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Resources | Combo Shrink Systems

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General Questions

How to set the Impulse Controls


  1. Set Seal Control at: 07
  2. Set Trim Dial at: 7
  3. Set Cool (Dwell) at: 1 or 2
  4. Seal first package.
  5. If the first seal is not satisfactory, wait five (5) minutes, then increase seal control setting to a higher level.
  6. Seal another package, if the seal is not satisfactory then, repeat step five until a satisfactory seal is achieved.
  7. Now, seal packages at a normal production rate and then if the seal deteriorates, stop packaging for five (5) minutes and then increase trim setting one-quarter of a digit.
  8. Repeat step 7 until all your seals are consistent.
    • NOTE: Trim control normally should not be set any higher than eight (8) for routine packaging. If a higher setting appears to be required, repeat step two increasing the seal setting. Balance between seal and trim control is essential for consistent seal performance.
  • TROUBLESHOOTING: If first package has poor seals, adjust seal control to the first seal satisfaction. If that is not possible, the problem can be isolated to seal arm pressure, seal pad or seal wire condition.

How to thread film on L Sealers


  1. Place a roll of centerfold film on the film unwind rollers with the open side of the film facing the operator and thread the lower side of the film underneath the package tray.
    • (Refer to the threading diagram on the .pdf and on the film guide)
  2. Place a product to be wrapped on the package tray near the sealing area.
  3. Loosen the knobs under the film rollers and position the film rack so that the folded side of the film is in line with the back edge of the product to be wrapped.
  4. Re-tighten the knobs to hold the film rack position in place.
  5. If the correct width of film is being used, this position will provide an adequate amount of film across the front of the sealing area.
  6. This is a starting position and adjustments can be made to provide the appropriate amount of film around the package for shrinking and conservative use of the film. Discard the unused film when done.

Threading the Power Film Unwind on L Sealers


  • · Adjust the film inverter to the height necessary for your package by turning the knob with one hand and lowering the top bracket with the other hand.
  • · Place centerfold film on the film cradle between the rollers with the open, leading edges of the film to the right side of the cradle with the open edge feeding over top of the roll down towards the dancer bar.
  • · The threading diagram shows the proper way to thread the film across the rollers and dancer bar and up to the perforating rollers.
  • · To feed the film into the film inverter, pull a couple feet of film through the unwind and separate the two edges of the film and feed one edge over the top inverter plate and feed the other edge under the bottom edge between the top of the bottom edges and underneath the product tray.
  • · Then pull both edges of the film towards the sealing area meanwhile smoothing the film out on the edge of the inverter plates.
  • · Once this is done, seal the open edges of the film and place your package on the tray ready to be sealed.

Comparison of RapidHS Shrink Machines


  • For a comparison on Heat Seal's RapidHS Shrink Combination Systems, please see the attached download.

What is an RS-5 Plus controller and what are the benefits?


*The RS-5 Plus Replaces the RS-3 Controller*
  • The RS-5 Plus is a programmable electronic controller designed to control an L Sealer or Combination Shrink System. The RS-5 Plus is setup to control several machine configurations through the digital keypad. The controller can be configured to control either impulse or hot knife L Sealers equipped with or without a shrink tunnel.
  • The RS-5 Plus controls: Seal Time, Side & Front Seal Temp, Seal Conveyor Run Time, Seal Conveyor Speed, Tunnel Conveyor Speed, Tunnel Temperature, Cycle Count, and Heated Hole Punch. 
  • Benefits of the RS-5 Plus Digital Controller:
    • Intuitive User Interface - Easy to use and understand control screens
    • Control Assurance - Precise, accurate digital settings
    • Durable and Robust - Heavy Duty Controller for high volume usage with repeatable results
    • Reliable - Precise PID temperature controls provide the most consistent operating temperature
    • Universal - Common controller across multiple Heat Seal machines
    • Certified - Meets UL 508A Standards
    • All with an Industry First - THREE Year Warranty on the machine’s original controller

Application Data


Your Heat Seal sales rep may require an application data sheet and product samples for certain applications.  Please contact your Heat Seal rep for questions or concerns.

 


Gravity Turnaround Conveyor Flow Guide


Which direction to you want the finished product to go? 

This guide will help.

 


Troubleshooting

Film splits along centerfold

Film splits at hole punch


  • Check hole punch for proper alignment.
  • Check the condition of the punched holes.

Film splits at top of package


  • Check hole punch for proper alignment.
  • Check the condition of the punched holes.
  • Make sure the tunnel is functioning properly.
  • Speed up the tunnel conveyor.
  • Decrease the tunnel temperature.
  • Adjust the air flow.

