Chub Operators Manual

R.A JONES & Co.
- Davenport
807 West Kimberly Road
Davenport, Iowa 52806 U.S.A.
Phone (563) 391-1100
Manual Part No.: 075-16395-000
OPERATOR
ChubMaker 4100
NOTICE TO USERS
R.A JONES & Co. reserves the right to modify the contents of this manual at any time.
R.A JONES & Co. shall not be held liable for errors contained herein, for omissions, or
for incidental or consequential damages in connection with furnishing, performance, or
use of this material. This document contains proprietary information which is protected
by copyright - all rights reserved.
No part of this document may be photocopied or reproduced in any form without prior
written consent of R.A JONES & Co. This document contains information which
concerns or relates to trade secrets, processes, operations, style of work, design,
performance, or apparatus of R.A JONES & Co. Such information is being submitted
in confidence with the understanding that it will not be disclosed to a third party, in whole
or in part, without the written consent of R.A JONES & Co.
Printed in U.S.A.
Copyright 2013 - All Rights Reserved - R.A JONES & Co.
Table of Contents
List of Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Package Size Range . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Film Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Available Wire Diameters. . . . . . . . . . . . . . . . . . . .
Recommended Wire Alloy . . . . . . . . . . . . . . . . . . .
Wire Supplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-2
2-3
2-3
2-3
2-3
2-3
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Uncrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Air Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-1
4-2
Machine Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Start / Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Function Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Film Tension / Squeeze Roll Controls / Product
Piston Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Air Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Wire Clamp Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
PanelView. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Startup Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Sizing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
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Table of Contents
Film Arbor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Film Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Setting the Tensioner Balance. . . . . . . . . . . . . . . 8-15
Film Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Film Threading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Film Spreader Adjustment . . . . . . . . . . . . . . . . . . . . . . .
Drive Wheels Adjustment . . . . . . . . . . . . . . . . . . . . . . . .
Breaker Roller Setting. . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
10-4
10-5
10-6
Film Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Static Charges on Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Sealing Polyethylene Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Setting Heat Temperature . . . . . . . . . . . . . . . . . . . . . . 13-12
Heat Seal Quick Warm-up Feature. . . . . . . . . . . . . . . . 13-13
Heat Seal Over Temperature Fault Feature . . . . . . . . . 13-14
Clipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Description of Clipping Operation . . . . . . . . . . . . . . . . . . 14-1
M7 Clipping Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Removal of M7 Clipping Head Components . . . . 14-2
Gathering Plates . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Standard Stroke M7 Head Assembly Six Plates . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Assembly of Gathering Plates. . . . . . . . . 14-13
Standard Stroke M7 Head Assembly Nine Plates . . . . . . . . . . . . . . . . . . . . . . . 14-15
Assembly of Gathering Plates. . . . . . . . . 14-16
Installation of M7 Clipping Head
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18
Loading Wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
Wire Lubricator - Standard Stroke M7 Head. . . . . . . . . 14-30
Wire Feed Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 14-32
Inspection of Clip Tightness . . . . . . . . . . . . . . . . . . . . . 14-37
Adjustment of Clip Tightness . . . . . . . . . . . . . . . . . . . . 14-37
Clip Leakage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-38
Package Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Adjusting Film Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Chub Package Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
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Table of Contents
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Film Splice Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Package Breakout Detector . . . . . . . . . . . . . . . . . . . . . . 18-1
Optional Film Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
Registration Control Components. . . . . . . . . . . . . . . . . 19-17
Scanner Control Unit . . . . . . . . . . . . . . . . . . . . . 19-17
Fiber Optic Light Guide . . . . . . . . . . . . . . . . . . . 19-17
Clamp Mode Proximity Switch . . . . . . . . . . . . . . 19-17
Fiber Optic Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-18
Setup Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
Opaque (Non-Foil) Film . . . . . . . . . . . . . . . . . . . 19-20
Shiny Foil Film . . . . . . . . . . . . . . . . . . . . . . . . . . 19-22
Transparent Film . . . . . . . . . . . . . . . . . . . . . . . . 19-26
Hints and Helps . . . . . . . . . . . . . . . . . . . . . . . . . 19-27
Film Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Optional Voider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
Setting Void Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
Setting Void Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-8
Setting Voider Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-11
Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 21-13
Product Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22-1
22-1
22-6
22-8
22-8
Optional Markem Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2
Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of the Cut-Off Knife . . . . . . . . . . . . . . . . . . . . .
Setting Air Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of the Cut-Off Knife. . . . . . . . . . . . . . . . . . . .
24-1
24-1
24-6
24-9
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-1
Bacterial Contaminants. . . . . . . . . . . . . . . . . . . . . . . . . . 26-4
Inspection and Monitoring. . . . . . . . . . . . . . . . . . . . . . . 26-12
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Table of Contents
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-1
Daily Maintenance Check List . . . . . . . . . . . . . . . . . . . . 27-1
Weekly Maintenance Check List. . . . . . . . . . . . . . . . . . . 27-8
Monthly Maintenance Check List . . . . . . . . . . . . . . . . . 27-10
Annual Maintenance Check List . . . . . . . . . . . . . . . . . . 27-12
Left Spline Shaft Bearing Replacement . . . . . . . . . . . . 27-14
Sensor/Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Key Items . . . . . . . . . . . . . . . . . . . . . .
Follow-Up Applications . . . . . . . . . . . . . . . . . . . .
28-1
28-1
28-4
28-5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-1
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Clipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Film Arbor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
Optional Registration . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
Optional Voider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
Product Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-1
Technical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-1
Machine Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-1
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-1
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075-16395-000 / June, 2013
List of Illustrations
4-1: Installation Drawing - Front View . . . . . . . . . . . . . . . . . . . . . 4-2

4-4: Installation Drawing - Rear View . . . . . . . . . . . . . . . . . . . . . 4-6
4-5: Installation Drawing - Top View . . . . . . . . . . . . . . . . . . . . . . 4-7
5-1: ChubMaker 4100 Front Controls . . . . . . . . . . . . . . . . . . . . 5-1
5-2: Start / Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-3: Function Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-4: Film Tension / Squeeze Roll Controls . . . . . . . . . . . . . . . . . 5-6
5-5: ChubMaker 4100 Rear Controls . . . . . . . . . . . . . . . . . . . . 5-7
5-6: Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-7: Wire Clamp Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-8: PanelView . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-9: HOME Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-10: RUN CONTROL 1 Screen . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-14: SENSOR CONTROL Screen . . . . . . . . . . . . . . . . . . . . . . 5-24
5-15: HEATER CONTROL Screen . . . . . . . . . . . . . . . . . . . . . . 5-26
5-16: ACTIVE ALARMS Screen . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5-17: ALARM HISTORY Screen . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5-18: MAINTENANCE SETUP Screen . . . . . . . . . . . . . . . . . . . 5-34
5-19: PARAMETER MAINTENANCE 1 Screen . . . . . . . . . . . . 5-36
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5-27: RECIPE MAINTENANCE 1 Screen . . . . . . . . . . . . . . . . . 5-52
5-28: HEATER MAINTENANCE Screen . . . . . . . . . . . . . . . . . . 5-56
5-29: PLS SETUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5-30: REGISTRATION DIAGNOSTICS Screen . . . . . . . . . . . . 5-62
5-31: IO DIAGNOSTIC 1 Screen. . . . . . . . . . . . . . . . . . . . . . . . 5-64
5-35: SERVO HOME MAINTENANCE Screen . . . . . . . . . . . . . 5-72
7-1: Quick-Change Sizing Parts . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
9-1: Package Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-2: Package Shape & Cross Section Area. . . . . . . . . . . . . . . . . 9-2
9-3: Squeeze Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
10-1: Film Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10-2: Film Spreader Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10-4
10-3: Drive Wheels Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10-4: Breaker Roller Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
11-1: Folder Installation Top View . . . . . . . . . . . . . . . . . . . . . . . 11-3
13-1: S1 Heat Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
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075-16395-000 / June, 2013
13-2: Air Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13-3: Smooth Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
13-4: Wrinkled Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
14-1: M7 Clipping Head Components . . . . . . . . . . . . . . . . . . . . 14-2
14-2: Standard M7 Gathering Plates - 6 Plates. . . . . . . . . . . . 14-15
14-1: Standard M7 Gathering Plates - 9 Plates. . . . . . . . . . . . 14-18
14-2: Standard Wire Lubricator . . . . . . . . . . . . . . . . . . . . . . . . 14-31
14-3: Micro-Clip Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-37
14-4: Clip Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-38
15-1: Package Setup Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
17-1: Chub Package Dimensions . . . . . . . . . . . . . . . . . . . . . . . 17-1
19-1: Label Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-13
19-2: *Smarteye Scanner Control Unit . . . . . . . . . . . . . . . . . 19-19
19-3: Position for Opaque Film . . . . . . . . . . . . . . . . . . . . . . . . 19-20
19-4: Position for Shiny Foil Film. . . . . . . . . . . . . . . . . . . . . . . 19-23
19-5: Position A for Shiny Foil Film . . . . . . . . . . . . . . . . . . . . 19-25
19-6: Position B for Shiny Foil Film . . . . . . . . . . . . . . . . . . . . 19-25
20-1: Film Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
22-1: Air Cylinder Speed Control. . . . . . . . . . . . . . . . . . . . . . . . 22-4
22-2: Removing the Product Cylinder Piston. . . . . . . . . . . . . . 22-12
22-3: Removing the Product Cylinder Piston ORing. . . . . . . . 22-13
23-1: Markem SmartDate 5 Printer Control . . . . . . . . . . . . . . 23-1
23-2: Print Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-7
24-1: Pressure Gage Locations - Front of Machine. . . . . . . . . . 24-7
24-2: Pressure Gage Locations - Rear of Machine . . . . . . . . . . 24-8
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27-1: Bearing Push Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-14
27-2: Clip Forming Die Housing Lube Fittings. . . . . . . . . . . . . 27-15
27-3: Lower the Clip Forming Die Housing . . . . . . . . . . . . . . . 27-16
27-4: Crank Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-18
27-5: Setting the Clipping Head Height . . . . . . . . . . . . . . . . . . 27-20
27-6: setting the Pin Yoke Tool . . . . . . . . . . . . . . . . . . . . . . . . 27-24
27-7: Inspect and Clean Bearing Bore . . . . . . . . . . . . . . . . . . 27-27
27-8: Tapping the Bearing Into the Bore . . . . . . . . . . . . . . . . . 27-29
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List of Tables
List of Tables
5-1: Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

7-1: Callouts for Figure 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
13-1: Suggested Heat Seal Temperature Settings . . . . . . . . . . 13-6
24-1: Air Settings Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-6
26-1: Sanitizing Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-7
26-2: Sanitizing Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-8
26-3: Sanitizing Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-10
29-1: Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-1
29-2: Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . 29-11
June, 2013 / 075-16395-000
ix
Foreword
Foreword
Although packaging industries are fairly well established,
changes do occur. Over the years, R.A JONES & Co. has made
improvements in its publications to keep pace with those changes.
This manual has been prepared to provide correct operating
and maintenance procedures. Read and understand this manual
before attempting operation, cleanup, or maintenance. Instructions
in this manual are intended to guide your safe, efficient operation of
the machine. Please pay particular attention to safety instructions.
We have tried to make this manual as complete and
comprehensive as possible. It is now your responsibility to read and
to adhere to the procedures, CAUTIONS!, WARNINGS!, and
instructions.
If there is something in this manual you do not understand,
cannot find, or is in error, contact the Technical Publications
Department of R.A JONES & Co. at (563) 3911100.
Trademarks and registered trademarks indicated within this
document are owned by their respective companies.
075-16395-000 / June, 2013
Safety
Throughout this manual, safety related information is displayed with
a signal word. The signal word designates the level of hazard. The
following examples explain the level of hazard connected with each
signal word.
Safety
DANGER
DANGER statements refer to immediate hazards or unsafe
practices which WILL result in severe personal injury or
death; including extensive machine or property damage.
WARNING
WARNING statements refer to hazards or unsafe practices

which COULD result in severe personal injury or death;
including major machine or property damage.
CAUTION
CAUTION statements refer to hazards or unsafe practices
which COULD result in minor personal injury, or minor
personal injury and damage to the machine or property.
NOTICE
NOTICE statements refer to special instructions to avoid
unnecessary steps, avoid damage to parts, or to make a
procedure easier. These statements are NOT USUALLY safety
related.
June, 2013 / 075-16395-000
1-1
Safety
Safety should be a constant concern of EVERYONE. This concern
must not be taken lightly when working in or around any type of
machinery. While normal safety precautions were taken in the
design and manufacture of this machine, there are some potential
safety hazards. EVERYONE connected with the operation and
maintenance of this machine should follow the instructions listed
below to avoid injury.
NOTICE
If any safety related signs or legends become damaged,
worn, or missing, contact the R.A JONES & Co. Parts
Department, with the part number. Upon verification that the
sign or legend being ordered is safety related, the sign or
legend will be replaced at no charge. Free replacement only
applies to signs or legends that have been determined to be
safety related, by R.A JONES & Co., and does not apply to
non-safety related signs or legends.
WARNING
ARC FLASH
High voltage (above 120 VAC) circuits are prone to arc flash
between active terminals and any short to ground, such as a
nearby hand-held tool.
Personal Protective Equipment (PPE) must be used by those
opening any high voltage enclosure to minimize the potential
for injury. Reference NFPA 70E.
Injuries resulting from arc flash include, but are not limited
to, loss of limbs, extremely severe and painful burns,
disfigurement, or death.
1-2
075-16395-000 / June, 2013
Safety
NOTICE
This machine is designed specifically to package meat
products for human consumption, within the meat packing
industry.
This machine is designed for installation, use, and operation
in a classified non-hazardous location, free from explosive or
flammable gasses, dusts, and vapors
It is not designed nor equipped to be used for any other
purpose, nor is it designed to be operated in a classified
hazardous environment where explosive or flammable gases,
dusts, or vapors may exist.
If there is any doubt to the use and application of this
machine, contact R.A JONES & Co. to verify and confirm.
R.A JONES & Co. assumes no responsibilities for damage
or injury to property or persons, in the event this machine is
used outside the scope of its intended purpose.
The main electrical disconnect switch must be turned
OFF and LOCKED OUT before servicing the
machine.
The main air supply disconnect valve must be turned
OFF and LOCKED OUT before servicing the
machine.
ALWAYS replace the safety guards after servicing the
machine. NEVER operate the machine with the safety guards
removed -- SERIOUS INJURY CAN RESULT!
Before starting the machine, or after repairing or changing
a n y c o m p o n e n t s , A LWAY S T U R N T H E M A C H I N E
THROUGH AT LEAST ONE COMPLETE CYCLE WITH THE
HANDWHEEL. Make certain the machine turns freely and
quietly.
Before starting machine, make sure EVERYONE is clear of
machine. Be certain machine is clear of any possible jams.
NEVER wear loose fitting clothing or jewelry when working
around the machine, conveyors or related equipment.
June, 2013 / 075-16395-000
1-3
Safety
PERSONS WITH LONG HAIR should wear a hat or net to
prevent their hair from being caught in moving machinery.
DO NOT try to make adjustments to the head area while the
machine is operating.
NEVER place your hands or any hand-held objects near the
clipping head when the machine is operating.
DO NOT place your hands into the inspection access or into
the clipping head components if there is any possibility of
handwheel movement. Serious injury may result.
When working with materials which are caustic, toxic or
flammable, use extreme caution. Wear protective clothing
and use adequate face protection. Follow the manufacturer's
instructions.
NEVER CLIMB on the machine. Use a safe step ladder when
making adjustments or installing components.
KEEP THE AREA AROUND THE MACHINE CLEAN AND
DRY.
Avoid undue or repetitive bending to remove packaged
product. Back strain or injury may result.
Avoid prolonged abnormal posture during periods of setup,
cleanup, or service. Muscle strain and back related pain can
result from prolonged exposure to unnatural posture.
Avoid back injury when lifting wire reels, film rolls, or other
related components. Always lift using your legs. If the object
is too heavy, get help!
Keep fingers away from the cam tracks inside the clipping
head. The cam follower and the track create a severe pinch
point during operation that will sever fingers.
Never operate the machine with the access covers (on the
front of the table) removed. Severe pinch points capable of
amputation exist within the drive components. In addition, oil
contamination of product can occur. See Table 29-2 on page
-11 for recommended lubricants.
1-4
075-16395-000 / June, 2013
Safety
WARNING
Only qualified electricians should work on the electrical

components of this machine. To prevent bodily injury and
machine malfunction, the machine must be electrically
grounded in accordance with the current issue of the
National Electrical Code.
Power supplied to this machine must be of the proper
voltage and frequency. Check the manufacturers nameplate
(located on the Control Enclosure) for electrical requirements
before making any power connections. All electrical power
connections must be made in accordance with the current
issue of the National Electrical Code.
WARNING
This machine is equipped with a servo motor clip drive. This

drive does have a brake. However, if power is turned off,
the brake releases. Therefore, if the machine is stopped with
the power off and the clipping head is not in the bottom
most position, the head may coast down. As the head coasts
down, the plates inside the head will close.
Keep hands and fingers out of the clipping head area, even
when power is off, unless you are absolutely certain the
clipping head is in the bottom most position. A serious
bruise or cut can result from having your hands inside the
head between the plates, or if your hands are between the
head and the table top.
Exercise extreme care when handling, sharpening, or
replacing the cut-off knife for the clipping head. A severe cut
from the razor-sharp edge may result if not handled properly.
Avoid directing the release of air pressure from the machine
toward yourself or others. Loose material within the air lines
can become imbedded beneath skin or cause eye injuries.
Use caution when touching or handling sheet metal parts
along edges. Some edges may be sharp enough to cut.
June, 2013 / 075-16395-000
1-5
Safety
NEVER reach into the package discharge chute when the
machine is running. If product becomes entangled, STOP the
machine.
DO NOT OVERRIDE ANY SAFETY INTERLOCKS ON THE
MACHINE! SERIOUS OR FATAL INJURY MAY OCCUR!
Packaging or handling hot products (above 250F [121C]) is
not recommended on this machine. Failure of product contact
parts, resulting in spills, leaks, and subsequent burns to
personnel may occur.
Packaging or handling food related products, if not
completely or properly cleaned from all contact surfaces of
the machine, may pose a sanitary health hazard. Contact a
professional familiar with the products and sanitary health
hazards you may encounter, and make the necessary
installations, modifications, or procedure changes. This
machine is not designed nor intended to fill all food related
liquids or products. Therefore, further consideration by you is
important.
Use care when handling clipping wire. Sharp wire ends can
scratch, cut, or puncture.
Electric motor surfaces can become quite hot to the touch.
First degree burns to skin are possible if contact is made. DO
NOT touch electric motor enclosures during or shortly after
operation.
Wear adequate hearing protection while in the vicinity of the
machine during operation. It is possible that prolonged
exposure to noise levels generated by the machine during
operation could have an affect on hearing.
If packaging food related products with this machine, avoid
use and contact with oils and lubricants that c ould
contaminate those products. Some oils and lubricants may
be hazardous to humans. When packaging food-related
products, use only food grade lubricants on the machine.
Refer to Lubrication on page 29-1 and Table 29-2 on page
-11.
The use of food grade lubricants is mandatory. Some food
grade lubricants are anti-microbial, some are not. It is your
responsibility to determine which type of food grade
lubricants best suit your application and facility.
1-6
075-16395-000 / June, 2013
Safety
If packaging food related products with this machine,
ALWAYS thoroughly clean the machine to remove all product
residue. Spoiled product serves as a host to a wide variety of
bacterium and will contaminate fresh product if contact is
made.
Heat exchanger fan blades can cause a serious cut or bruise
injury. DO NOT engage fingers or hand-held objects through
guarding into the blades.
CAUTION
ALWAYS start at the top of machine when removing pipe.
This will help avoid damaging the machine canopy.
ALWAYS start at the bottom of machine when installing pipe.
This will help avoid damaging the machine canopy.
This machine is designed for installation, use, and operation
in a classified non-hazardous location, free from explosive or
flammable gasses, dusts, and vapors.
NEVER make adjustments while the machine is in
operation.
Keep all wire covers and sealtite connectors tight to prevent
electrical shock.
WARNING
ELECTROCUTION SHOCK HAZARD

Servicing machine while standing on wet surface subjects
personnel to increased electrical shock hazards. Such
hazards may cause severe or fatal injury.
June, 2013 / 075-16395-000
1-7
Safety
DANGER
Do not alter any Control Enclosure or electrical connections
on the ChubMaker 4100 in any way. Also, do not connect
external wiring with any wiring in the machine controls other
than as shown on installation or wiring diagrams. Alterations
to this system could defeat safety features resulting in
malfunction of the machine and/or other serious hazards.
EXPOSED TERMINALS AND COMPONENTS INSIDE
ELECTRICAL ENCLOSURES, THAT ARE ELECTRICALLY
ENERGIZED, MAY CAUSE DEATH BY ELECTROCUTION, IF
TOUCHED. Only qualified and properly trained personnel are
to open the control cabinet door and work or replace
components contained inside.
NEVER assume power is off. ALWAYS turn OFF and LOCK
OUT the main electrical disconnect switch to the machine
before attempting repairs, service, or other maintenance.
NOTICE
ANY CHANGES TO THE MACHINE MAY REDUCE THE SAFETY
LEVEL OF THE MACHINE. PRIOR TO MAKING ANY CHANGES,
ALTERATIONS, OR MODIFICATIONS TO THE MACHINE, CONTACT
T H E R.A JONES & Co. E N G I N E E R I NG D E PA R T M E N T,
REGARDING SUCH CHANGES.
CAUTION
Do not touch drive motor or other energized device surfaces
during or shortly after operation. Surface temperatures can
cause a burn. Pull back reaction can lead to an impact injury
with surrounding components.
1-8
075-16395-000 / June, 2013
Specifications
The following specifications are subject to change without notice.
Specifications
This machine is designed for installation, use, and operation in a

classified non-hazardous location, free from explosive or
flammable gasses, dusts, and vapors.
Package Size Range
Diameter . . . . . . . . . . . . . . . 5/8 to 4-1/8 [15 mm to 104 mm]

Length. . . . . . . . Inside Cams - 6 to 12 [152 mm to 305 mm]
*Outside Cams - 12 to 16 [305 mm to 406 mm]
Weight. . . . . . . . . . . 1 oz. to 48 oz. [28 g to 1,350 g] nominal
Higher weights are possible, depending on product density.
Above sizes are those for which standard parts are available.
*Not all machines are equipped with outside cams.
Machine Speed
30 to 150 packages per minute (PPM), dependent upon

package size.
Machine Size
Crated Weight. . . . . . . . . . . . . . . . . . . . . 4,715 lbs. [2,143 kg]

**Crated Dimensions . . . . . . 124 wide x 72 deep x 96 high
[3,150 mm x 1,829 mm x 2,438 mm]
Maximum Net Weight . . . . . . . . . . . . . . . 4,200 lbs. [1,909 kg]
Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . 88 [2,235 mm]
Overall Depth . . . . . . . . . . . . . . . . . . . . . . . 57.5 [1,461 mm]
Overall Height (with Pump). . . . . . . . . . . . . . . . . . . . . . . . N/A
Overall Height (without Pump) . . . . . . . . . . 95.6 [2,428 mm]
**Approximate. Actual dimensions may vary. Mounting feet
removed for shipment.
June, 2013 / 075-16395-000
2-1
Specifications
Maximum Film Speed
1,350 inches per minute [34,290 mm/minute] - approximate

Seal Rate
The seal rate can exceed the film rate of the ChubMaker
4100 and, therefore, does not limit the speed of the machine.
Electrical Requirements
VOLTS
FLA
STD
AMPS
FLA
WITH
P-8
AMPS
FREQ.
PHASE
MAX
INTERRUPT
AMPS
MAX
MAX
LOAD
LOAD
W/O P-8 WITH P-8
200
208
230
380
40.28
51.66
50/60
65000
18
18.2
400
38.42
49.46
50/60
65000
18
18
415
37.14
47.56
50/60
65000
18
18
460
33.80
43.20
50/60
65000
18
18
575
*NOTE: Information was not available at the time of publication.
The chart above is provided as a reference. For specific

voltage/frequency/amps requirements for your machine, refer
to the manufacturers nameplate on the machine.
Air Requirements
Heat Seal . . . . . . . . . . . . . . . . 40 psig [280 kPa] @ 14 SCFM

*NOTE: Air requirements based on 80 packages per minute.
2-2
075-16395-000 / June, 2013
Specifications
Noise Emissions
Airborne Noise Emissions near machine, less than 88 db*

*A continuous A-Weighted sound pressure level
measurement has not been performed.
Wire Specifications
Available Wire Diameters
Standard . . . . . . . . . . . . . . . . . . . . 0.091 diameter +/- 0.001

. . . . . . . . . . . . . . . . . . . . . . . . 2.311 mm +/- 0.025 mm
Available . . . . . . . . . . . . . . . . . . . . 0.068 diameter +/- 0.001
. . . . . . . . . . . . . . . . . . . . . . . . 1.727 mm +/- 0.025 mm
. . . . . . . . . . . . . . . . . . . . . . . . 2.083 mm +/- 0.025 mm
Available . . . . . . . . . . . . . . . . . . 0.1055 diameter +/- 0.0010
. . . . . . . . . . . . . . . . . . . . . . . . 2.680 mm +/- 0.025 mm
. . . . . . . . . . . . . . . . . . . . . . . . 3.048 mm +/- 0.025 mm
Coil Size . . . . . . . . . 13.5 O.D. (max) x 8.17 I.D. x 3.5 Wide
. . . . 343mm O.D. (max) x 208 mm I.D. x 89 mm Wide
Recommended Wire Alloy
Aluminum with a tensile strength of

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28,000 psi to 32,000 psi
[193,054 kPa to 220,634 kPa]
Wire Supplier
R.A JONES & Co.
June, 2013 / 075-16395-000
2-3
Specifications
Notes . . . .
2-4
075-16395-000 / June, 2013
Principle of Operation
The ChubMaker 4100 Chub Packaging Machine packages
various food products with controlled weight and package size. The
package is a tube shape and is sealed at both ends with wire clips.
The machine forms the package tube from roll film, introduces
product into the package tube, seals and clips the package, and
separates each package from the formed tube.
Plastic films are used for package material. A wide variety of poly
films are sealable with hot air. Hot air is directed in a narrow stream
onto the film overlap.
Film is fed through a series of rollers and over a folder. The folder
forms the film into a tube shape. The film is next sealed through the
overlapped area to form an airtight tube.
Product is pumped through a mandrel which is inside the formed
film tube. A variable-speed, positive-displacement metering pump is
used to pump product into the package. By controlling pump flow
rate, rate of tube formation, and machine clipping speed, weight and
length of packages are maintained.
The tube-shaped film containing the product is propelled by a set of
drive wheels. Drive wheels are powered by a variable speed electric
motor. Below the drive wheels are a set of squeeze rolls. These
squeeze rolls contact the filled tube to squeeze the product up
around the mandrel. This helps to minimize air in the package.
Positioned below the squeeze rolls would be the optional voider
rolls. Voider rolls automatically exclude product from the tube where
clips will be applied. This helps to minimize clip cuts and to
maximize clean package ends when running viscous products.
Clipping takes place in the clipping head. When the closure plates
come together, the top of one package and the bottom of the next
package are clipped. At this point, wire has already been fed from
the wire coils, cut to length, preformed, and positioned to be
clinched around the gathered package film. Before the closure
plates open, a cut-off knife cuts the gathered film midway between
the two clips. The lower package is now complete and slides down
the package discharge chute into a customer supplied container or
take-away conveyor.
June, 2013 / 075-16395-000
3-1
Notes . . . .
3-2
075-16395-000 / June, 2013
Installation
Uncrating
Installation
Carefully unpack the machine and check for damage. If any

damage is noted, contact the delivering carrier
immediately. Hold all shipping papers for the R.A JONES &
Co. Service Representative.
Machine Installation
Move the machine to its approximate location for production.

