra 31
Seksyen 2, Taman Pinggiran Putra,
43300 Seri Kembangan, Selangor, Malaysia
Tel : 603-8958 3038
Fax : 603-8948 9827
E-mail: maxpack2020@yahoo.com
Person to Contact : Mr Thoh Kim Hua
Mobile Phone : +6012-2892927
2
1.4 PLAN AND ELEVATION
3
1.5 MACHINE DESCRIPTION
Maxpack Form Fill and Seal machines is designed to automatically produce closed heat-
sealed bags, starting from plain or preprinted film roll. The machine is equipped with PLC
(Programmable-Controller) advanced control and driving system as well as high performance
and high efficiency of sealing and film changing devices and a Touch Screen control. The
Maxpack vertical form fill machine works on packing material starting from a single sheet.
The flat sheet is form into a forming tube by a suitable forming sleeve and sealed vertically.
Then the horizontal sealing of the bottom takes place, followed by the filling with the product
and the horizontal sealing of the full bag. A cutting blade separates the bags which are then
left on a chute for the output and guiding of the bag to a conveyor. It is possible to use
“continuously print” sheet by making use of the encoder timer or to use “centrally print’ with
photo eye mark by using a photoelectric cell.
4
5
MAXPACK 2 - SECURITY MEASURES
SECURITY MEASURES
2.1 INTRODUCTION
The main causes of accidents during the use and the maintenance of machines, are due to
transgression or negligence of fundamental and elementary rules of prevention and safety.
The placement of the machine in a suitable position, where internal means of transfer
cleaning , are important details for personnel safety.
The operator must pay great attention during operations, even if they are usual, and he must
always remember the possible danger of the situation in which he is working.
Before using the machine and before any lubrication or maintenance operation the operator
must have read this manual and have acquired deep knowledge of the cross- reference marks
DANGER, WARNING, CAUTION. These directions have the following meaning:
DANGER it refers to procedures or practices that, if they are not carried out correctly,
cause serious damages for health, lesions or death.
WARNING it refers to procedures or practices that, if they are not carried out correctly, can
cause serious damages for health, lesions or death.
CAUTION it refers to procedures or practices that, if they are not carried out correctly, can
cause damages to the product.
In the manual they will be preceded by this symbol
Although this machine is designed and manufactured in conformity with the international
provisions on safety, it is impossible to foresee all the circumstances which can create
damages to the operator during the use or the maintenance. For the reason above stated, all
directions given in this manual and on the machine, by labels, cannot include all the possible
situations of danger.
6
2.2 MACHINE SAFETY SYSTEMS
i) Protective doors in front of machine are of polycarbonate suitable for covering the
machine at the point of movement and danger.
ii) Electrical and pneumatic components are enclosed into control cabinet attached to
either side of machine.
iii) The access door to the electrical panel is fitted with a main switch for the main
machine electrical power supply. This is of the type that can be padlocked and is
fitted with a mechanical lock, which does not allow the electrical cabinet to be opened
unless the switch is at the ‘O’ position preventing the risk of electrocution from the
live voltage.
iv) The front polycarbonate doors are fitted with microswitches that if triggered (when
door is opened) stop the operation of machine.
7
2.3 MOVING AND LIFT SECURITY
If the machine is to be removed, please proceed as follows:
1) Operations are to be carried out by qualified personnel, competent to move bulky

materials and drive fork trucks;
2) Balance the load, block the free parts; act with maximum circumspection to avoid
undesired and dangerous movements;
3) Block the charge to the lifting and transport means, in order to avoid dangerous and
undesired movements;
4) Keep at a safe distance from the moving load, when you are not involved in the
transport operations.
2.4 ADJUSTMENT AND MAINTENANCE SECURITY
Adjustment and maintenance operations are to be carried out by technical qualified personnel,
that knows the machine to perfection; read the supplied documentation carefully and
completely.
Especially, attend the following precautions:
 During maintenance operations, follow all the safety rules and take right precaution for
every kind of operation.
 The parts of the machine supplied with dangerous devices, such as moving or electrical
parts, are marked by labels.
ATTENTION Pay attention to label advises, especially before carrying out disassembly
and adjusting operations.
 If this manual doesn’t specify it, avoid repairing or adjusting the machine or its parts,
when it is working, in order to avoid being hooked by moving parts. Only after fitting up
or adjusting the mechanical part, start the machine and verify how it works with
circumspection;
 In the event of persistent malfunctioning of the machine or damages to its components,

contact JETPACK, without carrying out other operations.
8
All information listed in this manual should be considered to be correct; nevertheless

