HayssenSandiacre Training

225 Spartangreen Blvd. Offering you the option to select from our standard training
Duncan, SC 29334 courses or design a course to meet your individual requirements. Not all
864.486.4111
www.hayssensandiacre.com businesses are the same so why not work with our professional training
staff to ensure your training is business centric?
Contacts
Training workshops are conducted at our Duncan, SC, facility or we can
Phyllis Millard conduct a field program at your facility.
Manager, Technical Training
(864) 486-4057
Who better to train your staff on HayssenSandiacre equipment than a
phyllis.millard@hayssensandiacre.com
certified HayssenSandiacre trainer?
Becky Lovin
Training Coordinator A sample of the topics covered
(864) 486-4111 Ext. 8138
becky.lovin@hayssensandiacre.com
Theory of Operation Programming Registration & Placement

Mechanical Setups Mechanical Adjustments Electrical Troubleshooting

Scale and Bagger Timing Preventive Maintenance

Pneumatics

Types of Training
• Workshop. Includes both classroom and hands-on.

• Field Program. Includes both classroom and hands-on.

• OJT. (On-the-job-training). All hands-on. Does not include classroom.

• Dedicated Workshop. Includes both classroom and hands-on. Only

personnel from your company may attend.

Who should attend?

Operators Mechanics

Line Supervisors Team Leaders

 Instruction Manual

Macro Logic
Model: 12-16HR Lance INC
Rev: 5 M334U19790

Macro Logic
 USING THE PARTS MANUAL TO ORDER
REPLACEMENT PARTS
Parts Identification
IMPORTANT:
Do not order parts from the Instruction Manual or Training Man-
ual.

The part needed may be part of an assembly or an entire assembly. The

Description of each major assembly, located in the Table of Contents
in the Parts Manual, can help identify the specific bill of material
required.

IMPORTANT:
• The major assemblies of the machine make up the Table
of Content for each parts manual.
• Parts that can be ordered are identified by a Line #.
• The Line # corresponds to the number identifying the
part on the assembly drawing.
• The assembly drawing faces the bill of material for the
assembly.
• For assembly drawings referencing multiple bills of
material, refer to the legend on the drawing to identify
specific assembly.

Figure 1: Example of a Bill of Material Page

How to Order Parts 1. Identify the assembly/part in the Table of Contents which
corresponds with the part needed. (The description helps
identify assemblies.)
2. Turn to the page identified in the Table of Contents to
locate the bill of material for the assembly/part.
3. Note the Line #. for the part ordering.
 4. Locate the corresponding number on the drawing to verify
this is the required part.

IMPORTANT:
Numbers such as 1.1 and 1.2, on assembly drawings, indicate that
these parts are part of item number 1.

5.

Assembly
Drawing
Number

If applicable, a legend is
on the drawing for
multiple BOMs

Key Line #

Figure 2: Assembly Drawing

6. Complete the Parts Request form included in this section

and call or fax the order.
If the part required does not look like the illustration or is not shown in
the Parts Manual, check the original part for a cast or stamped number.
All HayssenSandiacre part numbers have 10 digits.
If a number is not visible, completely describe the part. Draw an illus-
tration with dimensions. Include a photo if possible. Specify left or
right hand when applicable.
Keep the Parts Manual current by adding, changing or deleting bills of
material which represent modifications to the machine.
 These abbreviations are in the Parts Manual.

Abbreviation Meaning
B/M NBR Bill of Material number

REV Revision letter

ASSY NBR Assembly drawing number

ECN Code for HayssenSandiacre use

PARTS BOOK NR Parts book number

Numerical listing of parts found

ITEM
on the Bill of Material

DRWG NBR Drawing/Part number

Quantity per unit of measure

QTY/P UM
(each, ft. inch, etc...)

SC/SQ Code for HayssenSandiacre use

EMSP Code for HayssenSandiacre use

Contacting
HayssenSandiacre Address
HayssenSandiacre
Attention: (enter department name or person)
225 Spartangreen Blvd.
Duncan, SC 29334

Telephone
[864]
Customer Service
486-4111

After dialing Customer Service, choose from the

following.

Known Extension Press 1

Replacement Parts Press 2

Technical Support Press 3

Field Service Press 4

Training Classes Press 5

Operator Assistance Press 0

[864]
Customer Service Fax
486-4222
 IMPORTANT:
• Always state Model Number and Serial Number of the
machine. Many machines are built to special customer
specifications. We must have the serial number to
ensure we provide those parts required for the equip-
ment.

Important • List all 10 digits, such as 00000X0000, of the part number.

Information The sixth digit is always a letter and indicates drawing
size.
• Specify method of shipment; truck, RPS, UPS, Air Parcel
Post, Air Freight, etc. HayssenSandiacre® reserves the
right to select the most practical shipping method.
• Machine down, rush and emergency orders are shipped
Air Freight, and an “Emergency Handling” charge may be
added.
• If parts are to be exported, advise HayssenSandiacre about
any special documents the government may require.
• When confirming a telephone order by mail, indicate in
BOLD PRINT that this order confirms the phone order.
Include the date of phone order, and name of the person at
HayssenSandiacre who took the order. HayssenSandiacre
is not responsible for duplicate shipments if the order is
not marked as a confirmation.
• HayssenSandiacre is not responsible and does not issue
credit for parts inappropriately supplied when no machine
serial number has been specified in the parts order.
• HayssenSandiacre reserves the right to substitute vendors.
Replacement Parts Request Form
Please print the following information clearly.
1 Company Information
Machine Serial Number Date

Billing Information Company Name

Address Telephone Number

City State Zip Code Fax Number

Contact E-Mail Address

Ship To Information Company Name

Address Telephone Number

City State Zip Code Fax Number

Contact E-Mail Address

2 Requested Parts
Hayssen Part Number Quantity Part Name and Description Customer Part Number

3 Payment and Approval 4 Submit Replacement Parts Request Form

Date Required Delivery Date Confirmed
 (864) 486-4111. When calling, please have
the information requested on the
Purchase Order Number OR Credit Card Number and Expiration Date Replacement Parts Request Form available.
 Fax the Replacement Parts Request Form
Authorizing Signature
to, (864) 486-4222.
Job Title  Request Hayssen Replacement Parts online
at http://www.barry-wehmiller.com
R2
www.barry
www.barry-
-wehmiller.com
wehmiller.com
 Introduction
Thank you for purchasing a HayssenSandiacre packaging machine. HayssenSandiacre strives to
deliver the best packaging technology combined with rugged, durable construction to provide a
productive and reliable means of packaging your product.

To ensure the packaging machine lives up to all expectations, it is important to read and comply
with this instruction manual. Please store this manual near the machine for easy access, as it is an
important resource for all personnel involved with the operation and maintenance of the
HayssenSandiacre machine.

This manual provides personnel with the information needed to safely operate and maintain the
HayssenSandiacre machine. It has been designed and written to be used as an instructional tool, as
well as a reference tool, for everyday work. To improve understanding by all levels of users, step-
by-step instructions are provided where possible. Important tags mark information about the best
ways to operate the machine, and this information can be valuable in maximizing the production
and longevity of the machine.

It is important that all personnel read and understand the Safety Chapter BEFORE operating the
machine. Also, read all Warning and Caution notices at the beginning of each chapter BEFORE
attempting to make any adjustments or changes. Warning and Caution notices are also positioned
in strategic areas throughout the manual to point out any hazards that may arise from machine
setup and/or adjustment procedures.

If there are further questions about the operation or maintenance of the machine, please contact
the HayssenSandiacre Service Department at (864) 486-4111, option 3. For ordering additional
manuals or replacement parts, please contact the Parts Department at (864) 486-4111, option 2.
Both the Parts Manual and the Instruction Manual also include an ordering guide for assistance
when ordering parts. To gain the most from the machine, always use genuine HayssenSandiacre
parts. Visit www.HayssenSandiacre.com for more information about equipment and parts.

Illustrations may be changed without notice. All dimensions and

specifications are approximate and drawings are not to scale.
Machines are shown without guards for illustration only. Guards
are supplied and must be in place before operation. Sales are
subject to prevailing terms and conditions of sale.
Specifications are subject to change without notice.
 Copyright © 2012 by
HayssenSandiacre, A Barry-Wehmiller Company

ALL RIGHTS RESERVED.

THE REPRODUCTION OR UTILIZATION OF THIS
WORK IN ANY FORM IS FORBIDDEN WITHOUT
THE PERMISSION OF THE PUBLISHER
 Table of Contents

Chapter 1: Machine Description

Guards............................................................................................... 1-1
Product Jam Detector...................................................................... 1-2
Ground Fault Circuit Interrupter (GFCI) ......................................... 1-2

Chapter 2: Safety

Safety Overview ............................................................................... 2-1

Safety Signals ......................................................................... 2-1
Basic Danger and Warning Notices ............................................... 2-1
Installation ............................................................................... 2-1
Guards..................................................................................... 2-1
Machine Location .................................................................... 2-2
Burn, Nip, and Pinch Points .................................................... 2-3
Electrical.................................................................................. 2-3
Replacement Parts.................................................................. 2-4
Lubrication............................................................................... 2-4

Chapter 3: Installation

Machine Delivery.............................................................................. 3-1

Prepare Site and Utilities for Machine............................................ 3-1
Installing Air Devices....................................................................... 3-1
Installing Electrical Devices............................................................ 3-2
Ground Fault Circuit Interrupter (GFCI)................................... 3-3
Power Source for External Devices......................................... 3-3
To Lift Machine from Skid ............................................................... 3-3
Product Feed Interface Installation and Operation ....................... 3-5
Feed System Electrical............................................................ 3-5
Timing...................................................................................... 3-5
Product Spacing ...................................................................... 3-5
Mechanical Interface ............................................................... 3-6
Double Dumping...................................................................... 3-6
Mezzanine Installation ..................................................................... 3-7

Ultima Macro® Page 1/Rev 5

 Chapter 4: Preventative Maintenance

Lubrication ........................................................................................4-1
Lubrication Chart .....................................................................4-2
General Maintenance .......................................................................4-3
Rollers......................................................................................4-3
Belts.........................................................................................4-3
Applying LocTite®............................................................................4-3
Rust Colored Stain On Stainless Steel - Causes and Solutions ..4-4
Guidelines For Washdown Environments .....................................4-5
Bagger .....................................................................................4-5
Scale........................................................................................4-6

Chapter 5: Operator Interface

Macro-Logic System ........................................................................5-1

Operator Panel and Controls...........................................................5-1
Master Stop .............................................................................5-1
Reset .......................................................................................5-1
Keylock Switch.........................................................................5-2
Screen Descriptions.........................................................................5-2

Chapter 6: Recipe Setup - Macro-Logic

Macro-Logic System ........................................................................6-1

Timing................................................................................................6-1
Load a Recipe ...................................................................................6-2
Bar Code Reader Wand ..........................................................6-2
Modifying Existing Barcodes.........................................6-2
Create or Edit a Recipe ....................................................................6-3
General Information .................................................................6-3
Changing a Parameter Value........................................6-3
Degree and Millisecond Range................................................6-3
Edit Functions on the Manual Operation Screen .....................6-3
Edit Functions on the Machine Timed Functions 1 Screen .....6-4
Edit Functions on the Machine Timed Functions 2 Screen .....6-6
Edit Functions on the Real Time Functions Screen.................6-7
Edit Functions on the Counter & Temperature Screen............6-8

Page 2/Rev 5 Ultima Macro®

 Saving a Modified Recipe................................................................ 6-9
Setting the Date and Time ............................................................... 6-9
Automatic Setup Procedure.......................................................... 6-10
Double Pull Recipe......................................................................... 6-11

Chapter 7: Unwind Assembly

Principles of Operation.................................................................... 7-1

Unwind Stand Components ............................................................ 7-2
Spindle Support Plates............................................................ 7-2
Stationary Rollers .................................................................... 7-2
Dancer Rollers......................................................................... 7-3
Roll Brake Mechanism ............................................................ 7-3
Roll Spindle ............................................................................. 7-3
Spindle Tube ........................................................................... 7-3
Positioning Ruler ..................................................................... 7-3
Roll Locating Collar ................................................................. 7-4
Spindle Roll Brake Drum ......................................................... 7-4
Low Film Bar ........................................................................... 7-4
Unwind Motor .......................................................................... 7-4
Unwind Stand Operation ................................................................. 7-5
Dancer Roll and Brake Adjustment ........................................ 7-6
Removing a Depleted Roll of Film........................................... 7-7
Loading a Roll of Film.............................................................. 7-7
Threading Film Through the Machine ..................................... 7-8
Motorized Unwind Edge Adjustment ....................................... 7-9
Determining Film Width ........................................................... 7-9
Determining Seam Seal Type........................................................ 7-10
Dimensions for Lap Back Seam Seal (IN.) ................................... 7-11
Dimensions for Lap Back Seam Seal (MM).................................. 7-12