Consideration should be given for access to the machine for
adjustments, maintenance, lubrication, and repairs. Enough
room must also be allowed for any auxiliary equipment.
If your machine was ordered with certain accessories, they
may have been removed and packed separately for shipping.
The machine table must be level in all directions. Use the
adjustable feet supplied with the machine, to make
adjustments. Fasten the machine to the floor using
heavy-duty bolt anchors.
NOTICE
With certain options, or at high operating speeds, the
ChubMaker 4100 may become unstable if not properly
anchored to the floor. Make certain the machine is securely
anchored to the floor at all four (4) feet.
Make the necessary electrical connections. Only a qualified
electrician is to perform electrical power and ground
connections.
WARNING
Electrical wiring components and procedures MUST conform

to applicable sections of the NATIONAL ELECTRICAL CODE
and all applicable state and local codes. Electric power
supplied, must be as specified on manufacturers nameplate.
June, 2013 / 075-16395-000
4-1
Installation
Main Air Supply
Air supplied to the machine should be piped through a

minimum 1/2 [13 mm] inside diameter line, in order to
provide enough volume as well as pressure. We strongly
recommend the supply line be other than steel or iron to
prevent rust and foreign material from entering pneumatic
components of the machine. Supply air must be clean and
free of water.
16 [406 mm] Diameter

Film Roll
B
C
Film Control
3 Male Sanitary Thread
D
E
F
G
PanelView
Operator Controls
Handwheel
Lift Fork Location
Figure 4-1: Installation Drawing - Front View
4-2
075-16395-000 / June, 2013
Installation
E
D
A
*B
C
D
19.3 [490 mm]

E
5.5 [140 mm]
24.6 [625 mm]
F
17.6 [447 mm]
87.8 [2,230 mm]
G 10 [254 mm]
45 [1,143 mm]
*H 15.3 389 mm]
*NOTE: Dimension is nominal +/- 1 [25 mm].
June, 2013 / 075-16395-000
4-3
Installation
K
J
I
H
G
F
D
E
C
B
A
B
C
D
E
F
6.1 [155 mm]

G *41.3 [1,049 mm]
13.2 [335 mm]
H 90.3 [2,294 mm]
*18.5 [470 mm]
I
*95.6 [2,428 mm]
24.8 [630 mm]
J
3 Male Sanitary Thread
*30.1 [765 mm]
K
39.9 [1,013 mm]
36 [914 mm]
L
38o
4-4
075-16395-000 / June, 2013
Installation
W
U
X
V
T
R
Y
N
M
Q
M
N
O
P
Q
R
S
34.9 [886 mm]

Lifting forks much reach
through entire width of
machine.
14.7 [373 mm]
7.4 [188 mm]
2.6 [66 mm]
*12.6 [320 mm]
43.6 [1,107 mm]
June, 2013 / 075-16395-000
T
U
*48.8 [1,240 mm]

83.3 [2,108 mm]
V
W
X
Y
*88.5 [2,248 mm]

85.1 [2,162 mm]
*90.4 [2,296 mm]
*5.3 [135 mm] (Height
adjustment for leveling
only.)
4-5
Installation
3/8 NPT Air Supply - 100

psig [7 BAR] 120 scfm
maximum
Wire Lubricator - Use
food grade oil. See Table
29-2 on page 29-11.
Wire Feed Controls
Reservoir - Requires 20
to 25 gallons [78 to 95
liters] food grade oil. See
Table 29-2 on page
29-11.
Reservoir Oil Drain Valve
Figure 4-4: Installation Drawing - Rear View
4-6
075-16395-000 / June, 2013
Installation
H
I
J
F
A
E
C
D
A
B
C
D
E
14.5 [368 mm] Maximum Film Roll Width

1.7: [43 mm]
5.2 [130 mm]
25 [635 mm]
19.9 [505 mm] Radius Folded Door Swing
F
G
H
I
J
36 [914 mm] Radius Door Swing

13.8 [351 mm]
19.9 [505 mm] Radius Folded Door Swing
5.1 [130 mm]
5.7 [825 mm]
Figure 4-5: Installation Drawing - Top View
June, 2013 / 075-16395-000
4-7
Installation
Notes . . . .
4-8
075-16395-000 / June, 2013
Machine Controls
The information on the following pages describes the machine
controls for the ChubMaker 4100.
Machine Controls
A
B
C
PanelView
Start / Stop Controls
Handwheel
D
E
Function Controls
Film Arbor / Squeeze
Rolls Controls
Figure 5-1: ChubMaker 4100 Front Controls
June, 2013 / 075-16395-000
5-1
Machine Controls
Start / Stop Controls
Figure 5-2: Start / Stop Controls

The Start / Stop Controls are located directly beneath the
PanelView, and provide the following:
A SYSTEM RESET PUSH BUTTON: Pulls in master control
relay, allows power to outputs. Functional only if all
safety/alarm conditions are met.
B CYCLE STOP PUSH BUTTON: Stops the machine, when
pushed, by allowing the machine to finish the current cycle.
This avoids making unnecessary partial or incomplete
packages and enables the system to utilize remaining
product.
C EMERGENCY STOP MUSHROOM PUSH BUTTON:
Stops all machine motion, then drops master control relay.
Removes power from output devices.
5-2
075-16395-000 / June, 2013
Machine Controls
Notes . . . .
June, 2013 / 075-16395-000
5-3
Machine Controls
Function Controls
Figure 5-3: Function Controls

A HOT AIR PRESSURE GAGE: This gage indicates air
pressure for sealer hot air.
B HOT AIR PRESSURE REGULATOR: Turn clockwise to
increase hot air pressure; counter-clockwise to decrease hot
air pressure.
C VOIDER GAGE (OPTIONAL): This gage indicates air
pressure for open and close voider rollers.
D VOIDER REGULATOR (OPTIONAL): Turn clockwise to
increase air pressure; counter-clockwise to decrease air
pressure to voider rollers.
E COLD AIR PRESSURE GAGE: This gage indicates air
pressure for sealer cool air.
F COLD AIR PRESSURE REGULATOR: Turn clockwise to
increase cool air pressure; counter-clockwise to decrease
cool air.
5-4
075-16395-000 / June, 2013
Machine Controls
G HANDWHEEL SWITCH: Turn to ENGAGE to allow use of
the handwheel; to DISENGAGE to make the handwheel
non-functional.
H WIRE CLAMP OFF/ON SWITCH: Turn to OFF to prevent
formation of package clips; to ON to allow package clips to be
made.
June, 2013 / 075-16395-000
5-5
Machine Controls
Film Tension / Squeeze Roll Controls / Product Piston Controls
Figure 5-4: Film Tension / Squeeze Roll Controls

A PRODUCT PISTON RETRACT: This flow control will
control the speed of travel for retracting the product piston.
Tu r n f l o w c o n t r o l c l o c k w i s e t o r e s t r i c t t h e f l o w o r
counterclockwise to open the flow.
B PRODUCT PISTON EXTEND: This flow control will control
the speed of travel for extending the product piston. Turn flow
control clockwise to restrict the flow or counterclockwise to
open the flow.
C SQUEEZE ROLL ADJUST: Turn clockwise to bring the
squeeze rolls together closer. Turn counter-clockwise to set
the squeeze rolls farther apart.
D FILM TENSION PRESSURE GAGE: This gage indicates
air pressure for the film tension air cylinder.
5-6
075-16395-000 / June, 2013
Machine Controls
E F I L M T E N S I O N P R E S S U R E R E G U L ATO R : Tu r n
clockwise to increase air pressure; counter-clockwise to
decrease air pressure to the film tension air cylinder.
F FILM TENSION SWITCH: Turn to OFF to deactivate the
film tension air cylinder; to ON to activate the film tension air
cylinder.
A
B
Air Control
Wire Clamp Controls
Reservoir Oil Drain Valve
Figure 5-5: ChubMaker 4100 Rear Controls
June, 2013 / 075-16395-000
5-7
Machine Controls
Air Control
Figure 5-6: Air Control

A SHUTOFF / EXHAUST VALVE: Turn the knob to position
A1 to allow air flow to the system. Turn to the knob to
position A2 to shut off the air supply to the machine and
exhaust the machine system of air. In the illustration below,
arrow F indicates the direction of air flow.
B PRESSURE REGULATOR: Turn clockwise to increase air

pressure; counter-clockwise to decrease system air pressure.
C PRESSURE GAGE: This gage indicates system air
pressure.
5-8
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Machine Controls
Wire Clamp Controls
Figure 5-7: Wire Clamp Controls

A WIRE CLAMP PRESSURE GAGE: This gage indicates
the pressure supplied to the wire clamp air cylinders.
B WIRE CLAMP PRESSURE REGULATOR: Turn clockwise
to increase air pressure; counter-clockwise to decrease wire
clamp air pressure.
D WIRE CLAMP SWITCH: Turn to OFF to prevent formation
of package clips; to ON to allow package clips to be made.
June, 2013 / 075-16395-000
5-9
Machine Controls
PanelView
Figure 5-8: PanelView

The PanelView display is a touch screen, enabling the
operator and maintenance personnel to access various
portions of the control program. Touching a displayed pad or
button, actuates the associated function.
Screens
The following illustrations represent the various display

screens for the ChubMaker 4100. Some screens are
password restricted; requiring a password to gain access.
5-10
075-16395-000 / June, 2013
Machine Controls
Notes . . . .
June, 2013 / 075-16395-000
5-11
Machine Controls
10/15/2007 9:15:23
DRIVE NOT READY
SPEED
(PPM)
POSITION
(DEG)
EON #####
NNN
NNN
ChubMaker 4100
807 West Kimberly Road Davenport IA 52806 USA

Ph (800) 257-5622 (563) 391-0000 Fax (563)-391-0699
www.oystar.packt.com
HOME
RUN
SENSOR
HEATER
CONTROL CONTROL CONTROL
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Figure 5-9: HOME Screen

This screen is the first to display upon powering the machine,
once the program has loaded.
10/15/2007 . . .: This is the date and time indicator.
DRIVE NOT READY: This panel displays important status
information, including the following:
MCR OFF: - The master control relay is not energized.
SERVO / DRIVE NOT READY: - The machine control
program is initializing.
READY: - The machine is ready.
CYCLE STOP: - The machine is in a cycle stop mode.
CYCLE PAUSE: - The machine is in a cycle pause
mode.
JOGGING: - The machine is jogging.
RUNNING: - The machine is running packages.
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075-16395-000 / June, 2013
Machine Controls
ALARM: - An alarm is active.
SEALER TEMP LOW: - The sealer temperature is
low, requiring attention.
MANUAL MODE: - The machine is being operated in
manual mode.
WAITING FOR REGN MARK: - The machine has
temporarily halted and is waiting for a registration
mark to continue.
SENSOR OVERRIDE: The machine is operating with
the sensor functions in override.
SPEED (PPM): This displays the speed of the machine in
packages per minute.
POSITION (DEG): This displays the position of the under
carriage main shaft in radial degrees from 0 to 360.
EON. . . .: This shows the machines serial number.
ChubMaker 4100: Indicates the machine model.
HOME: This pad is greyed out and has no function on this
screen.
R U N C O N T R O L : To u c h t h i s pa d t o o p e n t h e R U N
CONTROL 1 screen.
SENSOR CONTROL: Touch this pad to open the SENSOR
CONTROL screen.
HEATER CONTROL: Touch this pad to open the HEATER
CONTROL screen.
ACTIVE ALARMS: Touch this pad to open the ACTIVE
ALARMS screen.
ALARM HISTORY: Touch this pad to open the ALARM
HISTORY screen.
SETUP: Touch this pad to open the MAINTENANCE SETUP
screen.
June, 2013 / 075-16395-000
5-13
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
##.# %
ENGAGE FILM
OPEN
CLOSE
HOME
RUN
RUN *
CONTROL
REG ERROR %
PACKAGE
LENGTH
#####
##.##mm
in
SENSOR
CONTROL
HEATER
CONTROL
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
Figure 5-10: RUN CONTROL 1 Screen

RESET: Touch this pad to reset the production count to 0.
(LEFT) CURSOR: Touch this pad to scroll through the
RUN CONTROL screens.
(RIGHT) CURSOR: Touch this pad to scroll through the
HEAT SEAL FRAME
RAISE: Touch this pad to raise the heat seal frame
away from the package tube.
AUTO: Touch this pad to allow the heat seal frame to
raise and lower according to programmed parameters.
(Recommended for production runs.)
LOWER: Touch this pad to lower the heat seal frame
to the sealing position along the package tube.
ENGAGE FILM - OPEN / CLOSE: Touch this area to toggle
the film drive wheels. When OPEN, the film drive wheels
are disengaged and will not pull film through the machine.
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Machine Controls
When CLOSE, the film drive wheels are engaged and will
pull film through the machine.
FILM - OFF / ON: Touch this area to toggle the film drive
motor. When OFF, the motor is stopped and the film drive
wheels do not rotate. When ON, the motor is running and
the film drive wheels will rotate.
PUMP - OFF / ON: Touch this area to toggle the optional
pump. When OFF, the pump is not operating. When ON,
the pump is operating.
CLIP - OFF / ON: Touch this area to toggle the clip drive
servo motor. When OFF, the motor is stopped and the
clipping head does not raise or lower. When ON, the motor
is running and the clipping head raises and lowers.
PACKAGE LENGTH ##### mm: This displays the package
length in millimeters. (Inch display is also available.) Touch
this area to change. A numeric keypad will display. Key in the
new value and press ENTER to confirm.
(DOWN) CURSOR: Touch this pad to decrease the
package length one increment at a time.
(UP) CURSOR: Touch this pad to increase the
PACKAGE WEIGHT ##### gm: This displays the package
weight in grams. Touch this area to change. A numeric
keypad will display. Key in the new value and press ENTER
to confirm. OR:
package weight one increment at a time.
package weight one increment at a time.
June, 2013 / 075-16395-000
5-15
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
##.# %
ENGAGE FILM
OPEN
CLOSE
HOME
RUN
RUN *
CONTROL
REG ERROR %
PACKAGE
LENGTH
#####
##.##mm
in
SENSOR
CONTROL
HEATER
CONTROL
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
MACHINE SPEED ###.# ppm: This displays the machine

speed in packages per minute (ppm). Touch this area to
change. A numeric keypad will display. Key in the new value
and press ENTER to confirm.
machine speed one increment at a time.
machine speed one increment at a time.
HOME: Touch this pad to open the HOME screen.
RUN CONTROL: This pad is greyed out and has no function
on this screen.
CONTROL screen.
CONTROL screen.
ALARMS screen.
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Machine Controls
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-17
Machine Controls
PRODUCTION
COUNT
JOGGING
VOIDER
OFF
ON
VOID
POSITION
#####
##.##mm
in
HOME
RUN
CONTROL
SENSOR
RUN
CONTROL
CONTROL 2
SCREEN 1
RESET
NNNNNNNNNN
PRODUCT
PISTON
OFF
LEFT
ON
SIDELAY
ADJUST
RIGHT
VOID
LENGTH
#####
##.##mm
in
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

VOIDER - OFF / ON: Touch this area to toggle the voider.
When OFF, the voider system does not function. When
ON, the voider system does function.
VOIDER POSITION ##### in: This displays the voider
position in inches. (Millimeter display is also available.) Touch
voider position one increment at a time.
voider position one increment at a time.
5-18
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Machine Controls
VOIDER LENGTH ##### in: This displays the package
length in inches. (Millimeter display is also available.) Touch
voider length one increment at a time.
voider length one increment at a time.
PRODUCT PISTON - OFF / ON: Touch this area to toggle
the product piston. When OFF, the product piston does not
function. When ON, the product piston does function.
SIDELAY ADJUST: Touch the LEFT or RIGHT buttons to
adjust the sidelay left or right.
on this screen.
CONTROL screen.
CONTROL screen.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-19
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
REGISTRATION
OFF
DATER
CLUTCH BRAKE
ON
OFF
LABEL
POSITION
#####
##.##mm
in
HOME
RUN
CONTROL 3
RESET
OFF
ON
CLIPPING SPEED
FINE ADUST
###.# %
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ON
PRINT
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

REGISTRATION - OFF / ON: Touch this area to toggle
package registration. When OFF, the registration system
does not function. When ON, the registration system does
function.
LABEL POSITION ##.## in: Displays the label position in
inches. Touch this area to change. A numeric keypad will
display. Key in the new value and press ENTER to confirm.
OR:
(DOWN) CURSOR: Touch this pad to lower the
label position on the package one increment at a time.
(UP) CURSOR: Touch this pad to raise the label
position on the package one increment at a time.
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Machine Controls
CLUTCH BRAKE - OFF / ON: Touch this area to toggle the
clutch brake. When OFF, the clutch brake does not
function. When ON, the clutch brake does function.
CLIPPING SPEED FINE ADJUST ###.#%: Displays the
clipping speed fine adjustment in a percentage. Touch this
area to change. A numeric keypad will display. Key in the new
value and press ENTER to confirm. OR:
DATER - OFF / ON: Touch this area to toggle the dater.
When OFF, the dater does not imprint onto the package
film. When ON, the dater imprints onto the package film.
PRINT POSITION ##.## in: Displays the print position in
inches. Touch this area to change. A numeric keypad will
display. Key in the new value and press ENTER to confirm.
OR:
print position on the package one increment at a time.
(UP) CURSOR: Touch this pad to raise the print
on this screen.
CONTROL screen.
CONTROL screen.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-21
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
RECIPE NAME
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
VALUE
SETTING
PACKAGE LENGTH
PACKAGE WEIGHT
FEEDER PUMP RATIO
PACKAGING SPEED
SEAL TEMPERATURE
REGISTRATION LABEL PSN
VOIDER 0=OFF 1=ON
VOIDER POSITION
VOID LENGTH
PRINT POSITION
CLUTCH BRAKE 0=OFF 1=ON
CLUTCH BRAKE FINE ADJ
HEATED PIPING TEMP
Restore
HOME
SENSOR
RUN
CONTROL
CONTROL 4
SCREEN 1
RESET
Download
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

RECIPE NAME: This box lists recipes that have been saved.
DOUBLE ARROW (UP): Touch this button to scroll up
through the list a page at a time.
(UP) CURSOR: Touch this pad to cursor up through
the list of recipes.
(DOWN) CURSOR: Touch this pad to cursor down
through the list of recipes.
DOUBLE ARROW (DOWN): Touch this button to
scroll down through the list a page at a time.
RESTORE: Touch this pad to restore a recipe.
5-22
075-16395-000 / June, 2013
Machine Controls
DOWNLOAD: Touch this pad to write the selected recipe into
the active machine settings.
NOTE: Parameter values may change as different recipes
are highlighted.
SETTING: This listing of adjustable parameters are factory
set. Not all parameters listed will have application to all
machines. Only authorized and properly trained persons
should make changes to any parameter.
VALUE: Touch the pad under VALUE that corresponds to the
parameter you wish to adjust. A numeric keypad will display.
Key in the new value and touch ENTER to confirm.
on this screen.
CONTROL screen.
CONTROL screen.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-23
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
EXT RUN
PERMISS
OVERRIDE
AUTO
HOME
SENSOR
CONTROL
RESET
END OF FILM
OVERRIDE
OVERRIDE AUTO
RUN
CONTROL
SENSOR
CONTROL
OVERRIDE
HEATER
CONTROL
END OF WIRE
OVERRIDE
AUTO
OVERRIDE
ACTIVE
ALARMS
BREAKOUT DET
OVERRIDE
AUTO
OVERRIDE
ALARM
HISTORY
SETUP
Figure 5-14: SENSOR CONTROL Screen

EXT RUN PERMISS OVERRIDE - AUTO / OVERRIDE:
Touch this area to toggle the external run permission
override. When AUTO, the override feature will not function
and the external sensor will respond. When OVERRIDE,
the override feature will function and the external sensor will
not respond.
END OF FILM OVERRIDE - AUTO / OVERRIDE: Touch this
area to toggle the end of film override. When AUTO, the
override feature will not function and the end of film sensor
will respond when the end of film is reached. When
OVERRIDE, the override feature will function and the end of
film sensor will not respond when the end of film is reached.
END OF WIRE OVERRIDE - AUTO / OVERRIDE: Touch this
area to toggle the end of wire override. When AUTO, the
override feature will not function and the end of wire sensor
will respond when the end of wire is reached. When
OVERRIDE, the override feature will function and the end of
wire sensor will not respond when the end of wire is reached.
5-24
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Machine Controls
BREAKOUT DET OVERRIDE - AUTO / OVERRIDE: Touch
this area to toggle the package breakout detector override.
When AUTO, the override feature will not function and the
package breakout sensor will respond when product breaks
out of the package tube. When OVERRIDE, the override
feature will function and the package breakout sensor will not
respond when product breaks out of the package tube.
CONTROL 1 screen.
SENSOR CONTROL: This pad is greyed out and has no
function on this screen.
CONTROL screen.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-25
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
HEAT SEALER
HEAT
SEALER
OFF
HEATER
CONTROL
RESET
ON
MEASURED
MEASURED == #####
#####C
F
STATUS
AT TEMP
SET POINT =
HEATED PIPING
PUMP
OFF
ON
HEATED PIPING
HEATERS
OFF
ON
#####C
####F
HEATED PIPING
MEASURED = ###.# C
F
STATUS
AT TEMP
SET POINT =
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
##.#C
##.#F
ALARM
HISTORY
SETUP
Figure 5-15: HEATER CONTROL Screen

HEAT SEALER - OFF / ON: Touch this area to toggle the
heat sealer. When OFF, heat is not generated within the
sealing unit. When ON, heat is generated within the sealing
unit.
HEAT SEALER
MEASURED = ##### o C: Displays the measured
temperature of the heat seal. The horizontal bar graph
shows the measured temperature along the top,
corresponding to the value displayed.
SET POINT = ##### o C: Displays the set point
temperature of the heat seal. The horizontal bar graph
shows the set point temperature along the bottom,
corresponding to the value displayed. Touch ##### oC
to change the set point value. A numeric keypad will
display. Key in the new value and touch ENTER to
confirm. The new set point temperature will now
display.
STATUS - SENSOR BREAK: This panel displays
important status information, including the following:
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075-16395-000 / June, 2013
Machine Controls
SENSOR BREAK: Indicates the thermocouple
wiring has a break and needs to be replaced.
OFF: Indicates the heat sealer is turned OFF.
STAND-BY: Indicates the heat sealer is in
stand-by mode.
HEATING: Indicates the heat sealer is heating
up, but not yet at the set point temperature.
AT TEMP: Indicates the heat sealer is at
operating temperature.
June, 2013 / 075-16395-000
5-27
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
HEAT SEALER
HEAT
SEALER
OFF
HEATER
CONTROL
RESET
ON
MEASURED
MEASURED == #####
#####C
F
STATUS
AT TEMP
SET POINT =
HEATED PIPING
PUMP
OFF
ON
HEATED PIPING
HEATERS
OFF
ON
#####C
####F
HEATED PIPING
MEASURED = ###.# C
F
STATUS
AT TEMP
SET POINT =
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
##.#C
##.#F
ALARM
HISTORY
SETUP
HEATED PIPING PUMP - OFF / ON: Touch this area to

toggle the heated piping pump OFF or ON.
HEATED PIPING HEATERS - OFF / ON: Touch this area to
toggle the heated piping. When OFF, heat is not generated
within the heated piping unit. When ON, heat is generated
within the heated piping unit.
HEATED PIPING
MEASURED = ##### o C: Displays the measured
temperature of the heated piping. The horizontal bar
graph shows the measured temperature along the top,
corresponding to the value displayed.
SET POINT = ##### o C: Displays the set point
temperature of the heated piping. The horizontal bar
graph shows the set point temperature along the
bottom, corresponding to the value displayed. Touch
##### o C to change the set point value. A numeric
keypad will display. Key in the new value and touch
ENTER to confirm. The new set point temperature will
now display.
STATUS - AT TEMP: This panel displays important
status information, including the following:
5-28
075-16395-000 / June, 2013
Machine Controls
SENSOR BREAK: Indicates the thermocouple
wiring has a break and needs to be replaced.
OFF: Indicates the heated piping is turned
OFF.
STAND-BY: Indicates the heated piping is in
stand-by mode.
HEATING: Indicates the heated piping is
heating up, but not yet at the set point
temperature.
AT TEMP: Indicates the heated piping is at
operating temperature.
CONTROL 1 screen.
CONTROL screen.
HEATER CONTROL: This pad is greyed out and has no
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-29
Machine Controls
?
1:04:06 PM 6/28/2011
Active Alarms
Qty Acc Time Message
9999 00:00:00 ABCDE FGHIJK LMNOPQ RSTUV WXYZ ABCDE FGHIJK LMNOPQ RSTUV WXYZ
PREVIOUS
SCREEN
HOME
RUN
CONTROL
SENSOR
CONTROL
PREVIOUS
SCREEN
HEATER
CONTROL
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Figure 5-16: ACTIVE ALARMS Screen

This screen lists current active alarms.
(DOWN) CURSOR: Touch this pad to cursor down through
the list of alarms.
(UP) CURSOR: Touch this pad to cursor up through the
list of alarms.
PREVIOUS SCREEN: Touch this pad to return to the
previously viewed screen.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
ACTIVE ALARMS: This pad is greyed out and has no
5-30
075-16395-000 / June, 2013
Machine Controls
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-31
Machine Controls
ALARM HISTORY
Alarm time
* 6/12/2007 7:17:05 AM
Acknowledge time
6/12/2007 7:17:05 AM
Message
ABCDE FGHIJK LMNOPQ RSTUV WXYZ ABC*
CLEAR
HISTORY
HOME
RUN
SENSOR
HEATER
ACTIVE
ALARMS
PREVIOUS
SCREEN
ALARM
HISTORY
SETUP
Figure 5-17: ALARM HISTORY Screen

This screen lists the history of alarms.
the list of alarms.
list of alarms.
CLEAR HISTORY: Touch this pad to clear the alarm history.
If an alarm has not been corrected, it cannot be cleared from
the history.
PREVIOUS SCREEN: Touch this pad to return to the
previously viewed screen.
CONTROL 1 screen.
CONTROL screen.
5-32
075-16395-000 / June, 2013
Machine Controls
CONTROL screen.
ALARMS screen.
ALARM HISTORY: This pad is greyed out and has no
screen.
June, 2013 / 075-16395-000
5-33
Machine Controls
PRODUCTION
COUNT
JOGGING
MAINTENANCE
SELECT
RESET
NNNNNNNNNN
PARAMETER
MAINT
RECIPE MAINT
PLS
SETUP
REGN
DIAGN
IO
DIAGNOSTICS
SERVO HOME
MAINT
ENGLISH
PANEL
VIEW
CONFIG
HOME
LOG IN
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ESPAOL
LOG OUT
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Figure 5-18: MAINTENANCE SETUP Screen

PA R A M E T E R M A I N T: To u c h t h i s p a d t o o p e n t h e
PARAMETER MAINTENANCE 1 screen. Requires login.
RECIPE MAINT: Touch this pad to open the RECIPE
MAINTENANCE 1 screen. Requires login.
PLS SETUP: Touch this pad to open the PLS SETUP 1
screen. Requires login.
REGN DIAGN: Touch this pad to open the REGISTRATION
DIAGNOSTICS screen. Requires login.
IO MAINT: Touch this pad to open the IO DIAGNOSTICS 1
screen. Requires login.
SERVO HOME MAINT: Touch this pad to open the SERVO
HOME MAINTENANCE screen. Requires login.
LOG IN: Touch this pad to open a keypad and window. Key in
your password and touch ENTER to confirm.
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Machine Controls
LOG OUT: Touch this pad to log out. This prevents others
from accessing certain restricted areas of the program.
PANELVIEW CONFIG: Touch this pad to configure the
PanelView settings.
ENGLISH: Touch this area of the screen to select English
displays.
ESPAOL: Touch this area of the screen to select Spanish
displays.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
ALARMS screen.
HISTORY screen.
SETUP: This pad is greyed out and has no function on this
screen.
June, 2013 / 075-16395-000
5-35
Machine Controls
PRODUCTION
COUNT
JOGGING
PARAMETER
MAINT 1
RESET
NNNNNNNNNN
PARAMETER
VALUE
UNIT
1 FILM CALIBRATE
####.#
NUM
2 PUMP CALIBRATE
####.#
3 CLIP CALIBRATE
####.#
NUM
4 SEALER 1=Heat 2=RF3=Extruder
NUM
5 UNITS 0=Metric 1=English
NUM
6 HEATSEAL: Proportional
##.#####
NUM
7 HEATSEAL: Integral
##.#####
NUM
8 HEATSEAL: Derivative
##.#####
NUM
9 HEATSEAL: Feed Forward
##.#####
NUM
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
PANEL
VIEW
CONFIG
ACTIVE
ALARMS
GRAM/MIN
ALARM
HISTORY
SETUP
Figure 5-19: PARAMETER MAINTENANCE 1 Screen

This is the first in a series of eight screens. Not all parameters
listed within the screen series, are options on any specific
machine.
PARAMETER MAINTENANCE screens.
PARAMETER: This listing of adjustable parameters are
factory set. Not all parameters listed will have application to
all machines. Only authorized and properly trained persons
5-36
075-16395-000 / June, 2013
Machine Controls
UNIT: The listed units correspond to the adjacent value for
each parameter. Units listed are:
NUM - This indicates a number, relative to the
parameter.
GRAM/MIN - This indicates grams per minute.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
PanelView settings.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-37
Machine Controls
PRODUCTION
COUNT
JOGGING
PARAMETER
MAINT 2
RESET
NNNNNNNNNN
VALUE
UNIT
10 HEATED PIPING? 0=No 1=Yes
NUM
11 HEATED PIPING: Proportional
#####
NUM
12 HEATED PIPING: Integral
#####
NUM
13 HEATED PIPING: Derivative
#####
NUM
14 BRAKE:1=Clutch 2=Clamp 3=Servo
#####
NUM
PARAMETER
15 REGISTRATION LIMIT: Increase
##.#
16 REGISTRATION LIMIT: Decrease
##.#
17 LANGUAGE: 1=English 2= 2nd Language
NUM
18 CHECKWEIGHER: 0=No,1=Pump,2=PPM
NUM
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
PANEL
VIEW
CONFIG
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

parameter.
% - This indicates percent.
5-38
075-16395-000 / June, 2013
Machine Controls
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
PanelView settings.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-39
Machine Controls
PRODUCTION
COUNT
JOGGING
PARAMETER
MAINT 3
RESET
NNNNNNNNNN
PARAMETER
VALUE
UNIT
19 EXTRUDER DIE ZONE: Proportional
#####
NUM
20 EXTRUDER DIE ZONE: Integral
#####
NUM
21 EXTRUDER DIE ZONE: Derivative
#####
NUM
22 EXTRUDER DIE ZONE: Max Temp
#####
NUM
23 EXTRUDER MELT ZONE: Proportional
#####
NUM
24 EXTRUDER MELT ZONE: Integral
#####
NUM
25 EXTRUDER MELT ZONE: Derivative
#####
NUM
26 EXTRUDER MELT ZONE: Max Temp
#####
NUM
27 EXTRUDER FEED ZONE: Proportional
#####
NUM
ACTIVE
ALARMS
ALARM
HISTORY
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
PANEL
VIEW
CONFIG
SETUP

parameter.
5-40
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Machine Controls
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
PanelView settings.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-41
Machine Controls
PRODUCTION
COUNT
JOGGING
PARAMETER
MAINT 4
RESET
NNNNNNNNNN
PARAMETER
VALUE
UNIT
28 EXTRUDER FEED ZONE: Integral
#####
NUM
29 EXTRUDER FEED ZONE: Derivative
#####
NUM
30 EXTRUDER FEED ZONE: Max Temp
#####
DEG
##.#
NUM
32 CUTOFF:1=Internal 2=External
NUM
33 CUTOFF POSITION: 0-360Deg
###.#
DEG
34 CUTOFF TIME
#.###
SEC
35 EON #
#####
NUM
NUM
31
36 EASY OPEN? 0=No 1=Yes
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
PANEL
VIEW
CONFIG
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

5-42
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Machine Controls
parameter.
DEG - This indicates radial degrees or temperature,
depending on the parameter.
SEC - This indicates seconds.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
PanelView settings.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-43
Machine Controls
PRODUCTION
COUNT
JOGGING
PARAMETER
MAINT 5
RESET
NNNNNNNNNN
PARAMETER
VALUE
UNIT
37 EZO KNIFE POSITION
###.#
DEG
38 EZO KNIFE DELAY
#.###
SEC
39 EZO FEED POSITION
###.#
DEG
40 EZO FEED DELAY
#.###
SEC
41 EZO VACUUM DELAY
#.###
SEC
42 BLOW OFF DELAY
#.###
SEC
43 BLOW OFF DURATION
#.###
SEC
44 SEAL BAR IN POSITION
###.#
DEG
45 SEAL BAR IN DELAY
#.###
SEC
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
PANEL
VIEW
CONFIG
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

5-44
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Machine Controls
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
PanelView settings.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-45
Machine Controls
PRODUCTION
COUNT
JOGGING
PARAMETER
MAINT 6
RESET
NNNNNNNNNN
VALUE
UNIT
46 SEAL BAR OUT DELAY
#.###
SEC
47 SEAL BAR CHECK
###.#
DEG
48 EZO FILM BLOWER
###.#
DEG
49 HEAT SEAL: Max Temp
#####
DEG
50 WIRE FEED: Position
###.#
DEG
51 WIRE FEED: Delay
#.###
SEC
52 VOIDER: Ratio: Voider Speed / Film Speed
#.###
NUM
53 DATER: Print Time
#.###
SEC
54 DATER: Actuation Delay
#.###
SEC
PARAMETER
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
PANEL
VIEW
CONFIG
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

5-46
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Machine Controls
parameter.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
PanelView settings.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-47
Machine Controls
PRODUCTION
COUNT
JOGGING
PARAMETER MAINT
7
RESET
NNNNNNNNNN
PARAMETER
55 EASY PEEL: Knife Delay

56 PROD PRESS:0=None,1=Analog,2=Switch
VALUE
UNIT
#.###
SEC
PSI
57 PRODUCT PRESS: Sensor Range
###.##
BAR
58 PRODUCT PRESS: Max Pressure
###.##
PSI
59 PRODUCT PRESS: Min Press Delay
#.###
SEC
60 PRODUCT PRESS: Max Press Delay
#.###
SEC
61 PRODUCT PRESS: Init Delay
#.###
SEC
62
#####
NUM
63 REG'N:Clamp Intercept 30ppm
###.#
DEG
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
PANEL
VIEW
CONFIG
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

5-48
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Machine Controls
parameter.
BAR - This indicates pressure.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
PanelView settings.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-49
Machine Controls
PRODUCTION
COUNT
JOGGING
PARAMETER MAINT
8
RESET
NNNNNNNNNN
VALUE
UNIT
64 REG'N:Clamp Intercept 120ppm
###.#
DEG
65 MIST LUBE: On Time
#.###
SEC
66 MIST LUBE: Interval
#.###
SEC
67 SEALARM: In Delay
#.###
SEC
68 SEALARM: Out Delay
#.###
SEC
69 MASTER LOCK POSITION
###.#
NUM
70
###.#
71
#.###
72
#.###
PARAMETER
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
PANEL
VIEW
CONFIG
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