JETPACK don’t consider itself responsible for any non-listed operation carried out.
- In the event of a failure or malfunction of the machine contact the manufacturing

company.
- Unauthorised or unqualified persons should not be allowed to start up, regulate, work or
repair the machine. Please consult this manual before carrying out any necessary
operations.
- The mechanical parts and electrical/electronic components located inside the machine are
protected by completely closed paneling.
- Before cleaning and/or carrying out maintenance work on the machine and before
removing any protection, make sure that the main switch is in the ‘OFF’ ‘O’ position, so
as to turn off the electrical input to the machine while the above mentioned is being
carried out.
- The power supply must be equipped with an automatic release system mounted on the
main switch of the machine and with a suitable earthling system which meets the
requirements of the industrial standard for the prevention of the accidents.
- If work has to be done to the main switch or in the vicinity of the main switch turn off the
voltage reaching the line to which the main switch is connected.
All checks and maintenance requiring the removal of the safeguards are carried out entirely at
the user’s own risk. Therefore, please make sure that these operations are carried out
exclusively by specialized and authorised technicians.
- Check that all safety devices (barriers, guards, crankcase, micro switches, etc.) have not
been tempered with and that they are in perfect working order before beginning work, if
that is not the case they must be fixed.
- Do not remove safety devices.
- So as to avoid personal risk, only use electrical equipment that has been correctly
connected to the earth and which conforms to national safety standards.
- For no reason the electrical system or any other mechanism must be tampered with.
- Do not leave the working machine unattended.
- Do not attempt to climb up over the working machine.
- Do not wear rings, watches, jewellery, torn or dangling clothes such as ties, scarves,
unbuttoned jackets or any other item of clothing that can get caught up in the moving
parts of the machinery. Instead, when necessary wear safety clothing such as helmets,
non-skids shoes, work gloves, ear protection and safety equipment.
9
- If repairs need to be carried out in the vicinity or under the machine, make sure:
* there are no moving parts that can start moving.
* no unstable parts are placed on the machine or near it. In any case make sure they are
locked in place by the necessary equipment.
- Do not use your hands instead of suitable tools to work on the machine.
- Do not use your hands or other objects to stop any moving parts.
- It is absolutely forbidden for anyone to use the machine for any other purpose other than
those expressly intended and documented. The machine must be used according to the
times, ways and places of good technical norms of the laws enforced in every country,
even if there are no specific norms regulating the sector in the country in question.
ATTENTION Company declines any responsibility for accidents or damages to persons or

things arising from not having followed the instructions regarding safety or
the regulations herein. Such instructions, along with the regulations
regarding the installation of the machine as well as the electrical connections,
form an integral part of the Industrial Safety Regulations of each single
country. These safety regulations are an integral part of the safety norms
which are locally enforced and are not a substitute for them.
- Hasty repairs are never to be carried out, as they could compromise the good working
order of the machine.
When in doubt, always call a specialised technician.
- The construction company has absolutely no responsibility for any mishandling on behalf
of the user and makes the user solely responsible towards the competent societies for the
prevention of accidents.
- Utilisation of non original parts release company any eventual fault or damage.
10
MAXPACK 3 - SETTING UP
SETTING UP
3.1 PACKING AND UNPACKING
To facilitate the machine’s transport and to safeguard its integrity, JETPACK will split it in
suitable number of parts.
JETPACK foresees 3 different delivery modes of the machines according to the means of
transport or place of destination.
- Machine without packaging (mainly for local deliveries).

- Machine fitted to a pallet.
- Machine fitted to a pallet with wooden crate.
- Machine inside a closed case.
At the arrival, containers are to be handled carefully and moved by suitable means, according
to their tonnage, weight and volume. After opening the case, we suggest dividing the packing
material by type and to provide for disposal of them according to the laws of the destination
country.
CAUTION
Pay attention to any direction impressed on containers, giving every
caution for moving.
11
3.2 LOADING AND UNLOADING INSTRUCTIONS
For unloading and moving operations it is necessary to employ an elevator lift truck
provided that its loading shovels are long enough and its capacity load bigger than the
machine mass.
If they are too short, then use a U-iron of a section sufficient to bear the weight without
bending (minimum dimensions 120x55): take care of posing some cardboards between the
loading shovels and the U-iron.
CAUTION
Unloading by using U-irons, operate slowly and carefully avoiding sharp
maneuvers.
Before any displacement after unloading, lower the shovels at 20 cm.
from the ground; When the machine is set, screw the legs supporting screws.
12
3.2.1 FORBIDDEN LIFTING MEANS
Do not use lifting means of system that do not comply with safety norms, such as :
- Lifting capacity lower than machine/package weight.