Chapter 8: Registration Rollers

Registration Roller Components .................................................... 8-1

Registration Roller Spacing ............................................................ 8-2
Super CMB Models 12-16, 12-19, & SF................................. 8-2
Adjustment Procedure .................................................. 8-2
Print Registration ............................................................................. 8-2

Ultima Macro® Page 3/Rev 5

 Registration Scanner Components ................................................8-4
Scanner Control Unit Components ..........................................8-4
Offset Adjustment Pot ...................................................8-4
Eye Spot Indicator.........................................................8-4
Background Selector Switch .........................................8-5
Contrast Level Indicator ................................................8-5
Offset Control................................................................8-5
Registration Mark Sensor Setup..............................................8-6
Opaque (non-foil) Material ............................................8-6
Foil Material ..................................................................8-6
Transparent Material.....................................................8-7
Printer ......................................................................................8-7
Printer Take-Up Roller .............................................................8-8
Electrical............................................................................................8-9
Accu-Track...............................................................................8-9
Maintenance....................................................................................8-10
Pressure Roller Adjustment ...................................................8-10
Cleaning.................................................................................8-10
Lubrication .............................................................................8-10
Miscellaneous Adjustments ...................................................8-10
Clutch/Brake Repeatability Test ............................................8-10
Burnishing..............................................................................8-11
Clutch/Brake Pressure Roller Replacement ..........................8-11

Chapter 9: Pull Belt Assembly

Pull Belt Operation ...........................................................................9-2

Pull Belt Performance ......................................................................9-3
Pull Belt Centering and Pressure Adjustment - Non CMB.......9-4
Pull Belt Pressure Adjustment on CMB Machine.....................9-4
CMB Assembly to Tube Alignment ..........................................9-5
Maintenance......................................................................................9-5
Cleaning Pull Belts...................................................................9-5
Replacing Pull Belts.................................................................9-6
Replacing Upper Pulleys .........................................................9-6
Replacing Bottom Pulleys........................................................9-7
Pull Belt Drive Shaft Universal Joint Lubrication......................9-7

Page 4/Rev 5 Ultima Macro®

 Chapter 10: Forming System

Forming Tube Assembly Components ........................................ 10-2

Former................................................................................... 10-2
Forming Tube ........................................................................ 10-2
Last Roller ............................................................................. 10-2
Tube Stop.............................................................................. 10-2
Inserts.................................................................................... 10-3
Spreaders.............................................................................. 10-3
Sponge Tape......................................................................... 10-4
Open Back Forming Tubes ................................................... 10-4
Tube Air................................................................................. 10-4
Air Displacement System ...................................................... 10-4
Baffles ................................................................................... 10-4
Back Seal Types............................................................................. 10-5
Adjustable Forming Tubes............................................................ 10-5
Film Width Calculation .................................................................. 10-6
Storage and Handling .................................................................... 10-7
Maintenance and Adjustments ..................................................... 10-7
Seam Seal Sponge Tape Replacement ................................ 10-7
Tube Stop Adjustment........................................................... 10-7
Tube and Former Concentricity Adjustment.......................... 10-7
Last Roller Position Adjustment ............................................ 10-8
Forming Assembly Removal ................................................. 10-8
Removal, Cleaning and Installation of the Pull Belt Inserts... 10-8

Chapter 11: Platen Assembly

Platen Operation ............................................................................ 11-2

Platen Cushion Inspection ............................................................ 11-2
Polyethylene Platen Air Cooling System ..................................... 11-2
Platen Adjustments........................................................................ 11-3
Centering Adjustment............................................................ 11-3
Distance Adjustment ............................................................. 11-3
Speed Adjustment ................................................................. 11-4

Ultima Macro® Page 5/Rev 5

 Chapter 12: End Seal Assembly

How the End Seal System Works..................................................12-2

ABC Jaw Opening Adjustment.....................................................12-2
Change Jaw Opening Position ..............................................12-4
Jaw Face Pressure Adjustment for Resistance Jaws............12-4
Jaw Closed Proximity Switch Adjustment ..............................12-6
Jaw Open and Close, Speed, and Cushion Controls ............12-7
Knife Adjustments..........................................................................12-8
Knife Position Adjustment......................................................12-9
Knife Speed Adjustment ........................................................12-9
Preliminary Knife setting .............................................12-9
Knife Blade Replacement ....................................................12-10
Combination End Seal System - Resistance Sealing System..12-10
Removing and Installing Sealing Jaw Faces .......................12-10
Removing the Front or Rear Jaw Face .....................12-10
Installing the Front or Rear Jaw Face .......................12-11
Replacing Sealing Jaw Heaters ................................12-11
Front and Rear Sealing Jaw Face Alignment .....................12-12
Resistance Hole Punches............................................................12-13
Heated ProPunch ................................................................12-13
Heated ProPunch Adjustments.................................12-14
Round Mechanical Hole Punch ...........................................12-15
Hole Punch Alignment ..............................................12-16
Change Hole Size .....................................................12-16
Sealing Pressure Adjustment....................................12-17
Punch Rod Removal............................................................12-17
Punch Cylinder Timing.........................................................12-17
Running Bags Without Punch..............................................12-17
Rod and Bushing Maintenance............................................12-18
Combination End Seal System - Quali-Seal System .................12-18
How Quali-Seal Works.........................................................12-19
Temperature Controllers......................................................12-19
Teflon Fiberglass Tape ........................................................12-19
Jaw Set-Up ..........................................................................12-20
Additional Jaw Face Adjustment..........................................12-23
Timing Considerations .........................................................12-24
Additional Checks ................................................................12-24
4-Sealing Rib Variations ......................................................12-25

Page 6/Rev 5 Ultima Macro®

 Optional Round Sealed Hole Punch.................................... 12-29
Set-Up ...................................................................... 12-29
Adjust Gripping Pressure.......................................... 12-30
Punch Rod Location Adjustment .............................. 12-30
Heat Control Adjustment .......................................... 12-30
To Run Bags without a Hole Punch.......................... 12-30
Punch Cylinder Timing ............................................. 12-31
Hole Punch Maintenance ......................................... 12-31
Changing End Seal Systems....................................................... 12-31
Change from Poly to Cellophane ........................................ 12-31
Change from Cellophane to Poly ........................................ 12-32
Impulse Sealing System .............................................................. 12-33
Sealing Jaw Alignment ........................................................ 12-33
Changing End Seal Systems............................................... 12-34
Poly to Cellophane ................................................... 12-34
Cellophane To Poly .................................................. 12-35
Optional Accessories Poly Impulse Sealing ............................. 12-36
First Bag SCR Sealing System ........................................... 12-36
Controls and Calibration ........................................... 12-36
Setup and Calibration Example ................................ 12-38
Change Cellophane to Poly................................................. 12-39
Water Cooling Unit....................................................................... 12-40
Filling the System ................................................................ 12-40
Replacing the Temperature Controller ................................ 12-41
Replacing the Temperature Controller at the Compressor.. 12-41

Chapter 13: Transmission & Encoder

Long/Short Lever................................................................... 13-1

Motor ..................................................................................... 13-1
Encoder........................................................................................... 13-2
Operation............................................................................... 13-2
Maintenance ................................................................................... 13-2
Changing Transmission Oil ................................................... 13-2
Encoder Removal and Replacement..................................... 13-3
Motor Inspection.................................................................... 13-3

Ultima Macro® Page 7/Rev 5

 Chapter 14: Pneumatic System

Air Input System .............................................................................14-2

Filter Regulator with Gauge ...................................................14-2
CMB Regulator with Gauge ...................................................14-2
Dataweigh Regulator with Gauge ..........................................14-2
Lubricator...............................................................................14-2
Shut Off and Dump Valve ......................................................14-2
Air Pressure Switch ...............................................................14-2
Flow Control Valves...............................................................14-2
Air Valve and Manifold Assembly ..........................................14-3
Exhaust Silencer Separator ...................................................14-3
Optional Maintenance Alert and Prevention System (MAPS)14-3
Pneumatic System Maintenance...................................................14-4
Air Filter/Regulator.................................................................14-4
Exhauster/Silencer.................................................................14-4
Lubricator...............................................................................14-4
Oil Delivery Rate....................................................................14-4
Lubricator Bowl ......................................................................14-4

Chapter 15: Troubleshooting

Troubleshooting Guidelines..........................................................15-1
Basic Troubleshooting For Operators..........................................15-2
Packaging Material Feed System..................................................15-3
Print Registration ...........................................................................15-4
Registration Roller Clutch/brake Problems .................................15-5
Seam Seal System..........................................................................15-7
Bag Cutoff .......................................................................................15-7
End Seal System.............................................................................15-8
Error Messages.............................................................................15-10
Display Messages................................................................15-10
Information Messages .........................................................15-11
Controlled Shutdown Error Messages .................................15-12
Immediate Shutdown Error Messages.................................15-13

Page 8/Rev 5 Ultima Macro®

 Chapter 16: Optional Accessories

Bag Support And Eject .................................................................. 16-1

Assembly Adjustment............................................................ 16-1
Eject Air Cylinder Timing ....................................................... 16-2
Ejector Plate Changeover ..................................................... 16-2
Ejector Plate Positioning ....................................................... 16-2
Flat Bottom Bag ............................................................................. 16-2
Adjustments........................................................................... 16-3
Stager/cooler .................................................................................. 16-4
Sequence of Operation ......................................................... 16-5
Speed Adjustment ................................................................. 16-5
Linear Stager .................................................................................. 16-6
Sequence of Operation ......................................................... 16-7
Speed Adjustment ................................................................. 16-7
Stager Plate Gap Adjustment................................................ 16-7
Product Stripper............................................................................. 16-8
Electrical and Pneumatic Speed Adjustment ........................ 16-9
Stripper Proximity Switch Electrical Adjustment.................... 16-9
Stripper Cylinder Pneumatic Speed Adjustment ................. 16-10
Stripper Bar Adjustments .................................................... 16-11
Stripper Bar Gap Adjustment .............................................. 16-12
Stripper Cylinder Pneumatic Speed Adjustment ................. 16-13
Stripper Proximity Switch Adjustment ................................. 16-14
Stripper Linkage Adjustment ............................................... 16-15
Poker ............................................................................................. 16-17
Air Cylinder Speed Adjustment ........................................... 16-17
Film Splicer Instructions ............................................................. 16-18
Accu-Track Automatic Unwind Edge Adjustment .................... 16-21
Operation............................................................................. 16-21
Positioning the Sensor Guide Assembly ............................. 16-23
Sensitivity Adjustment ......................................................... 16-23
Basic Function of the Controller .......................................... 16-23

Ultima Macro® Page 9/Rev 5

 Shaker Jaw Assembly..................................................................16-25
Operation .............................................................................16-26
Shaker Jaw Removal...........................................................16-27
Shaker Jaw Installation........................................................16-28
Shaker Jaws Speed.............................................................16-28
Jaw Cylinder Cushion ..........................................................16-28
Shaker Amplitude Manual Adjustment.................................16-28
Shaker Smoothness Tuning ................................................16-28
Clamp Release Time ...........................................................16-28
Proximity Switch Position.....................................................16-28
Auger Feed System ......................................................................16-29
Setup ...................................................................................16-29
Automatic Adjustment..........................................................16-32
Calibration.................................................................16-32
Auto Operation.....................................................................16-34
Change Setting Value..........................................................16-34
Volumetric Feed System..............................................................16-35
Component Identification .....................................................16-35
Operation Overview .............................................................16-36
Setup ...................................................................................16-36
Dump Sensor ............................................................16-36
Preliminary Dump Sensor Adjustment ......................16-37
Volume Cup Adjustment ...........................................16-38
Trap Door Adjustment...............................................16-38
Coordination Of Drop Timing ....................................16-39
Brush/Scraper Adjustment ........................................16-39
Changing Sets of Cups .............................................16-39
Dump Plate Height Adjustment.................................16-40
Clutch Adjustment (small motor)...............................16-40
Chain Adjustment (small Motor)................................16-40
Belt Adjustment (large motor) ...................................16-40
Gas Flush (Modified Atmosphere Packaging) ...........................16-41
Spinach Agitator...........................................................................16-43
Assembly Components........................................................16-44
Installation............................................................................16-44
Motor Settings......................................................................16-45
Motor Start/Stop........................................................16-45
Motor Speed Adjustment ..........................................16-45