5-50
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Machine Controls
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
PanelView settings.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-51
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
RECIPE NAME
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
Save
Rename
Restore
Delete
HOME
RUN
CONTROL
RECIPE
MAINTENANCE
RESET
VALUE
SETTING
PACKAGE LENGTH
PACKAGE WEIGHT
FEEDER PUMP RATIO
PACKAGING SPEED
SEAL TEMPERATURE
VOIDER 0=OFF 1=ON
VOIDER POSITION
VOID LENGTH
PRINT POSITION
HEATED PIPING TEMP
Upload
SENSOR
CONTROL
HEATER
CONTROL
Upload and
Create
ACTIVE
ALARMS
Download
ALARM
HISTORY
SETUP
Figure 5-27: RECIPE MAINTENANCE 1 Screen

Not all parameters listed within the screen, are options on
any specific machine.
RECIPE NAME: This box lists recipes that have been saved.
DOUBLE ARROW (UP): Touch this button to scroll up
through the list a page at a time.
through the list of recipes.
DOUBLE ARROW (DOWN): Touch this button to
scroll down through the list a page at a time.
SAVE: Touch this pad to save the selected recipe.
RENAME: Touch this pad to rename the current highlighted
recipe. An alpha/numeric keypad will display. Key in the
name and press ENTER to confirm.
RESTORE: Touch this pad to restore settings for a recipe.
5-52
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Machine Controls
DELETE: Touch this pad to delete the selected recipe.
NOTE: Parameter values may change as different recipes
are highlighted.
SETTING: This listing of adjustable parameters are factory
set. Not all parameters listed will have application to all
machines. Only authorized and properly trained persons
Values listed are:
INCH - This indicates inches. Millimeters also
available.
LB - This indicates pounds. Grams (GM) also
available.
PPM - This indicates packages per minutes.
DEG - This indicates temperature.
list of recipes.
June, 2013 / 075-16395-000
5-53
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
RECIPE NAME
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
unit unit unit unit
Save
Rename
Restore
Delete
HOME
RUN
CONTROL
RECIPE
MAINTENANCE
RESET
VALUE
SETTING
PACKAGE LENGTH
PACKAGE WEIGHT
FEEDER PUMP RATIO
PACKAGING SPEED
SEAL TEMPERATURE
VOIDER 0=OFF 1=ON
VOIDER POSITION
VOID LENGTH
PRINT POSITION
HEATED PIPING TEMP
Upload
SENSOR
CONTROL
HEATER
CONTROL
Upload and
Create
ACTIVE
ALARMS
Download
ALARM
HISTORY
SETUP
ENTER ARROW: Touch this pad to accept the highlighted

setting and value.
UPLOAD: Touch this pad to upload a recipe.
UPLOAD AND CREATE: Touch this pad to upload and
create a new recipe listing. When UPLOAD AND CREATE is
selected, the Recipe Plus feature loads a set of default
values into the Setting/Value table. These values must be
modified to match the new package and new recipe. After
entering Values for a new recipe, touch SAVE to save the
new values.
DOWNLOAD: Touch this pad to write the selected recipe into
the active machine settings.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
5-54
075-16395-000 / June, 2013
Machine Controls
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-55
Machine Controls
PRODUCTION
COUNT
JOGGING
HEATER
MAINTENANCE
RESET
NNNNNNNNNN
HEAT CONTROLLER
HEATER SELECT
HEATER PARAMETER
VALUE
HEATER ENABLE
DISABLE
ALARM RANGE
HEAT SEALER
UNIT
###.#
MEASURED = ##### F
HEATER AUTO-TUNING FUNCTION

STATUS
ACTIVE
*** FAIL ***

CANCEL
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Figure 5-28: HEATER MAINTENANCE Screen

HEAT CONTROLLER / HEATER SELECT
through the list of options.
the list of options.
NOTE: Parameter values may change as different
options are highlighted.
5-56
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Machine Controls
NOTE: MEASURED = ##### oC is not a parameter, but an
indication of current temperature. See below.
MEASURED = ##### oC: Displays the measured
temperature of the heat seal, or the highlighted option.
HEATER AUTO-TUNING FUNCTION
STATUS: This panel displays important status
information, including the following:
IN PROCESS: Indicates the auto-tune is in
process.
COMPLETE: Indicates the auto-tune process is
finished.
*** FAIL ***: Indicates the auto-tune process
has failed.
START: Touch this pad to start the auto-tune process.
CANCEL: Touch this pad to cancel the auto-tune
process.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-57
Machine Controls
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
CAM (DEGREES)
PLS
PARAMETER
HOME
PLS SETUP
RESET
LEADTIME (SEC)
ON
OFF
ON
OFF
CYCLE STOP
###
###
#.###
#.###
WIRE FEED
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
CONFIG
MODE
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Figure 5-29: PLS SETUP Screen

PLS PARAMETER: This listing of adjustable parameters are
CYCLE STOP - CAM DEGREES ON: The value displayed is
the point in the cycle, out of 360, when the cycle stop cam is
turned ON.
CYCLE STOP - CAM DEGREES OFF: The value displayed
is the point in the cycle, out of 360, when the cycle stop cam
is turned OFF.
CYCLE STOP - LEAD TIME ON: The value displayed is
time, in seconds. This value is automatically multiplied by the
machine current speed (degrees/second) to fire the cam on
early, by the number of degrees from the res ulting
multiplication. The faster the machine is running, the sooner
this takes place.
5-58
075-16395-000 / June, 2013
Machine Controls
Example: If the machine speed is 10 degrees per second,
and a value of 1 second is entered, the cam off will fire 10
seconds prior.
CYCLE STOP - LEAD TIME OFF: The value displayed is
time, in seconds. This value is automatically multiplied by the
machine current speed (degrees/second) to fire the cam off
this takes place.
NOTE: VOIDER CLOSE is only on machines equipped with
optional voider.
WIRE FEED - CAM DEGREES ON: The value displayed is
the point in the cycle, out of 360, when the wire feed cam is
turned ON.
WIRE FEED - CAM DEGREES OFF: The value displayed is
the point in the cycle, out of 360, when the wire feed cam is
turned OFF.
WIRE FEED - LEAD TIME ON: The value displayed is time,
in seconds. This value is automatically multiplied by the
machine current speed (degrees/second) to fire the cam on
this takes place.
Example: If the machine speed is 10 degrees per second,
and a value of 1 second is entered, the cam off will fire 10
seconds prior.
WIRE FEED - LEAD TIME OFF: The value displayed is time,
in seconds. This value is automatically multiplied by the
machine current speed (degrees/second) to fire the cam off
this takes place.
June, 2013 / 075-16395-000
5-59
Machine Controls
PRODUCTION
COUNT
JOGGING
CAM (DEGREES)
PLS
PARAMETER
HOME
PLS SETUP
RESET
NNNNNNNNNN
LEADTIME (SEC)
ON
OFF
ON
OFF
CYCLE STOP
###
###
#.###
#.###
WIRE FEED
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
###
###
#.###
#.###
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
CONFIG
MODE
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
CONFIG MODE: Touch this pad to configure the PanelView
settings.
ALARMS screen.
HISTORY screen.
screen.
5-60
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Machine Controls
Notes . . . .
June, 2013 / 075-16395-000
5-61
Machine Controls
PRODUCTION
COUNT
JOGGING
FILM
OFF
ON
REGISTRATION
DIAGNOSTICS
RESET
NNNNNNNNNN
CLIP
OFF
CLIP CYCLE TIME

ON
AVERAGE CLIP CYCLE
#### Msec
#### Msec
REGN MARK TIME
AVERAGE MARK TIME
#### Msec
#### Msec
REGISTRATION ERROR
LABEL
POSITION
#####
##.##mm
in
##.# %
FILM SPEED ADJUST
REGISTRATION
OFF
##.# %
ON
PACKAGE
LENGTH
#####
##.##mm
in
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
REGN MARK / CLIP TIME
#####
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Figure 5-30: REGISTRATION DIAGNOSTICS Screen

FILM - OFF / ON: Touch this area to toggle the film drive
motor. When OFF, the motor is stopped and the film drive
wheels do not rotate. When ON, the motor is running and
the film drive wheels will rotate.
CLIP - OFF / ON: Touch this area to toggle the clip drive
servo motor. When OFF, the motor is stopped and the
clipping head does not raise or lower. When ON, the motor
is running and the clipping head raises and lowers.
REGISTRATION - OFF / ON: Touch this area to toggle
package registration. When OFF, the registration system
does not function. When ON, the registration system does
function.
CLIP CYCLE TIME: Displays the clip cycle time in
milliseconds.
REGN MARK TIME: Displays the registration mark time in
milliseconds.
5-62
075-16395-000 / June, 2013
Machine Controls
LABEL POSITION ##.## in: Touch this pad to change the
value. A numeric keypad will display. Key in the new value
and touch ENTER to confirm. The new label position will now
display. OR:
PACKAGE LENGTH ##### mm: This displays the package
length in millimeters. (Inch display is also available.) Touch
new value and press ENTER to confirm. OR:
(DOWN) CURSOR: Touch this pad to decrease
(UP) CURSOR: Touch this pad to increase package
length one increment at a time.
AVERAGE CLIP CYCLE: Displays the average clip cycle
speed time in milliseconds.
AVERAGE MARK TIME: Displays the average registration
mark time in milliseconds.
REGISTRATION ERROR: Displays registration error as
percent.
FILM SPEED ADJUST: Displays the film speed adjustment
as a percent.
REGN MARK / CLIP TIME: Displays the registration mark as
a ratio of clip time.
June, 2013 / 075-16395-000
5-63
Machine Controls
PRODUCTION
COUNT
JOGGING
SLOT 2
INPUTS
HOME
RUN
CONTROL
IO DIAGNOSTIC
1
RESET
NNNNNNNNNN
12
13
10
14
11
15
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
FAST CHANGING
I/O MAY NOT BE
DISPLAYED
ALARM
HISTORY
SETUP
Figure 5-31: IO DIAGNOSTIC 1 Screen

(LEFT) CURSOR: Touch this pad to scroll through the IO
DIAGNOSTIC screens.
(RIGHT) CURSOR: Touch this pad to scroll through the IO
DIAGNOSTIC screens.
SLOT 2 INPUTS: Displays inputs for slot 2. When OFF, an
indicator displays a 0 and is dark grey. When ON, an
indicator displays a 1 and is red/orange.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
ALARMS screen.
5-64
075-16395-000 / June, 2013
Machine Controls
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-65
Machine Controls
PRODUCTION
COUNT
JOGGING
SLOT 3
INPUTS
HOME
RUN
CONTROL
IO DIAGNOSTIC
2
RESET
NNNNNNNNNN
12
13
10
14
11
15
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
FAST CHANGING
I/O MAY NOT BE
DISPLAYED
ALARM
HISTORY
SETUP

DIAGNOSTIC screens.
DIAGNOSTIC screens.
SLOT 3 INPUTS: Displays inputs for slot 3. When OFF, an
indicator displays a 0 and is dark grey. When ON, an
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
5-66
075-16395-000 / June, 2013
Machine Controls
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-67
Machine Controls
PRODUCTION
COUNT
JOGGING
SLOT 6
OUTPUTS
HOME
RUN
CONTROL
IO DIAGNOSTIC
3
RESET
NNNNNNNNNN
12
13
10
14
11
15
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
FAST CHANGING
I/O MAY NOT BE
DISPLAYED
ALARM
HISTORY
SETUP

DIAGNOSTIC screens.
DIAGNOSTIC screens.
SLOT 6 OUTPUTS: Displays outputs for slot 6. When OFF,
an indicator displays a 0 and is dark grey. When ON, an
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
5-68
075-16395-000 / June, 2013
Machine Controls
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-69
Machine Controls
PRODUCTION
COUNT
JOGGING
SLOT 7
OUTPUTS
HOME
RUN
CONTROL
IO DIAGNOSTIC
4
RESET
NNNNNNNNNN
12
13
10
14
11
15
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
FAST CHANGING
I/O MAY NOT BE
DISPLAYED
ALARM
HISTORY
SETUP

DIAGNOSTIC screens.
DIAGNOSTIC screens.
SLOT 7 OUTPUTS: Displays outputs for slot 7. When OFF,
an indicator displays a 0 and is dark grey. When ON, an
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
5-70
075-16395-000 / June, 2013
Machine Controls
ALARMS screen.
HISTORY screen.
screen.
June, 2013 / 075-16395-000
5-71
Machine Controls
PRODUCTION
COUNT
JOGGING
SERVO HOME
MAINTENANCE
RESET
NNNNNNNNNN
IF THE SERVO MOTOR OR ITS BELT IS REPLACED, IT MUST BE HOMED TO SYNCHRONIZE

ITS POSITION WITH THE PHYSICAL POSITION OF THE CLIPPING HEAD.
1. REMOVE FILM FROM THE CLIPPING HEAD AND TURN OFF THE WIRE CLAMP.
2. CLOSE GUARDS, UNLATCH THE ESTOP BUTTON, AND PRESS THE SYSTEM RESET
BUTTON. WAIT FOR THE CONTROL TO INITIALIZE.
3. PRESS THE HOME SERVO MOTOR BUTTON. THE CLIPPING HEAD WILL MOVE TO THE
HOME PROXIMITY SWITCH AND RESET THE PERMANENT MOTOR POSITION TO ZERO.
HOME SERVO
MOTOR
HOME
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Figure 5-35: SERVO HOME MAINTENANCE Screen

This screen gives procedures on homing the servo motor.
HOME SERVO MOTOR: Touch this button to home the servo
motor.
CONTROL 1 screen.
CONTROL screen.
CONTROL screen.
ALARMS screen.
HISTORY screen.
5-72
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Machine Controls
screen.
June, 2013 / 075-16395-000
5-73
Machine Controls
Screen Navigation
The following table should help with becoming familiar with

navigating through the various screens. Once you are familiar
with the screens and the relationships between them, this
chart will probably be used less often.
Table 5-1: Screen Navigation
CURRENT SCREEN
TOUCH
OPENS THIS SCREEN
HOME
RUN CONTROL
RUN CONTROL 1
SCREEN
SENSOR CONTROL
SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
RUN CONTROL 1
5-74
HOME
HOME
SENSOR CONTROL
SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
RUN CONTROL 2
SCREEN
RUN CONTROL 4
SCREEN
075-16395-000 / June, 2013
Machine Controls
CURRENT SCREEN
TOUCH
OPENS THIS SCREEN
RUN CONTROL 2
HOME
HOME
SENSOR CONTROL
SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
RUN CONTROL 3
SCREEN
RUN CONTROL 1
SCREEN
HOME
HOME
SENSOR CONTROL
SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
RUN CONTROL 4
SCREEN
RUN CONTROL 2
SCREEN
HOME
HOME
SENSOR CONTROL
SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
RUN CONTROL 1
SCREEN
RUN CONTROL 3
SCREEN
RUN CONTROL 3
RUN CONTROL 4
June, 2013 / 075-16395-000
5-75
Machine Controls
CURRENT SCREEN
TOUCH
OPENS THIS SCREEN
SENSOR CONTROL
HOME
HOME
RUN CONTROL
RUN CONTROL 1
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
HOME
HOME
RUN CONTROL
RUN CONTROL 1
SCREEN
SENSOR CONTROL
SENSOR CONTROL
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
HOME
HOME
RUN CONTROL
RUN CONTROL 1
SCREEN
SENSOR CONTROL
SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
PREVIOUS SCREEN
OPENS PREVIOUS
SCREEN
HEATER CONTROL
ACTIVE ALARMS
5-76
075-16395-000 / June, 2013
Machine Controls
CURRENT SCREEN
TOUCH
OPENS THIS SCREEN
ALARM HISTORY
HOME
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RUN CONTROL
RUN CONTROL 1
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HEATER CONTROL
HEATER CONTROL
SCREEN
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ACTIVE ALARMS
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
PREVIOUS SCREEN
OPENS PREVIOUS
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RUN CONTROL
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SCREEN
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PARAMETER MAINT
PARAMETER
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RECIPE MAINTENANCE 1
SCREEN
PLS SETUP
PLS SETUP 1 SCREEN
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REGISTRATION
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IO DIAGN
IO DIAGNOSTICS 1
SCREEN
SERVO HOME MAINT
SERVO HOME
MAINTENANCE SCREEN
PANELVIEW CONFIG
PANELVIEW
CONFIGURATION
SCREEN
LOGIN
ALPHA/NUMERIC
DISPLAY
LOGOUT
N/A
MAINTENANCE SELECT
June, 2013 / 075-16395-000
5-77
Machine Controls
CURRENT SCREEN
TOUCH
OPENS THIS SCREEN
PARAMETER
MAINTENANCE 1
HOME
HOME
RUN CONTROL
RUN CONTROL 1
SCREEN
SENSOR CONTROL
SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
PANELVIEW CONFIG
PANELVIEW
CONFIGURATION
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
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ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
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SCREEN
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SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
THROUGH
PARAMETER
MAINTENANCE 8
RECIPE MAINTENANCE
1
5-78
075-16395-000 / June, 2013
Machine Controls
CURRENT SCREEN
TOUCH
OPENS THIS SCREEN
HEATER MAINTENANCE
HOME
HOME
RUN CONTROL
RUN CONTROL 1
SCREEN
SENSOR CONTROL
SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
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RUN CONTROL 1
SCREEN
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SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
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PANELVIEW
CONFIGURATION
SCREEN
ACTIVE ALARMS
ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
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SETUP
MAINTENANCE SELECT
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RUN CONTROL
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SCREEN
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SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
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ACTIVE ALARMS
ACTIVE ALARMS
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ALARM HISTORY
ALARM HISTORY
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MAINTENANCE SELECT
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REGISTRATION
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June, 2013 / 075-16395-000
5-79
Machine Controls
CURRENT SCREEN
TOUCH
OPENS THIS SCREEN
I/O DIAGNOSTIC 1
HOME
HOME
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SCREEN
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SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
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ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
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HOME
RUN CONTROL
RUN CONTROL 1
SCREEN
SENSOR CONTROL
SENSOR CONTROL
SCREEN
HEATER CONTROL
HEATER CONTROL
SCREEN
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ACTIVE ALARMS
SCREEN
ALARM HISTORY
ALARM HISTORY
SCREEN
SETUP
MAINTENANCE SELECT
SCREEN
THROUGH
I/O DIAGNOSTIC 4
SERVO HOME
MAINTENACE
5-80
075-16395-000 / June, 2013
Startup Check List

Use this check list to check out the ChubMaker 4100 before
turning power on, before initial startup, and prior to each additional
startup.
Startup Check List
__1.
Turn OFF and LOCK OUT the main electrical

disconnect switch at the main power source to
avoid possible injury.
__2.
Check fluid level in air line lubricator (A). If low, fill with
food grade lubricant. Refer to Lubrication on page
29-1 and Table 29-2 on page 29-11 for lubricant type.
__3.
Check fluid level in wire lubricator (B). If low, fill with

29-1 and Table 29-2 on page 29-11 for lubricant type
AutoLube
Inside
__4.
June, 2013 / 075-16395-000
Check the autolube reservoir, located in the lower

portion of the side cabinet. Fill with food grade
6-1
Startup Check List

lubricant. Refer to Lubrication on page 29-1 and Table
29-2 on page 29-11 for lubricant type.
__5.
Check fluid level in table reservoir by removing one of

the access covers (C). If below the LOW mark, add
food grade oil to regain proper level. (Oil level indicator
marks are located inside reservoir; one on the right
side, one on the left side.) Refer to Lubrication on
page 29-1 and Table 29-2 on page 29-11 for lubricant
type.
6-2
__6.
Check all air tubing for breaks or loose connections.

Tighten as required.
__7.
Lubricate those items on the Lubrication Chart on

page 29-1 indicated for Daily frequency.
__8.
Check condition of anvils (E), knock-out punches (F),

gathering plates (G), and cut-off punch (H) for wear,
075-16395-000 / June, 2013
Startup Check List

breaks, nicks, warpage, or other abnormalities.
Replace as required.
__9.
Clean and lubricate anvils (E), knock-out punches (F),

gathering plates (G), and cut-off punch (H) as outlined
under Cleanup on page 26-1.
__10. Check the clipping head area for small pieces of wire
or pieces broken off from wire clipping components.
Remove all broken material found.
NOTE: Anvils (E) are located beneath and between gathering

plates (G).
June, 2013 / 075-16395-000
6-3
Startup Check List

__11. Check the film for proper threading through the rollers
and folder, and check for correct position of the film
drive wheels. Refer to Film Threading on page 10-1.
__12. Check the clip wire (I) for proper insertion into the wire
lubricator (B) and into the wire feed mechanism (J).
__13. Inspect two inlet bushings (K) and two outlet bushings
(L) on the wire lubricator (B) for wear. If grooved,
rotate the bushings as needed to allow wire to run
along a new surface. Replace bushings when worn
beyond continued use.
__14. Check for dents, nicks, or other abrasions in sizing

parts. Polish out or replace as needed.
__15. Check installation of sizing parts (including mandrel)
for proper fit and adjustment. Improperly installed
and/or adjusted sizing parts can lead to film tracking
and sealing problems. Refer to Sizing Parts on page
7-1.
6-4
075-16395-000 / June, 2013
Startup Check List

__16. Check integrity of all safety guards and interlocks.
Replace any damaged or missing parts. DO NOT
O V E R R I D E A N Y S A F E T Y F E AT U R E S O R
OPERATE MACHINE WITH GUARDS MISSING.
__17. Set the HAND WHEEL switch (N) to ENGAGE and
turn the machine through several complete cycles with
the handwheel (O). Make certain no binding exists and
that the machine turns freely. If binding, excessive
backlash, or rough spots are encountered, contact the
R.A JONES & Co. Service Department for advice
and assistance.
__18. With air supply to the machine on, check all air
pressure regulators against the Air Settings Chart on
page 24-6.
__19. Set the HAND WHEEL switch (N) to DISENGAGE.
June, 2013 / 075-16395-000
6-5
Startup Check List

Notes . . . .
6-6
075-16395-000 / June, 2013
Sizing Parts
Sizing Parts
Figure 7-1: Quick-Change Sizing Parts

A
B
C
D
Sleeve ORing
Sleeve
Top Plate
Mandrel ORing
I
J
K
L
Mandrel
F
G
H
Folder
Heat Seal Sizing Ring
Pressure Pad
N
O
Pressure Pad ORing

Spreader
RF Seal Ring (Optional)
RF Seal Ring ORing
(Optional)
Package Guide (Mounts on
top of Clipping Head Guard.)
Support Column
Folder Mounting Plate
Table 7-1: Callouts for Figure 7-1

June, 2013 / 075-16395-000
7-1
Sizing Parts
Initial Installation
The machine is void of the Quick-Change Sizing Parts.
1.
7-2
Open the front guard door to gain access to the

machine.
075-16395-000 / June, 2013
Sizing Parts
A
2.
Loosen the knob (A) slightly, that secures the roller

carriage.
3.
Push the roller carriage

machine-center position.
(3)
away
from
its
C
A
B
4.
If the film drive wheel carriers are not apart as shown

above, loosen the knob (A) that secures the lock arm.
5.
Swing the lock arm (B) up to unlock the front of the film
drive.
6.
Make sure the rear lock (C) is in the up position.
June, 2013 / 075-16395-000
7-3
Sizing Parts
C
A
7.
7-4
Position the Quick-Change Sizing Parts Unit (A) to

engage the top of the mandrel (B) with the adapter at
(C) and push up (7). A twisting motion will help as the
mandrel enters the adapter.
075-16395-000 / June, 2013
Sizing Parts
8.
Engage the two locator knobs (A) and turn both at the
same time, in a clockwise direction. Make sure the top
of the cone on each remains below the lower plate (B).
Continue until both locator knobs are securely tight.
NOTE: Make sure the open slots in the lower plate (B)
fully engage the locator knobs (A) while tightening.
The cones on each locator knob mate with and seat
into the lower plate. This locates the Quick-Change
Sizing Parts Unit.
June, 2013 / 075-16395-000
7-5
Sizing Parts
9.
Install and tighten both upper lock knobs (C) to secure

the upper portion of the Quick-Change Sizing Parts
Unit.
2
1
E
D
F
7-6
10.
Grasp the handle (D) on the film drive. Pivot up (1),

swing to the right (2), and lower down (3) until the film
drive section comes to a rest.
11.
Swing the lock arm (E) to engage the stud of the knob
(F) and tighten the knob to secure.
075-16395-000 / June, 2013
Sizing Parts
12.
Pivot the rear lock lever (G) down until it engages, to

lock the rear of the film drive.
13.
June, 2013 / 075-16395-000
Lower both wheel guards (H) onto their pins.
7-7
Sizing Parts
A
14
7-8
14.
Push the roller carriage (14) towards

machine-center position until it hits the stop.
15.
Tighten the knob (A) to secure the roller carriage.
its
075-16395-000 / June, 2013
Film Arbor
Film Arbor
The film arbor provides the mounting for the film roll on the
machine. Film tension is accomplished by a spring-loaded
strap and an adjustable air operated tensioning system.
A sensor located on the film infeed detects when film is
present. When the film on the roll runs out or breaks, a signal
is sent to the machine's CPU and the drive motors on the
machine (film, clamp, pump, etc.) stop. Enough film remains
near the accessory, to allow the operator to attach film from a
new roll.
Setup
Setup is fairly simple and quick to perform. Follow the

instructions below:
1.
Press the SYSTEM RESET push button (A). Do not

operate the machine or any accessories at this time.
2.
Turn the air supply to the machine on.
June, 2013 / 075-16395-000
8-1
Film Arbor
3.
Turn the FILM TENSION switch (B) to off.
4.
Adjust the FILM TENSION regulator (C) until the FILM

TENSION gage (D) reads 0.
5.
Pull up on the strap (E) and remove from the pulley on

the arbor shaft (H).
NOTE: The spring (F) will stretch. Also, the strap
should be fairly loose with the air pressure at 0.
8-2
075-16395-000 / June, 2013
Film Arbor
June, 2013 / 075-16395-000
8-3
Film Arbor
6.
Push the plastic retainer pin (G) in the direction of the

arrow. This pin serves to capture and retain the arbor
shaft (H).
7.
8-4
Lift the entire arbor shaft (H) from the machine and set
on a suitable work surface.
075-16395-000 / June, 2013
Film Arbor
8.
Depress the button in the lock pin (I) and pull the pin
from the adjustable cone (J). Set the pin aside.
June, 2013 / 075-16395-000
8-5
Film Arbor
9.
Slide the adjustable cone (J) off the film arbor shaft (H)
and set aside.
10.
If changing film width, it may be necessary to pull the

pin for the stationary cone (K), reposition the cone
along the film arbor shaft (H) and insert the pin into a
new hole.
11.
8-6
Slide a roll of film (L) onto the film arbor shaft (H) until
it contacts the stationary cone (K). The film must feed
off the film roll from the top as shown by the arrow.
075-16395-000 / June, 2013
Film Arbor
K
12.
Slide the adjustable cone (J) onto the film arbor shaft
(H) until it contact or nearly contacts the film roll (L).
13.
Insert pin (I) through both the adjustable cone (J) and
the film arbor shaft (H) to lock the cone to the shaft.
H
J
June, 2013 / 075-16395-000
8-7
Film Arbor
J1
J
L
J2
8-8
14.
Grasp the rods (J1) and (J2) and turn the adjustable
cone (J), as indicated by the arrow, to tighten against
the core of the film roll (L).
15.
Give the rod (J1) several sharp blows with a plastic or

rubber mallet, to further tighten the film roll (L).
16.
Set the entire film arbor shaft assembly so the groove

in the film arbor shaft (H) resets on the guide (M).
17.
Wrap the belt (E) over the pulley of the film arbor shaft.
075-16395-000 / June, 2013
Film Arbor
June, 2013 / 075-16395-000
8-9
Film Arbor
18.
Push the plastic retainer pin (G) in the direction of the

arrow. This pin serves to capture and retain the arbor
shaft (H).
19.
8-10
Thread film from the roll through the rollers as shown

in Figure 10-1 on page 10-1 and on the arbor
mounting plate.
075-16395-000 / June, 2013
Film Arbor
NOTE: Further film threading through the remaining
rollers on the machine will be as illustrated on
additional plates on the machine.
20.
Turn the FILM TENSION selector switch (B) to on.
21.
Adjust the FILM TENSION air pressure (C) to 5 psig

[35 kPa or 0.35 kg/sq cm].
NOTE: The film tension pressure regulator is located
on the front of the machine, along the left upright.
June, 2013 / 075-16395-000
8-11
Film Arbor
Film Tension Adjustment
Film tension air pressure may require adjustment from its

original setting. Use the film tension regulator (C) to adjust
the film tension air pressure. If the pressure is set too low, the
film may free wheel off the roll.
If the pressure is set too high, there will be too much tension.
This could possibly cause film breakage or film drive wheel
slippage.
The film tension regulator (C) is located on the front of the
machine, along the left upright.
8-12
075-16395-000 / June, 2013
Film Arbor
Maintenance
The film arbor is virtually maintenance free. A few

precautions will prolong the life of components.
1.
Use the lowest film tension settings (C) and (D)

possible. This will minimize wear on components.
June, 2013 / 075-16395-000
8-13
Film Arbor
2.
8-14
When washing the machine down, cover the film arbor

area with plastic. This will help prevent water and
steam from getting into the bearings, the film sensor
end, and other components.
075-16395-000 / June, 2013
Film Arbor
Setting the Tensioner Balance
The tensioner balance is set at the factory. Over time,

or when certain ambient conditions change, it may be
necessary to reset the tensioner balance.
June, 2013 / 075-16395-000
1.
Remove the cover panel that encloses the side

cabinet on the film arbor side of the machine.
2.
Turn the FILM TENSION switch, located on the

left front of the machine, to the OFF position.
8-15
Film Arbor
8-16
3.
Remove all film from the film arbor and between

all rollers.
4.
Adjust the pressure regulator (B) to achieve

balance on the tension arm (D). Balance is
defined as just enough pressure to pivot the
tension arm to its upper most position.
075-16395-000 / June, 2013
Film Arbor
June, 2013 / 075-16395-000
5.
The air cylinder (C) should be fully retracted.

There should be air pressure supplied to the
lower port, and no air pressure at the upper
port.
6.
Make sure the tension belt (E) has some slack.

If the tension belt is taut, adjust as necessary to
provide some slack.
8-17
Film Arbor
7.
8-18
Replace the cover panel, turn the FILM

TENSION switch to the ON position.
075-16395-000 / June, 2013
Film Drive
The film drive wheels on the ChubMaker 4100 perform a three
fold function:
Film Drive
Pull or propel film through machine.
Create back pressure on the product which keeps air

out of the package.
Regulate the amount of product in the film tube, so a

proper Chub-shaped package can be made.
The amount of product in the film tube, before clips are applied is
extremely important. Too much product and the package will burst.
Too little product and the package will be loose and poorly shaped.
The amount of product in the tube is affected by the space between
squeeze rolls1: more gap, more product.
The following diagrams will help you understand these two basic
problems and overcome them. In Figure 9-1 package X and
package Y have the same length and same diameter. However,
because of the spherical ends on package Y (Chub package) it
contains less volume than package X.
Figure 9-1: Package Volume
1. Squeeze rolls are optional.