- Unsuitable constructive lifter features (example forks too short).
- Constructive features worn out.
- Ropes or cables don’t comply with norms in force.
- Ropes or cables worn out.
ATTENTION : JETPACK TECHNOLOGIES SDN BHD is not liable for damages to the
machine caused by the non-observance of the transport and lifting norms.
We moreover decline all responsible for possible arrangements on
transport means that don’t comply with the normal safety procedures on
the load arrangement.
13
3.3 LEVELLING
Usually the machine is supplied fully assembled. Whenever some parts have been
disassembled for transport or shipment reasons, it is necessary to reassemble the machine.
Anyway the first operation to do it is to position it by mounting the adjustable legs.
In order to do a safe job, it is advised to lift uniformly the machine 20-25 cm from the ground,
possible by employing an elevator, in such a way as to screw on the basement the adjustment
screws (see drawing); then set the legs by adjusting the screws one at time and set the
machine at the same height of the working table so that it is set in line with the other
machines.
Check with a spirit level that the working table is perfectly horizontal both lengthways and
cross wise (see drawing).
14
3.4 CONNECTION
3.4.1 ELECTRICAL CONNECTION
Before connecting the machine to the mains check that the mains voltage corresponds to that
shown on the machine’s data plate. Normally machine is already prepared to work at the
voltage used at the customer’s factory. Connect cable to terminal board, upon connection of
the cables, fit the provided accident preventing cover. Verify the proper rotation sense of
engine, otherwise invert the connection of 2 of the 3 phase wires (R-S-T)
3.4.2 SERVICE CONNECTION (PNEUMATIC)
Identity the Service Unit (Filter, Regulator and Lubricator) located on the rear of the machine
[see below] and with a quick coupling pipe connect the flexible hose from the main supply.
Ensure that there is sufficient amount of lubricating oil on the lubricator and check that the
manometer shows the correct working pressure. (7 bar)
Note : Machine will not operate until air supply is turn ‘ON’.
15
MAXPACK 4 - OPERATION PROCEDURE
OPERATION PROCEDURE
4.1 PRINCIPLE OF OPERATION
This model “MAXPACK” Vertical Form Fill and Seal machine from JETPACK is design to
work on packing material starting from a single reel. The flat sheet is formed into a tube by a
suitable forming sleeve and sealed vertically. Then the horizontal sealing of the bottom take
place, followed the filling of the product and the horizontal sealing of the fill bag. A blade
separate the bag which are then guided by a chute to be discharge into the conveyor.
4.2 INTENDED USE OF THE MACHINE
The model “MAXPACK” Vertical Form Fill and Seal packing machine is designed to use for
packing liquid by using the following materials.
“POLYPROPYLENE” for model MAXPACK 2000 ‘HB’

if equipped with “Hot Bar Sealer”.
“POLYETHYLENE” for model MAXPACK 2000 ‘IP’

if equipped with “Impulse Sealer”.
This packing machine cannot be used for filling bags made of materials other than that
describe above.
The packing machine must be used only for packing products shown in the purchase contract.
16
4.3 VERTICAL ROLLER
The vertical roller rotation is provided by a geared transmission controlled by a geared motor.
This through the gears and with two universal joints transmits the drive to the toothed wheel
that turn the belt.
This system provides the two vertical rollers to move in a clockwise and anti-clockwise
rotation thus allowing the bag to move forward.
This film-drawing units is controlled by the PLC. It is the pulse of a consequence of the start
work cycle given by the dosing unit when the required weight or volume has been reached to
the PLC that enables the film drawing unit to start.
The rotation is stopped by a pulse that is given by two different control devices for the bag
length which are a encoder system and a photoelectric sensor detecting eye-mark reference
on the film.
17
4.4 FILM UNWINDING UNIT
The unwinding unit consist of a geared motor complete with timing belt and pulley to turn the
film reel. This devise is controlled by positing the 3 proximity sensor located at side of
machine and function as below:
Sensor (1) - activate geared motor to start unwind.

Sensor (2) - stop geared motor.
Sensor (3) - Indicate end of film.
18
4.5 PHOTOELECTRIC SENSOR FOR BAG LENGTH
In the case where the film use is printed with eye-mark type, the stop is ordered by the
photoelectric-sensor device.
The stop signal is detected by an optical head when the eye-mark stamp on the film passed
through. In the case where the photoelectric sensor does not give the pulse to stop the film
unwinding and encoder system is activated and stops the film unwinding as soon as the set
bag length is achieve.
To adjust the device.
- Move the photoelectric sensor device until the line indicated in the device is on line with
the printed eye-mark by using the adjustment knob (1).
19
4.6 ENCODER UNIT FOR BAG LENGTH SETTING
The machine is provided with an Encoder unit for the use of continuously print film-roll. The
bag length are accurately measured by the Encoder Unit and can be easily set in the Touch
Screen Control.
20
4.7 HORIZONTAL HOT BAR SEALER
Horizontal sealing of bags is carried out by a pair of toothed grippers moved by a single
pneumatic cylinder and the sealing time determined by the PLC. After the grippers are
closed and time is achieve the film is cut with a blade. The knife is inside a gripper and is
activated by a pneumatic cylinder controlled by the PLC. The temperature of the pairs of
grippers can be regulated by thermoregulator and controlled by a thermocouple.
To adjust the closing speed of the grippers use the air flow regulator on the pneumatic piston.
BEWARE OF HIGH TEMPERATURE. Before doing any work on the sealing grippers
ensure that their temperature is less than 50oC as shown on the control panel.
21
4.8 VERTICAL HOT BAR SEALER
This sealing is carried out by a gripper moved by a pneumatic cylinder and the closing and
sealing time is controlled by the PLC. The temperature is controlled by a thermoregulator
controlled by a thermocouple located in the gripper. The pressure required for different type
of material used can be adjusted through the pressure regulator located on the pneumatic
control panel.
BEWARE OF HIGH TEMPERATURE. Before doing any work on the sealing grippers
ensure that their temperature is less than 50oC as shown on the control panel.
22
4.9 BAG DISCHARGE CHUTE
A chute to guide the finished product to a conveyor is located under the horizontal sealing
bars. The bag guiding chute is fitted as standard on most machine.
23
MAXPACK 5 - MACHINE CONTROL
MACHINE CONTROL
5.1 INTRODUCTION
Before starting the machine it is necessary to know its control well. The machine is supplied
with a control board and a Touch Screen which controls all the working sequence. For this
reason it is useful to carefully read the description shown below.
5.2 MAIN SWITCH
Main switch with mechanical release allows the door of the electrical control cabinet to be
opened only in the “O” position. The switch is the type which can be locked with a padlock.
24
5.3 CONTROL PANEL
Maxpack 1 Touch Screen Operator Panel