Film smokes excessively


  • Check and clean wire and wire insulation
  • Check and clean knife blade
  • Check condition of sealing pads
  • Check condition of Non-stick tape
  • Check for even arm and magnet pressure
  • Check the minimum sealing temperatures
  • Increase the sealing temperatures
  • Decrease the dwell time

Angel hair


  • Check and clean wire, wire insulation or knife blades
  • Check condition of sealing pads and Non-stick tape, change if necessary
  • Check for even arm and magnet pressure, make sure the magnets release at the same time
  • Check the minimum sealing temperatures
  • Check the seal cycles is complete
  • Check the condition of the air evacuation holes
  • Increase the sealing temperatures

Burn holes (Hot spots)


  • Check the condition of the air evacuation holes
  • Speed up the tunnel conveyor
  • Decrease the tunnel chamber temperature

Erratic Shrink


  • Make sure the tunnel is functioning properly
  • Slow down tunnel conveyor
  • Adjust the tunnel air flow
  • Increase tunnel chamber temperature

Severe Ballooning


  • Increase the tunnel temperature
  • Check condition/position of air evacuation holes

Film won't separate; Static or film collapses package

Off-centered seal


  • Adjust the package platform.
  • Loosen the knobs on the tension blocks.

Dog ears


  • Use less film around the package
  • Slow down the tunnel conveyor
  • Check the condition of the air evacuation holes
  • Increase the tunnel temperature

Fish eyes


  • Make sure tunnel is functioning properly
  • Slow down tunnel conveyor
  • Use less film around the package
  • Increase the tunnel temperature

Crows feet


  • Slow down tunnel conveyor
  • Increase the tunnel chamber temperature

Film buildup on sealing wire


  • Check and clean wire, wire insulation or knife blades
  • Check the condition of the sealing pads
  • Check the Non-stick tape, change if necessary
  • Check for even arm and magnet pressure
  • Check the minimum sealing temperatures, or increase the sealing temperatures

Maintenance

Shrink Tunnel Maintenance


  • LUBRICATION OF TUNNEL BELT
  • The chain and sprockets on all Heat Seal shrink tunnels must be maintained to provide for long life and smooth operation. The tunnel chain must be lubricated after every 40 hours of operation with Heat Seal Chain Gel lubricant. (Part No. 5406-066)

L Sealer Tape and Pad Maintenance


  • Check the seal pads
  • The L Sealer seal pad will show wear from constant use and will need replaced when problems occur or it no longer provides a constant seal for your packages. 

How to change elements of Hot Knife Seal Bars


  • MAKE SURE ALL POWER HAS BEEN SHUT OFF AND DISCONNECTED AND ELEMENTS HAVE COOLED BEFORE SERVICING THE ELEMENTS TO PREVENT PERSONAL INJURY TO THE SERVICE TECHNICIAN AND DAMAGE TO EQUIPMENT. QUALIFIED SERVICE TECHS SHOULD PERFORM THIS SERVICING.
  • DISASSEMBLY PROCEDURE
  1. When replacing an old heater rod with a new heater rod assembly, the element should be removed as well as the cable assemblies going to the terminal block underneath the product tray.
  2. Removal of the cable assemblies from the arms will require disconnecting the rigid conduit and flex conduit from the seal arm assembly.
  3. To remove the element from the front seal bar, loosen the set screw and loosen the wire fasteners to slide out the element and cable assembly.
  4. Thermocouple wires require re-threading with the cable assembly of the elements.
  5. For the side seal bar, loosen the wire fasteners, set screw, bracket and the acorn nut to slide the element out. With the preceding steps complete, reassembly of the new elements, cable assemblies and thermocouple wires re-threading can begin.
  • RE-ASSEMBLY PROCEDURE
  • NOTE: Tag the front seal bar and side seal bar wires and cables for reference.
  1. For re-assembly of the side element rod, insert rod into seal bar and tighten the set screw, reassemble seal bar to arm by re-tightening the acorn nut and wire fasteners. For the front heater rod, insert the rod into the seal bar and re-tighten the set screw and wire fasteners.
  2. With the side and front heater rods in place, the cable assemblies and thermocouple wires can be threaded into the rigid and flexible conduit.
    • NOTE: Re-thread thermocouple wires and cable assemblies simultaneously.
  3. With the front cable assembly and thermocouple wires inserted up to the elbow, re-thread the side wires through the ½ inch hole on the elbow. Then re-thread all thermocouple wires through the flexible conduit.
  4. After all the cable assemblies and wires are through the flexible conduit, reinsert into the control housing and reconnect to the terminal block.