June, 2013 / 075-16395-000
9-1
Film Drive
Package shapes AA, BB and CC (Figure 9-2) each have the
same circumference (distance around outside of package).
However, because their shapes vary, so does the area of each. By
changing from a perfect circle (AA) to an oval (BB), area is
reduced by about 25%. If changed to a flat (CC), area is
completely eliminated.
It is important to note that package shape AA corresponds to
section A-A of Figure 9-3 (above squeeze rolls1) and that package
shape BB corresponds to section B-B of Figure 9-3 (at or below
squeeze rolls1).
A
B
AA
BB
CC
3 [76 mm] Diameter

C 3.9 [99 mm]
1-1/2 [38 mm]
D 4.7 [119 mm]
9.4 [239 mm] Circumference
7.1 sq. in. [4581 sq. mm] Area
9.4 [239 mm] Circumference
5.3 sq. in. [3419 sq. mm] Area
9.4 [239 mm] Circumference / 0.0 sq. in. [0.0 sq. mm] Area
Figure 9-2: Package Shape & Cross Section Area

9-2
075-16395-000 / June, 2013
Film Drive
In Figure 9-3, product is flowing through the mandrel (C) into the film
tube (F). The four wheel drive has two squeeze rollers1 (E) that
deform the perfect circle at section A-A, creating back pressure
(D). At section B-B, the film tube has become oval shaped and has
less area than at section A-A. This type of film drive promotes
uniform packages and avoids film damage when product has sharp
particles.
C
D
E
Product Mandrel
Back Pressure
Squeeze Rolls1
F
G
H
Film Tube
Escaping Air
Product Flow
Figure 9-3: Squeeze Rolls

June, 2013 / 075-16395-000
9-3
Film Drive
Notes . . . .
9-4
075-16395-000 / June, 2013
Film Threading
Film threading is an important factor in operating the ChubMaker
4100 properly. Follow the guidelines and procedures in this section
to enhance your operation.
Film Threading
WARNING
W h e n l i ft i n g w i r e r e e l s , f i l m r o l l s , o r o t h e r r e l a t e d
components, always lift using your legs and not your back to
avoid back injury. If the object is too heavy, get help!
Based upon package size:
1.
Select the proper film folder (E), mandrel, and film width to
coincide.
2.
Install the film to unroll in the direction shown in Figure 10-1

below.
3.
Thread film through idler rollers (B), (C), and (D) and over
folder (E) as shown.
A
B
C
Film Roll
Idler Rollers
Carriage Rollers
D
E
Break Roller
Film Folder
Figure 10-1: Film Threading

June, 2013 / 075-16395-000
10-1
Film Threading
4.
Pull film downward by hand from below the folder (E). There
should be a 1/2 [13 mm] minimum film overlap as it is formed
into a tube.
5.
Turn knob (F) to adjust the film roll position front-to-back, in

order to center the film with respect to the film folder (E).
NOTE: The edges of the film should be vertical and centered
within the edges of the folder overlap. If film extends past
either edge of the folder, poor tracking will result.
DANGER
Movement of certain types of film can create a static
electrical charge. If there are combustible, flammable or
explosive gases or materials in the area, a static eliminator
MUST be used to reduce possibility of sparking. Refer to
information on page 13-1 of this manual under Static
Charges On Film.
10-2
075-16395-000 / June, 2013
Film Threading
Notes . . . .
June, 2013 / 075-16395-000
10-3
Film Threading
Film Spreader Adjustment
The ChubMaker 4100 Chub Packaging Machine is

equipped with Four Wheel Film Drive. The film spreader (A)
must be set so the fingers, or prongs, are close enough to the
drive wheels (B) to keep the film properly tracking between
wheels. See Figure 10-2 below for the following steps.
A
B
1.
Loosen the set screw on the film spreader (A) and

raise or lower film spreader as necessary.
2.
Pull the film over the folder and down between the film
drive wheels (B).
Film Spreader
Film Drive Wheels
C
D
Mandrel
1/4 [6.4 mm]
Figure 10-2: Film Spreader Adjustment
10-4
075-16395-000 / June, 2013
Film Threading
Drive Wheels Adjustment
The opposing film drive wheels should be in line with each

other and spaced so the outer edge of the treads (C) are 1/8
[3 mm] inside the outer edge of the film spreader (B) fingers,
or prongs.
A
B
Mandrel
Film Spreader
C
D
Film Drive Wheel Tread

1/8 [3 mm]
Figure 10-3: Drive Wheels Adjustment
June, 2013 / 075-16395-000
10-5
Film Threading
DANGER
Do not try to thread film, engage, or disengage film drive
wheels while they are rotating. Serious and painful injury will
result.
Breaker Roller Setting
The film should fold over folder (B) at a smooth, uniform rate.
The overlap of film should be constant. The breaker roller (A)
should be adjusted so the film lays flat on the folder wing.
Breaker Roller
Folder
Figure 10-4: Breaker Roller Setting

1.
10-6
Loosen locking knob (C) and slide to adjust the

breaker roller (A).
075-16395-000 / June, 2013
Film Threading
2.
Tighten locking knob (C) when breaker roller (A) is

positioned correctly.
NOTE: Additional adjustment will be necessary when
folder or film size is changed.
June, 2013 / 075-16395-000
10-7
Film Threading
Notes . . . .
10-8
075-16395-000 / June, 2013
Film Tracking
Film tracking problems can usually be corrected as follows:
Film Tracking
1.
If the overlap moves in one direction, toward the front or back

of the machine, adjust film roll in the opposite direction by
turning arbor position knob (A).
June, 2013 / 075-16395-000
11-1
Film Tracking
2.
11-2
Check all rollers (B), (C), and (D) to see if they rotate freely.
Replace or resolve any rollers that bind, stick, or drag.
075-16395-000 / June, 2013
Film Tracking
3.
Check orientation of the film folder (C). The back edge (C1)
of the folder should be parallel to the rear edge (D) of the
mounting plate (D1). The folder should be centered about the
mandrel (E).
C
D
E
G
Film Folder
Mounting Plate Rear
Edge
Mandrel
Folder Mount Base Plate
C1
D1
F
Film Folder Back Edge

Mounting Plate
Clamp Mount Plate
Figure 11-1: Folder Installation Top View

4.
Check the film drive wheels. If they are not centered with
mandrel they will pull film to one side. See Figure 10-3 on
page 10-5.
5.
If trouble continues, try another roll of film. Some films have

faults which cause frequent forming problems.
June, 2013 / 075-16395-000
11-3
Film Tracking
Notes . . . .
11-4
075-16395-000 / June, 2013
Static Charges on Film

Static charges on film can pose serious hazards for some use
applications of the ChubMaker 4100. For Class I (Explosive
Vapor) and Class II (Explosive Dust) locations, special purged or
pressurized electrical control systems and UL rated explosion proof
motors are available. In addition to these and other safety
provisions, consideration must be given to prevention of static
electrical discharges on or near machine.
Static charges may develop on packaging film as it moves through

rollers of machine. Under certain conditions, these charges can
reach very high voltage levels. These high voltage charges can
cause shocks or sparks between operator (a conductor) and
grounded machine, as operator comes into contact with charged
film.
Sparks may also occur directly between film and grounded machine
components as film passes through machine. The energy level of
these discharges has not been measured. However, based on
Factory Mutual Insurance Company data, estimated energy
contained in a spark from a conductor with capacitance of human
body is sufficient to cause ignition.
The safest and most effective way of controlling static charges in
hazardous locations is by use of Nuclear Static Eliminators. These
are alpha particle emitters and their use is licensed by governmental
agencies. They may be leased from the 3M Company. Periodic
regeneration of eliminators is necessary due to radioactive decay.
We strongly recommend that all customers operating Chub
Packaging Machines in hazardous locations request the 3M
Company to conduct a survey of their installation for possible
hazardous static electrical buildup and to install recommended static
eliminators. Personnel from 3M are available to survey your facility
and equipment and to make necessary recommendations. The 3M
Company maintains regional representation for this product. For
further information, in the United States and Canada, contact:
Static Control Systems/3M
3M Austin Center
Building 145-3M-01
Austin, TX 78769-2963
Phone: 1-800-328-1368 (toll free in the US & Canada)
1-512-984-6510
June, 2013 / 075-16395-000
12-1

Notes . . . .
12-2
075-16395-000 / June, 2013
Sealing Polyethylene Film

Sealing polyethylene film is fairly easy and is affected by time,
pressure, and temperature. Time is controlled by the speed of the
film through the machine. Pressure is controlled by the force of
heated air on the film. Temperature is controlled by the setting made
on the operator control panel and the gap between the heater
nozzle and the film.
DANGER
Contact with the heat coil or frame near the heat coil will
cause a severe burn.
WARNING
Excessive heat (run away) of the heat seal coil in areas where
toxic or volatile (fume producing) materials are present, can
produce fire, explosion, or other health risks. Take proper
steps to ensure personnel safety.
NOTICE
Always turn the air supply to sealer ON BEFORE pressing
the SEALER ON/OFF push button to ON. When turning the
heat sealer OFF, ALWAYS press the SEALER ON/OFF push
button BEFORE turning the air supply OFF. This ensures a
flow of air through the coils and prevents premature burn out
of the unit.
Always keep the heat sealer in its RAISED position when
not running film, to prevent burning the film through.
June, 2013 / 075-16395-000
13-1
A
B
C
D
E
F
Breaker Roller
Stop Adjustment
Cooling Nozzle
1/8-3/16
[3 - 5 mm] Gap
Loosen and shim/adjust
to set angle G.
Heat Seal Nozzle
G
H
I
Parallel within 5
Fine Adjust Knob
Alignment Knob
Pressure Pad / Sealing

Ring
Mandrel
Figure 13-1: S1 Heat Sealer

1.
Set the heat seal nozzle (F) (or sealing iron) parallel with the
vertical plane of the mandrel within 5o (G) as shown in Figure
13-1.
NOTE: The top of the pressure pad / seal ring (J) should be
even with the top of the heat seal nozzle (F), as much as is
possible.
2.
13-2
Set the gap (D) between the heat seal nozzle and the film at
between 1/8 [3mm] and 3/16 [5 mm] by rotating the fine
adjust knob (H).
075-16395-000 / June, 2013

3.
Push SYSTEM RESET if the PanelView is not displaying a

control screen.
4.
Turn the air supply to the sealer on and adjust:

a.
The HOT air pressure to 20 psig [140 kPa] minimum

pressure (40 psig [280 kPa] maximum).
b.
The COLD air pressure to 20 psig [140 kPa] minimum

pressure (40 psig [280 kPa] maximum).
Figure 13-2: Air Pressure Settings

June, 2013 / 075-16395-000
13-3

5.
From the HOME or any other screen, touch RUN CONTROL

to open the RUN CONTROL 1 screen.
NOTE: If the RUN CONTROL 1 screen is already displayed,
Step 5 will not be required.
DRIVE NOT READY
SPEED
(PPM)
POSITION
(DEG)
EON #####
NNN
NNN
ChubMaker 4100

Ph (800) 257-5622 (563) 391-0000 Fax (563)-391-0699
HOME
13-4
RUN
SENSOR
HEATER
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
075-16395-000 / June, 2013

6.
From the RUN CONTROL 1 screen, touch RAISE under

HEAT SEAL FRAME. This will raise the heat seal assembly
to its uppermost position.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
RAISE
RUN
CONTROL
SCREEN 1
RESET
FILM
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
7.
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
Touch HEATER CONTROL to open the HEATER CONTROL

screen.
June, 2013 / 075-16395-000
13-5

8.
Touch HEAT SEALER to toggle to the ON position. This will

turn the heat sealer on.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEALER
HEAT
SEALER
OFF
HEATER
CONTROL
SCREEN
RESET
ON
MEASURED = #####
#####CF
STATUS
SENSOR
BREAK
SET POINT =
HEATED PIPING
HEATED
PIPING
OFF
#####C
####F
ON
MEASURED = ###.# C
STATUS
AT TEMP
SET POINT =
HOME
RUN
SENSOR
CONTROL CONTROL
HEATER
CONTROL
##.#C
##.#F
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
9.
Touch #####oC (or the value displayed on this pad). This will
open a numeric display.
10.
Set the temperature by entering a value on the numeric

keypad, followed by pressing ENTER to confirm. The new
SET POINT temperature is now set. Refer to Table 13-1
below for suggested temperature settings.
NOTE: It will require a few minutes for the coils to heat up.
SUGGESTED HEAT SEAL TEMPERATURE SETTINGS
PPM
PPM Clutch/Brake
MIN TEMP
MAX TEMP
100-110
8-15
450o F [232o C]
600o F [313o C]
110-120
15-25
550o F [288o C]
700o F [371o C]
120-130
25-35
650o F [343o C]
800o F [427o C]
130-140
35-45
750o F [399o C]
900o F [482o C]
140-150
15-50
850o F [454o C]
1,000o F [538o C]
Table 13-1: Suggested Heat Seal Temperature Settings

13-6
075-16395-000 / June, 2013
NOTICE
Suggested temperature settings are provided as a starting
point. Film characteristics and other conditions may affect
seal quality and the actual temperature setting used for your
application may vary from those listed in Table 13-1.
11.
Touch RUN CONTROL to return to the RUN CONTROL 1

screen.
12.
At the RUN CONTROL 1 screen, touch ENGAGE FILM to

toggle to the CLOSE position.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
RAISE
RUN
CONTROL
SCREEN 1
RESET
FILM
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
13.
Touch FILM to toggle to the ON position. This will start the

film drive motor. Film should now begin to pull through the
machine.
14.
If film is tracking properly, touch LOWER under HEAT SEAL

FRAME to lower the heat sealer assembly.
15.
Turn the fine adjust knob (H) to position the heat seal nozzle
(F) closer or farther from the film, as needed to achieve the
desired seal quality. See Figure 13-1 on page 13-2.
June, 2013 / 075-16395-000
13-7

16.
Run about one or two feet of sealed film and swing the heat
sealer to its raised position.
17.
Stop the machine and inspect the quality of the seal just
made.
Figure 13-3: Smooth Seal

a.
Cut a 1" [25.4 mm] length of sealed film.
b.
Hook both forefingers inside the sample and pull.

NOTE: A good seal will be smooth (Figure 13-3) and
can withstand stretching 200% prior to breaking. If the
seal easily pulls apart, more heat or pressure is
required.
13-8
075-16395-000 / June, 2013

18.
If the seal area looks as though film melted and the seal
easily pulls apart, increase the COLD AIR PRESSURE. Air
pressure should be set between 15 psig [105 kPa] and 40
psig [280 kPa].
June, 2013 / 075-16395-000
13-9

19.
If the seal area shows little evidence of melting and easily

pulls apart, touc h HEAT ER CONTROL on the RUN
CONTROL 1 screen. This will open the HEATER CONTROL
screen.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
RAISE
RUN
CONTROL
SCREEN 1
RESET
FILM
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
20.
Touch #####oC (or the value displayed on this pad). This will
open a numeric display.
21.
Set the temperature by entering a value greater than what

was displayed on the numeric keypad, followed by pressing
ENTER to confirm. The new SET POINT temperature is now
set.
NOTE: It will require a few minutes for the coils to heat up.
13-10
075-16395-000 / June, 2013

6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEALER
HEAT
SEALER
OFF
HEATER
CONTROL
SCREEN
RESET
ON
MEASURED = #####
#####CF
STATUS
SENSOR
BREAK
SET POINT =
HEATED PIPING
HEATED
PIPING
OFF
#####C
####F
ON
MEASURED = ###.# C
STATUS
AT TEMP
SET POINT =
HOME
22.
RUN
SENSOR
CONTROL CONTROL
HEATER
CONTROL
##.#C
##.#F
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Touch RUN CONTROL to return to the RUN CONTROL 1

screen.
Figure 13-4: Wrinkled Seal

23.
If wrinkles (Figure 13-4) appear, they can usually be avoided.

Increase the amount of cooling air directed at the seal.
June, 2013 / 075-16395-000
13-11

NOTE: In some cases, all of these wrinkles cannot be
eliminated. Wrinkles do not necessarily indicate a bad seal.
Under some conditions, wrinkles will have to be tolerated.
Setting Heat Temperature
1.
From virtually any screen displayed on the PanelView,

touch HEATER CONTROL to open the HEATER
CONTROL screen.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
2.
From the HEATER CONTROL screen, touch HEAT

SEALER to toggle to the ON position.
3.
Touch #####oC (or the value displayed on this pad).

This will open a numeric display.
4.
Set the temperature by entering a value on the

numeric keypad, followed by pressing ENTER to
confirm. The SET POINT temperature is now set.
NOTE: It will require a few minutes for the coils to heat
up.
13-12
075-16395-000 / June, 2013

6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEALER
HEAT
SEALER
OFF
HEATER
CONTROL
SCREEN
RESET
ON
MEASURED = #####
#####CF
STATUS
SENSOR
BREAK
SET POINT =
HEATED PIPING
HEATED
PIPING
OFF
#####C
####F
ON
MEASURED = ###.# C
STATUS
AT TEMP
SET POINT =
HOME
RUN
SENSOR
CONTROL CONTROL
HEATER
CONTROL
##.#C
##.#F
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Heat Seal Quick Warm-up Feature
To help the ChubMaker 4100 heat sealer achieve its

operating temperature in as short a time as possible, the heat
seal coil incorporates a quick warmup feature.
This feature provides 75% of maximum drive power to the
heat seal coil for 15 seconds, or until the heat seal coil is at
33% of the target temperature, whichever comes first.
Quick warmup will occur when the sealer is first started for
the day. It will also occur whenever the sealer power is
interrupted and the sealer coil temperature falls below 33% of
the target temperature.
It is important to note that due to the quick warmup feature in
the heat sealer, if power to the sealer has been interrupted
and the sealer coil temperature has dropped below 33% of
the target temperature, but not down to ambient room
t e m p e r a t u r e , a t e m p o r a r y o v e r s h o o t o f t h e ta r g e t
temperature may result (coils glow red). This is NOT a
malfunction and the temperature will settle to its targeted
level.
June, 2013 / 075-16395-000
13-13

Heat Seal Over Temperature Fault Feature
The ChubMaker 4100 heat seal accessory is also

equipped with a sealer over temperature fault feature. If at
any time, the heat seal controller senses 1,200oF [649oC] on
the thermocouple, it will register an over temperature fault.
The result of the fault will be:
13-14
1.
Machine stops.
2.
Sealer shuts off.
3.
Over temperature indicator flashes.
4.
Audible alarm sounds (option).
075-16395-000 / June, 2013
Clipping
Description of Clipping Operation
Clipping
Wire from two reels mounted to the rear of the machine is fed
through tubes of the wire lubricator. The wire lubricator
applies a film of oil to the wires. (This keeps the wires from
galling and jamming the wire feed mechanism.) After leaving
the wire lubricator, wires are threaded through a series of
rollers that help straighten wire. Both wires then enter the
wire feed mechanism.
The wire feed mechanism is air-operated and pulls wires
from the reels and advances wires through a wire guide and
cut-off round. When the predetermined amount of wire has
been fed, wire feeding stops. At this point the cut-off punch
cuts both wires.
The clipping head moves down to its lowest position while the
clip forming die swings up and forms both wires into U
shaped clips. The clip forming die then returns. The anvils of
the clipping head move toward and receive the clips.
The clipping head begins its upward motion and at its highest
position performs the following:
1.
Closes on film and gathers it into a snug confinement.
2.
Moves clips around the gathered film.
3.
Forms clips into their final clinched shape.
4.
Advances the cut-off knife and cuts the film between

clips.
June, 2013 / 075-16395-000
14-1
Clipping
M7 Clipping Head
Refer to Figure 14-1 for location of M7 clipping head

components.
NOTE: Illustrations are shown with head guard removed.
A
B
Micro-Clip Adjustment
Drive Pin Retainer
F
G
Wire Size Adjustment

Punches
C
D
E
Knife Pin
Plate Pin
Gathering Plates
H
I
J
Lock Bar
Anvils
Cut-off Knife
Figure 14-1: M7 Clipping Head Components

Removal of M7 Clipping Head Components
1.
14-2
With electrical and air power to the machine,

set the HAND WHEEL switch (A) to ENGAGE
and turn the handwheel (B) until the gathering
plates (C) are fully opened.
075-16395-000 / June, 2013
Clipping
June, 2013 / 075-16395-000
2.
Turn OFF and LOCK OUT the main

electrical disconnect switch at the main
power source.
3.
Open the front guard door.
4.
Remove head guard.
5.
Set Micro Adjust knob to 0.

14-3
Clipping
14-4
6.
Remove two (retainer) thumb screws (D) and

offset washers (E) securing the plate guide
assembly (F).
7.
Remove locating pin with chain (G), lock nut

(H), and washer (I) securing wire guide (J).
(This step is not required to complete Step 9
and beyond.)
075-16395-000 / June, 2013
Clipping
June, 2013 / 075-16395-000
8.
Remove the wire guide (J). (This step is not

required to complete Step 9 and beyond.)
9.
Rotate drive pin retainer (K) to gain access to

the knife pin (L) and plate pin (M).
14-5
Clipping
14-6
10.
Pull the knife pin (L) out.
11.
Pull the plate pin (M) out.
075-16395-000 / June, 2013
Clipping
12.
Use a small screwdriver and push the cut-off

knife (N) towards the center of clipping head.
Carefully remove the cut-off knife (N) to avoid
getting cut.
WARNING
The cut-off knife can be extremely sharp. Handle with care.

Serious cuts and lacerations to fingers and hands are
possible.
June, 2013 / 075-16395-000
14-7
Clipping
14-8
13.
Rotate drive pin retainer (O) to gain access to

the plate pin (P)
14.
Pull plate pin (P) out.
075-16395-000 / June, 2013
Clipping
NOTICE
When performing Steps 15 through 17, do not allow any
plates to slip out of the plate guide assembly. If plates fall
and become damaged, replacement will be necessary to
ensure safe smooth operation.
15.
June, 2013 / 075-16395-000
Slide the right hand gathering plates (C) into the

plate guide assembly (F) until they clear the
anvils (Q).
14-9
Clipping
16.
Slide the left hand gathering plates (C) into the

plate guide assembly (F) until they clear the
cut-off punches (R).
17.
Carefully lift the plate guide assembly (F) out of

the clipping head. If the plate guide assembly is
difficult to remove, turn the Micro-Adjust knob
(S) to zero.
NOTE: Be sure to reset the Micro-Adjust knob to the

original setting (above zero), before hand cranking or
operating the machine.
14-10
075-16395-000 / June, 2013
Clipping
June, 2013 / 075-16395-000
18.
Remove cut-off punches (R) while pulling the

cut-off punch lock bar (T) toward the front of the
machine. Remove the upper cut-off punch, then
the lower cut-off punch.
19.
Slide knock-out punches (U) out of cut-off

punches (R).
14-11
Clipping
20.
Loosen socket head cap screw (V) enough to

slide upper anvil (Q) out.
21.
Repeat step 16 for lower anvil (W).
NOTE: Anvils are marked with an L or an U to

indicate lower and upper anvil.
14-12
075-16395-000 / June, 2013
Clipping
Gathering Plates
The ChubMaker 4100 uses either six gathering plates or

nine gathering plates. Standard M7 Head plates are not
interchangeable with other types of clipping heads. Each type
of head set is different.
Standard Stroke M7 Head Assembly - Six Plates
Three plates are on the left side and three plates are
on the right side. See Figure 14-2 on page 14-15.
On the left, plates 1A, 2B, and 2C are identical. On the
right, plates 1C and 2A are identical. Plate 1B, the
center Knife Plate, is different from the others.
NOTICE
It is extremely important that all plates are assembled
properly, according to instructions that follow. Improper
assembly can result in serious damage to machine.
Assembly of Gathering Plates
The following will help in assembling gathering

plates. Refer to Figure 14-2 on page 14-15:
June, 2013 / 075-16395-000
1.
Turn OFF and LOCK OUT the

main electrical disconnect switch at
the main power source.
2.
Straighten any bent plates. File off and

polish any nicks in the V area or in the
notch. Inspect all parts and replace any
broken punches, fingers, or other parts.
3.
Place plate guide assembly on a clean

work surface. Note the three grooves are
labeled A, B and C from the bottom
up. Two plates slide into each of the
grooves.
4.
Lubricate all plates and plate guide

assembly with lubricant. Refer to
14-13
Clipping
Lubrication on page 29-1 for lubricant
type.
14-14
5.
Groove A -- Plate 1A: Insert one of

the smooth plates from the set on the
left, into the bottom of groove A.
6.
Groove A -- Plate 2A: Place one of

the two identical plates from the set on
the right, on top of the first plate (1A).
7.
Groove B -- Plate 1B: Slide center

Knife Plate from the set on the right into
groove B.
8.
Groove B -- Plate 2B: Insert the

second of the three left side plates into
the center gap of the plate guide, on top
of the knife plate (1B).
9.
Groove C -- Plate 1C: Slide the last

plate on the right, into the bottom of
groove C.
10.
Groove C -- Plate 2C: Place the final

plate from the left, on top of the first plate
(1C).
11.
IMPORTANT NOTE: MAKE SURE ALL

PLATES ARE FULLY PUSHED INTO
THE PLATE GUIDE ASSEMBLY. THEY
SHOULD SLIDE FREELY. IF NOT,
C H E C K F O R B E N T, N I C K E D , O R
MISASSEMBLED PLATES.
075-16395-000 / June, 2013
Clipping
Figure 14-2: Standard M7 Gathering Plates - 6 Plates

Standard Stroke M7 Head Assembly - Nine Plates
Four plates are on the left side and five plates

are on the right. (See Figure 14-1 on page
14-18.) Plates on the left side have a tab
opposite the V notch. Plates on the right side
have no tab.
On the left, plates 2B and 4B are identical;
plates 1A and 2C are identical. On the right,
plates 1B, 1C, 2A and 5B are identical. Plate
3B, the center Knife Plate, is different from the
others.
June, 2013 / 075-16395-000
14-15
Clipping
Clipping
NOTICE
It is extremely important that all plates are assembled

properly, according to instructions that follow. Improper
assembly can result in serious damage to machine.
Assembly of Gathering Plates
The following will help in assembling gathering

plates. See Figure 14-1 on page 14-18:
14-16
1.
Turn OFF and LOCK OUT the

main electrical disconnect switch at
the main power source.
2.
Straighten any bent plates. File off and

polish any nicks in the V area or in the
notch. Inspect all parts and replace any
broken punches or other parts.
3.
Place the plate guide assembly on a

work surface. Note the three grooves are
labeled A, B and C from the bottom
up. Two plates slide into each of the
grooves.
4.
Lubricate all plates and grooves. Refer

to Lubrication on page 29-1 for lubricant
type.
5.
Groove A -- Plate 1A: Insert one of

the smooth plates from the set on the
left, into the bottom of groove A.
6.
Groove A -- Plate 2A: Place one of

the four identical plates from the set on
the right, on top of the first plate (1A).
7.
Groove B -- Plate 1B: Slide another of

the four identical plates from the set on
the right into groove B.
075-16395-000 / June, 2013
Clipping
June, 2013 / 075-16395-000
8.
Groove B -- Plate 2B: Insert one of

the two left side plates with a spacer on
the tab and a rectangular button on the
opposite side, on top of the first plate
(1B). Make certain the rectangular button
faces down.
9.
Groove B -- Plate 3B: Place the Knife

Plate from the set on the right, on top of
the second plate (2B).
10.
Groove B -- Plate 4B: Slide the

r e m a i n i n g l e ft s i d e p l a t e w i t h t h e
rectangular button and spacer on the
tab, above the third plate (3B). Make
certain the spacer faces down and the
rectangular button faces up.
11.
Groove B -- Plate 5B: Place another

of the four identical plates from the set
on the right, on top of the fourth plate
(4B).
12.
Groove C -- Plate 1C: Slide the last

plate on the right, into the bottom of
groove C.
13.
Groove C -- Second, Plate 2C: Place

the final plate from the left, on top of
plate (1C).
14.
IMPORTANT NOTE: MAKE SURE ALL

PLATES ARE FULLY PUSHED INTO
THE MAGAZINE. THEY SHOULD
SLIDE FREELY. IF NOT, CHECK FOR
BENT, NICKED, OR MISASSEMBLED
PLATES.
14-17
Clipping
Groove A
Square Tab
Groove B
Rectangular Tab
Groove C
Plate Guide Assembly
Figure 14-1: Standard M7 Gathering Plates - 9 Plates

Installation of M7 Clipping Head Components
1.
Turn OFF and LOCK OUT the main

electrical disconnect switch at the main
power source.
2.
3.
Slide lower anvil (W) into position and secure

by tightening socket head cap screw (V).
NOTE: Anvils are marked with an L or an U to

indicate lower and upper anvil.
4.
14-18
Repeat step 3 to install upper anvil (Q).
075-16395-000 / June, 2013
Clipping
5.
June, 2013 / 075-16395-000
Slide knock-out punches (U) into cut-off

punches (R).
14-19
Clipping
NOTICE
Make certain to note the difference between upper and lower
punches. When replacing them, it is important to assemble
them in their proper position, making certain they lock in.
Otherwise, damage to the clipping head may result. (Punches
only lock in, in the correct position.)
14-20
6.
Slide cut-off punches (R) (insert lower cut-off

punch first) in position while pulling the cut-off
punch lock bar (T) toward the front of the
machine.
7.
Carefully install the plate guide assembly (F).