Page 10/Rev 5 Ultima Macro®

 Chapter 17: Feed Systems

Scale Feed System......................................................................... 17-1

Scale/Ultima Timing ....................................................................... 17-2
Auger Feed System........................................................................ 17-3
Auger Operating Procedure .................................................. 17-3
Volumetric Feed System ............................................................... 17-6
Operator Panel ...................................................................... 17-7
Volume Cup Adjustment........................................................ 17-7
Trap Door Dump Adjustment (Timing) .................................. 17-8
Coordination of Drop Timing ................................................. 17-8
Brushes or Scrapers.............................................................. 17-8
Changing Sets of Cups on Five, Six or Nine Cup Volumetric
Feed ...................................................................................... 17-8
How to Set Software for an Adjustable Volumetric Feed
System .................................................................................. 17-9
How to Use the Operation Modes ....................................... 17-11
Dump Sensor Adjustment ................................................... 17-13
Calibration ........................................................................... 17-14
Manual Adjustment................................................... 17-14
Automatic Adjustment (Optional).............................. 17-14
Auto Operation .................................................................... 17-20
Change Setting Value Screen ............................................. 17-20

Ultima Macro® Page 11/Rev 5

Page 12/Rev 5 Ultima Macro®
 1
CHAPTER 1: MACHINE DESCRIPTION
The Hayssen Ultima vertical form, fill, and seal machine forms pack-
aging material into a bag, fills the bag with product, seals, and ejects
the filled bag.
The machine's exclusive packaging material registration rollers and
continuous motion pull belts, form and pull the packaging material to
create packages at high speeds.
A forming tube assembly bonds the outside of the packaging material
to form a tube. During the next cycle, the tube is lowered to the end
seal and product fill position.
The end seal jaws close, sealing the bottom of the tube and the top of
the previously filled bag. At this time, a measured amount of product is
directed into the bag and the jaws separate the two bags.
When the end seal is secure the jaws open, the bag is ejected, and the
cycle is repeated.

GUARDS
Safety guards are installed to protect personnel from injury. To to pro-
vide maximum protection, guards must remain closed at all times
while the machine is running.

Door Handle

Front Guard
Door

Door Interlock

Figure 1: Front Guards

Ultima® Macro 1-1/Rev 5

Product Jam Detector

Figure 2: Side Guards

Safety switches are located on each guard. If a guard opens while the
machine is running, the machine stops and the visual display shows
which door is open.
To restart the machine, close the guard door to close the safety switch,
push the Reset button, then push the Start button.

CAUTION:
When running the machine or working on it, do not bypass or dis-
connect safety switches.

PRODUCT JAM DETECTOR

The Ultima has an automatic product jam detector that opens the jaws
if the jaw closed indicator is not On within the same number of degrees
from the previous cycle.
If there is a product jam, the knife does not actuate.
This system is designed to reduce jaw and die face damage if product
or hardware gets caught in the jaw assembly. It also prolongs the life of
the machine by eliminating undue stress on related components. The
proximity switch is factory set but can be adjusted.

GROUND FAULT CIRCUIT INTERRUPTER (GFCI)

Correct installation and monthly testing of the circuit breaker is impor-
tant for safety. Record each test in the maintenance records for the
machine.

1-2/Rev 5 Ultima®Macro
 1

WARNING:
The GFCI is installed to protect the machine operator. Do not dis-
able it. It protects against overloads, short circuits, and from
potential ground fault conditions.

Current can flow if a person touches the electrically hot 120 VAC lines
while also touching the machine. The GFCI acts as an overload device
that senses ground currents that can be caused by wet wiring in equip-
ment or by persons touching hot lines while standing on the ground.

WARNING:
A GFCI helps reduce the amount of shock but does not eliminate
it. Persons with heart problems or ill health could be seriously
injured. Always be sure all power to the machine is turned OFF
before servicing electrical components.

Ultima® Macro 1-3/Rev 5

Ground Fault Circuit Interrupter (GFCI)

1-4/Rev 5 Ultima®Macro
 2

CHAPTER 2: SAFETY
SAFETY OVERVIEW
Safety depends on everyone who operates, maintains, services, or
works nearby operating equipment. Any person involved with the
operation of this equipment should be familiar with the following dan-
ger, warning, and caution notices.
Personnel should NOT operate this machine until trained on its func-
tion and purpose.

IMPORTANT:
HayssenSandiacre’s liability is limited to operation using the orig-
inal program. Machines are shown without guards for illustration
purposes only.

Safety Signals The following signal words are used to inform about potential hazards
and proper machine usage.

WARNING:
Alerts to a potential hazard that results in serious personal injury or pos-
sible death unless avoided.

CAUTION:
Alerts to a potential hazard that may result in personal injury, or
an unsafe practice that causes damage to the equipment or prop-
erty if not avoided.

IMPORTANT:
Identifies specific information that will assist with machine opera-
tion, prevent damage to the machine, or extend the life of machine
parts.

BASIC DANGER AND WARNING NOTICES

Installation Only trained machinery movers, using appropriate and well-main-
tained equipment, should handle, move, and install the machine. Please
refer to the installation chapter in this manual for complete instruction
and safety information.

Guards Guards are supplied with the machine and must be in place before
operation begins. NEVER bypass or disconnect safety switches.
Doing so could greatly increase the chance for personal injury.

Ultima® Macro 2-1/Rev 5

Basic Danger and Warning Notices

Guards are installed to protect personnel working on or around the

machine. Guards MUST be closed when the machine is operating.

Figure 1: Guards Warning Notice

Side Door Guard Front Door Guard

Figure 2: Machine Guards

Safety switches are located on each guard. If a guard is opened while

the machine is running, the machine stops and the operator interface
indicates which door is open.
Guard design is based on level machine footings that are even with the
work area. Raising the machine or using platforms, staircases, stools,
or ladders near the machine creates hazardous operating conditions.
Guards shield personnel from moving parts. Reaching over, under, or
through a guard, blocking it open, or tampering with a guard interlock
is EXTREMELY hazardous and must NEVER be attempted. Guards
should NEVER be altered from factory setup.
Work with special care when guards are removed for lubrication,
adjustment, and part replacement. All guards should be reinstalled cor-
rectly immediately following maintenance or repair.
Opening a guard DOES NOT disconnect electrical power in the con-
trol cabinet. To disconnect control power, padlock the main disconnect
in the OFF position.

Machine Location • Machine location must provide sound footing, adequate

lighting, and accessibility from all sides.

2-2/Rev 5 Ultima®Macro
 2
• DO NOT install the machine in a combustible environment
or near combustible or explosive material.
• Keep the area around the machine clean and free of obsta-
cles to avoid injuries due to falls.

Burn, Nip, and NEVER touch or repair components while they are hot. If heat compo-
Pinch Points nents must be handled, use insulated gloves and mechanical devices
where practical.

BURN POINTS NIP POINTS PINCH POINTS

KNIFE BELTS ELECTRICAL

Figure 3: Safety Symbols

Be EXTREMELY careful when working near nip points and pinch
points. Keep body parts, hair, neckties, clothing, and tools away from
these hazards to prevent serious injury or death. DO NOT wear rings,
watches, or necklaces near the machine.
All notices, labels, and plates must be in place and legible. Immedi-
ately replace damaged or missing labels and notices. Contact Hayssen-
Sandiacre Parts for replacement notices, labels, and plates.
Electrical

Figure 4: Electrical Warning Notices

Ultima® Macro 2-3/Rev 5

Basic Danger and Warning Notices

A qualified electrician must install and repair electrical equipment and

verify electrical ground. Complete electrical information is provided in
the electrical chapter of this manual.
• ALWAYS padlock the electrical disconnect in the OFF
position before adjusting, cleaning, lubricating, or maintain-
ing the machine.
• DO NOT make revisions or additions to the programmable
controller. This impairs the operation of the machine.
• NEVER use jumper wires to bypass electrical circuits.
Doing so may activate parts of the machine which could cut,
crush, or seriously injure persons in the immediate area.
• Modifications or additions to the electrical system causes
machine malfunction and creates safety hazards for person-
nel.
• The electronic controller on the machine requires an electri-
cally clean environment.
• DO NOT break the seal, bypass, or change settings to the
air pressure switch.
.

IMPORTANT:
Any changes not authorized by HayssenSandiacre may void the
machine warranty. If there are any question or a need for modifi-
cation, contact HayssenSandiacre.

Replacement Parts Parts should be replaced by maintenance personnel familiar with the
machine. Please contact HayssenSandiacre for assistance.
• High voltage electrical shocks cause serious injury or death
if repairs are made with power applied.
• DO NOT replace parts while the machine is in operation.
• DO NOT operate the machine while parts are removed.
• Removing parts with power applied stalls processors and
causes problems in other areas of operation due to stray
voltage.

IMPORTANT:
NEVER remove or replace any part with power applied

Lubrication ALWAYS padlock the electrical disconnect in the OFF position before
lubricating the machine. Specific lubrication instructions are located in
the Preventive Maintenance chapter of this manual.
• Lubricate manual fittings BEFORE operation.
• Verify lubrication system is operational.

2-4/Rev 5 Ultima®Macro
 2

Ultima® Macro 2-5/Rev 5

2-6/Rev 5 Ultima®Macro
 3

CHAPTER 3: INSTALLATION
MACHINE DELIVERY
When the machine arrives, inspect the entire shipment for damage. If
there is damage, photograph for verification and immediately file a
claim with the carrier.
• Provide competent machinery movers when the machine
arrives.
• Note the gross weight of the machine shown on machine
order acknowledgement and on the bill of lading.
• Study the mass and weight distribution of the machine.
• Refer to the illustration showing recommended lifting
points.

PREPARE SITE AND UTILITIES FOR MACHINE

Select the machine site carefully. The structure must support the
machine and production activities. The area should be well lit for oper-
ator efficiency and accessible from all sides for service, maintenance
and operation.

WARNING:
DO NOT install the machine in a combustible environment or
near explosives.

INSTALLING AIR DEVICES

• Supply clean dry air with a minimum of 65 PSI
• Use pipe that is at least the size of the inlet (minimum 1/2").
A smaller pipe can be used only if a surge tank is in place.
• The following chart may be used as a guide for installing air
devices.

IMPORTANT:
The exact consumption may vary slightly. Consumption depends
on model, speed, and auxiliary equipment. Call HayssenSandi-
acre for exact specifications.

Ultima® Macro 3-1/Rev 5

Installing Electrical Devices

Model Bags/Minute scfm

Single Tube w/ Resistance Seal 10 2.5 scfm

Single Tube w/ Quali-Seal 10 3.5
Twin Tube w/ Combination Seal 10/side 7.0
Twin Tube w/ Resistance Seal 20 (10/side) 5.0
Twin Tube w/ Quali-Seal 20 (10/side) 7.0
Twin Tube w/ Combination Seal 20 (10/side) 7.0

INSTALLING ELECTRICAL DEVICES

A fused disconnect must be provided for the machine. The micropro-
cessor in the machine requires an isolated, clean voltage power source.
Follow voltage requirements as specified in the Order Acknowledge-
ment.

WARNING:
External power MUST be wired through the bottom rear side of
the electrical enclosure. This eliminates the possibility of metal
chips coming in contact with the boards or components, possibly
causing sparks, shock or machine damage.

The proper location for wiring external power without a voltage trans-
former has been designated with the customer power decal. If a voltage
transformer is required, the external power should:
• Enter the transformer on the primary side terminals inside
the transformer.
• The secondary side terminals go to the location designated
with the customer power decal.
Machines are prewired to the Order Acknowledgement. Check the
name plate on the electrical cabinet for the exact power requirements.
A labeled terminal is provided in the electrical enclosure for this con-
nection. If further assistance is needed, contact the HayssenSandiacre
Service Department.

WARNING:
Ground the machine using an earth permanent device. Failure to
ground the machine could result in electric shock and damage to
the machine.

3-2/Rev 5 Ultima®Macro
 3
Ground Fault Current can flow through a person if electrically hot lines are touched
Circuit Interrupter while an individual is also touching the machine. The GFCI acts as an
(GFCI) overload device that senses ground currents which can be caused by
wet wiring in equipment or contact with hot lines.
Proper installation and monthly circuit breaker testing are important
for the protection of personnel and proper maintenance. Record each
circuit breaker test in the machine maintenance records.
The GFCI is intended to protect all personnel who are associated with
machine operation.