for setting operation data
2 Thermoregulator for setting
1 Horizontal Bar - 1 temperature
Horizontal Bar - 2 temperature
3 130 130
2
Vertical Bar temperature
4 110 160
5 5 Thermoregulator for setting
Printer temperature ( Optional )
6 5 EMERGENCY STOP Button.

Turn to right to realese it.
Fig: 14
25
5.4 TOUCH SCREEN - OPERATION INTERFACE
The machine is provided with a Touch Screen Control Board where all the settings and
operations command can be easily activated. The Touch Screen is a sensitive control board
and the required command or setting can be activated by just touching the screen with a finger
tip (must be dry).
When starting the machine by turning the main switch (Fig – 13) to position 1 the Touch
Screen workstation will begin a system check and machine main menu will appear
OPERATOR
MACHINE STATUS
SUPERVISOR
For normal operations press "OPERATOR" mode
For amendments of individual settings, go to "MACHINE STATUS" mode (on/off for

individual components.
For advance settings, go to "SUPERVISOR" mode (timer & machine system settings)
Supervisor Password required. Password: 1234
Message "INVALID PASSWORD" will show if

INVALID PASSWORD wrong password is inserted.
If password correct, the "SUPERVISOR" page

PASSWORD: #### will be displayed.
OK CANCEL
26
5.5 MACHINE CONTROL - MANUAL MODE
MANUAL INDEX VERTICAL HORIZONTAL 1 CYCLE

MAGAZINE BAR BAR TEST
STOP OPEN OPEN STOP
AUTO START CLOSE CLOSE START
PULL BELT CIP MODE

OPEN
STOP
PULL BELT
START
CLOSE
Select Manual (manual mode) to view all the manual toggle switch.
Toggle Switch to Open/Close the pull belt roller.
Toggle Switch to Start the film indexing cycle. Alarm will be popup when I-mark
sensor failed to be detected.
Toggle Switch to Open the Vertical Bar Close cycle. The cutter will only be
energised when the cutter (machine status) is turned ON.
Toggle Switch to Open the Horizontal Bar Close cycle. Alarm will popup when
the cylinder stoke magnetic sensor (Back) failed to be detected.
Toggle Switch to Start the One complete cycle. Alarm will popup when the I-mark
sensor failed (if I-mark mode selected) or Encoder failed (if bag length mode
selected)/ cylinder stoke magnetic sensor (Back) failed to be detected.
Toggle Switch to Start/Stop the C.I.P. Mode. The filling cylinder will be energised
during C.I.P mode.
Go to Alarm Summary Page (Display all the instantaneous alarms)
Go to Main Menu Page
27
5.6 MACHINE CONTROL - AUTO MODE
BAG TOP SINGLE AUTO

MANUAL AUTO CYCLE LENGTH FILL CYCLE END BAG
START STOP
I-MARK BOTTOM DOUBLE ON

FILL CYCLE
AUTO
PULL BELT FILLING RUNNING BAG 12345 BAGS

OPEN ON/OFF
RUNNING P.P.M. 12345 PACK/MIN
OFF
PULL BELT SPEED 12345 Hz
PRESET BAG LENGTH 12345 mm

PULL BELT
CLOSE ON RUNNING HOURS 12345 HRS
Select AUTO (AUTO mode) to view all the parameter related to Auto
Cycle and also the machine Start/Stop button.
Toggle Switch to Open/Close the pull belt roller.
Toggle Switch to Start/Stop the machine auto cycle.
Display selected mode related to auto cycle. (Not adjustable here, refer to
SUPERVISOR mode - Filling Status)
Toggle Switch to On/Off the Filling Cylinder.
Display the machine running parameter related to auto cycle. (Not

adjustable here, refer to SUPERVISOR mode - Filling Status)
Go to Alarm Summary Page (Display all the instantaneous alarms)
Go to Main Menu Page
28
5.7 MACHINE STATUS
HORIZONTAL VERTICAL
HEATER HEATER
OFF OFF
ON ON
PULL BELT FILM CONVEYOR PRINTER

MOTOR MOTOR MOTOR SIGNAL
OFF OFF OFF OFF
ON ON ON ON
Toggle Switch to On/Off the Horizontal Heater.
Toggle Switch to On/Off the Vertical Heater.
Toggle Switch to On/Off the Pull Belt Inverter.
Toggle Switch to On/Off the Film Motor.
Toggle Switch to On/Off the Conveyor Motor.
Toggle Switch to On/Off the Printer Signal Output.
29
5.8 SUPERVISOR MODE
FILLING STATUS
TIMER SETTING
Select "FILLING STATUS" Selection Page for amendment of settings of filling process.
Select "TIMER SETTING" Selection Page for amendment of time settings (close time/delay
open time/ cooling time etc.)
Go to "MAIN MENU" page.
30
5.9 FILLING STATUS
BAG PRESET AUTO TARGET BAG CURRENT BAG

LENGTH END BAG
BAG-LENGTH
12345 12345
123 mm
RESET
AUTO BAG
I-MARK ON COUNTER
TOP SINGLE PULL BELT

FILL CYCLE
INVERTER SPEED
123 Hz
BOTTOM DOUBLE
FILL CYCLE
Toggle switch to select Bag-Length/I-Mark mode.