Reset the Micro-Adjust knob (S) to the original
setting if it was changed during the removal of
the plate guide assembly.
8.
Slide the left hand gathering plates (C) towards

the cut-off punches (R).
075-16395-000 / June, 2013
Clipping
June, 2013 / 075-16395-000
14-21
Clipping
14-22
9.
Slide the right hand gathering plates (C)

towards the anvils (Q).
10.
Insert plate pin (P).
11.
Rotate drive pin retainer (O) over plate pin (P).
075-16395-000 / June, 2013
Clipping
12.
Being extremely careful, install the cut-off knife

(N). Use a pencil or screwdriver to push the
cut-off knife in position.
WARNING

possible.
June, 2013 / 075-16395-000
14-23
Clipping
14-24
13.
Install knife pin (L) and plate pin (M).
14.
Rotate drive pin retainer (K) over knife pin (L)

and plate pin (M).
075-16395-000 / June, 2013
Clipping
June, 2013 / 075-16395-000
15.
Install the wire guide (J).
16.
Align the wire guide (J) and secure with washer

(I) and lock nut (H). Insert the locating pin with
chain (G) into the correct wire length hole.
14-25
Clipping
14-26
17.
Install two (retainer) thumb screws (D) and

offset washers (E) to secure the plate guide
assembly (F).
18.
Reinstall head guard.
19.
Close the front guard door.
20.
Restore electrical power to the machine.
21.
Press the SYSTEM RESET push button (X).
075-16395-000 / June, 2013
Clipping
June, 2013 / 075-16395-000
22.
Turn the machine through several cycles using

the hand wheel (B), to make sure all
components move without hitting.
23.
Set the HAND

DISENGAGE.
WHEEL
switch
(A)
to
14-27
Clipping
Loading Wire
WARNING
Use caution when handling clipping wire. Avoid wire ends

which can cause puncture wounds.
When lifting wire reels, or other related components, always
lift using your legs and not your back to avoid back injury. If
the object is too heavy, get help!
Mount wire coils onto the wire reels as follows:
14-28
1.
Separate each reel (A) into two halves and place one
half of each reel on a table.
2.
Place a wire coil (B) on one half of each reel with the
banding straps (C) between reel spokes. DO NOT
CUT BANDING STRAPS!
3.
Install the other halves of the wire reels (A) and fasten
with two expansion bolts (D) each. Tighten bolts two
full turns beyond the point where springs start to
expand.
4.
Install the wire reels (A) onto the machine, making

certain the end of each wire faces the machine when it
is at top of the reel.
5.
Make sure the wire reels turn freely.
6.
Cut and remove the banding straps (C) from the wire
coils (B).
075-16395-000 / June, 2013
Clipping
June, 2013 / 075-16395-000
14-29
Clipping
Wire Lubricator - Standard Stroke M7 Head
Remove the top from the wire lubricator reservoir (A) and fill
with one of the lubricants listed in Recommended Lubricants
on page 29-11.
Feed wire into each tube of the wire lubricator. Figure 14-2 on
page 14-31 indicates Wire In and Wire Out points. It may
be necessary to remove the knurled wire wipers in order to
run wire out beyond the end of each tube. If this is done,
simply slide the wire wipers over each wire and reinstall in the
clear vinyl tubing.
To adjust the amount of oil applied to each wire, loosen the
knurled caps on the wire wipers to allow more oil to remain on
the wires; or tighten the knurled caps to reduce the amount of
oil applied to the wires.
14-30
075-16395-000 / June, 2013
Clipping
Wire IN
Wire OUT
Knurled Cap
(on Wire Wiper)
Reservoir
Figure 14-2: Standard Wire Lubricator
NOTICE
Always make certain the wire lubricator reservoir contains
oil. It may be necessary to frequently check the level of oil in
the reservoir until a usage rate can be determined. Whenever
the top of reservoir is removed, a check valve in the wire
lubricator shuts off flow of oil from the reservoir. We
recommend that the oil filled immersion tubes be flushed out
periodically to reduce contaminant buildup.
DO NOT USE MINERAL OIL as a lubricant in the wire
lubricator. Mineral oil does not provide enough lubrication.
Material buildup from the wire will deposit in the clipping
head, leading to poor performance and potential parts
breakage. Refer to Table 29-2 on page 29-11 for proper
lubricant.
June, 2013 / 075-16395-000
14-31
Clipping
Wire Feed Mechanism
To setup the wire feed mechanism for operation, perform the

following steps:
1.
Disengage the wire feed by turning the WIRE CLAMP

selector switch to off.
NOTE: The wire clamp air circuit includes two selector
switches; one located on the front of the machine (A1),
the other on the rear (A2). Either switch will operate
the wire clamp. However, both switches must be set to
on for the wire clamp to engage. To operate the wire
clamp off and on with one switch, the other switch
must be set to on.
A2
2.
14-32
Refer to Removal of the Cut-Off Knife on page 24-1 to

remove the cut-off knife from the clipping head.
075-16395-000 / June, 2013
Clipping
3.
Set the HAND WHEEL switch (B) to ENGAGE and

turn the machine with the handwheel (C) until the
cut-off punches (D) are clear of the wire path (E).
June, 2013 / 075-16395-000
14-33
Clipping
4.
14-34
Set the front WIRE CLAMP selector switch (A1) to

on.
075-16395-000 / June, 2013
Clipping
5.
With the rear WIRE CLAMP selector switch (A2) off,

feed both strands of wire (F) through the wire
straightener (G) and into the clipping head, until about
6" [152 mm] of each wire is exposed. It is important
that the wire is smooth and free of any nicks or flat
spots.
A2
June, 2013 / 075-16395-000
14-35
Clipping
6.
Engage the wire feed by turning WIRE CLAMP

selector switch (A2) to on.
A2
7.
14-36
Turn machine slowly with handwheel (C) until clips are

formed.
075-16395-000 / June, 2013
Clipping
Inspection of Clip Tightness
Proper clip tightness is judged by two checks:

1.
The clip cannot be pulled off the package film.
2.
The package film has not been cut by the clip.
Adjustment of Clip Tightness
Clip tightness can be adjusted by rotating the dial rim of the

micro-clip dial. This dial is located on the closure plate crank
pin on the right side of the clipping head. Lift the dial rim and
turn to make adjustment. The smaller the number at indicator
mark, the tighter the clip. Making this adjustment will also
change tightness of film gathering plates. Whenever the
micro-clip adjustment is changed, the film gathering
adjustment should be checked and necessary changes
made.
WARNING
Never change the micro-clip adjustment when the machine is

in motion. Always turn OFF and LOCK OUT the main
electrical disconnect switch when making this adjustment.
3
2
Dial Rim
Clamp Screw
Figure 14-3: Micro-Clip Dial
June, 2013 / 075-16395-000
14-37
Clipping
After the machine has been in production for some time,
additional tightness adjustment may be necessary.
CAUTION
Running the machine with overtight clips puts tremendous
stress on clipping head components, resulting in excessive
part breakage.
Clip Leakage Test
To check for leakage, fill a portion of sealed film tube, clipped

at one end, with water. Twist the open end to create pressure
inside the tube. Observe the clipped end of the tube for any
leakage. If leakage occurs at Point B, shown below, the film
has been cut or torn. If leakage occurs at Point A, the clip
may be too loose. This test should be done for both the upper
and lower clips.
When setting clip tightness for leak proof packages, it is
necessary to accurately measure across the clip closure with
a micrometer. This will enable more precise adjustments.
A
B
Observe for Leakage

Observe for Leakage
C
D
Water Filled Package

Twist Film to Create
Pressure
Figure 14-4: Clip Leakage Test
14-38
075-16395-000 / June, 2013
Package Setup
When determining packages per minute, several factors are
involved.
Package Setup
Cut-off length of the package film.
2.
Maximum film speed.
3.
Maximum sealing rate of film.
4.
Weight of the package.
5.
Rated capacity of the product pump.
Package Length (Inches)
1.
USING CLUTCH AND

INSIDE CAMS
USING INSIDE CAMS
USING OPTIONAL OUTSIDE
CAMS
1350 INCHES PER MINUTE
FILM SPEED LIMIT
Packages Per Minute

Figure 15-1: Package Setup Chart
NOTE: The above chart applies to machines supplied with standard
cams and the clutch feature. Results may vary for machines
equipped with special cams.
While the ChubMaker 4100 is designed to operate up to 150 PPM
(Packages Per Minute), it may not be possible to produce this
amount depending on five factors listed above. There is a direct
relationship between package length and clip speed (packages per
minute).
The maximum film speed for this machine is 1,350 inches per
minute [34,290 mm per minute]. Packages of nine inches
[228.6 mm] in length or less can be produced at 150 per minute.
June, 2013 / 075-16395-000
15-1
Package Setup
For package lengths up to twelve inches [305 mm], the standard
cams alone, offer the best performance. Package lengths between
twelve inches [305 mm] and sixteen inches [406 mm] may be
produced using the clutch feature. Package lengths over sixteen
inches [406 mm], using the clutch feature, may or may not be
possible. No data on this was available at the time this publication
was published.
Refer to Figure 15-1 on page 15-1 as a guide to help determine the
best production setup for your application.
It may not be possible to seal film at the rated speed, due to the film
type, condition of the sealer or how it is adjusted. Determine the
maximum rate at which film can be sealed. If the maximum seal rate
is less than 1,350 inches per minute [34,290 mm per minute], use
the actual sealing rate of your film in place of the 1,350 inches per
minute used in the following calculation:
1350
PPM = -----------CL
WHERE:
PPM = Packages Per Minute

CL = Cut-Off Length of Package
EXAMPLE: PPM = Packages Per Minute

CL = 10 inch (no clutch feature)
1350
------------ = 150
9
CL = 14 inch (clutch feature required)
1350
------------ = 96
14
15-2
075-16395-000 / June, 2013
Package Setup
A cut-off length of 16 inches [406 mm] is usually the maximum using
the clutch feature. Longer packages may not be possible. These
package sizes cannot be produced at a rate of 150 PPM.
Package weight and rated capacity of product pump are also
important factors in determining PPM. The following formula is used
to determine PPM based on pump rate and package weight:
PRPPM = -------PW
WHERE:

PR = Pump Rate
PW = Package Weight

PR = 100 pounds/minute
PW = 1 pound
100
--------- = 100
1
EXAMPLE:

PR = 100 pounds/minute
PW = 2 pounds
100
--------- = 50
2
June, 2013 / 075-16395-000
15-3
Package Setup
After Film Speed/Cut-Off Length and Pump Rate/Package
Weight formulas have been worked out, compare the answers. The
lower of the two will be the maximum PPM that can be run for that
package. Keep in mind that these examples are provided only as a
guide and that your actual findings may vary from those calculated.
15-4
075-16395-000 / June, 2013
Adjusting Film Speed

Once machine speed is set to run a specific number of packages
per minute, adjustment of the package length is required to achieve
the required film speed. Follow the procedure below:
1.

disconnect switch at the main power source.
2.
Thread film through clipping head (A) with approximately 18"

[457 mm] to 24" [610 mm] of film hanging into chute (B).
3.
Turn main electrical disconnect switch on at the main power

supply.
June, 2013 / 075-16395-000
16-1

4.
Touch SYSTEM RESET to power the machine control
5.
The HOME screen will display.
DRIVE NOT READY
SPEED
(PPM)
POSITION
(DEG)
EON #####
NNN
NNN
ChubMaker 4100

Ph (800) 257-5622 (563) 391-0000 Fax (563)-391-0699
HOME
16-2
RUN
SENSOR
HEATER
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
6.
Touch RUN CONTROL to open the RUN CONTROL 1

screen.
7.
The RUN CONTROL 1 screen will display.
075-16395-000 / June, 2013

6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
8.
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
To adjust the package length, and thereby, affect the film

speed:
a.
Touch PACKAGE LENGTH. A numeric keypad

will display.
b.
Key in a new value and press ENTER to

confirm.
OR:
c.
Touch the (DOWN) CURSOR to decrease or

the (UP) CURSOR to increase the package
NOTE: Refer to additional notes on the following page.
June, 2013 / 075-16395-000
16-3

NOTE: When production begins, inspect several completed
packages. Further adjustment may be required to produce an
accurate package length.
NOTE: Package length for registered film is measured from eye spot
to eye spot. Package length for plain or unprinted film must be
specified.
See Sealing Polyethylene Film on page 13-1 for information
regarding Heat Sealing.
16-4
075-16395-000 / June, 2013
Chub Package Dimensions

Determining Chub package dimensions is not exacting due to
variations in products. These variations can make a difference in
final package size when a certain weight of package is required.
Following are several formulas to help determine package size. It is
important to note that these formulas come close, but may not give
exact dimensional requirements.
C
D
Cut-Off Length
Package Diameter
L
X
Package Length
0.4 [10 mm]
Figure 17-1: Chub Package Dimensions

NOTE: Dimensions entered on the PanelView is cut-off length of the
film. Sealed package length will be shorter.
To find Package Length (L), when you know Package Diameter (D),
Weight in pounds (W) and Specific Gravity (G):
Where:
L = Package Length
D = Package Diameter
W = Package Weight (in pounds)
G = Specific Gravity of Product
( 35.26 W )
L = ------------------------------ + ( 0.333 D )
(D D) G
June, 2013 / 075-16395-000
17-1

An example follows:
Example:
L = Package Length
D = 3 inches
W = 2 pounds
G = 1.095
( 35.26 2 )
L = ------------------------------------ + ( 0.333 3 )
( 3 3 ) 1.095
70.52
L = ---------------------- + 0.999
9 1.095
70.52
L = ------------- + 0.999
9.855
L = 7.16 + 0.999
L = 8.16 inches
To find Package Length (L), when you know Package Diameter (D),
Weight in pounds (W) and Density (d):
Where:
L = Package Length
W = Package Weight (in pounds)
d = Density of Product (pounds per inch3)
( 1.273 W )
L = ----------------------------- + ( 0.333 D )
(D D) d
17-2
075-16395-000 / June, 2013

An example follows:
Example:
L = Package Length
D = 2.5 inches
W = 1.5 pounds
d = 0.042 lbs/in3
( 1.273 1.5 )
L = --------------------------------------------- + ( 0.333 2.5 )
( 2.5 2.5 ) 0.042
1.910
L = ------------------------------ + 0.832
6.25 0.042
1.910
L = ------------- + 0.832
0.262
L = 7.29 + 0.832
L = 8.12 inches
To find Film Cut-Off Length (C), when you know Package Length (L)
and Package Diameter (D):
Where:
C = Film Cut-Off Length

L = Package Length
C = L + ( 0.571 D ) + 0.75
June, 2013 / 075-16395-000
17-3

An example follows:
Example:
C = Film Cut-Off Length

L = 13.8 inches
D = 5 inches
C = 13.8 + ( 0.571 5 ) + 0.75
C = 13.8 + 2.855 + 0.75
C = 17.405 inches
17-4
075-16395-000 / June, 2013
Options
Film Splice Detector
Options
The film splice detector detects a splice in the film. Clear film
passes through the detector. The machine will shut down
when a splice (dark tape connecting cut film) is detected.
Package Breakout Detector
The Package Breakout Detector uses low voltage and a

spring loaded wire loop(s) to detect when product has come
out of a package. Since most breaks, if they occur, will occur
along the seal, the wire loop(s) is (are) located along the seal
side.
When a package breaks, product comes into contact with the
wire loop(s). This creates a short in the low voltage system,
causing the machine to shut down. By shutting down, product
loss is minimized.
June, 2013 / 075-16395-000
18-1
Options
Notes . . . .
18-2
075-16395-000 / June, 2013
Optional Film Registration

Film Registration is necessary when using printed film. This section
explains the operation and adjustments to maintain proper
registration.
NOTICE
The diameter and length of a Chub package must be correct
to result in a tight package with proper weight. Package
diameter corresponds to film width. Package length
corresponds to the distance between registration marks.
Products vary in density and some require additional
processing after packaging. These and other factors must be
taken into account when selecting packaging film. We
strongly recommend that you carefully study your
requirements and application before having film printed for
package registration.
When printed film is used with F1 Registration, the label

(printed design) must be in a fixed position between the two
clips of the package. For example, if the ChubMaker 4100
clamp speed is set to produce 30 packages per minute and
each package requires 8 inches [203 mm] of film, the film
drive should be set for 8 inches [203 mm] package cut-off
length. The computer will calculate and set the film drive
motor to feed precisely 240 inches [6,096 mm] of film per
minute. The F1 Registration Accessory helps maintain
precise film speed.
On the edge of the printed film is a registration mark, printed
once for each package length. It is important to understand
that the film registration control actually positions the
registration mark and not the package label.
The fiber-optic sensor, senses each passing registration
mark. The CPU calculates the film speed based on the
distance between marks; and either slows down or speeds
up the film drive.
June, 2013 / 075-16395-000
19-1

Startup
To ensure that the F1 Registration Accessory works properly,

follow the steps outlined in their correct order. Registration
may be turned on at any time.
19-2
1.
Turn the main electrical disconnect switch on at the

main power supply.
2.
3.
Push the SYSTEM RESET button (C).
4.
Check all air pressure gages and adjust as required.

Refer to Setting Air Pressures on page 24-6.
5.
Set the HAND WHEEL switch (A) to ENGAGE and

turn the machine through one complete cycle with the
handwheel (B).
075-16395-000 / June, 2013
NOTE: Legends shown are prototypes.

6.
Close all guard doors and secure all other guards.
7.
Set the HAND WHEEL switch (A) to DISENGAGE.
8.
Measure the pitch (center to center distance) of the

film's registration marks.
NOTE: Pitch equals package length.
June, 2013 / 075-16395-000
19-3

9.
Navigate to the RUN CONTROL 1 screen.
10.
Touch PACKAGE LENGTH. A numeric keypad will

display.
a.
Key in the specified package length in inches

(or mm), determined in Step 8 and press
ENTER to confirm.
OR:
b.

length one increment at a time, until the
specified package length determined in Step 8
is reached.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
19-4
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
11.
Load a roll of packaging film with registration marks,

onto the film arbor of the ChubMaker 4100. Refer to
Film Arbor on page 8-1.
12.
Thread the film through the rollers and film folder as

illustrated on the film path legend on the front of the
ChubMaker 4100. Refer to Film Threading on page
10-1.
075-16395-000 / June, 2013

13.
June, 2013 / 075-16395-000
To adjust the fiber optic light guide (K1) horizontally, so

the fiber optic light guide is centered over the film
registration marks as packages pass by.
a.
Loosen the lock knob (K2).
b.
Turn the adjust knob (K3), to move the fiber

optic light guide (K1) across the film web.
c.
Tighten the lock knob (K2) to secure the

adjustment.
19-5

14.
Navigate to the RUN CONTROL 1 screen, unless

already displayed.
15.
Touch MACHINE SPEED. A numeric keypad will

display.
a.
Key in the specified package per minute and

press ENTER to confirm.
OR:
b.

per minute one increment at a time.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
19-6
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
16.
Touch the (RIGHT) CURSOR, in the upper right

corner of the display, to navigate to the RUN
CONTROL 3 screen.
17.
At the RUN CONTROL 3 screen, touch

REGISTRATION to toggle to the OFF position.
075-16395-000 / June, 2013

PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
REGISTRATION
OFF
18.
June, 2013 / 075-16395-000
DATER
CLUTCH BRAKE
ON
OFF
LABEL
POSITION
#####
##.##mm
in
HOME
RUN
CONTROL 3
RESET
OFF
ON
CLIPPING SPEED
FINE ADUST
###.# %
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ON
PRINT
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
Touch the (LEFT) CURSOR, in the upper right

CONTROL 1 screen.
19-7

19.
Touch FILM ENGAGE to toggle to CLOSE.
20.
Touch FILM to toggle to ON.
21.
Touch AUTO beneath HEAT SEAL FRAME.
22.
Touch PUMP to toggle to ON.
23.
Touch CLIP to toggle to ON.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
19-8
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
24.
Make a few packages.
25.
Press CYCLE STOP.
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
075-16395-000 / June, 2013

26.
Weigh the packages produced. If the packages are off

weight from the specification, go to the next step.
27.
At the RUN CONTROL 1 screen, touch PACKAGE

WEIGHT. A numeric keypad will display.
a.
Key in the specified package weight and press

ENTER to confirm.
OR:
b.

weight one increment at a time.
NOTE: The speed of the pump affects the amount of

product introduced into each package. Slower pump
speeds provide less product while faster pump speeds
provide more product.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
28.
Record all settings to simplify the setup process in the

future.
29.
Repeat Step 24 through Step 28 until correct weight is

achieved.
June, 2013 / 075-16395-000
19-9

30.
31.
32.
33.

CONTROL 3 screen.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
RAISE
RUN
CONTROL
SCREEN 1
RESET
FILM
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
19-10
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
075-16395-000 / June, 2013

PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
REGISTRATION
OFF
DATER
CLUTCH BRAKE
ON
OFF
LABEL
POSITION
#####
##.##mm
in
HOME
RUN
CONTROL 3
RESET
OFF
ON
CLIPPING SPEED
FINE ADUST
###.# %
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
PRINT
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
34.
On the RUN CONTROL 3

REGISTRATION to toggle to ON.
35.
36.
Press CYCLE STOP.
June, 2013 / 075-16395-000
ON
ALARM
HISTORY
screen,
SETUP
touch
19-11
19-12
37.
Note the position of the package label or printing with

respect to the package ends.
38.
Determine the amount of upward or downward

movement required to reposition the printing correctly.
Refer to Figure 19-1.
075-16395-000 / June, 2013
INCORRECT POSITION
Z
Distance from
registration mark to
package end.
AA Upward movement value
required to reposition
label.
CORRECT POSITION
AB Display Value
Figure 19-1: Label Positioning
June, 2013 / 075-16395-000
19-13

PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
REGISTRATION
OFF
39.
DATER
CLUTCH BRAKE
ON
OFF
LABEL
POSITION
#####
##.##mm
in
HOME
RUN
CONTROL 3
RESET
OFF
ON
CLIPPING SPEED
FINE ADUST
###.# %
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ON
PRINT
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
For upward movement, subtract upward movement,

the value from Step 38, from the display value (AC)
below the Label Position Graphic (AD).
a.
If the value derived from Step 38 is a positive

value press the (UP) CURSOR to change
the display value to match your result.
b.
If the value derived from Step 38 is a negative

value, subtract this value from the package
length value. (The package length value is
found on the RUN CONTROL 1 screen, in the
lower left area of the display. Press the (UP)
CURSOR or the (DOWN) CURSOR to
change the display value to match the newer
value.
WHEN:
UM = Upward Movement Required
DV = Display Value
PL = Package Length
NV = New Value
19-14
075-16395-000 / June, 2013

Example 1: DV - UM = NV -- when NV is a positive
value.
If (DV) is 6 (inches) and the label needs to
move upward by 2 (inches) (UM):
6 (DV) - 2 (UM) = 4 (NV) -- Adjust the display
value to 4.
Example 2: DV - UM = - NV, then PL + DV - UM = NV
If (DV) is 3 (inches) and the label needs to
3 (DV) - 4 (UM) = -1 -- Disregard this result
since it is a negative value. Use the following
formula.
If (PL) is 12 (inches) and the label needs to
12 (PL) + 3 (DV) - 4 (UM) = 11 (NV) -- Adjust
the display value to 11.
40.
June, 2013 / 075-16395-000
For downward movement, add downward movement,

the value from Step 38, to the display value (AC)
below the Label Position Graphic (AD).
a.
If the value derived from Step 40 is less than

the package length, press the (UP)
CURSOR or the (DOWN) CURSOR to
change the display value to match the result.
b.
If the value derived from Step 40 is greater than

the package length, subtract the package
length from the derived value and press the
(UP) CURSOR or the (DOWN) CURSOR to
change the display value to match the result.
19-15

WHEN:
DM = Downward Movement Required
DV = Display Value
PL = Package Length
IV = Intermediate Value
NV = New Value
Example 1: DV + DM = NV -- when NV < PL.
If (PL) is 12 (inches), (DV) is 6 (inches) and the
label needs to move downward by 2 (inches)
(DM):
6 (DV) + 2 (DM) = 8 (NV) -- Adjust the display
value to 8, since package length is 12 (inches).
Example 2: DV + DM = NV -- when NV > PL.
If (PL) is 12 (inches), (DV) is 10 (inches) and
the label needs to move downward by 5
(inches) (DM):
10 (DV) + 5 (DM) = 15 (IV) -- Since this result
exceeds the package length of 12 (inches), use
the following formula:
15 (IV) - 12 (PL) = 3 (NV) -- Adjust the display
value to 3.
19-16
41.
Touch FILM on the RUN CONTROL 1 screen to toggle

to ON. Begin making packages. Once you become
familiar with the adjustment process, adjustments can
be made while the machine is in operation.
42.
Retrimming adjustments may be necessary as roll of

film nears core.
075-16395-000 / June, 2013

Registration Control Components
The F1 Registration Accessory Control consists of three main

components. These are:
1.
Scanner Control Unit
2.
Fiber Optic Light Guide
3.
Clamp Mode Proximity Switch
Scanner Control Unit
This black box unit sends and receives green LED

light to and from the fiber optic light guide. This unit
recognizes contrast (the difference between light and
dark objects), such as package film background and
registration marks. Whenever the change in contrast is
noted, an electrical signal is sent to the solid state
control assembly.
The Fiber Optic Light Guide houses an array of optical

fibers. Half of the fibers transmit light from the scanner
control unit's LED. The other half receive reflected
light and transmit that back to the control unit. When a
registration mark passes by the fiber optic light guide,
the reflected light changes. This change creates a
signal which is sensed by the scanner control unit as
contrast.
Clamp Mode Proximity Switch
The clamp mode proximity switch senses the position

of the clipping mechanism.
June, 2013 / 075-16395-000
19-17

Fiber Optic Scanner
The Fiber Optic *SMARTEYE Mark III is a high speed, solid

state registration control scanner that detects printed
registration marks on packaging materials. The three
categories of material types are:
1.
Opaque (non-foil)
2.
Shiny Foil
3.
Transparent
This sensing task is accomplished by detecting the variation

in contrast between the light reflected off the mark vs. the
light reflected off the surface of the material it is printed on.
This scanner offers superior performance and ease of
adjustment. The contrast indicator (N) simplifies setup so you
can quickly optimize scanner adjustments.
The contrast indicator (N) shows the level of light received by
the scanner's photo detector. The more light, the higher the
reading on the indicator; the less light, the lower the reading.
Contrast is a comparison of the amount of light striking the
detector in the lightest and darkest states. The greater the
contrast deviation as displayed on the indicator, the greater
the reliability and performance of the scanner.
The scanner has an open collector NPN transistor switching
output. The output transistor and the output status indicator
(K) come on when the mark comes into view. A light/dark
selector switch (G) is used to assure that the machine control
functions on the leading edge of either a light or dark mark.
The output of the scanner switches at the threshold point of
5 on the contrast indicator (N). The offset control (H)
adjustment is used to preset the contrast indicator to an
optimum level based upon the amount of light being returned
to the scanner's detector. (Refer to the setup instructions on
the following pages.) The offset is not a sensitivity control.
The sensitivity or gain of the scanner is fixed at maximum.
However, the offset can be set so that the threshold of 5
on the contrast indicator is crossed at a pre-determined light
level, thus duplicating the function of a sensitivity adjustment.
*SMARTEYE is a registered trade name of Tri-Tronics Company,
Inc.
19-18
075-16395-000 / June, 2013

The scanner is designed to be used with flexible fiber optic
light guides which allow the scanner to be located at a
remote, convenient location. In addition, fiber bundle size and
shape can provide optical advantages. In this application a
96" long, bifurcated light guide is used so the scanner
electronics can be located in the electrical cabinet.
The scanner is equipped with a green LED light source
combined with a photo detector that responds to almost any
color mark on any color background. If the mark produces
enough contrast to be seen by the human eye, the scanner,
in most cases will respond accordingly (a yellow/white
combination is the exception).
A
B
C
D
E
F
G
24 Volt DC
Load
Red +24 Volt
White Output
Green N/A
Black Negative
Light/Dark Switch
H
I
J
K
L
M
N
Offset Control
Beam Status Indicator
EDR Indicator
Output Status Indicator
Optical Block
Fiber Optic Input/Output
Contrast Indicator
Figure 19-2: *Smarteye Scanner Control Unit

*SMARTEYE is a registered trade name of Tri-Tronics Company,
Inc.
June, 2013 / 075-16395-000
19-19

Setup Instructions
Opaque (Non-Foil) Film
A
B
1.
Position the fiber optic light guide (C) as shown in

Figure 19-3. The light guide should be positioned 1/4
(B) from the roller (A), looking directly at the roller
along its center line.
2.
Place the film (D) BACKGROUND in view of the fiber

optic light guide (C).
Backup Roller
.250 [6.4 mm]
C
D

Package Film
Figure 19-3: Position for Opaque Film

3.
4.
19-20
Adjust the OFFSET as follows using the offset

control (H):
a.
For DARK MARK on LIGHT BACKGROUND

adjust for a reading of 7 on the contrast
indicator with the background in view.
b.
For LIGHT MARK on DARK BACKGROUND

adjust for a reading of 3 on the contrast
indicator with the background in view.
Set the light/dark switch (G) to DARK for DARK

MARK or LITE for LIGHT MARK.
075-16395-000 / June, 2013
5.
Move mark into view. Note the new contrast reading. If

this reading has deviated from the initial reading by 4
to 5 bars or more, enough contrast exists for proper
detection.
June, 2013 / 075-16395-000
19-21

Shiny Foil Film
1.
BA
U
CK
2.
19-22
Position the fiber optic light guide (C):

a.
For BLACK or DARK MARK on shiny foil, as

shown in Figure 19-4.
b.
For WHITE or LIGHT MARK on shiny foil, as

shown in Figure 19-5 on page 19-25 or Figure
19-6 on page 19-25.
c.
Loosen locking hex nuts on shank of fiber optic

light guide (K1) and position the end up or down
(Figure 19-6 on page 19-25) from the center
line of the backup roller to obtain the best
results. Tighten the hex nuts.
R
LE
L
O
Loosen the lower locking hex nut on shank of fiber

optic light guide (K1) and pivot the end sideways
(Figure 19-5 on page 19-25) from a straight on view to
obtain the best results. Tighten the hex nut.
075-16395-000 / June, 2013
A
B
Backup Roller
.250 [6.4 mm]
C
D

Package Film
Figure 19-4: Position for Shiny Foil Film

3.
Place MARK in view of fiber optic light guide (K1).
4.
Adjust the OFFSET as follows using the Offset

Control (H):
a.
For BLACK or DARK MARK on shiny foil adjust

for a reading of 1 when the BLACK or DARK
MARK is in view.
b.
For WHITE or LIGHT MARK on shiny foil adjust

for a reading of 7 when the WHITE or LIGHT
MARK is in view.
5.
Set the light/dark switch (G) to LITE for LIGHT

MARK or DARK for DARK MARK.
June, 2013 / 075-16395-000
19-23
6.
19-24
Move the MARK out of view of the fiber optic light

guide (C). With the BACKGROUND in view, note the
new contrast reading. If this reading has deviated from
the initial reading by 4 to 5 bars or more, enough
contrast exists for proper detection.
075-16395-000 / June, 2013
A
B
C
Backup Roller
.250 [6.4 mm]
D
E
F
Package Film
Registration Mark or Spot
Pivot Fiber Optic Light
Guide as needed to
obtain the best results
Figure 19-5: Position A for Shiny Foil Film
A
B
Backup Roller
.250 [6.4 mm]
D
G
Package Film
Adjust Fiber Optic Light
Guide up or down to
obtain best results
Figure 19-6: Position B for Shiny Foil Film
June, 2013 / 075-16395-000
19-25

Transparent Film
19-26
1.
Position the fiber optic light guide (C) as shown in

Figure 19-3 on page 19-20. The light guide should be
positioned 1/4 (B) from the roller (A), looking directly
at the roller along its center line.
2.
Place the film (D) BACKGROUND (transparent area)

in view of the fiber optic light guide (C).
3.
Adjust the OFFSET using the offset control (H), for a

reading of 9 or 10 on the contrast indicator (N).
4.
Set the light/dark switch (G) to DARK for DARK

MARK or LITE for LIGHT MARK.
5.
Move mark into view. Note the new contrast reading. If

this reading has deviated from the initial reading by 6
to 8 bars or more, enough contrast exists for proper
detection.
075-16395-000 / June, 2013

Hints and Helps
1.
False tripping or erratic operation is usually caused by

excessive web flutter of the film, wrinkles or variations
in material background color or marks. MINOR
ADJUSTMENTS OF THE OFFSET CAN HELP TO
ELIMINATE ERRATIC OPERATION.
2.
If the surface of opaque (non-foil) film is EXTREMELY

SHINY, consider placing the fiber optic light guide as
outlined for Figure 19-5 on page 19-25 or Figure 19-6
on page 19-25. The position that results in the
maximum contrast deviation as displayed on the
contrast indicator (J) will give the most reliable
performance.
3.
The back-up roller for the fiber optic light guide

eliminates web flutter and wrinkles and provides a
shiny background when sensing marks on transparent
film.
June, 2013 / 075-16395-000
19-27

Notes . . . .
19-28
075-16395-000 / June, 2013
Film Printing Specifications

The following film printing specifications are provided as a general
guide. See Figure 20-1 on page 20-2. Your actual application may
require special considerations.
A - Registration mark path, 5/8 [16 mm] minimum width. Path must have
only two color contrasts. One color may be clear or manufacturer's
pigment. Attempt as much color contrast as possible. Avoid light shades
of yellow, red, or green to contrast each other, or with white or clear film.
B - Registration mark with a standard machine can be anywhere within
width of film. All additional printing should be clear of registration mark
path.
C - Registration mark length to be 1/4 [6 mm] minimum. No maximum
limit to within 1/2 [13 mm] of total package length.
D - Denotes printed side.
E - All rolls can be 3" [76 mm] or 6" [152 mm] cores up to 16" [406 mm]
maximum diameter. Right hand bottom unwind as shown.
F - Denotes seal area. Must be free of all printing, lacquer, and surface
treatment except manufacturer's pigment. Polyethylene requires 3/4
[19 mm] on one edge only. See Option 3 (Figure 20-1 on page 20-2) for
registration mark in seal area of polyethylene.
G - Film web width is established by adding 1/2 [13 mm] to 3 /4 [19 mm]
to circumference of package diameter. Always arrive at an even 1/8
[3 mm] increment.
H - Film cut-off length or one complete package.
I - Printed registration mark in seal area - polyethylene only. This area
must be free of all printing, except for registration mark. See J below.
J - When registration mark is in seal area, formed tube will NOT seal for
this 1/2 [13 mm] length. Printed design must allow for package clips to be
placed in this area.
OPTION 1 - Most common polyethylene design. Registration mark
required on one side only. Left side is most common.
OPTION 2 - Most common where art design requires printing or copy to
extend to left edge (bleed edge). Registration mark path frequency found
in center of film sheet. See B on previous page.
OPTION 3 - This design is used when background pattern is simulated
cloth, basket weave, etc., which prohibits use of one solid color in
registration mark path. Printed copy may extend to left edge. Ink from
registration mark will be inside package and must not bleed into product.
June, 2013 / 075-16395-000
20-1
K
L
M
Eye Spot either Side of

Film
Product
Film Folder
Cut-Off Knife
O
P
Wire Clips
Printed Side of Film
Figure 20-1: Film Layouts
20-2
075-16395-000 / June, 2013
Optional Voider
Your machine may be equipped with a Voider accessory, designed
to void the package of product, where the clips will be applied. This
aids in making neater packages and helps prevent packages from
splitting during production. Also, the clipping head area does not
become clogged by product build-up from the clipping operation.
Optional Voider
The voider rollers rotate at a surface speed equal to the film speed.
The rollers are mounted on swing arms which are moved in and out
by an air cylinder. When VOID POSITION and VOID LENGTH are
properly adjusted, the voider rollers close to void the package of
product in one area. As the package tube moves downward, this
voided area enters the head. The clipping head closes on the
voided area, places the clips and cuts the filled package from the
tube. This procedure is repeated for each package.
NOTE: Machine speed (packages per minute), the regulator, void
length, and void position all work together to open and close the
voider.
Setting Void Position
When the voider rollers close, product will be squeezed out,

or voided from an area of the package tube. If the voided
area is above or below the clips, the void position needs to be
set. Ideally, clips should be placed in the middle of the void.
1.

main power supply.
2.
3.
June, 2013 / 075-16395-000
21-1
Optional Voider
4.