WARNING:
• DO NOT disable the GFCI. It protects against over-
loads, short circuits, and potential ground fault condi-
tions that cause serious injury or death.
• The GFCI DOES NOT eliminate shock but only
reduces the amount of shock a victim feels. Persons
with heart problems or poor health could be seriously
injured.
• Machine power must be OFF before service or mainte-
nance.

Power Source for External devices need a power source separate from the bagger. Some
External Devices external devices (metal detector, coupon inserter, etc.) can cause ran-
dom, strange behavior in the bagger control system when they are
powered off the bagger’s power supply.

TO LIFT MACHINE FROM SKID

The machine should remain on the platform or skid until it has been
moved to the installation site.

WARNING:
When lifting or moving the machine adhere to the following
guidelines to prevent harm to personnel or machinery:

• Use the recommended lift points. Damage resulting from

incorrect lifting may require the machine be returned to the
manufacturer for repair at the customer’s expense.
• Handling, moving, and installation should be done only by
trained machinery movers using appropriate equipment.
• Use equipment with adequate capacity.
• Prevent anyone from walking, crawling, or reaching under
the machine while it is solely supported by a forklift or
other device.

Ultima® Macro 3-3/Rev 5

To Lift Machine from Skid

• Keep hands and feet clear of the machine, platform, or skid

and the wheels of the lifting equipment.
• Watch for overhead utility lines, low clearances, and other
obstructions.
• Remain alert and careful.
• Before lifting the machine, remove all unsecure items,
blocks, and fasteners from the skid.

Forks
Fork Lift

Front Straps

Rear Straps
1
2

Figure 1: Lift Points

IMPORTANT:
When lifting the machine, carefully secure slings to the four top
outside corners of the machine frame.

To lift the machine, a fork lift or other suitable lifting device and four
hoist straps are required.
1. Loop a hoist strap under each corner of the frame (1 and
2).
2. Position the fork lift at the front of the machine with forks
raised.
3. Slide the loose end of each hoist strap over the adjacent
fork, front straps first.
3-4/Rev 5 Ultima®Macro
 3
4. Slowly lift the machine.
5. Remove platform or skid.
6. Install leveling feet.
7. Lower and position machine onto floor pads.
8. Remove hoist straps.
9. Adjust feet to level the machine.

PRODUCT FEED INTERFACE INSTALLATION AND

OPERATION
Feed System Use the interface schematic provided to connect the bagger to the feed
Electrical system. The schematic is included in the panel set of drawing shipped
with the machine and in the parts manual.

IMPORTANT:
Follow electrical requirements outlined in the feed system
instruction manual. The feed system should have its own pro-
tected line supply. In most cases, an earth ground is required. If it
is required, the feed system earth ground should be terminated on
the same grounding bus as the machine.

Timing The control unit contains a time delay signal with a maximum delay
equal to the cycle time. It cannot delay a dump signal into the next
cycle. This delay is used to approximate the time the product takes to
fall from the feed system to the jaw area.
Frequently time delay may not be sufficient to account for the total
drop time. Additional transfer time delays must be provided by the
feed system. Provide a maximum of 1000 milliseconds delay between
the actual dump signal and the signal given to the machine.

Product Spacing There must be sufficient space between dumps to allow the jaws to
close without catching the product. The amount of space depends on
bag width, product volume, speed, funnel slope and product drop char-
acteristics. One or more of these might require modification if product
stringout does not allow enough space.
Inadequate space between dumps may:
• cause product to be caught in the end seal resulting in waste
and cleanup problems.
• cause product intended for one bag to transfer to another
with corresponding under/over weight results.

Ultima® Macro 3-5/Rev 5

Product Feed Interface Installation and Operation

Mechanical The usual mechanical interface is a transition chute between the end of
Interface the feed system discharge and the entrance to the forming tube assem-
bly funnel.

1. Poker 2. Product Shield

A. Width of Poker B. Height of C. Diameter of
Access Hole Poker Access Transition Chute
Hole

Figure 2: Transition Chute

Double Dumping Double dumping to achieve larger weights is not recommended in most
cases. However, machines with a volumetric feed system can have dou-
ble dumps. The feed system should give a signal on each dump.

3-6/Rev 5 Ultima®Macro
 3
MEZZANINE INSTALLATION

WARNING:
To prevent injury to personnel and equipment damage, use
proper lifting, and equipment moving techniques. Restrict per-
sonnel from walking, crawling, or reaching under equipment
while it is supported.

Platform Railing
Deck Assembly

Front & Rear

Railing
Platform

Left Hand
Railing Mounting Pads
Tie Bars
Ladder

Right Hand
Railing

Tie Bars

Support
Support Legs
Legs
Stairs

Figure 3: Typical Scale Mezzanine Components

1. Measure the length of the tie bar assemblies and set the
legs upright this distance apart.
2. Attach the tie bars to the legs.
3. Secure all mounting bolts and attach the mezzanine to the
floor to eliminate rocking.
4. Ensure the mezzanine is level by placing shims under as
needed.
5. Attach the hoist hooks to the eye bolts on the scale and lift
it with the hoist. Use a sling, as needed, to distribute the
weight. Lift the scale and place it onto the mezzanine on
mounting pads.
6. Level the scale on the mezzanine by shimming between
the pads and scale frame. Level to 1/32" (0.8mm) per foot.
Ultima® Macro 3-7/Rev 5
 7. If the scale does not rest on all four pads, shim the corners
to support the scale before tightening the mounting bolts.
8. If the mezzanine has a stairway and platform instead of a
ladder:
a. Install the railing which is adjacent to the stairway.
b. Bolt the platform in place.
c. Bolt the platform rail in place.
d. Lift the stairway into place and bolt onto the platform.
9. Place the deck assembly in position.Secure railings in
position.
10. Secure the ladder in the appropriate place.

IMPORTANT:
The ladder, or stairway and platform may be moved to the oppo-
site side of the mezzanine by reversing railings. This places the
ladder or stairs at the right hand front.

3-8/Rev 5 Ultima®Macro
 4
CHAPTER 4: PREVENTATIVE MAINTENANCE
HayssenSandiacre packaging machines are designed for minimum
maintenance. There are a few areas that must be serviced regularly.

WARNING:
Turn all power to the machine OFF before doing any lubrication,
cleaning, adjustments or maintenance.

LUBRICATION
Use HayssenSandiacre Lubri-Can™ food grade lubricants to properly
maintain the machine. A full line of H1 approved oil and grease is
available.

Figure 1: HayssenSandiacre Lubri-Can Food Lubricants

Type of Lubricant Size

1 gallon

Pneumatic System 5 gallon

55 gallon

Volumetric and Auger Gear Oil 1 gallon

Grease 14.5 ounces

Ultima® Macro 4-1/Rev 5

Lubrication

Lubrication Chart

Item Area of Machine Lubricant Change Clean Frequency

1. Clevis Pin On End Seal
grease every 8 hours
Jaw

2. Trunion Mounts grease every 160 hours

3. Universal Joints On Drive

grease every 6 months
Shafts Of Pull Belts

4. Pneumatic sys- every 8 hours or as

Air Line Lubricator
tem oil needed

5. Air Filter none X drain as needed

6. Oil Recovery Filter X drain as needed

7. Spur Gears On End Of

multi-purpose
Registration Roller every 40 hours
grease
Assembly

8. Stub Shaft On Unwind multi-purpose

every 40 hours
Motor grease

9. Support Shafts Of Unwind

light weight oil every 40 hours
Stand

10. Registration Eye

light weight oil every 40 hours
Threaded Shaft

11. Jaw Guide Shafts none X every 40 hours

12. Pull Belt Support Shafts light weight oil X every 40 hours

13. Pull Belts X as needed

14. Jaw Motor Drive Belts

(applies to SU only) X yearly
(N/A to Quad Seal)

15. every 5 million

Jaw Cylinders X
cycles

16. Platen Actuator Shafts

(front and rear) light oil every 40 hours
Quad Seal Only

17. Pull Belt Auxiliary Drive

Belt light oil every 40 hours
(Quad Seal Only)

18. every 3 months or

Platen Air Cylinder Shaft light oil
as required

19. HayssenSandi-
acre Lubri-Can every 80 - 100
Bearings w/grease fittings
Food Grade hours
grease

4-2/Rev 5 Ultima®Macro
 4
GENERAL MAINTENANCE
Rollers Periodically inspect all rollers in the feed system. Remove any rollers
that do not turn freely and replace the bearings.
Bearing lubrication is not recommended as they operate under very
light loads. Lubricant attracts dust and dirt from the atmosphere and
accelerates contamination.

Belts Check the registration roller drive belt for excessive wear and slack
every 160 hours of operation. Inspect screws, bolts and setscrews.
Retighten where necessary.

APPLYING LOCTITE®

IMPORTANT:
• HayssenSandiacre uses only USDA approved LocTite®.
• When using LocTite®, DO NOT use lock washers.
• DO NOT use LocTite® on any adjustment screws.

The recommended amount of LocTite® to use is usually 1/3 of the

engaged area.
Primers are not required with threadlocker adhesives, but do speed the
cure and act as a cleaner.
Standard LocTite® is not designed for temperatures higher than 300°F
(149°C). In areas above 300°F, use LocTite® Product 620, which is
specifically designed for temperatures between 300°F and 450°F
(232°C).

Ultima® Macro 4-3/Rev 5

Rust Colored Stain On Stainless Steel - Causes and Solutions

RUST COLORED STAIN ON STAINLESS STEEL -

CAUSES AND SOLUTIONS

CAUTION:
This procedure is for WASHDOWN RATED MACHINES
ONLY!

Figure 2: Examples of rust color stain

Causes Solutions
1.Using a cleaning solution that is alkaline 1.Use neutral cleaning solution (pH 6-8).
(higher than pH 11). a.If the customer must use an alkaline solu-
2.The parts are not dried completely after they tion, rinse the detergent completely off.
are cleaned.
IMPORTANT:
3.Parts are not cleaned after the operation.
• Thorough rinsing is required when
4.Bacteria that causes the rust color are included using any kind of detergent.
in the water.
2.Dry the water completely off after the wash
down.
3.Examine the water to determine whether any
bacteria is included.
a.Eliminate any bacteria found in the water.

4-4/Rev 5 Ultima®Macro
 4
GUIDELINES FOR WASHDOWN ENVIRONMENTS
These recommendations should be followed to help prevent problems
from occurring in environments where machinery is exposed to water
during clean-up.

CAUTION:
• DO NOT use this procedure on painted machines; it will cause
rust.
• Use this procedure on STAINLESS STEEL MACHINES
ONLY!

Bagger
IMPORTANT:
• The preferred cleaning method is to wipe the unit down or to
blow the unit off with compressed air.
• If components such as clutches, brakes, or rollers get “wet”
some erratic operations, such as bag length variation due to slip,
can be expected until the components dry.

CAUTION:
• To avoid injury, ALL POWER TO THE INFEED MUST BE
OFF before completing this procedure.
• DO NOT apply the water stream directly on electrical compo-
nents.
• Water pressure used to rinse the machine should be regulated
to 5 psi maximum.
• A nozzle should NOT be used to increase force applied. Use
open ended hose only.
• Use neutral cleaning solution (pH 6-8).

1. Turn all power to the Infeed System Off.

Use appropriate lockout/tagout procedures.
2. Insure all openings to the electrical panels are sealed.
3. Cover all electrical enclosures, user interface and all
motors with plastic or suitable material prior to applying
any water to the machine.
4. Apply cleaning solution.
5. Use a soft brush or a plastic scraper to remove heavy
deposits.
6. Rinse with clean water.
7. Remove excess water.
8. Allow machine to dry.
9. Remove plastic covers from machine components.
10. Restore power to the machine.
Ultima® Macro 4-5/Rev 5
Guidelines For Washdown Environments

Scale
IMPORTANT:
• Refer to your scale operation manual for the manufac-
turers recommended cleaning procedure.
• It is strongly recommended that all buckets and vibra-
tory feed pans be removed prior to cleaning the main
scale body. The removed components should be
cleaned and/or sterilized while removed.

CAUTION:
• These units are NOT made to be pressure washed. Exceeding
the water pressure specified can cause seals to leak which may
result in damage to electrical components.
• Water pressure used to clean the machine should be
regulated to 5 psi maximum.
• A nozzle should NOT be used to increase force applied. Use
open ended hose only.
• Use neutral cleaning solution (pH 6-8).