Bag-Length – Bag length will be according to Preset Bag-Length entered.
I-Mark – Bag length will be according to I-Mark sensor
Touch on the value, a popup keypad will be prompt.

The required Preset Bag-Length is allowed to adjust here. (Only for Bag-
Length mode)
Popup Keypad
Toggle switch to select Auto End Bag mode.

When Auto End Bag mode is ON, the production will be automatically stop
when the Current Bag counter reach Target Bag counter.
Touch on the Target Bag value, a popup keypad will be prompt.
The required Target Bag counter is allowed to adjust here.
The Current Bag shows the current produced bags count. It can be RESET by
pressing the Reset Auto Bag Counter Toggle Switch.
Toggle switch to select Top/Bottom Fill mode.

When Top Fill mode is selected, the oil fill is done above the cutter.
When Bottom Fill mode is selected, the oil fill is done below the cutter.
Toggle switch to select Single/Double Cycle Fill mode.

When Single Cycle mode is selected, the oil fill is done once at each cycle. (1kg)
When Bottom Fill mode is selected, the oil fill is done twice at each cycle. (2kg)

The required Pull Belt Inverter Speed is allowed to adjust here.
(Maximum 50Hz)
31
5.10 TIMER SETTING
VERTICAL BAR HORIZONTAL HORIZONTAL HORIZONTAL

CLOSE TIME BAR BAR DELAY BAR
CLOSE TIME CLOSE TIME COOLING TIME
12.1 sec 12.1 sec 12.1 sec 12.1 sec
ENCODER FILLING SENSOR HORIZONTAL

SIGNAL ALARM ALARM CHECK SEAL SENSOR
CHECK TIMER TIMER ALARM CHECK
TIMER
12.1 sec 12.1 sec sec
12.1
VERTICAL BAR Touch on the value, a popup keypad will be prompt.

CLOSE TIME
The required Vertical Bar Close Time is allowed to adjust here. These setting shows
12.1 sec the Vertical Bar remain close time before open.
HORIZONTAL Touch on the value, a popup keypad will be prompt.

BAR
CLOSE TIME The required Horizontal Bar Close Time is allowed to adjust here. These setting
12.1 sec shows the Horizontal Bar remain close time after reaching the magnetic switch of the
cylinder and before open.
HORIZONTAL
BAR DELAY
CLOSE TIME The required Horizontal Bar Delay Close Time is allowed to adjust here. These
12.1 sec setting shows the delay time for Horizontal Bar start to close after the pull belt is
completed.
HORIZONTAL
BAR The required Horizontal Bar Cooling Time is allowed to adjust here. These setting
COOLINGTIME
shows the extra delay time for Horizontal Bar remain close after Horizontal Bar
12.1 sec
Close Time timeout before open.
(Mainly for Impulse machine – to cutoff heater and let the horizontal bar cool
down before open)
ENCODER
SIGNAL ALARM The required Encoder Signal Alarm Check Timer is allowed to adjust here.
CHECK TIMER
12.1 sec
(Mainly used for Bag-Length pull Mode)
If the encoder do not count enough pulse (Preset Bag-Length) within these timer, an
alarm message will be displayed)
FILLING SENSOR Touch on the value, a popup keypad will be prompt.
ALARM CHECK
TIMER The required Filling Sensor Alarm Check Timer is allowed to adjust here.
12.1 sec If the magnetic switch at the filling cylinder failed to detect within these timer, an
alarm message will be displayed)
HORIZONTAL Touch on the value, a popup keypad will be prompt.
SEAL SENSOR
ALARM CHECK The required Horinzontal Seal Sensor Alarm Check Timer is allowed to adjust
TIMER
here.
12.1 sec
If the magnetic switch at the Horizontal cylinder failed to detect within these timer,
an alarm message will be displayed)
32
5.11 ALARM SUMMARY PAGE
MESSAGE
xXxXxXxXxX
xXxXxXxXxX
xXxXxXxXxX
This page will display all the alarm summary
Alarm Reset button.
Go to Main Menu page.
33
5.12 ALARM POPUP MESSAGE
When the filling cylinder fail to detect the magnetic switch

FILL SENSOR FAULTY signal.
OR
FILLING TIMER TOO SHORT → sensor incorrect position
→ sensor failed
When the i-mark failed to detect the film mark. (i-mark mode)
I-MARK SENSOR FAULTY
OR → sensor incorrect position
PRESET BAR LENGTH TOO SHORT
→ sensor failed
→ Preset Bar Length setting value too short.
(Preset Bar Length > actual length of the bag)
When the Encoder fail to count (Bag-length mode)

ENCODER FAULTY
OR → Pull Belt cylinder do not clamp correctly.
ENCODER CHECK TIMER TOO SHORT
→ encoder failed
→ encoder alarm check timer setting value too short.
(Timer value > actual pulling time for complete bag)
HORZONTAL BAR SENSOR FAULTY When the horizontal bar cylinder fail to detect the magnetic
OR switch signal.
SENSOR CHECK TIMER TOO SHORT
→ sensor incorrect position.
→ sensor failed
→Horizontal sensor alarm check timer setting value too short.
(Timer value > actual time for cylinder full stroke)
When the emergency stop is pressed.