5.

handwheel (B).

6.
21-2
Set the voider air pressure to 50 PSI [350kPa]. (More

pressure may be required for thick product.)
075-16395-000 / June, 2013
Optional Voider
7.
8.

corner of the display, to open the RUN CONTROL 2
screen.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
9.
At the RUN CONTROL 2 screen, touch VOIDER to

toggle to the ON position.
June, 2013 / 075-16395-000
21-3
Optional Voider
6/12/2007 10:06:52 AM
PRODUCTION
COUNT
SEALERNOT
SERVO
TEMP
READY
LOW
NNNNNNNNNN
PRODUCT
PISTON
VOIDER
OFF
VOID
POSITION
#####
##.##mm
in
HOME
ON
VOID
LENGTH
#####
##.##mm
in
OFF
PROD PISTON
POSITION
#####
##.##mm
in
RUN
SENSOR
HEATER
10.
SENSOR
RUN
CONTROL
SCREEN 1
2
RESET
ACTIVE
ALARMS
ON
PROD PISTON
LENGTH
#####
##.##mm
in
ALARM
HISTORY
SETUP
To adjust the void position:

a.
Touch VOID POSITION. A numeric keypad will

display.
b.

confirm.
OR:
c.
21-4

the (UP) CURSOR to increase the void
position one increment at a time.
075-16395-000 / June, 2013
Optional Voider
6/12/2007 10:06:52 AM
SEALERNOT
SERVO
TEMP
READY
LOW
PRODUCTION
COUNT
NNNNNNNNNN
PRODUCT
PISTON
VOIDER
OFF
VOID
POSITION
#####
##.##mm
in
ON
VOID
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
HOME
SENSOR
RUN
CONTROL
SCREEN 1
2
RESET
OFF
PROD PISTON
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ON
PROD PISTON
LENGTH
#####
##.##mm
in
ALARM
HISTORY
SETUP
11.

screen.
12.
June, 2013 / 075-16395-000
21-5
Optional Voider
13.
14.
15.
16.
17.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
21-6
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
18.
Make a few packages. Take note of the void position in

each package.
19.
Press CYCLE STOP.
075-16395-000 / June, 2013
Optional Voider
20.
June, 2013 / 075-16395-000
Check to ensure the clip is in the center of the voided

area. Touch the (DOWN) CURSOR to decrease or
the (UP) CURSOR to increase the void position one
increment at a time until the clip is centered in the
voided area.
21-7
Optional Voider
Setting Void Length
If the void is long enough, the closure plates will clear the
product filled portions of the package tube. Voids that are too
long result in loose packages. Voids that are too short allow
closure plates to cut into the filled portion of the package. If
the void length is too long or too short, the void length must
be adjusted.
1.
Adjust the void position as outlined earlier if

necessary.
2.
3.
Determine the a reasonable amount of void length

required.
4.
Set the void length:

a.
At the RUN CONTROL 2 screen, touch VOID

LENGTH. A numeric keypad will display.
b.

confirm.
OR:
c.
5.
21-8

the (UP) CURSOR to increase the void

screen.
075-16395-000 / June, 2013
Optional Voider
6/12/2007 10:06:52 AM
SEALERNOT
SERVO
TEMP
READY
LOW
PRODUCTION
COUNT
SENSOR
RUN
CONTROL
SCREEN 1
2
RESET
NNNNNNNNNN
PRODUCT
PISTON
VOIDER
OFF
VOID
POSITION
#####
##.##mm
in
HOME
ON
VOID
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
OFF
PROD PISTON
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ON
PROD PISTON
LENGTH
#####
##.##mm
in
ALARM
HISTORY
6.
7.
8.
9.
10.
June, 2013 / 075-16395-000
SETUP
21-9
Optional Voider
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
11.
Make a few packages. Take note of the length of the

void (indication of dwell) in each package.
12.
Press CYCLE STOP.
NOTE: Once you are familiar with the adjustment

process, adjustments can be made while the machine
is in operation.
21-10
075-16395-000 / June, 2013
Optional Voider
Setting Voider Gap
The open gap between the voider rollers should be slightly

larger than the package diameter. To adjust this gap:
1.
Turn OFF and LOCK OUT the air supply to the

machine.
2.
Turn the lock handles (A) on the air cylinders (B) to

allow split collars (C) to be moved.
3.
Set the rollers (D) to the desired open positon.
NOTE: Ensure rollers (D) remain parallel when open.
June, 2013 / 075-16395-000
21-11
Optional Voider
4.
Slide the split collars (C) to rest against the bumpers

( E ) . Tu r n t h e l o c k h a n d l e s ( A ) t o s e c u r e t h e
adjustment.
With stiff products, where air in the package is a problem, the

voider rollers may be used as an extra set of squeeze rollers.
This is accomplished by adjusting the open gap slightly
smaller than the package diameter.
21-12
075-16395-000 / June, 2013
Optional Voider
Pressure Adjustment
If the voider rollers do not close enough, and not all product is
squeezed out of the void area, increase the voider air
pressure. Do not adjust the air pressure too high, as this will
cause early failure of the voider rollers.
June, 2013 / 075-16395-000
21-13
Optional Voider
Notes . . . .
21-14
075-16395-000 / June, 2013
Product Piston
The Product Piston is designed to operate in time with the Voider.
(The Voider must be ON for the Product Piston to operate.) The
piston pulls or sucks back a portion of the product from the product
flow, as the voider rollers close on the package tube. This prevents
an increase in pressure (in the package tube above the voider
rollers) as the voider rollers close.
Product Piston
Once the voider rollers have closed and begin to open, the piston
pushes forward to return the product into the package tube. The
piston and voider rollers work in unison to provide consistent
package weight, clean package ends, and minimal product loss.
Setup
1.

2.
Remove the knife from the clipping head. Refer to

Removal of the Cut-Off Knife on page 24-1.
3.
Make certain air to the machine is off and exhausted.
4.
Loosen the lock nut (A) on the adjusting rod (B) at the
back of the air cylinder (C) located on the top of the
machine.
NOTE: Setting the air cylinder is a trial and error

adjustment. As a starting point, use a stroke between 3 and
4 [76mm and 101mm]. Observe packages as they form. If
product bulging occurs, more stroke is needed. If the
package is slack, less stroke is needed.
June, 2013 / 075-16395-000
22-1
Product Piston
5.
Tighten the lock nut (A) to secure the adjustment.
6.
7.
Set the HAND WHEEL switch (D) to ENGAGE and

handwheel (E).
8.
Set the HAND WHEEL switch (D) to DISENGAGE.
22-2
9.
10.

main power supply.
11.

12.
13.

screen.
075-16395-000 / June, 2013
Product Piston
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
CLIP
OFF
ON
OFF
ON
AUTO
LOWER
PACKAGE
LENGTH
#####
##.##mm
in
ENGAGE FILM
OPEN
HOME
CLOSE
RUN
SENSOR
HEATER
RUN *
14.
SEALERNOT
SERVO
TEMP
READY
LOW
PRODUCTION
COUNT
OFF
VOID
POSITION
#####
##.##mm
in
June, 2013 / 075-16395-000
ALARM
HISTORY
SETUP
SENSOR
RUN
CONTROL
SCREEN 1
2
RESET
NNNNNNNNNN
PRODUCT
PISTON
VOIDER
ON
VOID
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
15.
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
At the RUN CONTROL 2 screen, touch PRODUCT

PISTON to toggle to the ON position.
6/12/2007 10:06:52 AM
HOME
PACKAGE
WEIGHT
###.###
##### gm
lb
OFF
PROD PISTON
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ON
PROD PISTON
LENGTH
#####
##.##mm
in
ALARM
HISTORY
SETUP
Adjust the air cylinder speed control (F) (Figure 22-1),

so the retracting stroke time equals the time the voider
rollers are closed on the package tube.
22-3
Product Piston
16.
Adjust the air cylinder speed control (G) (Figure 22-1),

so the forward stroke time is slightly less than the time
the voider rollers are open (or apart). This stroke
should be completed with a definite pause before the
next cycle.
Figure 22-1: Air Cylinder Speed Control
22-4
17.

18.
Replace the knife in the clipping head. Refer to

Installation of the Cut-Off Knife on page 24-9.
19.
Set the HAND WHEEL switch (D) to ENGAGE and

handwheel (E). Make certain the machine turns
smoothly and freely. Check for any obstructions.
075-16395-000 / June, 2013
Product Piston
20.
Set the HAND WHEEL switch (D) to DISENGAGE.

21.

CONTROL 1 screen.
6/12/2007 10:06:52 AM
SEALERNOT
SERVO
TEMP
READY
LOW
PRODUCTION
COUNT
NNNNNNNNNN
PRODUCT
PISTON
VOIDER
OFF
VOID
POSITION
#####
##.##mm
in
HOME
June, 2013 / 075-16395-000
SENSOR
RUN
CONTROL
SCREEN 1
2
RESET
ON
VOID
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
OFF
PROD PISTON
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ON
PROD PISTON
LENGTH
#####
##.##mm
in
ALARM
HISTORY
SETUP
22-5
Product Piston
22.
At the RUN CONTROL 1 screen, touch ENGAGE

FILM to toggle to CLOSE.
6/12/2007 10:06:52 AM
PRODUCTION
COUNT
SERVO NOT READY
NNNNNNNNNN
HEAT SEAL
FRAME
RAISE
RUN
CONTROL
SCREEN 1
RESET
FILM
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
Pre-Operation Check
It is important to make several inspections on the unit before

each production run.
WARNING
Make certain the following checks are performed with the air
supply turned OFF and LOCKED OUT and that the
system is EXHAUSTED of all pressure.
Make certain the following checks are performed with the
main electrical disconnect switch turned OFF and
LOCKED OUT.
Failure to make these checks and to take any necessary
corrective action, could result in damage to the machine and
personal injury.
22-6
075-16395-000 / June, 2013
Product Piston
1.
Check for wear or cracks in the lock pin (A).
2.
Check ALL clamps (B & C) and mounting screws (D)

for proper tightness.
B
D
June, 2013 / 075-16395-000
22-7
Product Piston
Operation
In the early moments of production, it is a good practice to

make a few checks on the Product Piston, to ensure
trouble-free operation. Startup the machine and make the
following checks:
1.
Observe the stroke of the piston air cylinder with

respect to the void. If timing between the two seems
out of sequence, or the return stroke is too fast or too
slow adjustment of the speed controls for the air
cylinder may be required. Refer to Step 15 and Step
16.
2.
If product is flowing into the package when the voider

rollers are closed, increase the length and speed of
the air cylinder stroke. Refer to Step 3 through Step 5
of Setup.
3.
If product is being withdrawn from the package when

the voider rollers are closed, decrease the length of
the air cylinder stroke. Refer to Step 3 through Step 5
of Setup.
NOTICE
The piston should begin to suck back as the voider rollers
begin to close. This suck back stroke should end just
before the voider rollers begin to open.
As the voider rollers begin to open, the piston should push
the product back into the product flow. This push stroke
should end just as the voider rollers begin to close.
It is very important that each stroke bottoms. Otherwise,
package weight variations will result.
Cleanup
The cleanup procedure should be followed at the end of each

production run. (In meat or food processing plants, more
frequent cleaning may be required by local, state or federal
agencies.) Follow the procedure as outlined below:
22-8
075-16395-000 / June, 2013
Product Piston
1.

2.
Turn OFF and LOCK OUT the main air supply

valve at the main air supply source.
3.
Disconnect both air lines, one from port (A) of air

cylinder (B) and one from the bulkhead fitting on the
conduit (not shown). To prevent contaminating air
lines:
a.
Attach the loose end of the air line attached to

the air cylinder to the other air cylinder port (A).
b.
Attach the loose end of the air line attached to

the bulkhead to the other bulkhead fitting on the
conduit.
A
B
A
4.
Disconnect the product supply from the machine at

point X.
June, 2013 / 075-16395-000
22-9
Product Piston
X
22-10
5.
Remove the clamp and gasket (C) and pull the air
cylinder (B) and product cylinder piston (D) out of the
product cylinder (E). Set the air cylinder (B) and
product cylinder piston (D) on a bench.
6.
Remove the clamp and gasket (F) and the product

cylinder (E). Set on a bench.
7.
Remove the quick change sizing parts.
8.
Remove the two knobs (G) securing the product piston

housing (H) to the canopy weldment.
9.
Remove the product piston housing (H) and set on a

bench.
075-16395-000 / June, 2013
Product Piston
H
F
E
C
June, 2013 / 075-16395-000
22-11
Product Piston
10.
Place two fingers under the flange of the lock pin (J)
and depress the plunger (K) with your thumb. Lift the
lock pin out.
Figure 22-2: Removing the Product Cylinder Piston

11.
Remove the product piston (D) from the air cylinder

(B).
12.
22-12
Remove the o'ring (L) from the product cylinder piston

(D). Using your thumb and second finger, press in on
the o'ring on opposite sides of the product cylinder
piston. Move your thumb and finger up along the sides
of the product cylinder piston. The o'ring will rise
above the groove. With your free hand, slip the o'ring
over the end of the product cylinder piston.
075-16395-000 / June, 2013
Product Piston
Product Cylinder Piston
ORing
Figure 22-3: Removing the Product Cylinder Piston ORing

13.
June, 2013 / 075-16395-000
Wash all parts using a procedure compatible with your

product. Avoid the use of strong acid or alkaline
solutions. Take care to avoid damaging the inside of
the cylinder or the outside surface of the product
cylinder piston.
22-13
Product Piston
22-14
14.
Coat the o'ring (L), product cylinder piston (D), and

cylinder (E) with edible oil.
15.
Insert the oring (L) onto the product cylinder piston

(D).
16.
Install the product cylinder piston (D) onto the air

cylinder (B).
075-16395-000 / June, 2013
Product Piston
17.
June, 2013 / 075-16395-000
Using the plunger (K), install the lock pin (J).
22-15
Product Piston
18.
Install the product piston housing (H) onto the canopy

weldment. Secure using two knobs (G).
19.
Connect the product cylinder (E) to the product piston

housing (H) using the clamp and gasket (F).
20.
Insert the product cylinder piston (D) and the air

cylinder (B) into the product cylinder (E). Connect with
the clamp and gasket (C).
F
E
C
21.
22-16
Connect the product supply to the machine at point X.
075-16395-000 / June, 2013
Product Piston
X
22.
Hookup the air lines to the ports (A) of air cylinder (B)
and the bulkhead fitting on the conduit (not shown). In
Step 3 one air line was attached to the bulkhead fitting
on the conduit and one air line was attached to the air
cylinder. Ensure one end of each air line is attached to
the air cylinder and bulkhead fitting.
A
B
A
23.
Install the quick change sizing parts.
24.
Turn the main air supply ON.
25.
Turn the main electrical disconnect switch ON at the

main power source.
June, 2013 / 075-16395-000
22-17
Product Piston
Notes . . . .
22-18
075-16395-000 / June, 2013
Optional Markem Printer

Refer to the manufacturers Operation Guides shipped with the
machine for detailed instructions concerning the Markem Printer.
Strictly adhere to cleaning and maintenance areas.
Figure 23-1: Markem SmartDate 5 Printer Control
June, 2013 / 075-16395-000
23-1

Startup
To ensure that the Dater/Printer works properly, follow the

steps outlined in their correct order.
23-2
1.

main power supply.
2.
3.
4.

5.

handwheel (B).
075-16395-000 / June, 2013

6.
7.
8.
Turn the Markem SmartDate 5 power switch ON.
June, 2013 / 075-16395-000
23-3
DRIVE NOT READY
SPEED
(PPM)
POSITION
(DEG)
EON #####
NNN
NNN
ChubMaker 4100

Ph (800) 257-5622 (563) 391-0000 Fax (563)-391-0699
HOME
RUN
SENSOR
HEATER
9.
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
From the HOME screen, touch RUN CONTROL. This

will open the RUN CONTROL 1 SCREEN.
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
RAISE
RUN
CONTROL
SCREEN 1
RESET
FILM
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
23-4
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
075-16395-000 / June, 2013

10.
Touch the (RIGHT) CURSOR to navigate to the

RUN CONTROL 3 screen.
11.
Touch DATER to toggle the dater ON.
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
REGISTRATION
OFF
12.
June, 2013 / 075-16395-000
DATER
CLUTCH BRAKE
ON
OFF
LABEL
POSITION
#####
##.##mm
in
HOME
RUN
CONTROL 3
RESET
OFF
ON
CLIPPING SPEED
FINE ADUST
###.# %
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ON
PRINT
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ALARM
HISTORY
SETUP

CONTROL 1 screen.
23-5

6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
23-6
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
13.
14.
15.
16.
17.
18.
19.
Press CYCLE STOP.
SETUP
075-16395-000 / June, 2013

20.
Note the position of the printing (AA) with respect to

the package end (Z).
PRINTED
DATE OR
CODE
Figure 23-2: Print Position

21.
June, 2013 / 075-16395-000
Determine the amount of upward or downward

movement required to reposition the printing correctly.
23-7

PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
REGISTRATION
OFF
DATER
CLUTCH BRAKE
ON
OFF
LABEL
POSITION
#####
##.##mm
in
HOME
RUN
CONTROL 3
RESET
OFF
ON
CLIPPING SPEED
FINE ADUST
###.# %
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ON
PRINT
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
22.
23.
Note the PRINT POSITION value displayed.
24.
If the print position needs to move up, add the amount

of movement to the PRINT POSITION value. Then:
a.
Press the (UP) CURSOR until the displayed

value matches the new value.
OR
23-8
b.
Touch PRINT POSITION. A numeric keypad

will display.
c.
Key in the new print position.
d.
Touch ENTER to confirm. The numeric keypad

will disappear.
075-16395-000 / June, 2013

25.
If the print position needs to move down, subtract the

amount of movement from the PRINT POSITION
value. Then:
a.
Press the (DOWN) CURSOR until the

displayed value matches the new value.
OR
b.
Touch PRINT POSITION. A numeric keypad

will display.
c.
Key in the new print position.
d.
Touch ENTER to confirm. The numeric keypad

will disappear.
26.
Touch FILM on the RUN CONTROL 1 screen to toggle

to ON. Begin making packages. Once you become
familiar with the adjustment process, adjustments can
be made while the machine is in operation.
27.
Retrimming adjustments may be necessary as roll of

film nears core.
June, 2013 / 075-16395-000
23-9

Notes . . . .
23-10
075-16395-000 / June, 2013
Machine Setup
Removal of the Cut-Off Knife
Machine Setup
Whenever setup is being performed, removal of the cut-off

knife in the clipping head makes the job much easier. To
remove the cut-off knife:
1.
2.
Remove head guard.
3.

turn the handwheel (B) until the gathering plates (C)
are fully opened.
4.

June, 2013 / 075-16395-000
24-1
Machine Setup
24-2
5.
Rotate the drive pin retainer (D) to gain access to the

knife pin (E) and plate pin (F).
6.
Pull the knife pin (E) and plate pin (F) out.
075-16395-000 / June, 2013
Machine Setup
7.
Use a small screwdriver and push the cut-off knife (G)

towards the center of clipping head. Carefully remove
the cut-off knife (G) to avoid getting cut.
WARNING

possible.
June, 2013 / 075-16395-000
24-3
Machine Setup
24-4
8.
Replace the knife pin (E) and plate pin (F).
9.
Rotate the drive pin retainer (D) over the knife pin (E)
and plate pin (F).
075-16395-000 / June, 2013
Machine Setup
10.
Replace head guard.
11.
Turn the power on at the main power source.
12.
Make sure the HAND WHEEL switch (A) is set to

ENGAGE and turn the machine through one
complete cycle with the handwheel (B). Ensure there
are no obstructions.

13.

NOTE: All guards must be in place for the machine to
operate.
14.
June, 2013 / 075-16395-000
24-5
Machine Setup
Setting Air Pressures
There are several air regulators for various components on

the machine. These must be set prior to operating the
machine. The chart below provides settings for air regulators
of various components. These settings may differ on your
machine due to film type, film speed, film weight, and
product/package weight.
ITEM
UNIT
PRESSURE SETTING
LOCATION
Film Tension
5/40 psig
35/280 kPa
Left Front
Heat Seal
HOT Air
15/40 psig
105/280 kPa
Right Front
Heat Seal
COLD Air
15/40 psig
105/280 kPa
Right Front
Wire Clamp
30/60 psig
210/420 kPa
Left Rear
System
Regulator
85/90 psig
595/630 kPa
Left Rear
Voider
Regulator
30/80 psig
210/560 kPa
Right Front
Table 24-1: Air Settings Chart
24-6
075-16395-000 / June, 2013
Machine Setup
Top view doesnt depict the optional voider regulator. Lower view
depicts the optional voider regulator.
Figure 24-1: Pressure Gage Locations - Front of Machine
June, 2013 / 075-16395-000
24-7
Machine Setup
Figure 24-2: Pressure Gage Locations - Rear of Machine
24-8
075-16395-000 / June, 2013
Machine Setup
Installation of the Cut-Off Knife
1.
2.
Remove head guard.
3.

turn the handwheel (B) until the gathering plates (C)
are fully opened.
4.

June, 2013 / 075-16395-000
24-9
Machine Setup
24-10
5.
Rotate the drive pin retainer (D) to gain access to the

knife pin (B) and plate pin (C).
6.
Pull the knife pin (E) and plate pin (F) out.
075-16395-000 / June, 2013
Machine Setup
7.
Being extremely careful, install the cut-off knife (G).

Use a pencil or screwdriver to push the cut-off knife in
position.
WARNING

possible.
June, 2013 / 075-16395-000
24-11
Machine Setup
24-12
8.
Install the plate pin (F) and the knife pin (E).
9.
Rotate the drive pin retainer (D) over the knife pin (E)
and plate pin (F).
075-16395-000 / June, 2013
Machine Setup
10.
Replace head guard.
11.
12.
Turn the power on at the main power source.
13.
Make sure the HAND WHEEL switch (A) is set to

ENGAGE and turn the machine through one
complete cycle with the handwheel (B). Ensure there
are no obstructions.

14.
June, 2013 / 075-16395-000
24-13
Machine Setup
Notes . . . .
24-14
075-16395-000 / June, 2013
Production
Before production can begin, any accessories that have been
supplied with your machine may require some adjustment. Please
refer to sections covering any accessories before beginning
production. Once these adjustments have been made, production
may begin. (Film must already be setup so it will feed and track
properly.) Follow the steps below:
Production
DANGER
Filling toxic, irritating, volatile (fume producing), flammable,
a n d / o r b i o - h a z a r d s u b s ta n c e s M AY E X P O S E Y O U R
PERSONNEL TO HEALTH RISKS. Make the necessary
installations, modifications, or procedure changes to ensure
their health and safety.
WARNING
Avoid undue or repetitive bending to remove packaged

product. Back strain or injury may result. DO NOT reach into
the package discharge chute while the machine is running.
1.

main power supply.
2.
3.

June, 2013 / 075-16395-000
25-1
Production
4.

handwheel (B).
25-2
5.
6.
7.
At the HOME screen, touch RUN CONTROL. This will

display the RUN CONTROL 1 screen.
075-16395-000 / June, 2013
Production
DRIVE NOT READY
SPEED
(PPM)
POSITION
(DEG)
EON #####
NNN
NNN
ChubMaker 4100

Ph (800) 257-5622 (563) 391-0000 Fax (563)-391-0699
HOME
June, 2013 / 075-16395-000
RUN
SENSOR
HEATER
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
25-3
Production
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
25-4
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
8.
9.
10.
11.

screen.
075-16395-000 / June, 2013
Production
PRODUCTION
COUNT
JOGGING
VOIDER
OFF
ON
VOID
POSITION
#####
##.##mm
in
HOME
RUN
CONTROL
SENSOR
RUN
CONTROL
CONTROL 2
SCREEN 1
RESET
NNNNNNNNNN
PRODUCT
PISTON
OFF
LEFT
ON
SIDELAY
ADJUST
RIGHT
VOID
LENGTH
#####
##.##mm
in
SENSOR
CONTROL
HEATER
CONTROL
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
12.
Touch VOIDER to toggle to ON.
13.
Touch PRODUCT PISTON to toggle to ON.
14.

corner of the display, to return to the RUN CONTROL
3 screen.
June, 2013 / 075-16395-000
25-5
Production
PRODUCTION
COUNT
JOGGING
NNNNNNNNNN
REGISTRATION
OFF
25-6
DATER
CLUTCH BRAKE
ON
OFF
LABEL
POSITION
#####
##.##mm
in
HOME
RUN
CONTROL 3
RESET
OFF
ON
CLIPPING SPEED
FINE ADUST
###.# %
RUN
CONTROL
SENSOR
CONTROL
HEATER
CONTROL
ON
PRINT
POSITION
#####
##.##mm
in
ACTIVE
ALARMS
ALARM
HISTORY
SETUP
15.
Touch REGISTRATION to toggle to ON.
16.
Touch CLUTCH BRAKE to toggle to ON, only if

running long packages.
17.
Touch DATER to toggle to ON.
18.

CONTROL 1 screen.
075-16395-000 / June, 2013
Production
6/12/2007 10:06:52 AM
SERVO NOT READY
PRODUCTION
COUNT
NNNNNNNNNN
HEAT SEAL
FRAME
FILM
RAISE
RUN
CONTROL
SCREEN 1
RESET
OFF
PUMP
ON
OFF
CLIP
ON
OFF
ON
AUTO
LOWER
ENGAGE FILM
OPEN
HOME
CLOSE
PACKAGE
LENGTH
#####
##.##mm
in
RUN
SENSOR
HEATER
RUN *
PACKAGE
WEIGHT
###.###
##### gm
lb
ACTIVE
ALARMS
19.
20.
MACHINE
SPEED
###.# ppm
ALARM
HISTORY
SETUP
Some adjustments may be necessary on film speed or

product flow once packages are being produced. Keep a
close watch for several minutes on package size, film
tightness, and package registration.
June, 2013 / 075-16395-000
25-7
Production
Notes . . . .
25-8
075-16395-000 / June, 2013
Cleanup
Cleanup of the ChubMaker 4100 should be done after each
production run, or at the end of each day. In production facilities that
have state or federal inspection, check to see if regulations require
more frequent cleanup.
Cleanup
WARNING
Before cleanup begins, make certain the main electrical

disconnect switch is turned OFF and is LOCKED OUT.
Make certain no entrance holes have been added to the top of
the control cabinet. Such holes will allow water to enter and
damage electrical components.
WATER DAMAGE TO ELECTRICAL COMPONENTS IS NOT
COVERED BY THE WARRANTY!
Do not use steam or high pressure water on any electrical
areas of the machine. The maximum limits for pressure and
water temperature for electrical areas/components are:
40 psig [280 kPa] maximum pressure and 140F [60C]
maximum temperature.
DO NOT use any highly-caustic, highly-acidic, or highly-alkaline
based cleaners or solvents to clean any portion of the ChubMaker
4100. (The term highly is defined as more than 400 ppm solution.)
Such cleaners and solvents may cause severe surface and internal
damage to critical components. Such damage may render your
machine unfit for operation under USDA (in the USA)
guidelines and will void any warranty.
Certain portions of this Chub Packaging Machine are made from
materials that may corrode from excessive moisture. These items
are located in the clipping head and should be thoroughly dried and
protected.
Take care not to spread lubricants from one area of the machine to
another, or from other machines. Keeping lubricants contained, can
minimize the distribution of potentially contaminated lubricants.
June, 2013 / 075-16395-000
26-1
Cleanup
CAUTION
All photo electric, printer head, printer encoder, and electric
control devices must be covered with plastic before cleanup
begins. Water infiltration into these devices may cause
damage.
DO NOT use steam or high pressure water on machine. The
maximum limits for pressure and temperature of water directed to
the electrical areas or components are: 40 psig [280 kPa] maximum
pressure and 140F [60C] maximum temperature.
CAUTION
Using high pressure water as a cleaning utility, promotes the
transmission and spread of bacteria, introducing such
organisms to contaminate areas that may have been
bacteria-free.
If you use a water source that provides high pressure or
temperature, such as a commercial pressure washer system,
STOP! Water infiltration into control cabinet and other components
is likely, and damage to those electrical components may result.
26-2
075-16395-000 / June, 2013
Cleanup
!
WARNING
FOR MACHINES USED IN MEAT PRODUCTION FACILITIES

It is the responsibility of the purchaser/user of this machine,
to install and qualify the cleaning regime per accepted
practices, guidelines, rules, and standards as set forth by the
USDA, or other government agency as it may apply.
It is also the responsibility of the purchaser/user of this
machine, to implement a monitoring system for the cleaning
process.
Failure to establish and follow a cleaning regimen, and failure
to monitor that cleaning regimen, can lead to bacterial
contamination of product, resulting in a potential public
health threat.
June, 2013 / 075-16395-000
26-3
Cleanup
Bacterial Contaminants
There are several forms of bacterium that must be constantly

monitored for and sanitized against: Salmonella, Escherichia
coli, and Listeria monocytogenes are three common
bacterium.
Salmonella is common. It is a dominant cause of food
poisoning. Rarely, is an infection from Salmonella fatal, but it
can be, and must be taken seriously.
E. coli can make persons extremely ill, and is sometimes
fatal. It affects infants, elderly, and others whose immune
systems are even slightly sub par. However, the risk of
symptoms is experienced by almost anyone who comes in
contact with the bacteria through ingestion.
Listeria m is a disease-causing bacterium that must not be
tolerated at any level. It affects infants, elderly, women who
are pregnant, and others who immune system is sub par.
Listeria m can be fatal as well.
Most bacteria is introduced by people, equipment, or supplies
entering the production facility. Once established, bacteria,
especially Listeria m, can be very difficult to eradicate and
control.
Listeria m develops a biofilm. Normal use of general purpose
cleaners or chlorine cleaners alone, are not effective in
removing or controlling this bacterium. Listeria m tolerates
cold temperatures and salt. It also will flourish in damp or
moist environments.
26-4
075-16395-000 / June, 2013
Cleanup
!
WARNING
It is YOUR responsibility to ensure your cleaning practices

and monitoring of same, are within any governmental
guidelines set forth for your industry.
It is also YOUR responsibility to take the necessary steps in
the event any monitoring sample tests positive for bacteria.
R.A JONES & Co. makes the following recommendations
which may or may not be specific enough for your
application or your industry group. This information is
provided as a guide and may need to be modified or adapted
by you to ensure the presence of bacteria is eliminated.
Failure to comply can lead to bacterial contamination of
product, resulting in a potential public health threat.
WARNING
DO NOT place any parts on the floor, between removal from

the machine and cleaning.
DO NOT place any parts on the floor following cleaning and
prior to re-installation on the machine.
Floor surfaces are potential harbor areas for Listeria m and
other forms of bacteria. Placing parts onto the floor will
contaminate those parts with any bacteria present on the
floor.
NOTICE
Persons who may come in contact with scrap handling
equipment or items in contact with floors, should NOT be
involved with cleaning any portions of the machine. This is
especially true of the product contact parts.
June, 2013 / 075-16395-000
26-5
Cleanup
R.A JONES & Co. recommends the following general guidelines
when washing your ChubMaker 4100:
1.