1. Insure all openings to the electrical panels are sealed.

2. Remove weigh buckets to prevent possible load cell dam-
age.
3. Cover the MDT, SCC or RCU.

4-6/Rev 5 Ultima®Macro
 5
CHAPTER 5: OPERATOR INTERFACE
MACRO-LOGIC SYSTEM
Macro-Logic is a control system residing in the bagger control cabinet.
It is designed to be used with the Macro-Logic display terminal to
completely control the operation of a bagger.
OPERATOR PANEL AND CONTROLS
The Macro-Logic display provides all operator controls for both the
bagger and scale in the form of a flat panel touch screen data entry sys-
tem. There are three other operator functions on the front face of the
Macro-Logic display:
• master stop
• reset
• keylock switch
Master Stop When the red master stop pushbutton is activated, the entire system
shuts down. The primary 24 VDC supply voltage to all bagger outputs
is disabled. The power sourcing of all 24 VDC outputs is disconnected.
The 120 VAC to the main motor drive turns Off. Also, the main pneu-
matic valve removes air to the system to assure no pneumatic devices
function.

IMPORTANT:
The effect of pressing the master stop pushbutton is the same as
opening a door, losing air pressure, or any other function associ-
ated with the master relay.

WARNING:
Temperature controls remain active when the master relay drops.
Use caution when servicing the machine. The sealing surfaces
may remain electrically and thermally hot.

Reset The green reset pushbutton is a common reset for all elements of the
system. When the safety interlocks are satisfied, the master relay for
that particular element energizes.
Any conditions not met for the correct operation of any element are on
the display. This prompts the operator to take the appropriate action to
enable the system to be operated.
In terms of bagger functions, the reset performs the following:
• energizes the main drive motor
• turns On the main air supply to the bagger
• enables the 24 VDC power supply to all outputs
Ultima® Macro 5-1/Rev 5
Screen Descriptions

Keylock Switch The key positions are designated in the upper right corner of all menu
screens.

Position Function
0 Nonfunctional

1 Key insertion/removal opera-

tors access

2 Setup and maintenance

3 Scale calibration and installa-

tion

4 System installation

All remaining functions are controlled through the touchscreens as

described in the following sections.

Power Up
Power Up From Shutdown Method
Main Power Switch E-Stop
1.Turn the switch to the ON 1.Press the green RESET but-
position. ton.

2.Restore air to the machine.

Main Power
Switch

SCREEN DESCRIPTIONS
The Macro-Logic system is menu-driven and allows the operator to
select one of approximately 60 screens. Screens containing a Ret
(return) pad generally revert back to the Main Menu if all requirements
for transfer to the next screen are met. A stop mode is necessary for
transfer from any screen back to the Main Menu.
There are three types of menu screens. Each screen is dependent on the
key position at the time the screen is called up. The first screen requires
no key and is designed as an operator screen.
5-2/Rev 5 Ultima®Macro
 5
All menu screens display the date, time, and the key position of the
selector switch in the upper right corner of the touchscreen.
At the bottom of the screen are system status comments to assist with
starting the operation. Information regarding the required steps to get
to a locked configuration also display at the bottom of the screen.
If the software installed is multi-language, the display can be changed
by touching the area where the E appears (center of the bottom line).
English (E), Italian (I), French (F), German (G), and Spanish (S) are
available on the Macro-Logic system.
The text can be changed any time the menu is displayed. To access a
screen from the Main Menu, touch the function pad.

Ultima® Macro 5-3/Rev 5

Screen Descriptions

KEY POSITION 1 MENU

This screen allows access to other screens on the system. The areas shown on the screen are
those that are available when the key is in position 1.

Program Selection Display the Program Selection screen.

Auto Operation Display the Auto Operation screen.

Manual Operation Display the Manual Operation screen.

Clean Out Purges product from the feed system through means of a modified bag-
ger cycle. The bagger pulls film and makes a back seal to form a tube
that extends below the jaws. Once completed, the bagger stops by turn-
ing the master relay and motor drive Off. Product is dumped into the
bag until there are several no weight dumps.

5-4/Rev 5 Ultima®Macro
 5

KEY POSITION 2 MENU

This screen allows access to other screens on the system. The key must be in position 2 for the
added access areas to be visible.

Program Setup Displays the Product Designator screen.

Date/Time & Print Displays the Date/Time & Print setup screen.

Monitor Displays the Bagmaker Monitor screen.

Troubleshooting Displays the Troubleshooting screens.

Auto Operation Set the machine to automatic operation mode.

Manual Operation Set the machine to manual operation mode.

Clean Out Purges product from the feed system through means of a modified bag-
ger cycle. The bagger pulls film and makes a back seal to form a tube
that extends below the jaws. Once completed, the bagger stops by turn-
ing the master relay and motor drive Off. Product is dumped into the
bag until there are several no weight dumps.

Program Selection Displays the Program Selection screen.

System Displays the System Installation screen.

Installation

Ultima® Macro 5-5/Rev 5

Screen Descriptions

PROGRAM SELECTION
This screen allows the operator to select programs and view physical parameters of the eye loca-
tion, transmission mode, and the target weight.

Program Number Displays the storage location of the program. This value is determined
when the program is saved to the EEPROM memory.

Eye Displays the location of the eye, either front (F) or rear (R). The loca-
tion of the eye is determined when the program is set up and is entered
through the Counter and Temperature screen.

L/S Bag Displays the position of the transmission for either short or long bag.
Bags less than 12 in. are considered short (S) bags. Bags longer than 12
in. are considered long (L) bags. This is determined at the same time as
the eye location.

Target Weight The volumetric or auger target weight. This value is entered through
the calibration screens.

Barcode Load programs using a bar code reader wand if the option is installed.

Next Advances the screen to the next 15 program entries.

5-6/Rev 5 Ultima®Macro
 5

AUTO OPERATION
This is a multi-function screen. It is designed to display run time data while the bagger is pro-
ducing filled bags. In the following screens, there are several items that are common displays.

Program Number Displays the currently loaded program.

Product name Describes the currently loaded program.

Target Weight The required weight expressed in grams (g). This may not appear in
some software versions.

Prod. Data Displays available production data. Speed are bag count are displayed.

Bags/Min Displays the bagger speed. This is computed and updated each
machine cycle. The speed is the time from the start of the bagmaking
cycle until the completion of that cycle. The filled bag rate is also com-
puted and displayed each cycle and is the time from one dump until the
next dump.

IMPORTANT:
When the system is running correctly, the empty bag speed
should be about 10% greater than the filled bags speed

Empty Displays the number of bagmaking cycles made with the feed system
Off.

Filled Displays the number of cycles made in filled bags mode. Filled bags
are made without any out of registration or jam jaw conditions.

Ultima® Macro 5-7/Rev 5

Screen Descriptions

Total Cycles Displays the total of all cycles made, regardless of mode or error condi-
tions.

IMPORTANT:
The counts are cleared when a new program is loaded or the key
is turned to position #2. The counts also cleared manually using
the Date/Time & Print screen.

Cycles Cleared Displays the last time the count data was cleared.

Error Messages Error messages appear to the right of the Cycles Cleared field. There
are three types of error messages:

Message Example
Information messages - do not affect opera- Waiting for Product
tion

Shutdown errors - cause controlled system Low Film, Out of Registration, Terminal
shutdowns Count

Safety errors - cause immediate system Left Door Open, Low Air Pressure, Emer-
shutdowns gency Stop

Jaw Front Displays the set and actual temperature of the front jaw surface. The
temperature is selectable in either °F or °C. The left figure represents
the set temperature and the right is the actual probe reading.

Jaw Rear Displays the set and actual temperature of the rear jaw surface. The
temperature is selectable in either °F or °C. The left figure represents
the set temperature and the right is the actual probe reading.

Platen Displays the set and actual temperature of the platen (back seal bar).

Reg Target The value that represents the optimum position of the eyespot during
the film pull. This value is equal to the registration roller TO value
minus (placement + window/2). Window/2 = 5 for a 10° window or 10
for a 20° window. The number to the right of the registration target
value is the actual machine degree when the eyespot is detected.

Jaw Closed The point in degrees at which the jaws are actually closed. The value
determines the repeatability of the jaw closure. It is also a reference for
the dwell time of the end seal operation.

5-8/Rev 5 Ultima®Macro
 5
Start/Stop Start or stop command for automatic bagmaking cycle mode. This
touchpad toggles between start and stop.

IMPORTANT:
Stopping the machine using the Start/Stop touchpad causes a
controlled system shutdown. Several bags may be made before
the bagger actually stops. This is necessary to keep the system
from jamming with product that has already been dumped into
the bagger. During this time the display reads Running Extra
Cycle.

Prog. Set Displays the Change Setting Value screen to provide access to the
parameters that can be modified while the bagger is operating. This
screen is accessible without a key.

Ultima Setup Displays the Machine Timed Functions 1 screen. The key must be in
position 2 or 3. This screen allows on-the-fly timing adjustments.

Ultima® Macro 5-9/Rev 5

Screen Descriptions

CHANGE SETTING VALUE

This screen allows minimal changes to the program during operation. No key is required.

Film Setup Pulls the film at the rate defined by the program. When an eyespot is
detected, the placement value is loaded to the counter and the down-
count begins. When the counter reaches zero (0), the pull is stopped
and the message Bag in Position displays.
If no eyespot is detected within a 350° pull, the pull stops and the mes-
sage "Eyespot Not Detected" appears.

Program Number Displays the program number currently being run.

Product Name Displays the type of product being packaged with the program.

Jaw Front Change the temperature of the front jaw.

Temperature

Jaw Rear Change the temperature of the rear jaw.

Temperature

Platen Change the temperature of the platen (back seal bar).

Temperature

Placement Degree Change the placement value to allow for variation in bag length from
roll to roll and from the beginning to the end of a single roll. Placement
is rolled in 0.5° increments.

5-10/Rev 5 Ultima®Macro
 5
Start/Stop Start or stop command for automatic bagmaking cycle mode. This
touchpad toggles between start and stop.

IMPORTANT:
Stopping the machine using the Start/Stop touchpad causes a
controlled system shutdown. Several bags may be made before
the bagger actually stops. This is necessary to keep the system
from jamming with product that has already been dumped into
the bagger. During this time the display reads Running Extra
Cycle.

Inc Increase the value of the selected bagger parameter.

Dec Decrease the value of the selected bagger parameter.

Enter Set the changed bagger parameter as the new value.

Ret Return the display to the Main Menu screen.

Ultima® Macro 5-11/Rev 5

Screen Descriptions

MANUAL OPERATION
This screen allows the bagger to be operated in empty bags mode. It provides specific functions
to check jaw alignment or to continuously pull film to check tracking or assist in film threading.

Empty Bags Set the machine to empty bags mode. The touchpad illuminates when
empty bags mode is selected.

Film Type Set the machine to use either registered or plain film. The touchpad
label toggles to display the film mode selected.
When set to plain film mode, the program operates in plain film mode
regardless of the registration status selected in the original program.
This allows the bag length to be checked without the need to change
the registration mode through the setup program.

Cycle Type Set the machine to run in either single or continuous cycle mode. The
touchpad label toggles to display the cycle mode selected.

Open/Close Jaws Open or close the jaws manually to check alignment. When the jaws
are open, the touchpad label reads Close Jaws. When the jaws are
closed, the touchpad label reads Open Jaws.

Continuous Tube Allows the film to be pulled at a slow rate to check film tracking and
assist in threading a new roll of film. The motor speed drops to about
20 bpm and the pull belts and registration rollers start running. This
process takes about three to five seconds. Film is pulled as long as the
Start pad is touched. When the pad is no longer touched, the pull stops
and the motor speed returns to the value set in the program.

5-12/Rev 5 Ultima®Macro
 5
Film Setup Pulls the film at the rate defined by the program. When an eyespot is
detected, the placement value is loaded to the counter and the down-
count begins. When the counter reaches zero (0), the pull is stopped
and the message Bag in Position displays.
If no eyespot is detected within a 350° pull, the pull stops and the mes-
sage "Eyespot Not Detected" appears.

Ret Return to the Main Menu when the Start/Stop touchpad is in normal
display.

Ultima Setup Displays the Machine timed functions 1 screen.