EMERGENCY STOP → emergency stop button pressed
→ emergency stop button fail (normally close contact)
When the safety cover opened

SAFETY COVER OPENED → safety cover opened
→safety cover limit switch fail (normally open contact in series)
When the conveyor motor overload

CONVEYOR MOTOR OVERLOAD → motor overload / fault
→ Thermal Overload Relay (Conveyor) trip
When the Film motor overload

FILM MOTOR OVERLOAD → motor overload / fault
→ Thermal Overload Relay (Film) trip
When the inverter overload or faulty

PULL BELT INVERTER → motor overload / fault
OVERLOAD
→ inverter overload / fault
→ MCB for inverter trip (no power supply).
34
When the Horizontal Thermostat Faulty (Impulse machine only)

HORIZONTAL THERMOSTAT
FAULTY
→ Horizontal Thermostat faulty
→ MCB for Horizontal Thermostat trip (no power supply)
When the Vertical Thermostat Faulty (Impulse machine only)

VERTICAL THERMOSTAT FAULTY → Vertical Thermostat faulty
→ MCB for Vertical Thermostat trip (no power supply)
When no more film

FILM EMPTY → no more film
→ film empty sensor failed (bottom sensor)
When the Horizontal/ Vertical Thermostat is off during auto

THERMOSTAT OFF OR FAULTY cycle.
AT AUTO MODE
→did not turn on Horizontal/ Vertical Thermostat at Machine
Status
→Horizontal/ Vertical Thermostat faulty
When the Film motor run more than 3 second