2.
Turn OFF and LOCK OUT the main air supply

shut-off valve.
3.
Install plastic over electrical cabinet and any other

electrical components (For example, photo electric
sensors.) Make certain plastic completely protects
against water infiltration.
NOTICE
Do not spray water directly toward the electrical cabinet or
other electrical components, even with plastic protection in
place.
4.
Remove any loose deposits of product or packaging

materials that may be present.
NOTE: Taking swab tests of surface areas on the machine, to
have tested for bacteria, should be done just prior to cleaning
and sanitizing. With proper documentation, this provides a
time certain when the machine was cleaned and sanitized,
should the swab test report back a positive.
26-6
5.
Remove the one-piece sizing parts unit with mandrel, product

piston assembly (if installed), the adapter at the top of the
machine, any connecting product pipes, and all other product
contact parts. DO NOT SET ANY PARTS ON THE FLOOR.
6.
Clean all product contact parts as follows:

a.
Wet all surfaces of the product contact parts.
b.
Apply a foam or thick viscous detergent solution with

warm water at 95F to 105F [35C to 41C] to all
parts.
c.
Wash and scrub all surfaces for a minimum of ten

minutes. Keep the detergent solution in contact with
075-16395-000 / June, 2013
Cleanup
the surfaces for a minimum of fifteen minutes without
drying.
d.
Thoroughly rinse all product contact parts using hot

water at a temperature between 185F to 195F [85C
to 91C].
e.
Apply a sanitizing solution to all surfaces and allow to

dry completely. Acceptable sanitizers may include, but
are not necessarily limited to the following:
Iodophor, Quatenary Ammonia, Chlorine,
Chlorine Dioxide and Peroxyacetic Acid.
NOTE: The following sanitizing solution formulas may
be used.
SANITIZING AGENT
Iodophor
Quaternary Ammonia
Chlorine or Chlorine Dioxide
Peroxyacetic Acid
SOLUTION
25 ppm
200 ppm
200 ppm
220 ppm
Table 26-1: Sanitizing Agents

f.
Allow parts to thoroughly dry.
g.
Place parts within sterile plastic wrap if re-installation

will not be immediate.
NOTICE
Rotate the sanitizing agent to a different solution at least
once every three months. For example, if using Iodophor
solution, after three months, change to using a Quaternary
Ammonia or other solution. This will reduce the possibility of
the bacteria developing a resistance to a specific sanitizer.
7.
Refer to Removal of M7 Clipping Head Components on page

14-2 to remove the M7 clipping head components.
8.
Check to make certain the main electrical disconnect

switch is turned OFF and is LOCKED OUT.
June, 2013 / 075-16395-000
26-7
Cleanup
9.
Place the plate guide assembly on a clean surface.
10.
Disassemble and clean all plates, plate magazine, cut-off,

and knock-out punches as follows:
a.
Wet all surfaces of the parts.
b.

warm water at 95F to 105F [35C to 41C] to all
parts.
c.
Wash and scrub all surfaces for a minimum of ten

minutes. Keep the detergent solution in contact with
the surfaces for a minimum of fifteen minutes without
drying.
d.
Thoroughly rinse all parts using hot water at a

temperature between 185F to 195F [85C to 91C].
e.

be used.
SANITIZING AGENT
Iodophor
Quaternary Ammonia
Peroxyacetic Acid
SOLUTION
25 ppm
200 ppm
200 ppm
220 ppm
26-8
f.
Allow parts to thoroughly dry.
g.
Place parts within sterile plastic wrap if re-installation

will not be immediate.
075-16395-000 / June, 2013
Cleanup
NOTICE
11.
Coat the plates, plate guide assembly, cut-off punches, and

knock-out punches with food grade lubricant. Refer to
Lubrication on page 29-1 and Table 29-2 on page 29-11 for
lubricant type.
12.
Wash the machine surfaces and any remaining non-product

contact components as follows:
a.
Wet all surfaces.
b.

warm water at 95F to 105F [35C to 41C] to one
surface area at a time.
c.
Wash all surfaces for a minimum of ten minutes. Keep

the detergent solution in contact with the surfaces for a
minimum of fifteen minutes without drying.
d.
Thoroughly rinse using hot water at a temperature

between 185F to 195F [85C to 91C].
e.

be used.
June, 2013 / 075-16395-000
26-9
Cleanup
SANITIZING AGENT
Iodophor
Quaternary Ammonia
SOLUTION
25 ppm
200 ppm
200 ppm
Peroxyacetic Acid
220 ppm

f.
Allow surfaces of the machine and any other

components to thoroughly dry.
NOTICE
26-10
13.
Coat parts with food grade lubricants for food applications.

Refer to Lubrication on page 29-1 and Table 29-2 on page
29-11 for lubricant type.
14.
Refer to Gathering Plates on page 14-13 to reassemble the

gathering plates.
15.
Refer to Installation of M7 Clipping Head Components on

page 14-18 to install the M7 clipping head components.
16.
Refer to Initial Installation on page 7-2 to install the sizing

parts.
17.
Remove plastic covering from all electrical components.
18.
Immediately after cleanup is complete:

a.
Open the electrical cabinet door and check for

condensation on interior surfaces of the outer walls
and top. Wipe down to remove any condensation as
needed.
b.
Unlock and turn on the main air supply to the machine.
075-16395-000 / June, 2013
Cleanup
c.
Unlock and turn on the main electrical disconnect

switch.
NOTE: This last series of steps makes certain the cabinet

heater is again on and aids in drying out any condensation
that may have built up inside the electrical cabinet during the
cleaning process.
June, 2013 / 075-16395-000
26-11
Cleanup
Inspection and Monitoring
All product contact areas should be thoroughly inspected. An

aseptic swab test should be performed on a regular on-going
basis. In the event any contamination is found, immediate
resolve to eliminate the contamination must be performed,
followed by a re-inspection.
Several issues to consider are:
Does a physical examination show any evidence of

cracking, pitting, or etching of the product contact
surface? Such areas may be difficult to impossible to
be properly sanitized.
How often are product contact or other surfaces

inspected? You should have written procedures in
place, taking into account any conditions that may
cause the introduction or retention of bacteria or other
contaminants.
How often is the product supply piping dismantled, to

allow for thorough cleaning and sanitizing, including
any gaskets? Are the gaskets then inspected for pits,
scores, cracks, and other failures that could harbor
bacteria?
How are product contact parts and surfaces handled

when installed initially or after periodic
inspection/cleaning? Proper cleaning and sanitizing of
is useless if reassembling re-contaminates the items
or the machine.
Is the cleaning agent and the sanitizer approved for

use and does it meet specifications of the application?
Sampling or testing for the presence of bacterial

contamination, can best be done by swabbing the product
contact and other prescribed areas. This should be done on a
regular on-going basis to ensure full compliance with health
and safety. An aseptic technique is necessary.
26-12
075-16395-000 / June, 2013
Cleanup
!
WARNING
Under no circumstances should product be packaged on this

or any machine, if bacteria or other contaminants are known
to be present in any area that comes into contact with the
product.
Severe public health issues may arise from producing
product on contaminated machines. It is YOUR responsibility
to ensure your facility maintains a standard of inspection and
incorporates a method of sanitizing that ensures your
product enters the food chain, free of bacteria and other
harmful contaminants.
June, 2013 / 075-16395-000
26-13
Cleanup
Notes . . . .
26-14
075-16395-000 / June, 2013
Preventive Maintenance
Preventive maintenance on your ChubMaker 4100 will help to
keep your machine running at top efficiency and reduce major
downtimes. The schedules that follow are provided as a guide. Your
application may require more or less.
Daily Maintenance Check List
It is important to check the machine over before turning the

power on. This check should be made before the initial
startup and prior to each additional startup.
__1.

__2.
Check fluid level in air line lubricator (A). If low, fill with
29-1 and Table 29-2 on page 29-11 for lubricant type.
June, 2013 / 075-16395-000
27-1
27-2
__3.
Check fluid level in wire lubricator (C). If low, fill with

29-1 and Table 29-2 on page 29-11 for lubricant type
__4.
Check the fluid level in the machine undercarriage

reservoir by removing one of the front access covers
(D) and viewing the oil level marker. If below the
LOW mark, add food grade oil to regain proper level.
(Oil level indicator marks are located inside reservoir;
one on the right side, one on the left side.) Refer to
Lubrication on page 29-1 and Table 29-2 on page
29-11 for lubricant type.
075-16395-000 / June, 2013
__5.
Check all air tubing for breaks or loose connections.

Tighten as required.
__6.
Lubricate those items on the Lubrication Chart on

page 29-1 indicated for Daily frequency.
June, 2013 / 075-16395-000
27-3
__7.
Check condition of anvils (E), knock-out punches (F),

gathering plates (G), and cut-off punch (H) for wear,
breaks, nicks, warpage, or other abnormalities. Refer
to Clipping on page 14-1 for procedures on removal
and installation of components. Replace as required.
__8.
Clean and lubricate anvils (E), knock-out punches (F),

gathering plates (G), and cut-off punch (H) as outlined
under Cleanup on page 26-1.
__9.
Check the clipping head area for small pieces of wire

or pieces broken off from wire clipping components.
Remove all broken material found.
__10. Check the film for proper threading through the rollers
and folder, and check for correct position of film drive
wheels. Refer to Film Threading on page 10-1.
__11. Check clip wire (I) for proper insertion into wire
lubricator (C) and into the wire feed mechanism (J).
27-4
075-16395-000 / June, 2013
__12. Inspect two inlet bushings (K) and two outlet bushings
(L) on the wire lubricator (C) for wear. If grooved,
rotate the bushings as needed to allow wire to run
along a new surface. Replace bushings when worn
beyond continued use.
__13. Check for dents, nicks, or other abrasions in sizing

parts. Polish out or replace as needed.
__14. Check installation of sizing parts (including mandrel)
for proper fit and adjustment. Improperly installed
and/or adjusted sizing parts can lead to film tracking
and sealing problems. Refer to Sizing Parts on page
7-1.
__15. Check integrity of all safety guards and interlocks.
Replace any damaged or missing parts. DO NOT
O V E R R I D E A N Y S A F E T Y F E AT U R E S O R
OPERATE THE MACHINE WITH GUARDS MISSING.
__16. Set the HAND WHEEL switch (N) to ENGAGE and
turn the machine through several complete cycles with
June, 2013 / 075-16395-000
27-5
the handwheel (O). Make certain no binding exists and
that the machine turns freely. If binding, excessive
backlash (more than 1/4), or rough spots are
encountered, contact the R.A JONES & Co.
Service Department for advice and assistance.
__17. With air supply to the machine on, check all air
pressure regulators against the Air Settings Chart on
page 24-6.
27-6
075-16395-000 / June, 2013
Notes . . . .
June, 2013 / 075-16395-000
27-7
Weekly Maintenance Check List
27-8
__1.

__2.
Check the machine drive timing belt (A) for wear and
cracks. Replace as needed.
__3.
Inspect all air tubing for cracks, splits, brittleness, and

clogging. Replace as needed.
__4.
Inspect the tread on the film drive wheels (B) for

excessive wear and gaps during engagement (Is film
slipping?). Replace the drive wheels as needed.
075-16395-000 / June, 2013
__5.
Check the heat seal coil (C) to make certain the coils
do not touch. Carefully wedge a screwdriver blade
between the coils that touch to spread them apart.
This will help extend coil life.
__6.
Check all caution, danger, warning, and instructional

signs for legibility. Replace any that are worn or
missing.
June, 2013 / 075-16395-000
27-9
__7.
Check the cut-off knife (D) for sharpness. Refer to

Machine Setup for procedures on removal and
installation of the cut-off knife. Replace as needed.
__8.
Inspect clip quality as outlined under Clipping. Refer

to Clipping on page 14-1.
Monthly Maintenance Check List
27-10
__1.
Inspect film rollers (A) (and voider rollers) for flatness

by laying a straight edge (B) along length of each
roller. Rotate the roller while keeping straight edge still.
If gaps of light are visible between a roller and straight
edge, replacing the roller may become necessary in
the near future.
__2.
Hand check all roller and drive wheel shafts for rigidity
by gently attempting to move shafts side to side
075-16395-000 / June, 2013
(across diameter rather than along length). A loose
condition may indicate the need for bearing
replacement.
__3.
Check level of the clipping head relation to the table

top. If one side is lower than the other by more than
0.010" [0.254 mm] contact the R.A JONES & Co.
Service Department for further information and
assistance.
__4.
Lubricate those items on the Table 29-1 on page 29-1

indicated for Monthly frequency.
June, 2013 / 075-16395-000
27-11
Annual Maintenance Check List
__1.
Drain the table reservoir (undercarriage mechanism

crankcase) of the machine by opening the drain valve
(A). Make certain to close the valve once all oil has
been drained.
__2.
Fill the table reservoir by removing one of the access

covers (B). (Oil level indicator marks are located inside
reservoir; one on the right side, one on the left side.)
See the Lubrication Chart on page 29-1 and Table
29-2 on page 29-11 for lubricant type.
__3.
27-12
Refer to the drive motor instruction manual concerning

required maintenance for the drive motor.
075-16395-000 / June, 2013
Notes . . . .
June, 2013 / 075-16395-000
27-13
Left Spline Shaft Bearing Replacement
The left spline shaft bearing should be replaced when

package clips can no longer be formed tight enough on the
package. The frequency of bearing replacement will depend
upon the speed at which the machine is normally operated,
the conditions in which the machine is operated in, and the
regularity, or lack of, maintenance.
This procedure requires the following tools:
Two-Piece Bearing Push Tool
3/8 Angle Hex Key
3/4 Deep Well Socket and 1/2 Drive Ratchet
Flat Blade Screw Driver
3/8, 7/16, and 1/2 Open End Wrenches
Plastic Hammer/Mallet
Wood Blocking
A
B
007-74872-000 Spacer
007-74870-000 Pin Yoke
Figure 27-1: Bearing Push Tool

1.
27-14
Refer to Removal of M7 Clipping Head Components

on page 14-2 and follow procedure through Step 19.
075-16395-000 / June, 2013
2.
Remove the lubrication fittings on the clip forming die

housing. It will be necessary to disconnect any lube
lines that are connected. See Figure 27-2.
Figure 27-2: Clip Forming Die Housing Lube Fittings

3.
Use a 3/4 deep well socket on a 1/2 drive ratchet to

loosen and remove the two lock nuts that secure the
clip forming die housing to the bottom of the clipping
head.
June, 2013 / 075-16395-000
27-15
4.
Carefully remove the clip forming die housing, by

lowering from the underside of the clipping head, and
set aside. See Figure 27-3.
Figure 27-3: Lower the Clip Forming Die Housing

5.
27-16
Remove hex head bolts that retain the hold-downs on

the left side of the clipping head.
075-16395-000 / June, 2013
NOTICE
Keep the shim material with the specific hold-down and take
care not to damage or misplace the shim material. It can be
reused. Shim material used on one clipping head, may not
provide the proper alignment and fit on another clipping
head, since these are individually shimmed to provide the
proper clearances for operation.
6.
Remove the hold-downs and their respective shims.

Keep together in sets. Do not lose the shims or mix
them.
7.
Lift the left hand cam unit from the clipping head and
set aside.
June, 2013 / 075-16395-000
27-17
Figure 27-4: Crank Arm
27-18
8.
Use a 3/8 hex key and loosen the socket head cap
screw in the left hand crank arm.
9.
Use a flat blade screwdriver to open the split in the

crank arm, making removal from the spline shaft
easier.
10.
Pull the crank arm straight up.
075-16395-000 / June, 2013
11.
Remove the large flat washer and key. Set aside.
12.
Engage the handwheel and raise the clipping head.
NOTE: When raising or lowering the head with the

handwheel, and the crank arm removed, it will be
necessary to grasp the wire feed actuator arm to keep
it free from being damaged by the split cam. See
Figure 27-5 on page 27-20.
June, 2013 / 075-16395-000
27-19
Figure 27-5: Setting the Clipping Head Height

13.
27-20
Place the spacer from the tool on top of the spline

shaft housing, below the split cam collar.
075-16395-000 / June, 2013
June, 2013 / 075-16395-000
27-21
27-22
14.
Place 5-1/2 to 6 of wood blocking between the

clipping head and the table top, next to the spline shaft
housing.
15.
Engage the handwheel and lower the clipping head.
075-16395-000 / June, 2013
it free from being damaged by the split cam.
June, 2013 / 075-16395-000
27-23
16.
Set the pin yoke portion of the tool as shown in See

Figure 27-6. The two pins need to be aligned with the
holes in the bottom of the clipping head casting.
Figure 27-6: setting the Pin Yoke Tool

17.
27-24
Engage the handwheel and slightly raise the clipping

head.
075-16395-000 / June, 2013
18.
Pull the wood block from between the clipping head

and the table top surface.
19.
Slowly lower the clipping head, using the handwheel.

NOTE: Several times during the lowering, turn the
handwheel in the opposite direction to slightly raise the
head. This helps keep the two pins properly aligned
and prevents binding.
June, 2013 / 075-16395-000
27-25
20.
Continue to lower the clipping head. The bearing will

begin to push up from the clipping head casting.
PIN
27-26
PIN
075-16395-000 / June, 2013
21.
Once the bearing is removed, clean the bore and

inspect for any grooves or other damage that would
prevent the new bearing from seating properly.
Figure 27-7: Inspect and Clean Bearing Bore
June, 2013 / 075-16395-000
27-27
22.

head.

23.
27-28
Remove the pin yoke and spacer portions of the tool

from the spline shaft. Set aside.
075-16395-000 / June, 2013
24.
Reinstall the wood block between the clipping head

and the table top surface.
25.
Slowly lower the clipping head, using the handwheel,

until the clipping head is resting firmly on the block.
26.
Set a new bearing in place over the bore.
27.
Tap the bearing into the bore using a plastic hammer

or mallet. Use a circular pattern when tapping on the
bearing to avoid binding the bearing to one side of the
bore.
Figure 27-8: Tapping the Bearing Into the Bore

28.
June, 2013 / 075-16395-000
Apply some grease (the same as used in the Autolube

unit - refer to Table 29-2 on page 29-11) to the inside
of the bearing. This will aid in the next series of steps.
27-29
29.

head.

30.
27-30
Remove the wood block from between the clipping

head and the table top surface.
075-16395-000 / June, 2013
31.
June, 2013 / 075-16395-000
Carefully set the clip forming die housing into the

clipping head from underneath, lining the two bolts into
the holes in both the clipping head and the clip forming
die housing.
27-31
32.
Install the two lock nuts onto the clip forming die
housing bolts.
33.
Use a 3/4 deep well socket on a 1/2 drive ratchet to

tighten the two lock nuts, to secure the clip forming die
housing to the bottom of the clipping head.
34.
Install the lubrication fittings back into the clip forming

die housing. Tighten with the proper size open end
wrench.
NOTE: Make sure the lubrication fittings that require
manual lubrication, point in a direction that will allow
access with the lubrication unit.
35.
27-32
Connect the lube line to the elbow on the housing, that

was previously removed.
075-16395-000 / June, 2013
June, 2013 / 075-16395-000
27-33
27-34
36.
Install the key and the large flat washer onto the left
spline shaft as shown below.
37.
Install the crank arm onto the spline shaft, with the
keyway aligned with the key as shown.
38.
Use a flat blade screwdriver to open the split in the

crank arm, making installation onto the spline shaft
easier.
075-16395-000 / June, 2013
39.
Use a 3/8 hex key and tighten the socket head cap
screw in the left hand crank arm.
40.
Lower the left hand cam unit into the clipping head,
making sure the cam follower and the cam track line
up.
June, 2013 / 075-16395-000
27-35
41.
Install the hold-downs on the left side of the clipping

head.
NOTICE
Keep the shim material with the specific hold-down and take
care not to damage or misplace the shim material. It can be
reused. Shim material used on one clipping head, may not
provide the proper alignment and fit on another clipping
head, since these are individually shimmed to provide the
proper clearances for operation.
27-36
42.
Tighten the hex head bolts to secure the hold-downs.
43.
Refer to Installation of M7 Clipping Head Components

on page 14-18 to complete installation of clipping parts
onto the clipping head.
075-16395-000 / June, 2013
Sensor/Cable Maintenance
Connections
Inspect each cable/sensor connection for water infiltration

and for any corrosion. If corrosion exists, sensor and/or cable
replacement may be necessary. If neither is found, or when
installing new components, the following procedure should be
adopted to ensure better protection against water infiltration
and subsequent sensor failure.
You will need the following items to successfully complete the
procedure:
Aerosol Electrical Contact Cleaner

Compressed Air with a Nozzle Gun attached
Dielectric Synthetic Grease (USDA H-1 rated) Available in a 400 gram container as
P/N 044-990-00910; or 3 ounce tube as
P/N 044-990-00915.
WARNING
ALWAYS turn OFF and LOCK OUT the main electrical

disconnect switch BEFORE performing the following steps. If
electrical power is allowed to remain on, a serious electrical
shock may result. Also, damage to components, including
machine control devices may occur, if the electrical power
remains connected.
1.
Separate the cable from

the sensor at the QD
(quick disconnect)
connector, by
unthreading. Check for
any signs of corrosion.
Notice if the connection
seemed tight or loose.
Tight connections are
less likely to suffer water
infiltration.
June, 2013 / 075-16395-000
28-1
2.
Blast each connection

with dry compressed air;
both the cable and the
sensor connections. This
is to remove any water or
condensation.
WARNING
Do not point the nozzle of the compressed air gun toward

yourself or others. Serious injury may result from directing
compressed air towards people.
3.
Use a good quality

aerosol electrical contact
cleaner and spray each
connector; both the cable
and the sensor
connections. Follow the
directions on the product
label.
4.
Once again, blast each

connection with dry
compressed air; both the
cable and the sensor
connections. This is to
remove any of the
contact cleaner.
WARNING
Do not point the nozzle of the compressed air gun toward

yourself or others. Serious injury may result from directing
compressed air towards people.
28-2
075-16395-000 / June, 2013
5.
Apply a quantity of
dielectric synthetic
grease (USDA H-1) to
both the threads and the
sensor connection area,
filling depressions and
hollow areas in the
connector.
NOTE: Photos show grease being applied from a tube.

6.
Apply a quantity of
dielectric synthetic
grease (USDA H-1) to
both the threads and the
cable connection area,
filling depressions and
hollow areas in the
connector.
NOTE: P/N 044-990-00910 or P/N 044-990-00915 are available

through the R.A JONES & Co. Parts Department.
June, 2013 / 075-16395-000
28-3
7.
Connect the cable

connector to the sensor
connector.
For connections with an
M8 or M12 fitting, use
Turck torque wrench part
number A9208 to tighten
fitting. Set the wrench to
0.6 Nm for M8 fittings
and 1.0 Nm for M12
fittings. Assure that
excess grease is
squeezed out and the
connector is fully seated.
If the connection does
not have an M8 or M12
fitting, fully tighten the
connection by hand,
assuring that excess
grease is squeezed out,
the connector is fully
seated and the threads
are tight.
Make certain the
connection is reasonably
tight. Tight connections
are less likely to suffer
water infiltration.
8.
Repeat Steps 1 through 7 for each cable/sensor

connection.
Additional Key Items
28-4
Shielding connections from direct water

exposure will help minimize problems. Installing
spray or drip shields may provide the needed
protection in areas of heavy exposure.
The female portion of the QC connector should

be located on top in vertical installations to
minimize water entrapment within the
connection.
075-16395-000 / June, 2013
On connections that are at the low end of a

cable run, adding a drip loop prior to the
connection may offer some protection from
water infiltration.
Follow-Up Applications
The dielectric synthetic grease (USDA H-1 rated)

should prevent water infiltration into the connection.
We recommend a periodic re-application of the
dielectric synthetic grease (USDA H-1 rated), as
outlined in this section.
The frequency of re-application may vary depending
upon how often your machines are washed-down, and
the type of chemicals used, along with the pressure
used during the wash-down process. The required
frequency of re-application may vary from facility to
facility. Therefore, you will need to determine the
frequency of re-application for your facility. An initial
reasonable frequency would be three months. Adjust
from this interval as deemed appropriate for your
installation.
If corrosion is encountered or a sensor is
unresponsive, it may be necessary to replace the
sensor and/or the cable. If replacement is necessary,
the procedure outlined in this section should be
followed to minimize cable/sensor connection
problems.
NOTICE
Anytime a sensor and cable are disconnected, for any
reason, re-application of the dielectric synthetic grease
(USDA H-1 rated), as outlined in this section, should be done.
June, 2013 / 075-16395-000
28-5
Notes . . . .
28-6
075-16395-000 / June, 2013
Lubrication
Proper and timely lubrication of the ChubMaker 4100 is important
to maintain operation and reduce downtime. The table below is
provided as a guide to help you perform lubrication as needed. The
frequency is based on eight hours of operation per day.
Lubrication
Take care not to spread lubricants from one area of the machine to
another, or from other machines. Keeping lubricants contained, can
minimize the distribution of potentially contaminated lubricants.
NOTICE
Do not over lubricate. Excess grease provides a harbor for
bacteria. Wipe all grease fittings after applying grease. Wipe
up all lubricant spills.
Table 29-1: Lubrication Chart
ITEM
METHOD
*LUBRICANT
DESIGNATOR
QTY
FREQUENCY
Clipping Head - Left

Side
Fitting (A)
Daily
*See the Recommended Lubricants on page 29-11.
June, 2013 / 075-16395-000
29-1
Lubrication
ITEM
METHOD
*LUBRICANT
DESIGNATOR
QTY
FREQUENCY
Clipping Head Middle
Fitting (B)
Daily
Clipping Head Right Side
Fitting (C)
Daily
29-2
075-16395-000 / June, 2013
Lubrication
ITEM
METHOD
*LUBRICANT
DESIGNATOR
QTY
FREQUENCY
Wire Feed Air

Cylinder Piston Rod
Pivot
Fitting (D1)
Daily
Wire Feed Air

Cylinder Mount
Pivot
Fitting (D2)
Daily
June, 2013 / 075-16395-000
29-3
Lubrication
ITEM
METHOD
*LUBRICANT
DESIGNATOR
QTY
FREQUENCY
Clip Forming Die
Fitting (D3)
Daily
Left Crank Arm
Fitting (D4)
Daily
29-4
075-16395-000 / June, 2013
Lubrication
ITEM
METHOD
*LUBRICANT
DESIGNATOR
QTY
FREQUENCY
Knock-Out
Punches (E)
See Note #1
Daily
Cut-Off Punches
(F)
See Note #1
Daily
June, 2013 / 075-16395-000
29-5
Lubrication
ITEM
METHOD
*LUBRICANT
DESIGNATOR
QTY
FREQUENCY
Gathering Plates
(G)
See Note #1
6/9
Daily
Film Drive Gears
Fitting (H)
Daily
29-6
075-16395-000 / June, 2013
Lubrication
ITEM
METHOD
*LUBRICANT
DESIGNATOR
QTY
FREQUENCY
Wire Lubricator (I)
Open & Fill
Daily
Air Lubricator (J)
Drain & Fill

See Note #2.
Daily
June, 2013 / 075-16395-000
29-7
Lubrication
ITEM
METHOD
*LUBRICANT
DESIGNATOR
QTY
FREQUENCY
Auto Lube
Reservoir (K)
Open and Fill

See Note #4.
Daily
LINE NO.
INJECTOR
COLOR
LINE DESTINATION
Black
Left Side - Elevating Rod Sleeve
Black
Left Side - Spline Shaft Sleeve
Black
Bottom of Clip Forming Die Housing for

Lubrication of Square Clip Forming Shaft
Black
Upper Pin of Clip Forming Die Housing
Black
Left Side - Spline Shaft Roller Bearing

(inside Clipping Head)
Black
Left Side - Rear Clipping Head Way
Black
Left Side - Front Clipping Head Way
Black
Right Side - Elevating Rod Sleeve
Black
Right Side - Spline Shaft Sleeve
10
Black
Right Side - Spline Shaft Roller Bearing

(inside Clipping Head)
11
Black
Right Side - Rear Clipping Head Way
12
Black
Right Side - Front Clipping Head Way
29-8
075-16395-000 / June, 2013
Lubrication
ITEM
METHOD
*LUBRICANT
DESIGNATOR
QTY
FREQUENCY
Wire Feed Clutch
Fitting (L)
Monthly
Table Reservoir
(Undercarriage
Mechanism
Crankcase)
Drain Valve
(N) & Fill
Openings (M)
See Note #3.
Annually
Note: Remove one access door (item M) to fill.