Ultima® Macro 5-13/Rev 5

Screen Descriptions

PRODUCT DESIGNATOR
Use this screen to select a program and select the destination for a modified program. This
screen is also used to enter a product name into the program.

Product Name Enter the name of the product to be run in the program. The product
name can be made of up to 20 characters that are entered using the key-
board on the touchscreen.

Bar Code Displays the bar code, if loaded, for the program.

Save Stores the data generated for the particular program that is being modi-
fied.

Ultima Setup Displays the Machine Timed Functions 1 screen.

Clear Clears an existing name and bar code before new data is entered.

Ret Return to the Main Menu screen.

5-14/Rev 5 Ultima®Macro
 5

MACHINE TIMED FUNCTIONS 1

This screen is used to set the FROM and TO values for machine components.

Save Stores the data generated for the particular program that is being modi-
fied.

Next Display the Machine Timed Functions 2 screen.

Auto Program Display the Auto Program screen.

Ret Return to the Main Menu screen.

Ultima® Macro 5-15/Rev 5

Screen Descriptions

MACHINE TIMED FUNCTIONS 2

This screen is used to set the FROM and TO values for all optional functions selected.

Save Stores the data generated for the particular program that is being modi-
fied.

Next Access the Real Timed Functions screen.

Ret Return to the Main Menu screen.

5-16/Rev 5 Ultima®Macro
 5

REAL TIME FUNCTIONS

This screen is used to set the start and stop parameters for machine functions that are based on
real-time (ms).

Save Stores the data generated for the particular program that is being modi-
fied.

Next Access the Counter and Temperature screen.

Ret Return to the Main Menu screen.

Ultima® Macro 5-17/Rev 5

Screen Descriptions

COUNTER AND TEMPERATURE

This screen contains the temperature adjustments for all zones and provides data entry for spe-
cialized functions.

Save Stores the data generated for the particular program that is being modi-
fied.

Next Access the Machine Timed Functions 1 screen.

Ret Return to the Main Menu screen.

5-18/Rev 5 Ultima®Macro
 5

DATE/TIME & PRINT

This screen is designed to set the clock and calendar for the system and specify the printer
options and commands.

Date Set the date for the system.

Time Set the time for the system.

Prog. List If an optional printer is installed, this touchpad prints the parameters
listed a program that has been loaded from the EEPROM.

Page Feed If an optional printer is installed, the paper pulls as long as the pad is
touched.

Clear Bag Counts Manually sets the bag counters to 0000.

IMPORTANT:
Loading a new program also clears the bag counts.

Ret Return to the Main Menu screen.

Ultima® Macro 5-19/Rev 5

Screen Descriptions

BAGMAKER MONITOR
This screen provides maintenance personnel with data concerning all system operating voltages.
This screen is intended as a tool that allows all voltages to be checked without opening the elec-
trical cabinet or using a meter.

5-20/Rev 5 Ultima®Macro
 5

ULTIMA AUTO PROGRAM

This screen is used for automatic setup.

Machine Speed Set the machine speed in bpm. Set the value 5 to 10% faster than the
required output rate.

Bag Length Set the bag length in millimeters. If the film is registered, the bag
length is the distance between the eyespots without any overpull.

Long or Short Bag Set the transmission position to either long or short mode.

Load Loads the values set on the screen.

Ultima® Macro 5-21/Rev 5

Screen Descriptions

TROUBLESHOOTING MAIN SCREEN

The troubleshooting menus are accessible from the Main Menu screen when the key is in posi-
tion 2 or 3.

5-22/Rev 5 Ultima®Macro
 5

MASTER RELAY TROUBLESHOOTING

These errors are concerned with failures of the master relay circuitry. This type of error usually
results in a total machine shutdown, signified by the main drive stopping.

Ultima® Macro 5-23/Rev 5

Screen Descriptions

MASTER RELAY TROUBLESHOOTING

5-24/Rev 5 Ultima®Macro
 5

OUT OF REGISTRATION TROUBLESHOOTING

Registration errors are those that cause a controlled shutdown when an attempt is made to run
registered film in filled bags mode.

Ultima® Macro 5-25/Rev 5

Screen Descriptions

SYSTEM ERROR TROUBLESHOOTING

These errors occur as a result of a hardware problem in the system components, or as a result of
incorrect setup parameters. These errors are the most difficult to diagnose, and as a result, consti-
tute the bulk of the troubleshooting information.

5-26/Rev 5 Ultima®Macro
 5

SYSTEM ERROR TROUBLESHOOTING

Ultima® Macro 5-27/Rev 5

Screen Descriptions

SYSTEM ERROR TROUBLESHOOTING

5-28/Rev 5 Ultima®Macro
 5

SYSTEM ERROR TROUBLESHOOTING

Ultima® Macro 5-29/Rev 5

Screen Descriptions

TEMPERATURE CONTROL TROUBLESHOOTING

Temperature control errors are generated by heater and probe failures, or may simply be mes-
sages that occur during warm-up. These prevent the bagger from cycling because the tempera-
tures are not up to the proportioning band.

5-30/Rev 5 Ultima®Macro
 5

MECHANICAL CHECK TROUBLESHOOTING

These errors are classified as "none of the above" type problems. Error messages are not neces-
sarily issued by the processor for this type of failure, since there is no electrical problem as far as
outputs are concerned.

Ultima® Macro 5-31/Rev 5

Screen Descriptions

5-32/Rev 5 Ultima®Macro
 6
CHAPTER 6: RECIPE SETUP - MACRO-LOGIC
MACRO-LOGIC SYSTEM
Macro-Logic is a control system residing in the bagger control cabinet.
It is designed to be used with the Macro-Logic display terminal to
completely control the operation of a bagger system.
The system is an integrated packaging line control system that requires
no external hard wired cables or signals to send information from one
system to another.
All interface signals are carried through fiber optic cables in integrated
systems. Hard wire interfaces are also available.
The protocol, or language the system uses to communicate) is under-
stood by all elements. Timing relationships are established by timing
of the protocol signals.

TIMING
The timing diagram illustrates the signals and their relationship
between the feed system and the bagger. The feed system controls the
bagmaking cycle. The timing shown in this diagram is relative to prod-
uct type, drop times, quantity of product, empty bag speed, filled bag
rate, and other parameters. The individual times selected need to be
adjusted according to system requirements.
The dump signal activates three delays in the system:
• Poker Delay - allows the product to pass the poker position
before the poker begins to go into the tube; the poker con-
tinues until the end of the timing cycle, as determined by the
setup
• Auxiliary Timer #1 - operates exactly like the poker and
can signal action a fixed time after receiving a dump from
the feed system
• Start/Delay - the fall time of the product from its position at
the end of the transfer delay to the stager; when the
start/delay is finished, the bagger begins a cycle
IMPORTANT:
The bagger must be in a cycle stopped position when the
start/delay times out. If it is not, the machine shuts down.

Ultima® Macro 6-1/Rev 5

Load a Recipe

LOAD A RECIPE
1. From the Main Menu screen, touch Program Selection
The Program Selection screen displays
1. Use the Next to scroll through the recipes until one
appears that is close to the required machine settings
2. Move the cursor with the two position keys or the Up and
Down pads in the bottom row until it is over the correct
recipe
3. Touch Enter
The recipe name and number appears on the top of the screen.
4. Touch Ret to return to the Main Menu to begin operation

Bar Code Reader If the bar code reader option is installed, load recipes with the bar code
Wand reader wand.
To use this function:
1. From the Program Selection screen, touch Barcode
The message Please Read Barcode flashes on the screen.
2. Run the wand over the bar code
3. If the barcode is valid
a. the recipe number and description appear at the top of
the screen
The Barcode pad returns to normal video
b. Touch Ret to return to the Main Menu to select the
operation mode
4. If the barcode is not valid
a. the message Can’t Find This Barcode appears
b. touch Enter to exit the mode

MODIFYING EXISTING BARCODES

Modification of an existing barcode may be necessary if a product is
replaced by another or if a different barcode is used to identify the
package.
To manually load the recipe number or to load the existing recipe by
using the old barcode, use the following procedure:
1. Load the recipe in the normal manner using the Program
Selection screen
2. With the key in position 2 or 3, select Program Setup
The Product Designator screen displays

6-2/Rev 5 Ultima®Macro
 6
3. To load a recipe manually
a. touch Source
b. key the recipe number on the keyboard
c. touch Ent

CREATE OR EDIT A RECIPE

General Complete this procedure after Load A Recipe is completed.
Information
CHANGING A PARAMETER VALUE
1. Touch the numeric value for the function
A blinking cursor appears
2. Enter the value by touching the numbers on the line at the
bottom of the screen
3. Touch Ent to save the entry
IMPORTANT:
Valid entries on all machine timed screens are from 000 to 359.
Leading zeros are not necessary. Invalid entries are ignored and
are indicated by a blinking cursor after touching Ent.

Degree and Degree values range from 0 to 359.

Millisecond Range
Millisecond values range from 0 to 9999.

IMPORTANT:
These instructions include information/typical values for
optional equipment that is not necessarily on every machine.
Functions that are being used must be enabled or turned On. If a
function is not being used, disable or turn the function Off.

Edit Functions on 1. From the Main Menu screen, touch Manual and edit
the Manual applicable parameters.
Operation Screen The Manual Operation screen displays
Empty Bags Mode
Set the machine to empty bags mode by touching the pad. The touch-
pad illuminates when empty bags mode is selected.
Film Type
Set the type of film to be run on the machine. The touchpad toggles
between registered film (eyespot) and plain film (no eyespot).

Ultima® Macro 6-3/Rev 5

Create or Edit a Recipe

Cycle Type
Set the type of machine cycle to be used. The touchpad toggles
between continuous tube and single cycle.
Continuous tube - a tube of film is continuously produced once
the Start pad is touched until the Stop pad is touched.
Single cycle - a single bag is produced each time the Start pad
is touched.
Open/Close Jaws
Touch the pad to manually operate the jaws. The pad toggles each time
it is touched.

Edit Functions on 2. Touch Ultima Set and edit the applicable parameters.
the Machine Timed The Machine Timed Functions 1 screen displays
Functions 1
Screen Reg. Rolls
This value represents the pull time in degrees. Approximately 1/8 in. is
equal to 1° in short bags mode and 3/16 in. is equal to 1° in long bags
mode.
The registration rollers must start at no less than 10°.

TYPICAL SETTING
Typical measuring roller values are FROM 30° plus the mea-
suring roller dwell time.

Pull Belts
The pull belts assist the film over the forming shoulder. The pull belt
FROM setting is about the same as the registration rollers. The TO set-
ting is about 10° less than the registration rollers, depending on the
machine configuration.

TYPICAL SETTING
Typical pull belt values are FROM 10° and the TO value is the
same as the measuring roller TO value.

6-4/Rev 5 Ultima®Macro
 6
Platen
The platen setting is the time (in degrees) the back seal is made. This
function is usually set to start after the measuring rollers stop and
remain on for the duration of the sealing operation. Double pull is an
exception to this rule.

TYPICAL SETTING
Typical platen dwell is 100°.

Jaw Close
The jaw close value is the dwell of the end seal function. This value is
usually adjusted from about 20° before the end of the registration roller
TO value to approximately 320°. These values are dependent on the
presence of a stripper.

TYPICAL SETTING
Typical jaw close FROM value is close to the measuring roller
TO value and the jaw close TO value is usually 300° - 330°.

Knife
The knife is interlocked to the jaw closure. The function does not oper-
ate until the jaws are closed, regardless of the timing set into this func-
tion. The actual knife cycle lasts until the jaw closed proximity switch
is broken. Set the knife FROM value about 100° after the Jaw FROM
setting.

TYPICAL SETTING
Typical knife dwell time is 50° - 100°.

Printer #1
The printer function is usually set to operate while the film is stopped.
If a bar code printer is used, it may be operated while the film is being
pulled.

TYPICAL SETTING
Typical stationary printer values are FROM 200° TO 300°.

Registration
On indicates the registration circuitry is enabled. Off indicates the
machine is set to plain film mode.

Ultima® Macro 6-5/Rev 5

Create or Edit a Recipe

Window
The registration window is usually set to 10°. With certain high speed
applications, a 20° window may be required.
Placement
The delay in degrees required to make the graphics line up with the
knife cut.