FILM MOTOR JAMMED → film jammed at the shaft
→ film motor stop sensor failed (middle sensor)
35
MAXPACK 6 - PRELIMINARY OPERATIONS
PRELIMINARY OPERATIONS
6.1 INTRODUCTION
The packing machine from JETPACK can be defined as an electro-pneumatic machine. The
movement of film drawing unit and the film unwinding unit are considered as Electro-
mechanical type action. The horizontal and vertical sealer are controlled by pneumatic
cylinders fitted to the movement levers. Before starting to work with the machine, it is
necessary to familiarise with the various devices present on the machine.
Before carrying out any operation of checking and adjusting part of the machine, ensure that
the main switch is in the "O" position.
36
6.2 FITTING AND REMOVING THE FORMING TUBE
i) Open the front mechanical protection doors to access the vertical grippers unit and the
forming tube.
ii) Remove the locking pins (1) (Fig – 15) from the vertical sealer and take the sealer
away from the forming tube.
iii) Insert or replaced the forming tube into the supports complete with sleeve chosen on
the basis of the bag to be used and fix it in position with the relevant screws (2) (Fig –
15).
iv) Put back the vertical sealer and fix it in position with the locking pin (1) (Fig – 15).
v) Carry out a move accurate positioning of the vertical sealer by adjusting the screw (3)
(Fig-15) and by positing the sealer bar at a distance of above 8-10mm from the
forming tube.
37
6.3 FITTING OF FILM REEL
i) Lower the left hand support (1) (Fig-16) for the reel-holding shaft (2).
ii) Release the two reel holding cones (3) and (4) by slackening the relevant screws (5).
iii) Remove the left-cone (3) completely and insert the correct reel and position the right
hand (4) cone so that the reel is about central with respect to the centre of machine.
iv) Unwind film and insert to rollers according to diagram shown in Fig 17.
v) Hold the reel against the right hand cone (4). Insert the left hand cone (3) and tightly
holding the reel and cone (3) against the right hand cone (4) and tighten screw (5).
vi) Put the left-hand reel-holding shaft support (1) back to its original position.
38
6.4 FITTING OF FILM
When the film has been completely fitted following the route shown and after having pulled it
so as to make it central in the last exit roller at the front of the machine, cut its end at 45 o (1)
to facilitate its entry into the forming collar.
Insert the film from the left side of the collar into the forming tube until it comes out. Pull the
film (2) until it correctly fits over the forming tube.
6.5 CENTERING OF FILM
If the reel is out of centre it will not have the correct overlap of the sides to be sealed together
for the vertical seal of the bag.
To adjust turn the hand wheel (6) Fig-19 to center the reel, taking the reel as near as possible
into the center.
39
6.6 STARTING OF MACHINE
Before starting the machine check and ensure that :
i) The electrical and pneumatic connections have been correctly made.
ii) The main switch is at the position “1”.
iii) The emergency stop button is released.
Ensure that the minimum pressure of the compressed air coming from the main supply line is
at 7 bars.
6.7 ADJUSTING THE TEMPERATURE OF THE SEALING BARS
Using the thermoregulators set the working temperature suitable for the type of sealing.
Normally the required temperature is prefix in the factory.
To have the temperature displayed press the “set” key (1) (Fig-20).
To change the temperature value press key (1) and the up or down key to increase or reduce
the temperature and press “set” key (1) again.
40
6.8 ADJUSTMENT OF PHOTOELECTRIC SENSOR
Slacken the screw (1) attached to sensor support (2) and slide the support block until the red
arrow mark (3) is in line and on top of eye-mark on film.
41
6.9 REPLACING THE FILM REEL
This is to replace the reel for the film before the film to be replaced is completely empty for a
continuous operation.
- Replace the reel with a new one ensuring that it is fitted so that the film unwinds the same
way.
- Join the two ends of the old and new film the following way. Bring the two ends together,
overlapping them slightly and temporary with a piece of adhesive tape (1). By gripping it
with both hands, stretch it uniformly thus obtaining a change from the old film to a new
one. Then apply a strip of adhesive tape (2) across the whole width of the film, taking
care to cut off the extra bits at the ends.
42
MAXPACK 7 - MAINTENANCE
MAINTENANCE
7.1 INTRODUCTION
Before any maintenance work can proceed ensure that the electrical power supply to the
machine is turn off and also ensure the access door to the electrical power supply cabinet of
the machine is closed. All maintenance work must be carried out by qualified and competent
personnel. All maintenance operation must be carried out under condition of maximum
safety.
At the end of maintenance operations, ensure that all the safety devices provided for the
machine have been replaced correctly before starting the working operations again.
7.2 ROUTINE MAINTENANCE
7.2.1 AFTER EVERY WORK SHIFT
At the end of each work shift and after having cut off the electrical power supply and having
released the compressed air from the machine carefully clean the machine and the dosing unit
the following way.
- Wait until the sealing bars have cooled down before carrying out any cleaning work.
Check that the thermoregulator shows a temperature of less than 50oC.
- With a jet of compressed air clean all the equipment for sealing (sealing bars, collar and
forming tube etc).
43
7.2.2 AFTER EVERY 40 WORKING HOURS
After every 40 working hours and after having cut off the electrical power supply and having
released the compressed air from the machine check carefully the following:
- The correct-tightness of the locking nuts on the vertical and horizontal sealing bars and on
the dosing unit.
- The correct tightness of the main bolts of the machine that are subject to movement or
vibration.
- Check the level of the oil in the lubricating filter (1) of the service unit. Top up if
necessary with the following oils – Festo special oil, BP Energol HLP32, Esso Nuto H32,
Mobil DTE 24, Shell Tellus oil DO32 or oils having a viscosity range of 32mm2/S at 40oC
ISO class VG32 as per ISO 3448.
- Check the condensation of the pressure regulator (2). Drain off the condensation by
opening the release valve (3).
44
- Grease all the parts provided with greasing nipple and subject to movement (4), (5), (6),
(7).
45
MAXPACK 8 - TROUBLESHOOTING
TROUBLESHOOTING
8.1 INTRODUCTION
In this chapter are shown some of the most likely problems that may prevent the packing
machine from operating well.
We have tried to give a reason for each, and to offer possible remedies. If after having
followed the instructions in this chapter, the problems should persist or repeat constantly,
please contact our Service Department.
The solving of problems encountered while operating the machine must be dealt with and
resolved only by the person trained for that task.
46
PROBLEMS PROBABLE CAUSES REMEDY
Unwind the film and check the

Defect in manufacturing of the film. quality and the width of the sheet
is constant. If not replace it.
THE FILM BREAKS The film is blocking during its Follow the route of the film and
travel. establish the cause. Remedy it.
The reel is of centre with respect to Turn the adjustment knob located
the axis of the forming tube. at the right rear of machine.
The drawing belts could be worn

differently or have encrustation on Clean them and replaced them if
THE FILM IS NOT them that prevents the right amount necessary.
CENTRE ON THE of adhesion for smooth running.
FORMING TUBE AND
MOVES FROM RIGHT
TO LEFT Where there is powdery product,
encrustation could develop on the Check and if necessary clean it.
forming tube.
Thermocouple damaged or burnt Replace it paying attention to the

out. polarity of the new connection.
Check that they operate with a

THE HORIZONTAL AND
VERTICAL SEALING Heating element damaged. tester and replaced them if
BARS DO NOT HEAT UP necessary.
Try replacing it with the other one
Thermoregulator out of order. and compare. If necessary replace
it with a new one.
Sealing bars dirty. Clean the sealing bars thoroughly.
Check and if necessary change this

Distance between the sealing bar
distance to 8-10mm by moving the
and the forming tube too wide.
vertical sealing bar.
INSUFFICIENT
VERTICAL SEALING Temperature set on the vertical
Adjust it until an optimum seal is
thermoregulator is not suitable for
obtained.
the material.
Check on the corresponding
Air pressure in cylinder for vertical
manometer that it is showing 3-4
bar movement is not sufficient.
bars.
47
PROBLEMS PROBABLE CAUSES REMEDY
Sealing bars dirty. Clean it thoroughly.
Temperature set on the horizontal