June, 2013 / 075-16395-000
29-9
Lubrication
NOTES:
1.
Knock-out punches, cut-off punches, and gathering plates

must be cleaned and thoroughly dried. Lubricant A should
be generously smeared on all areas to provide maximum
lubrication.
2.
The polycarbonate plastic bowl on the air lubricator can be

damaged and possibly fail if exposed to certain solvents,
strong alkaline substances, or compressor oils containing
aromatic hydrocarbons (fire retardant oils). Fumes of these
substances in contact with the bowl, either inside or outside,
can also cause damage and eventual failure.
3.
Use approximately 20 gallons [76 liters] to 25 gallons

[95 liters] of food grade oil to fill reservoir.
NOTICE
In wash-down applications, after the machine has been idle
for 48 hours or longer, open the drain valve located in the
bottom of the lower enclosure to drain any accumulated
water. Refill to the proper level as required.
4.
29-10
Use Chevron FM Grease EP NLGI 2. However, if a grease

other than Chevron FM Grease EP is used, all grease lines,
reservoir, and lubricated items must be completely cleaned
and void of all grease. DO NOT INTRODUCE ANOTHER
LUBRICANT OTHER THAN THE RECOMMENDED
L U B R I C A N T, W I T H O U T F U L LY P U R G I N G T H E
AUTOLUBE SYSTEM. LUBRICANT BREAKDOWN,
CRYSTALLIZATION, AND BRIDGING MAY OCCUR!
075-16395-000 / June, 2013
Lubrication
RECOMMENDED LUBRICANTS
*LUBRICANT
DESIGNATOR
LUBRICANT DESCRIPTION
A - Clipping
Head
AW Chesterton White Grease with Teflon 622

Lubriplate FGL-1 or FGL-2
**JAX Halo-Guard FG-LT or FG-2
**JAX Poly-Guard FG-LT or FG-2
B - Air Cylinder
Pivots, Clip
Transfer, Left
Crank Arm, and
Film Drive Gears
Lubriplate SFL-1
**JAX Halo-Guard FG-LT or FG-2
**JAX Poly-Guard FG-LT or FG-2
Lubriplate FMO-900 AW at or below 40oF Ambient
C - Wire
Lubricator
Lubriplate FMO-1100-AW at or above 40oF Ambient

**JAX Magna-Plate 78 at or below 40oF Ambient
**JAX Magna-Plate 220FG at or above 40oF Ambient
D - Air Line
Lubricator
Lubriplate FMO-150-AW
Lubrication Engineers, Inc. Quinplex 4010 White Oil
**JAX Magna-Plate 72 or 74
E - Autolube Unit
Chevron FM Grease EP (NLGI 2)

**JAX Halo-Guard FG-LT
DO NOT INTRODUCE ANOTHER LUBRICANT
OTHER THAN CHEVRON FM GREASE EP,
WITHOUT FULLY PURGING THE AUTOLUBE
SYSTEM. OTHERWISE, LUBRICANT BREAKDOWN,
CRYSTALLIZATION, AND BRIDGING MAY OCCUR
LEADING TO COMPONENT FAILURE.
FUndercarriage
Reservoir
Lubriplate FMO-150-AW at or below 40oF Ambient

Lubriplate FMO-500-AW at or above 40oF Ambient
**JAX Magna-Plate 62 at or below 40oF Ambient
**JAX Magna-Plate 78 at or above 40oF Ambient
NOTE: Order of listing is no indication of preference.

*Lubricant Designator is listed in Table 29-1 on page 29-1.
**Indicates the lubricant has antimicrobial or antibacterial properties, per
the manufacturer.
Table 29-2: Recommended Lubricants
June, 2013 / 075-16395-000
29-11
Lubrication
Notes . . . .
29-12
075-16395-000 / June, 2013
Troubleshooting
The troubleshooting charts that follow are provided as a general
guide. Specific problems not covered in these charts may occur.
Troubleshooting
Clipping
PROBLEM
Missed or short
clip.
Clip legs are of

different lengths.
June, 2013 / 075-16395-000
POSSIBLE CAUSE
POSSIBLE REMEDY
Tangled wire on
reel.
Untangle, check for

free turning of
reels.
Wire feed slipping.
Clean drive
wheels. Check for
binds.
Damaged wire.
Cut out and

discard.
Dirty wire guides.
Clean in solvent
and blast with
compressed air.
Wire out of
tolerance.
Wire should be
within 0.001
[0.025 mm] from
the nominal
diameter.
Wire is not being

straightened
properly.
Adjust straightener
rollers.
Tangled or bent
wire.
Straighten wire, cut

out bad section
and discard.
Wire not contacting

stop on cut-off
punch.
Adjust straightener
rollers.
30-1
Troubleshooting
PROBLEM
Malformed clips.
30-2
POSSIBLE CAUSE
POSSIBLE REMEDY
Refer to issues on page 30-1.

Punches are
misaligned.
Thoroughly inspect
clipping head for
causes. For
example, worn
cams, worn
punches, foreign
material buildup.
Broken punch.
Replace.
Excessive product
in plate area.
Clean plate area.
Little or no
lubrication on wire.
Fill lubricator with

food grade oil. DO
NOT USE
MINERAL OIL.
Refer to
Lubrication on
page 29-1 and
Table 29-2 on page
29-11 for proper
lubricant. Check for
proper operation.
075-16395-000 / June, 2013
Troubleshooting
PROBLEM
Twisted clips.
June, 2013 / 075-16395-000
POSSIBLE CAUSE
POSSIBLE REMEDY
Uneven clip leg

length.
Refer to above
section.
Excessive burr
from cut-off.
Check spring
behind cut-off
inserts.
Holding notch on
cut-off punch is
worn or broken.
Replace as
needed.
Spring on cut-off
punch lock bar is
broken.
Check spring on
lock bar and
replace as needed.
Cut-off punch lock

bar is worn or
broken.
Replace as
needed.
Aluminum galling
on anvils.
Polish or add more

lubricant. DO NOT
USE MINERAL
OIL. Refer to
Lubrication on
page 29-1 and
Table 29-2 on page
29-11 for proper
lubricant.
Broken cut-off
punch.
Replace.
No lubrication on
wire.
Fill lubricator with

food grade oil. DO
NOT USE
MINERAL OIL.
Refer to
Lubrication on
page 29-1 and
Table 29-2 on page
29-11 for proper
lubricant. Check for
proper operation.
30-3
Troubleshooting
Film
PROBLEM
Leaking package
or weak clips.
Clips cutting film.
30-4
POSSIBLE CAUSE
POSSIBLE REMEDY
Clips are too loose.
Move micro-clip
dial to a lower
number.
Weak wire due to

wrong alloy.
Consult with wire

supplier.
Clips are too long.
Convert to shorter
style clip.
Gathering plates
too loose.
Springs in clipping
head are too weak.
(Light Duty =
Green; Medium
Duty = Blue; Heavy
Duty = Red)
Clips are too short.
Convert to longer
style clip.
075-16395-000 / June, 2013
Troubleshooting
PROBLEM
Film cuts.
June, 2013 / 075-16395-000
POSSIBLE CAUSE
POSSIBLE REMEDY
Gathering plates
are too tight.
Springs in clipping
head are too stiff or
too strong. (Light
Duty = Green;
Medium Duty =
Blue; Heavy Duty =
Red)
Clips are set too

tight.
Move micro-clip
dial to a higher
number.
Burr on gathering
plate(s).
Polish or replace.
Burr on wire.
Check cut-off
insets and springs.
Replace as
needed.
Brittle film.
Change to softer
film. Consult film
supplier.
Sharp edge along

film path.
Check for sharp

edges or metal
imbedded in
plastic. Smooth
out.
Film spreader is
out of position.
Refer to page 10-4

and reset per
instructions.
30-5
Troubleshooting
PROBLEM
Film wanders in
machine.
30-6
POSSIBLE CAUSE
POSSIBLE REMEDY
Film roll is
misaligned.
Turn film alignment

knob to adjust film
roll in direction
opposite of
wandering
movement.
Too little tension on

film.
Increase film
tension regulator.
Roller(s) are
binding.
Check all rollers

and repair any that
bind.
Film folder is not

installed properly.
Install and align

folder properly.
Drive wheels are

off center with
mandrel.
Center drive
wheels with
mandrel.
Worn film folder or

sizing parts.
Replace worn parts
Breaker roller out

of adjustment and
causing film to bind
at folder.
Readjust breaker
roller. See page
10-6.
075-16395-000 / June, 2013
Troubleshooting
Sealing
PROBLEM
POSSIBLE CAUSE
Poor seal on film.

S1 Heat Sealer.
NOTE: Seal
surface should be
1/4 [6.4mm] wide,
smooth, and with
no blisters.
Too little heat from

sealer.
Increase heat
setting for sealer.
Too much heat

from sealer.
Decrease heat
setting for sealer.
Film overlap is too

small.
NOTE: Film
overlap should be
3/4 [19mm].
Too narrow of film

for package
diameter. Use film
with wider web
dimension.
Wrinkles in seal
area.
Increase flow of
cooling air.
Heat nozzle too far

or too close to film.
Adjust position.
Improper alignment
of sizing parts.
Check position and

align as needed.
Film characteristics
or quality issues.
Some films are

poor quality,
require better
quality film.
Seal temperature
drops when sealer
head is lowered
into sealing
position.
As the cool air

nozzle confronts
the film, some of
the cool air is
deflected upwards,
cooling the hot air
nozzle.
This is normal.
Sealer will bring
itself back up to
temperature
setting.
When sealer frame

is raised, sealer
head temperature
rises dramatically.
Constricted hot air

tubing.
Check hot and cool

air tubing to sealer
head. There should
be no kinks or
sharp bends when
frame is raised.
June, 2013 / 075-16395-000
POSSIBLE REMEDY
30-7
Troubleshooting
PROBLEM
Seal temperature
panel meter
readout plunges or
goes to maximum
when seal frame is
raised or lowered.
POSSIBLE CAUSE
Improperly
installed
thermocouple.
POSSIBLE REMEDY
Check that
thermocouple end
is not bottomed in
heat sealer nozzle,
and is 0.125
[3 mm] from
bottom.
Eliminate any
kinking in
thermocouple wire
from sealer to
controller.
Defective
thermocouple.
30-8
Replace
thermocouple.
Install so
thermocouple end
is not bottomed in
heat sealer nozzle
and is 0.125
[3 mm] from
bottom.
075-16395-000 / June, 2013
Troubleshooting
Film Arbor
PROBLEM
POSSIBLE CAUSE
POSSIBLE REMEDY
Film free-wheels off

roll.
Film tension air

pressure is too low
or is OFF.
Increase air
pressure as
needed. Make
certain air is ON.
Film is stretching or
breaking.
Film tension air

pressure is too
high.
Decrease air
pressure as
needed.
Film drive wheels slip

when pulling film.
Film tension air

pressure is too
high.
Decrease air
pressure as
needed.
Film roll spins on

arbor.
Adjustable hub is
loose.
Tighten adjustable
hub.
Machine does not

stop when film roll
runs out.
Film tension air

pressure is set too
low.
Set to 5 psig to
begin, slightly
higher if needed.
End of film sensor

is dirty.
Clean sensor.
June, 2013 / 075-16395-000
30-9
Troubleshooting
Optional Registration
If a problem occurs in film registration, determine if the

problem is mechanical or electrical.
ALWAYS make only ONE adjustment at a time. If the
problem continues, READJUST back to the original setting.
NEVER adjust the machine for a single (one time) or
infrequent failure.
WARNING
Turn OFF and LOCK OUT the main electrical disconnect

switch at the main power source before working on the
machine.
Listed below is a check for proper film travel and package
forming. Refer to this check list first when problems in these
areas occur.
30-10
__1.
Film pulls through machine smoothly.
__2.
Film arbor turns smoothly.
__3.
Film flows from film arbor without jerking or becoming

slack.
__4.
Film rollers are free turning and parallel with each

other.
__5.
Film drive gears are free turning, clean, and without

broken or badly worn teeth.
__6.
Sealed film tube fits freely on the film spreader or

lower sizing ring and does not stick to the mandrel.
__7.
Product pumping is consistent.
__8.
Film folder, sizing rings, sealing rings and film

spreader are a matched set.
__9.
Film drive wheels are centered to the product mandrel

and have a positive grip on the film.
075-16395-000 / June, 2013
Troubleshooting
DANGER
Hazardous voltages are present inside the electrical
enclosure when power is on. Any checks made inside the
electrical enclosure MUST be performed by a qualified
electrician OR NOT AT ALL!
PROBLEM
POSSIBLE CAUSE
POSSIBLE REMEDY
Package is slack.
(Too much film.)
Package length is
incorrectly
entered; too long.
Measure distance
from leading edge
to leading edge of
two consecutive
registration marks.
Adjust Film Speed.
Package is tight.
(Too little film.)
Package length is
incorrectly
entered; too short.
Measure distance
from leading edge
to leading edge of
two consecutive
registration marks.
Adjust Film Speed.
Packages split open

due to too little film.
Package length is
incorrectly
entered; too short.
Measure distance
from leading edge
to leading edge of
two consecutive
registration marks.
Adjust Film Speed.
Clip placement is
continually erratic.
Package length is
incorrectly
entered; either too
short or too long.
Measure distance
from leading edge
to leading edge of
two consecutive
registration marks.
Adjust Film Speed.
Clip placement is
constant, but in the
wrong place along
the film.
Clip position is out

of adjustment.
Adjust clip
placement.
June, 2013 / 075-16395-000
30-11
Troubleshooting
PROBLEM
Clip placement
slowly moves along
package length in
subsequent
packages.
POSSIBLE CAUSE
POSSIBLE REMEDY
Fiber optic light

guide is not in
position over
registration marks.
Adjust fiber optic

light guide position
to center over
registration marks.
Sensitivity of
scanner control
unit is too low.
Adjust for an
increase in
sensitivity.
Optional Voider
PROBLEM
Voider is not
operating.
30-12
POSSIBLE CAUSE
POSSIBLE REMEDY
Voider is off at
PanelView.
Turn voider on at
PanelView.
Void dwell time is

set too short (0).
Set void dwell time

to a longer time.
PLC output card is

bad as indicated
on output card.
Replace output
card.
Defective solenoid
valve.
Replace solenoid
valve.
Voider rollers stall

while voiding
package.
Voider gears are

worn.
Replace.
Clip comes off

package.
Clipping on
product, because
of too short of
dwell time.
Increase void dwell

time.
Clipping on
product caused by
off center or off
position void.
Change void
position at the
PanelView.
075-16395-000 / June, 2013
Troubleshooting
Product Piston
PROBLEM
Piston not working.
Product leaks past

piston.
Piston stroke is out

of time with Voider.
Package weight is
inconsistent.
June, 2013 / 075-16395-000
POSSIBLE CAUSE
POSSIBLE REMEDY
Air is not ON
Check main air

supply and shut-off
near air cylinder
solenoid.
Solenoid valve is
bad.
Replace.
Product piston is
off at PanelView.
Turn product
piston on at
PanelView.
Air pressure set

too low.
Increase air
pressure.
Voider is OFF.
Enable Voider.
Oring is worn or
missing.
Replace oring.
Grooves in
cylinder.
Replace cylinder.
Air cylinder speed

controls out of
adjustment.
Adjust.
Air cylinder speed

controls are
plugged.
Clean or replace.
Air pressure set

too low.
Increase air
pressure.
Stroke does not

bottom out at
each end.
Adjust air cylinder

speed controls.
30-13
Troubleshooting
PROBLEM
Bulge appears in
package.
30-14
POSSIBLE CAUSE
POSSIBLE REMEDY
Return stroke is
set too fast.
Adjust air cylinder

speed control R
(Figure 22-1 on
page 22-4).
Suck back stroke

is set too fast.
Adjust air cylinder

speed control Q
(Figure 22-1 on
page 22-4).
075-16395-000 / June, 2013
Ordering Parts
Ordering parts requires the following information:
Ordering Parts
1.
Purchase order number.
2.
Complete shipping instructions, including shipping

address which indicates actual location of your facility;
not a post office box.
3.
Part number(s), description(s), and quantity of each

part ordered.
Our Parts Department is staffed from 7:30 a.m. to 4:30 p.m. (Central
Time Zone - United States), Monday through Friday. Reduced staff
periods are between 12:30 p.m. to 1:00 p.m. (Central Time) and
between 4:00 p.m. and 4:30 p.m. (Central Time). Please keep this in
mind if calling during these time periods.
Orders may be telephoned, submitted by FAX, or mailed to the
following:
North American Location
R.A JONES & Co.

Davenport, IA 52806 USA
Phone: (563) 391-1100
1-800-257-5622 (USA)
FAX: (563) 391-4951
parts.dept@rajones.com
European Location
R.A JONES & Co.
Unit 22, Victoria Spr. Bus. Pk

Wormald Street
Heckmondwike, West Yorkshire
England, WF15 6RA
Aerosol Spares Only
Phone: +44-1895-202391
Dawson Spares & All Field Service
Phone: +44-1924-414600
FAX: +44-1924-414601
June, 2013 / 075-16395-000
31-1
Ordering Parts
Notes . . . .
31-2
075-16395-000 / June, 2013
Technical Service
Technical Service
Technical Service Representatives are available to provide
maintenance and repair service, and training, in your plant on

machines built by R.A JONES & Co. These representatives are
qualified to provide service to and operational maintenance
instruction for, the above machines. They are not qualified to give
service or advice relating to machinery or equipment sold or
manufactured by others, or to advise regarding manufacturing
processes or product formulations.
For additional information, or to schedule repair service,
periodic inspection, or in-plant training, contact the Technical
Service Department:
North American Location
R.A JONES & Co.

Davenport, IA 52806 USA
Phone: (563) 391-1100
1-800-257-5622 (USA)
FAX: (563) 391-4951
European Location
R.A JONES & Co.
Unit 22, Victoria Spr. Bus. Pk

Wormald Street
Heckmondwike, West Yorkshire
England, WF15 6RA
Aerosol Spares Only
Phone: +44-1895-202391
Dawson Spares & All Field Service
Phone: +44-1924-414600
FAX: +44-1924-414601
June, 2013 / 075-16395-000
32-1
Technical Service
Notes . . . .
32-2
075-16395-000 / June, 2013
Machine Disposal
Once the service life of the machine is done, proper disposal of the
machine and its components will be necessary. The following
guideline will enable you to safely dispose of the machine.
Machine Disposal
1.
Disconnect all electrical, air, and product lines from the

machine. Disconnect the machine from any conveyor
system.
2.
Remove any and all product from the machine. Dispose of

product in a manner consistent with local ordinance.
3.
Drain any fluids and lubricants from the drive unit. Such fluids
must be handled and disposed of in a manner consistent with
local ordinance.
4.
Remove any transformers from the electrical enclosures.

Dispose of transformers in a manner consistent with local
ordinance.
5.
If desired, salvage any usable components from the machine

for use elsewhere.
6.
Remove the machine mounting hardware.
7.
Deliver the machine to a salvage company or yard, for

recycling of materials.
June, 2013 / 075-16395-000
33-1
Machine Disposal
Notes . . . .
33-2
075-16395-000 / June, 2013
Glossary
Ambient Temperature - Temperature of the immediate area.
Glossary
Anvil - Machined part used in the clipping head to bend ends of wire
clips around the gathered package film.
Bead - A line of melted resin laid upon package film overlap, prior to
being sealed, when using an extrusion sealer.
Breaker Roller - Film roller immediately before the film folder, used
to set the angle of approach for the film, relative to the film folder.
Butt Clip - Wire clip which has both ends butted to one another.
Cam Change Lever - Lever located on the elevating posts (one on
each post), which enables switching between two different package
length cams.
Chub - Name for the machine and the package shape it produces. A
cylindrical package with spherical ends.
Clip - Wire shaped, formed, cut, and clinched around each end of a
Chub package to effectively seal the package ends.
Clip Carrier - Mechanical part that transports a formed clip from one
phase of the clipping cycle to another.
Clip Spacing - The vertical distance between the top clip of one
package and the bottom clip of the following package, prior to
package cut-off separation.
Clipping Head - Mechanism assembly that gathers film between
two forthcoming Chub packages; forms, places, and clinches wire
clips; separates the completed Chub package from the forming
packages; all while moving vertically up, and down in sync with the
film movement.
Clipping Head Speed - Measured as the downward vertical speed,
matched to the film speed.
Closure Plates - A set of plates with v notches, assembled into
the clipping head, that aid in gathering the package film together, to
allow for application of the clips.
June, 2013 / 075-16395-000
34-1
Glossary
Clutch Feature - A functional feature of the Chub Packaging
Machine, which allows the production of longer than normal
package lengths, by delaying the upward movement of the clipping
head during package formation.
CPU - Central Processing Unit; part of the machine control.
Cut-Off Knife - An angled knife blade, pinned to a specific closure
plate, that cuts the package film between two placed clips,
separating the lower completed Chub package from the forming
package above.
Cut-Off Length - The length of film required to form a complete
Chub package.
Cut-Off Punch - Machined part that cuts clip wire to specific length
and holds the wire while it is formed into a U shape.
Cycle Stop - A programmed stop of the machine, that once
initiated, enables certain machine functions to be completed before
the machine comes to a full stop.
Dancer Arm - Pivoting arm with film idler attached used on the dual
arbor tension control. Affects film arbor brake pressure depending if
arm is being raised or lowered.
Dater - Unit incorporated on the Chub Packaging Machine, which
enables imprinting upon the package film, prior to package
formation.
Drive Wheels - A set of rubber treaded wheels (usually four) that
pull the package film from below the folder and seal areas, through
the film rollers, and off the film rolls.
Elevating Shaft - Two are used on each machine and follow the
cams inside the lower mechanism of the Chub Packaging
Machine, to give the clipping head its vertical motion.
Enclosed Heat Sealer - A water-jacketed heat film sealer, which
utilizes electrical resistance to generate heat, over which air is
blown, to effect a package seal on polyethylene film. This unit is
used in specific applications where an open heat seal unit would
pose potential danger.
Eye Spot - See Registration Mark.
34-2
075-16395-000 / June, 2013
Glossary
Extruder - A water-jacketed hot resin sealer, which utilizes melted
plastic resin extruded into a continuous bead between the film
overlap area, to effect a package seal. This unit is used in specific
applications, predominantly for explosives products, where an open
heat seal unit would pose a serious potential danger.
Fiber Optic Light Guide - A sensor that emits light and detects
reflection and absence of reflection, of that light. Used within the
Registration accessory to detect the registration marks printed on
packaging film.
Film - Any of various thin plastic compound films, of various web
widths, used to form Chub packages.
Film Arbor - A rotating, horizontal clamping or clampable shaft, on
which the core of a roll of packaging film is installed.
Film Folder - A uniquely-shaped part, open through the center with
sloping shoulders and overlapping wings. This part enables the
formation of the Chub package tube from flat roll stock film.
Film Path - Where the flat package film is threaded over and under
various rollers through the Chub Packaging Machine, before it is
introduced to the film folder.
Film Rollers - Various shafted, free-spinning rollers, which the flat
package film is threaded over and under.
Film Speed - The downward vertical speed at which the film travels,
as measured at the film drive wheels. Usually interpreted in inches
per minute or millimeters per minute.
Film Splice Detector - A fiber-optic device which detects a film
edge or overlap, consistent with tape splicing of film. When
detected, machine operation halts, allowing the operator to feed the
film past the splice, and then continue operation.
Film Spreader - A ring with two small diameter bullet-nosed rods,
that fits over the mandrel and aids in keeping the film from dragging
on the mandrel and allows the film to be gripped by the film drive
wheels.
Film Tube - The traditional Chub package shape formed when the
package film exits the film folder and is sealed along the overlap.
Film Web - The width of the package film.
June, 2013 / 075-16395-000
34-3
Glossary
Finger - Machined part used in clip transfer clipping heads
(non-M7). Holds the U shaped (preformed) clip in place while film
is gathered in closure plates.
Food Grade - Any number of lubricants, cleaners, or materials
designated by the USDA as being acceptable to make contact with
food products during the production phases.
Gathering Plates - Same as Closure Plates.
Handwheel - A wheel, usually on the front or side of the Chub
Packaging Machine, used to turn the machine through (by hand)
without the aid of electrical power.
Heat Coil - A portion of the heat seal unit, made from hollow metal
tubing and coiled.
Heat Seal - A method of sealing polyethylene package film, using
blowing air heated by electrical resistance, followed by cool blowing
air.
Inspection Cover - One of two plates located on the front of the
Chub Packaging Machine either side of the package chute and
mounted on the lower enclosure. They provide access for inspection
and some minor servicing.
Jog - Interrupted, short-duration machine operation.
Knockout Punch - Machined part used in clipping head to push clip
out of cut-off punch in M7 clipping head (or fingers in clip transfer
non-M7 clipping head) and provide support to back of clip while the
clip ends are being formed around the gathered package film.
Label - Printed portion of package film.
Low Product Detector - Device in product supply pipe/tube leading
to Chub Packaging Machine that detects low product pressure and
signals control.
Main Electrical Disconnect Switch - A customer supplied lockable
switch device from which the electrical power is supplied to the
Chub Packaging Machine.
Mandrel - A metal tube, mounted from the top of the Chub
Packaging Machine, down through the film folder, ending above
the film drive wheels, through which product is introduced into the
Chub package.
34-4
075-16395-000 / June, 2013
Glossary
MCR - Master Control Relay.
Micro-Clip Dial - A numbered, toothed dial, which enables
adjustment of clip tightness.
National Electrical Code - In the United States, the code by which
most all electrical wiring must conform.
NFPA - National Fire Protection Association
Overlap - Where the package film overlaps itself when formed into
the traditional Chub package tube.
Package Breakout Detector - A low-voltage, spring-loaded metallic
device, which causes a ground fault upon product contact, resulting
in stoppage to all machine functions.
Package Chute - A trough, located within the lower enclosure of the
Chub Packaging Machine, directly beneath the clipping head, to
enable the exit of completed Chub packages from the machine.
Plate Guide - Assembly with grooved sides for closure plates to be
installed into.
PLC - Programmable Logic Controller.
Polyethylene Film - A common package film that is heat sealable,
but usually not RF sealable.
Polyvinylidene Chloride Film - A type of package film that is RF
sealable, but not heat sealable.
PPM - Packages Per Minute.
Product Piston - A Chub Packaging Machine accessory that
sucks back some of the product from the package tube, enabling
the voider accessory to void the package better.
PVDC Film - See Polyvinylidene Chloride Film.
Quick Change Cams - A feature that allows quick change from
inside to outside cams, providing production of a broader range of
package lengths. This feature is only available on machines
equipped with dual cams.
Registration - Accessory that keeps the package length and clip
position relative to the printed information on the film.
June, 2013 / 075-16395-000
34-5
Glossary
Registration Mark - A usually dark mark, evenly spaced with other
identical marks, that provides contrast on the package film, enabling
its detection by the registration system components.
Resin - Any number of various plastic bead adhesives used within
the extrusion sealer to enable a seal of the package film along the
overlap.
RF Seal - A seal made by radio frequency (RF), of PVDC film.
SAE - Society of Automotive Engineers.
Seal - Where film is adhered together, by heat, RF, or other
mechanical means.
Seal Rate - The amount of seal length that can be performed within
a given time period; usually expressed in inches per minute or
millimeters per minute.
Short Stroke Clipping Head - A special M7 clipping head that
provides a short stroke, enabling production of shorter Chub
packages.
Sizing Parts - A set of parts consisting of sizing ring, sealing ring,
mandrel, folder, and spreader, that enable the production and
sealing of Chub packages for a specific diameter or range of
diameters.
Specific Gravity - A number or value, indicating how many times a
specific volume of a material is heavier than an equal volume of
water.
Squeeze Rolls - An optional set of rollers, located beneath the film
drive platform, that apply equal pressure to two sides of the Chub
package, to aid in the elimination of air within the final package.
Standard Stroke Clipping Head - A commonly supplied and used
M7 clipping head that provides a broad range of package length
ability.
Static - An electrical charge that builds on the outside of objects,
usually plastic in structure, that when accumulated to sufficient
amount, can discharge.
USDA - United States Department of Agriculture.
V-Plates - See Closure Plates.
34-6
075-16395-000 / June, 2013
Glossary
Voider - An accessory that provides two rollers that come together
to void the forming package of product at a specific point, further
enhancing the clipping process and reducing the chance of package
breakout.
Voider Dwell - The delay time between voids.
Voider Gap - The distance between the voider rollers when open.
Voider Position - The place where the void occurs, relative to the
package length.
Wire Coil - Clipping wire in its bulk form, is supplied as a coil.
Wire Feed - The mechanism located at the back of the clipping
head that feeds wire from the wire coils into the clipping head, where
the wire clips are formed and clinched.
Wire Straightener - A small mechanism mounted to the wire feed,
made up of a series of rollers, adjusted such that curved wire
coming off the wire coils is straightened as it enters the wire feed.
Wire Lubricator - An oil reservoir unit, usually equipped with a
simple mechanical valve to control the flow of oil used to lubricate
wire used for clips.
Wrap-Around Clip - A clip with its ends that overlap.
June, 2013 / 075-16395-000
34-7

Chub Operators Manual

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Chub Operators Manual

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R.A JONES & Co.

Manual Part No.: 075-16395-000

Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Machine Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

June, 2013 / 075-16395-000

Film Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

075-16395-000 / June, 2013

Optional Markem Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1

June, 2013 / 075-16395-000

075-16395-000 / June, 2013

4-1: Installation Drawing - Front View . . . . . . . . . . . . . . . . . . . . . 4-2

June, 2013 / 075-16395-000

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June, 2013 / 075-16395-000

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5-1: Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

June, 2013 / 075-16395-000

Although packaging industries are fairly well established,

075-16395-000 / June, 2013

WARNING statements refer to hazards or unsafe practices

June, 2013 / 075-16395-000

075-16395-000 / June, 2013

075-16395-000 / June, 2013

Only qualified electricians should work on the electrical

This machine is equipped with a servo motor clip drive. This

June, 2013 / 075-16395-000

075-16395-000 / June, 2013

ELECTROCUTION SHOCK HAZARD

June, 2013 / 075-16395-000

075-16395-000 / June, 2013

This machine is designed for installation, use, and operation in a

Diameter . . . . . . . . . . . . . . . 5/8 to 4-1/8 [15 mm to 104 mm]

30 to 150 packages per minute (PPM), dependent upon

Crated Weight. . . . . . . . . . . . . . . . . . . . . 4,715 lbs. [2,143 kg]

June, 2013 / 075-16395-000

1,350 inches per minute [34,290 mm/minute] - approximate

*NOTE: Information was not available at the time of publication.

The chart above is provided as a reference. For specific

Heat Seal . . . . . . . . . . . . . . . . 40 psig [280 kPa] @ 14 SCFM

075-16395-000 / June, 2013

Airborne Noise Emissions near machine, less than 88 db*

Available Wire Diameters

Standard . . . . . . . . . . . . . . . . . . . . 0.091 diameter +/- 0.001

Aluminum with a tensile strength of

R.A JONES & Co.

June, 2013 / 075-16395-000

075-16395-000 / June, 2013

June, 2013 / 075-16395-000

075-16395-000 / June, 2013

Carefully unpack the machine and check for damage. If any

Move the machine to its approximate location for production.

Electrical wiring components and procedures MUST conform

June, 2013 / 075-16395-000

Air supplied to the machine should be piped through a

16 [406 mm] Diameter

Figure 4-1: Installation Drawing - Front View

075-16395-000 / June, 2013

19.3 [490 mm]

June, 2013 / 075-16395-000

6.1 [155 mm]

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34.9 [886 mm]

June, 2013 / 075-16395-000