Edit Functions on 3. Touch Next and edit applicable parameters.

the Machine Timed The Machine Timed Functions 2 screen displays
Functions 2
Screen Aux #1, #2, #3
FROM/TO values for auxiliary functions are determined based on the
function output.
Printer #2
The printer #2 function prints a date code on moving film. The printer
#2 function generally operates while the measuring roller is turning.
Hole Punch
The hole punch function is interlocked with the jaw closed proximity
switch, which makes it operate the same as the knife.
Start the hole punch about 100° after the jaw FROM setting.
Quali-Seal
Activate the Quali-Seal air cylinders to operate the jaws. The best set-
ting is the jaw proximity switch activation degree.
Stager
The stager turns on at the end of the film pull and usually remains on
until the next pull begins.

TYPICAL SETTING
Typical FROM and TO values range 100° - 350°.

Stripper
Set to prevent product and other loose material from entering the seal-
ing area. The FROM value of the stripper is the same as the FROM
value of the shaker jaw/shaker.

6-6/Rev 5 Ultima®Macro
 6
Shaker
Set the TO value of a shaker about 70° after the shaker jaw FROM
value. Set the dwell time between 25 and 30ms. Do not continue shak-
ing after the end seal jaws have closed on the bag.

Edit Functions on 4. Touch Next and edit applicable parameters.

the Real Time The Real Time Functions screen displays
Functions Screen
SS Air (Seam Seal Air)
Controls air being applied to cool the platen seal. Air starts when the
platen retracts and continues for XXms.
ES Air (End Seal Air)
Controls air being applied to cool the horizontal seal. Jaw seal air starts
when the jaw seal retracts and can continue until the film begins to
move.

TYPICAL SETTING
Typical end seal air values are FROM 50ms TO 1500ms.

Start Delay
The time from the receipt of a dump signal until the cycle starts. The
start delay can never be longer than the overall cycle.
Bag Drop
A bag drop is a 100ms pulse occurring after the time specified. Bag
drop is started when the jaw function is turned Off. It may be turned
Off. The bag drop can be used to replace an eye if a cartoner is used in
an automatic pack-off situation.
Empty Bag Rate (B/M)
The speed at which the bagger makes empty bags, per minute.
Aux Timer 1
The auxiliary timer 1 starts when a dump is received.
Aux Timer 2
The auxiliary timer 2 starts when the jaws open.

Ultima® Macro 6-7/Rev 5

Create or Edit a Recipe

Bag Eject
The bag eject supports the bottom of the bag as it is sealed and contin-
ues to hold the finished bag for a period of time, allowing the seals to
cool.

TYPICAL SETTING
Typical values are FROM 100ms TO 400ms.

Poker
The poker prevents product jams in the forming tube to ensure the
product is available for each machine cycle.

TYPICAL SETTING
Typical values are 100 - 400ms.

End Seal Air

End seal air provides cooling air on the seam seal.

TYPICAL SETTING
Typical values are 200 - 400ms.

Edit Functions on 5. Touch Next and edit applicable parameters.

the Counter & The Counter & Temperature screen displays
Temperature
Screen Bag Stop
This function is used to run a number of bags and then stop the
machine. This function does not include out of registration or double
length bags due to jams.
Bag Perf.
This function is used to perforate for a preset number of bags and cut
off the last bag. This forms a string of bags that can be torn apart for
individual serving.
Multi Dump
Allows a number of dumps to accumulate before beginning a bagmak-
ing cycle. Timing is critical in this application. Do not use the
multi-dump feature unless absolutely necessary.
Bag Spacer
This function is used to pull a gap in a string of bags. The function is
energized for a preset time for each bag.

6-8/Rev 5 Ultima®Macro
 6
Jaw Front Temp, Jaw Rear Temp, Platen Temp
Sealing temperatures cannot be predicted because they are film depen-
dent.
Temperatures vary from 200°F to 500°F. Generally, the film is run in
an empty bag mode at the required speed, and the temperatures are
increased until satisfactory seals are produced.
Pull Mode S/L
Set the transmission mode to short (s) bags or long (l) bags.
6. Touch Ret
The Main Menu screen displays

SAVING A MODIFIED RECIPE

Once a recipe has been modified it can be saved to the machine mem-
ory. Use the following procedure to save a recipe after all parameters
have been set.

IMPORTANT:
The keyswitch must be in position 2 to save recipes.

1. From the Main Menu touch Program Setup

The Product Designator screen
2. Use the keypad on the touchscreen to enter a name for the
recipe
3. Touch Save
IMPORTANT:
Recipe changes can be saved with any screen that has a Save
touchpad.

SETTING THE DATE AND TIME

1. From the Main Menu screen, touch Date/Time & Printer
The Date/Time & Printer screen displays
2. Touch the Date pad
The touchpad illuminates to indicate it is active
3. Use the numbers at the bottom of the screen to enter the
date in MM/DD/YY format
4. Touch Ent to save the value
5. Touch Time
The touchpad illuminates to indicate it is active

Ultima® Macro 6-9/Rev 5

Automatic Setup Procedure

6. Use the numbers at the bottom of the screen to enter the

time in 24 hour format (HHMM)
7. Touch Ent to save the value

AUTOMATIC SETUP PROCEDURE

The Macro-Logic has the ability to set up the bagger and feed system in
an automatic mode. This implies that some of the parameters are set to
nominal values and may not be perfect in all situations.
Parameters that are impossible to predict include the following:
• temperatures - due to various films and speeds
• placement values - due to bag length, forming tubes, and eye
location
• auxiliary function timing - due to unknown purpose
Despite these impossible to predict functions, almost 90% of the func-
tions in a recipe can be automatically set on the Macro-Logic system.
Speed ranges of 15 to 90 bpm are usually achievable in automatic
mode.
For speeds in excess of 90bpm, timing is critical and additional adjust-
ment is probably necessary.
To start the automatic setup mode for the bagger:

IMPORTANT:
The key must be in position 2 or 3 for automatic setup mode.

1. From the Main Menu, touch Program Selection

The Program Selection screen displays
2. Find a location for the recipe to be stored
3. Touch Ret
The Main Menu screen displays
4. Touch Program Setup
The Product Designator screen displays
5. Touch Clear to erase any old data in the recipe
6. Touch Product Name
7. Enter a name for the recipe
8. Touch Ultima Set
The Machine Timed Functions 1 screen displays
9. Select On or Off for registration
10. Touch Ent

6-10/Rev 5 Ultima®Macro
 6
11. Touch Auto Program
The Ultima Auto Program screen displays
12. At this point, there are three values that must be entered
into the system:
a. machine speed is entered in bpm and is generally set 5
to 10% faster than the required output rate
b. bag length is entered in mm and is the distance
between the eyespots without any overpull
The recipe provides the necessary overpull
c. set the transmission selector to either short or long
bags
13. Touch Load when all values have been entered
The pad turns to reverse video and returns to normal video when the
process is complete. The recipe is located in the RAM memory and
can be viewed with the setup screens.
14. Run several bags and measure the length
a. if using plain film, the measurement is the original
length
b. if using registered film, the measurement is about 3/8
in. longer than the repeat of the eyespots
15. If the length is not correct, touch Ultima Set
The Machine Timed Functions 1 screen displays
16. Adjust the TO value of the measuring rollers until the cor-
rect length is achieved

DOUBLE PULL RECIPE

The Micro-Logic System has the ability measure film longer than the
platen sealer bar. Typically this function is called double pull.
To change from single pull to double pull:
1. Shift the transmission gearbox to long bag mode. This
measures film at 0.162 in. per 10° of machine time, which
allows more end seal time.
2. Roll the display to Platen in the Micro-Logic. Change the
FROM setting to 0° and the TO setting to about 50°. The
FROM setting automatically sets the machine to double
pull mode. The TO setting can be adjusted to the required
dwell time for the platen function.

IMPORTANT:
In double pull mode, the Micro-Logic sends a signal to the regis-
tration rollers and pull belts to pull film ½ of the programmed set-
tings.

Ultima® Macro 6-11/Rev 5

Double Pull Recipe

The Micro-Logic sends a signal to stop pulling film. The platen oper-
ates for the degrees set in the program.
The Micro-Logic retracts the platen, waits for 5° and then sends a sig-
nal to the registration rollers and pull belts to pull the other half of the
bag. After the film has been pulled, the platen seals the other half of the
bag.
EXAMPLE: 20 in. bag in double pull
• Actual Micro-Logic Settings:
• Registration Rollers:FROM 20° TO 144°
• Pull Belts: FROM 10° TO 144°
• Platen:FROM 0° TO 50°
The Micro-Logic registration roller and pull belt settings stop at 144°.
In double pull mode, the platen setting plus 5° retract time is added to
stop the film at 199° as shown in the diagram below.

Figure 1: Double Pull Program

IMPORTANT:
All other functions relating to actual film stopping- must be
changed in Micro-Logic manually.

EXAMPLE: If the stager is closed at 125° in single pull, it

would now have to be modified to close later than the
actual film pull 199°.

6-12/Rev 5 Ultima®Macro
 6

Recipe Chart - Ultima Macro-Logic

Customer ______________________________ Program Name________________________________________________
Product _______________________________ Machine # ________________ Model # ___________________________
Weight __________ Bag Size _________ Eye Location: Front _______ Rear ________ Platen Distance ____________
Former Assembly 03032A_________ Set the distance between the Cutoff Knife and Bag Eject to _____________
Auxiliary #1 _______________________ Auxiliary #2 _______________________ Auxiliary #3 _______________________

Machine Timed Functions #1

Reg. Rolls On____Off_____FROM_____ TO_____ Jaw Close On____Off_____FROM_____ TO_____
Pull Belts On____Off_____FROM_____ TO_____ Knife On____Off_____FROM_____ TO_____
Platen On____Off_____FROM_____ TO_____ Printer #1 On____Off_____FROM_____ TO_____
Registration ______________ Window ______________ Placement _______________

Machine Timed Functions #2

Aux. #1 On____Off_____FROM_____ TO_____ Quali-Seal On____Off_____FROM_____ TO_____
Aux. #2 On____Off_____FROM_____ TO_____ Stager On____Off_____FROM_____ TO_____
Aux. #3 On____Off_____FROM_____ TO_____ Stripper On____Off_____FROM_____ TO_____
Printer #2 On____Off_____FROM_____ TO_____ Shaker On____Off_____FROM_____ TO_____
Hole Punch On____Off_____FROM_____ TO_____

Real Time Functions

SS Air On____Off_____FROM_____ TO_____ Aux Timer 2 On____Off_____FROM_____ TO_____ Start Delay _______
ES Air On____Off_____FROM_____ TO_____ Bag Drop On____Off_____FROM_____ TO_____ Empty bpm _______
Aux Timer 1 On____Off_____FROM_____ TO_____ Bag Eject On____Off_____FROM_____ TO_____
Poker On____Off_____FROM_____ TO_____ Tube Air On____Off_____FROM_____ TO_____

Counter & Temperature

Bag Stop On_____Off_____ Bags_________ Jaw Front Temp On_____Off_____ __________°
Bag Perf On_____Off_____ Bags_________ Jaw Rear Temp On_____Off_____ __________°
Multi Dump On_____Off_____ Bags_________ Platen Temp On_____Off_____ __________°
Bag Spacer On_____Off_____ Space_______ Every ______ Pull Mode Short______Long______
Eye Location Front_____Rear_____

Auto Program
Machine Speed ________________ Bag Length ________________ L/S Bag _________________

Notes

Ultima® Macro 6-13/Rev 5

Double Pull Recipe

6-14/Rev 5 Ultima®Macro
 6
CHAPTER 6: UNWIND ASSEMBLY
The unwind stand stores the film roll and provides initial film tracking
to establish film travel through the Ultima. The stand has a roll spindle,
spindle support plates, stationary rollers, dancer rollers, roll brake
mechanism, a lateral adjustment device, low film detector, and a brake
tension release device. A combination of fixed and movable rollers
ensures a smooth film pull through the measuring roller.

PRINCIPLES OF OPERATION
The measuring roller pulls the film at a rate determined by the pro-
grammed bag length and machine speed. Using a measuring roller to
pull film allows for a simple dancer roller system to control tension
and maintain tracking throughout the machine film pat. Tension can be
varied between unwind rollers and the measuring roller to correct for
film problems without concern for increased tension over the forming
tube.
As the measuring roller pulls the film, the dancer rollers start to rise.
The dancer assembly controls pressure at the brake surface to mini-
mize acceleration/deceleration oscillations of the film. This movement
causes the brake pad to rise from the brake drum, releasing pressure on
the spindle. The amount the brake pad rises is dependent upon the dis-
tance the dancer rollers move upward. As brake pressure decreases, the
film begins to unwind from the film roll. After a pulling time deter-
mined by programmed bag length and machine speed, the measuring
rollers slow their pulling and the dancer rollers return to their original
position and apply pressure to the brake drum through the brake pad
and spring pressure.
When enough film to make a bag has been pulled down the forming
tube, additional film is unwound and stored in the rollers for the next
bag. Film is accumulated in the dancer rollers and tension is controlled
by the movement of the dancer.
The entire unwind assembly is on a screw mechanism to allow left to
right movement. It is actuated via touchpads on the controller or auto-
matically using the optional Accu-Track film edge sensor. A motor
turns the screw to align the film path with the former.