Adjust it until an optimum seal is
thermoregulator is not suitable for
obtained.
the material.
INSUFFICIENT
HORIZONTAL SEALING Air pressure in cylinder for Check the corresponding
horizontal bar movement is not manometer that it is showing 7
sufficient. bars.
Malfunction in solenoid valve for Disassemble and clean it. If

horizontal sealing bar. necessary replace it.
The blade could be blunt or partly

Replace it.
broken.
Look for any worn pieces. Clean

The piston of the blade could have
and if necessary replace the worn
its travel partly blocked.
parts.
THE BLADE DOES NOT
CUT CORRECTLY Check the corresponding
Air pressure in cylinder for cutter
manometer that it is showing 5-6
movement is not sufficient.
bars.
Malfunction in solenoid valve for Disassemble and clean it. If

cutter. necessary replace it.
Center the eye-mark below the

Position for reading the eye-mark
photoelectric sensor by using the
present on the film is not optimum.
THE BAG IS NOT AT relevant adjustment knobs.
REGULAR LENGTH
Clean with a cloth soaked in
Film-drawing belts are dirty.
degreasing fluid (alcohol, tri etc.)
48
MAXPACK 9 - SPARE PARTS REFERENCE
SPARE PARTS REFERENCE
NOZZLES
Jetpack Technologies Sdn Bhd
49
NOZZLES
50
HORIZONTAL PUSHER
ffront ten
51
MAIN DRIVE REFERENCE
52
ENCODER SUPPORT
53
FRONT TENSION
54
PISTON FILLER REFERENCE
55
56
57
FORMER
58
FORMER
59
FORMER
60
FORMER
61
FORMER
62
FORMER
63
FILM CENTERING
64
FILM CENTERING SUPPORT
65
FILM GUIDE
66
POUCH GUIDE
67
VERTICAL ROLLER
68
VERTICAL SEALER
69
HOT BAR
70
HOT BAR
71
IMPULSE
72
IMPULSE
73
IMPULSE
74
IMPULSE
75
IMPULSE
76

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========================================

Vertical Form, Fill and Seal

SECURITY MEASURES ...................................................................................................................

OPERATION PROCEDURE ..............................................................................................................

PRELIMINARY OPERATIONS ........................................................................................................

SPARE PARTS REFERENCE ................................................................................................. 49 - 72

Therefore, the purpose of this manual is that of giving information :

1.3 MACHINE AND MANUFACTURERS IDENTIFICATION

This plate is the machine identification recognized by the manufacturer.

The customer may avail himself of assistance supplied by JETPACK.

At all events, the customer may apply directly to the manufacturer:

JETPACK TECHNOLOGIES SDN BHD

1.4 PLAN AND ELEVATION

1.5 MACHINE DESCRIPTION

2.2 MACHINE SAFETY SYSTEMS

2.3 MOVING AND LIFT SECURITY

If the machine is to be removed, please proceed as follows:

1) Operations are to be carried out by qualified personnel, competent to move bulky

2.4 ADJUSTMENT AND MAINTENANCE SECURITY

Especially, attend the following precautions:

 In the event of persistent malfunctioning of the machine or damages to its components,

All information listed in this manual should be considered to be correct; nevertheless

- In the event of a failure or malfunction of the machine contact the manufacturing

- Do not remove safety devices.

- Do not leave the working machine unattended.

- Do not attempt to climb up over the working machine.

ATTENTION Company declines any responsibility for accidents or damages to persons or

When in doubt, always call a specialised technician.

3.1 PACKING AND UNPACKING

- Machine without packaging (mainly for local deliveries).

3.2 LOADING AND UNLOADING INSTRUCTIONS

3.2.1 FORBIDDEN LIFTING MEANS

- Lifting capacity lower than machine/package weight.

3.4.1 ELECTRICAL CONNECTION

3.4.2 SERVICE CONNECTION (PNEUMATIC)

4.1 PRINCIPLE OF OPERATION

4.2 INTENDED USE OF THE MACHINE

“POLYPROPYLENE” for model MAXPACK 2000 ‘HB’

“POLYETHYLENE” for model MAXPACK 2000 ‘IP’

4.3 VERTICAL ROLLER

4.4 FILM UNWINDING UNIT

Sensor (1) - activate geared motor to start unwind.

4.5 PHOTOELECTRIC SENSOR FOR BAG LENGTH

To adjust the device.

4.6 ENCODER UNIT FOR BAG LENGTH SETTING

4.7 HORIZONTAL HOT BAR SEALER

4.8 VERTICAL HOT BAR SEALER

4.9 BAG DISCHARGE CHUTE

5.2 MAIN SWITCH

Maxpack 1 Touch Screen Operator Panel

6 5 EMERGENCY STOP Button.

For normal operations press "OPERATOR" mode

For amendments of individual settings, go to "MACHINE STATUS" mode (on/off for

Message "INVALID PASSWORD" will show if

If password correct, the "SUPERVISOR" page

MANUAL INDEX VERTICAL HORIZONTAL 1 CYCLE

AUTO START CLOSE CLOSE START