How to replace the Heavy Duty Seal Arm


  1. Remove the spring cover from the L sealer. Disassemble the seal arm assembly, torsion springs, shaft collars and seal arm shaft from the L sealer. The torsion springs and shaft collars will be used again. Set the seal arm shaft aside.
  2. Replace both of the original cast aluminum seal arms on the seal arm assembly with the new cast aluminum seal arms. Remove the seal arm stopper from the original left side seal arm and re-install it in the new left side seal arm.
  3. Re-install the seal arm assembly along with the original torsion springs and shaft collars and the new arm mount plates onto the L sealer using the new seal arm shaft. Be sure that the ½ diameter hole on the new seal arm is located on the outfeed/discharge side of the sealer and the shaft collars are placed on the inside of the pillow block bearings. In addition, be sure to orient each of the new arm mounting plates the same way. The group of four adjustment holes that includes a small clearance hole should be located on the bottom of the seal arm shaft.
  4. Place a square key into each of the keyways in the seal arm shaft and slide both of the arm mount plates over a key.
  5. Center the seal arm assembly on to the seal pads and reposition the seal arm shaft, arm mounting plates, torsion springs and shaft collars as required. Tighten the set screws on the shaft collars and the lock screws on the arm mounting plates.
  6. Place a rod in the ½ diameter hole in the seal arm shaft and rotate the seal arm shaft to adjust the spring tension. When the spring tension is near the set point, carefully align the two mounting holes in the cast aluminum seal arms with the nearest adjustment holes in the arm mounting plates. Secure the seal arm assembly to the arm mounting plates with the hardware supplied.
  7. Remove the rod from the ½ diameter hole in the seal arm shaft and check the spring tension on the seal arm assembly.
    • A. If the spring tension is too high, repeat Step 6 except rotate the seal arm shaft counter-clockwise to the next set of adjustment holes on the arm mounting plates until the spring tension is correct.
    • B. If the tension is too low, repeat Step 6 except rotate the seal arm shaft clockwise to the next set of adjustment holes on the arm mounting plates until the spring tension is correct.
    • C. If the spring tension is too high at one adjustment setting and two low at the next adjustment setting, disassemble the seal arm assembly, torsion springs, shaft collars, arm mounting plates and seal arm shaft from the L sealer. Repeat Steps 3 through 6 except orient the arm mounting plates so that the group of four adjustment holes that includes a small clearance hole is located on the top of the seal arm shaft.
  8. Replace the spring cover on the L sealer and adjust the seal arm assembly as required.

How to replace the L Bar Sealing Wire


  • TO REMOVE WIRES
  1. Tighten the knob on the tension block to relieve the sealing wire tension.
  2. Using a small screwdriver, loosen the screw in the side of the tension block and pull out the sealing wire.
  3. Loosen the screw at the other end where the wires cross and remove the sealing wire.
  4. Do the same for the side sealing wire repeating the above steps.
  • TO REPLACE WIRES
  1. Insert the new wire in the tension block and re-tighten the screw.
  2. With pliers in hand, tightly wrap the new wire around the screw at the other end and re-tighten the screw. Then loosen the knob to create tension on the new wire.
  3. Do the same for the side sealing wire repeating the above steps.
  4. COMPLETELY LOOSEN BOTH KNOBS ON THE TENSION BLOCKS BEFORE TESTING THE SEALER. IF THE WIRES ARE LOOSE WHEN COOL, FOLLOW THE REPLACEMENT STEPS ABOVE TO RETENSION WIRES.

How to adjust the Heavy Duty Seal Arm


  • BEFORE YOU BEGIN  Make sure to disconnect air if present and electrical power to the machine before adjusting the sealing arm. Then remove the covers covering the arm shaft. Loosen the clevises for the air cylinders from the arm shaft.
  • ADJUSTING THE SEAL ARM
  1. Adjust the arm springs so the arm just opens and stays in the open position by:
    • Putting a lever arm in the hole in the arm shaft that is at least 24 inches long.
    • Pull the lever towards the front of the machine to close the arm.
  2. While holding the lever tightly, loosen the 3/4” nuts on the arm casting. (Requires two people)
  3. To increase the opening force, rotate the arm shaft with the lever in the direction that will close the arm.Re-tighten the 3/4” nuts on the arm castings. Torque to 35 lb. per ft.
  4. Adjust the open stop to the desired maximum open position.
  5. Make sure the arm is all the way open and the cylinder fully retracted.
  6. Check that the cylinder is perpendicular to the arm shaft, then tighten the clevis on the shaft.
  7. Verify that the arm will easily close all the way. Do this by carefully pulling the arm down (the air should still be disconnected). If the arm feels smooth all the way down to the arm’s sealing position and there is less than 2 3/4 inches of the shaft extending out from the cylinder, then the arm is ok.
  8. If the arm will not close all the way, the maximum open position will need to be decreased. Loosen the cylinder clevis (see item 3) on the shaft, decrease the maximum position by changing the open stop, and repeat the procedure from the “adjust open stop” step listed above.