Ultima® Macro 6-1/Rev 5

Unwind Stand Components

UNWIND STAND COMPONENTS

Stationary Rollers

Brake Release Lever

Dancer Roller Assembly

Tension Assist Spring

Roll Brake

Unwind Adjust Motor

Figure 1: Unwind Stand

Spindle Support Spindle support plates are large metal pieces in the rear of the Ultima
Plates on each side of the machine. They hold the film roll spindle, rollers,
film roll brake, and other components necessary to control film feeding
into the bagger.
The unwind stand is electrically isolated form the machine. A flexible
grounding strap provides a secure connection to ground between the
spindle support plate and the Ultima frame. Inspect the grounding strap
periodically to ensure it is securely connected on both ends. If the
grounding strap is broken, there is no path to ground to discharge the
stat electricity created by the unwind film. Severe static problems can
be compensated for with the installation of an auxiliary static elimina-
tor.

Stationary Rollers The stationary rollers guide and support the film as it moves through
the unwind stand.
6-2/Rev 5 Ultima®Macro
 6
Dancer Rollers Dancer rollers work together with the stationary rollers to direct the
film toward the measuring roller. Dancer rollers move freely according
to the tension applied by the moving film to ensure a steady rate of
film travel. The rollers also unwind additional amounts of film from
the roll after the measuring rollers have stopped pulling.
The last roller of the dancer assembly is spring-loaded to prevent the
film from jerking when the measuring rollers start pulling. The spring
also serves as a static eliminator. If damaged or missing, the film may
track off center.

Roll Brake The roll brake mechanism prevents an excessive amount of film from
Mechanism being unwound. It maintains tension on the film between the unwind
stand and the registration rollers. It operates when the dancer rollers
rise and fall. The operator can manually release the brake to change a
roll of film.

Roll Spindle The roll spindle holds the roll of film. The spindle is comprised of:
• spindle tube
• roll locating collar
• core lock lobes and spreader blade
• brake drum
• hand wheel
Spindle support plates mounted on each side of the unwind stand have
a bearing assembly that supports the spindle on both ends. The bear-
ings allow the spindle to rotate as film is unwound from the roll.

Roll Brake
Roll Locating Collar Core Lock

Scale Core Lobe

Figure 2: Roll Spindle Components

Spindle Tube The spindle tube is an expandable core lock that locks the film roll
core tightly in place to prevent slipping during operation. Spreader
blades move outward to grip the interior of the core at the center of the
film roll. Turning a knob on one end of the spindle manually tightens
the core lock.

Positioning Ruler The spindle contains a graduated ruler to aid the operator in placing the
film roll in the exact center. The edge of the film roll is placed on the
number that corresponds with the width of the roll.

Ultima® Macro 6-3/Rev 5

Unwind Stand Components

Roll Locating For applications where film of the same width is always used, an
Collar optional collar can be installed on the spindle as a stop for the film roll.
It aids the operator in placing the film in the correct position, centered
on the unwind stand, every time a new film roll is installed.

Spindle Roll Brake The drum provides a surface for the roll brake pad to apply braking
Drum action to the film roll. A lever actuated brake release arm allows the
operator to release brake pressure in order to change a film roll.

Low Film Bar The low film detector bar lies against the unwinding film roll. The
detector bar is adjusted to signal an alert when a roll of film has
unwound nearly to the core. The bar is mechanically connected to a
limit switch that sends a signal to the computer to stop the machine
before the film roll is completely empty. A visual indication is dis-
played on the control panel. The low film bar can be lifted out of the
way during film roll changeovers. The low film bar on washdown
machines activates a proximity switch.

Unwind Motor The unwind motor moves the unwind stand horizontally so the film can
be centered on the tube and the former. This adjustment is made from
the control panel and has a limited amount of movement. Initially, cen-
tering is accomplished by correctly locating the roll in the exact center
of the spindle.

6-4/Rev 5 Ultima®Macro
 6

3
1 13

14

4C 4G 4D

4F

4E
8 10 9 11 12
4

4A 4B
Figure 3: Components of Packaging Unwind Stand

1. Spindle Support Plates 8. Bushing 14. Roll Locating Collar

15. Core Lock Lobes and

2. Stationary Rollers 9. Jam Nuts
Spreader Blade

3. Dancer Rollers 10. Spring 16. Brake Drum

4. Roll Brake Mechanism 11. Jam Nut 17. Handwheel

5. Brake Arm 12. Tension Spring 18. Brake Tension Release

6. Brake Pad 13. Spindle Shaft 19. Material Depletion Detector

7. Screw Holder

UNWIND STAND OPERATION

The registration rollers pull the film for a length of time set at the con-
trol panel.
As the registration rollers start pulling, the dancer roller starts to rise.
This movement causes the brake mechanism to move away from brake
drum, slowly releasing the brake pad until there is no pressure left on
the brake drum.

Ultima® Macro 6-5/Rev 5

Unwind Stand Operation

As this happens, the film starts to unwind from the roll. After the set
time, the registration rollers stop pulling, the dancer rollers lowers and
applies pressure to the brake drum through the brake pad and spring
pressure.
During this time an additional amount of film has been unwound from
the roll for the next package.
Dancer Roll and The dancer roller and brake are factory set and do not normally require
Brake Adjustment adjustment. If adjustment is necessary:
1. Remove power to the machine
2. If film is threaded through the unwind stand, with the roll
brake engaged, turn the roll spindle to relax the film and
remove all tension from the dancer roller assembly
3. Unhook the tension springs
4. Verify the brake pad to spindle drum alignment. If offset,
follow these steps:
a. Loosen the mechanisms mounting bolt to the frame
b. Turn the eccentric pivot shaft to realign
c. Retighten the mounting bolt
5. Loosen brake pressure spring adjustment jam nut
6. Turn the brake pressure spring adjustment nut to remove
any clearance between the spring assembly and the pivot
arm
7. Lock the brake pressure spring jam nut
8. Loosen jam nut on the brake release rod
9. Turn the brake release rod until the dancer is SLIGHTLY
ABOVE horizontal

IMPORTANT:
The dancer should not be on its stops or bumpers!

10. Lock the brake release rod jam nut

11. Reattach the tension assist springs
12. Verify the dancer arm is in the level position
13. Adjust the brake pressure spring to obtain a clearance of
approximately 1/4" between the bumpers and the cross
support.

IMPORTANT:
If the bumpers are in contact with the cross support, film tension
can be lost. This will create problems with tracking, package
length, and registration.

14. Reposition the tension assist springs to the second set of

holes from the bottom or the normal operating position
6-6/Rev 5 Ultima®Macro
 6
Removing a To remove a depleted roll of film from the machine:
Depleted Roll of
Film 1. Remove machine power
2. Release the roll brake
3. Raise the material depletion detector
4. If the remaining film is still threaded through the machine,
cut the film so that there is enough left to provide a tail for
splicing
5. Lift the spindle and roll from the machine

Pneumatic Mechanical
Deflate the spindle bladder. Turn the handwheel counterclock.
Slide the spindle out. Slide the spindle out.

Loading a Roll of This procedure may also be used to re-position a roll of film on a spin-
Film dle or after removing a depleted roll of film.
1. Bring the machine to a controlled stop

Roll Brake
Roll Locating Collar Core Lock

Scale Core Lobe

Figure 4: Mechanical Spindle

2. Measure the width of the roll of film installing

3. Release the roll brake
4. Using the scale as a guide, position the roll locating collar
so it aligns with the number corresponding to the width of
the roll
5. Lock the roll locating collar in place

IMPORTANT:
Place printed film on the spindle so the print faces the floor when
the roll is unwound. If the film is plain, make sure the outside of
the film faces the floor.

Ultima® Macro 6-7/Rev 5

Unwind Stand Operation

6. Insert the spindle into the roll until the collar rests against
the roll

Pneumatic Mechanical
Pressurize the spindle bladder a. If moving a roll on the spindle
while the spindle rests on the
unwind stand, position the
spindle so the core lock faces
down
b. If loading the roll with the
spindle off the unwind, posi-
tion the spindle so the core
lock faces up
c. Turn the hand wheel clock-
wise to secure the roll on the
spindle

7. If loading off the unwind, place the spindle on the unwind

stand

CAUTION:
Always use proper lifting techniques when moving or lifting rolls
of film.

8. If spindle safety locks are installed, engage the locks on

each side
9. Splice the new film to old film with tape, or thread film
through machine
10. Engage the brake
11. Reset the machine

Threading Film To thread film through the machine:

Through the
Machine 1. Remove machine power
2. Prepare the leading edge
3. Thread film to the tube former as shown on the threading
diagram found on the inside of the unwind stand frame
4. Open the front doors and the platen and release the film
pressure pads from the side of the forming tube
5. Feed the leading edge of the film downward at the top rear
center of the former until the leading edge appears below
the former
6. Pull downward on the leading edge
Keep the film centered on the former
7. Continue pulling downward until the film extends below
the end seal jaws and all slack between the former and the
registration rollers is removed

6-8/Rev 5 Ultima®Macro
 6
8. Check the pull belt adjustment and adjust, if needed
9. Close the platen
10. Re-engage the roll brake
11. Reposition the material depletion detector
12. Close the front doors and restore power

Motorized Unwind For edge adjustment, the final positioning of the film for the lap seam
Edge Adjustment is done using the push buttons on the front panel. These control a
motor drive to shift the roll of material.

Left/Right Push Buttons

& Indicator Lights

Figure 5: Motorized Unwind Edge Adjust

Shift the material ½ in. (12.7 mm) to either side of the forming tube
centerline.
1. Turn the toggle switch to Manual
2. Press the left button to move the material to the left
3. Press the right button to move the material to the right
Make this adjustment while the machine is producing bags so the seam
seal and the printing can be inspected to ensure they are located cor-
rectly on the package.

IMPORTANT:
Watch the center seam at all times and adjust as necessary.

Determining Film Film is determined by the outside diameter of the forming tube and the
Width former overlap requirement. To determine film width, refer to the Eng-
lish table or the Metric table.
Standard forming tube assembly includes the former, sealing tube, and
tube insert plate.

Ultima® Macro 6-9/Rev 5

Determining Seam Seal Type

Consult the Hayssen Parts Department for forming tube assembly pric-
ing for additional assemblies not ordered with the machine, when more
than one film is used per assembly, and for any special package sizes.

DETERMINING SEAM SEAL TYPE

Packaging Material Type of Seal

Cellophane Lap

MS-Pouch Paper Lap

Polyethylene Lap

Poly-Cel Fold-over-fin

Poly-Mylar Fold-over-fin

Poly-Paper Fin

6-10/Rev 5 Ultima®Macro
 6
DIMENSIONS FOR LAP BACK SEAM SEAL (IN.)

Packaging Material Width Appropriate Width of

Forming Tube OD
(Including Overlap) Finished Package
1¼ 49/16 21/16

13/8 5 2¼

1½ 53/8 27/16

15/8 511/16 25/8

17/8 69/16 3
2 7 3¼

2¼ 713/16 35/8
2½ 85/8 4

25/8 9 43/16
2¾ 93/8 43/8

27/8 913/16 49/16

3 103/16 413/16

31/8 105/8 5

3¼ 111/16 5¼

33/8 115/16 53/8

3½ 117/16 59/16

35/8 125/16 5¾

3¾ 12¾ 6

37/8 131/8 63/16

4 13½ 63/8

41/8 137/8 69/16

4¼ 14¼ 6¾
4½ 151/16 71/8
4¾ 157/8 79/16
5 165/8 715/16
5¼ X 5¼ 177/16 85/16
5½ X 5¼ 183/16 8¾

57/8 X 5¼ 20 9½

NOTE:
• A twin tube machine is limited to the dimensions shown within the lightly
shaded area of this table
• For a foldover/lap seam combination, the width of the packaging material is
2X the width of the finished package, plus one inch.
• Formers for tubes with an outside diameter of 5¼ in. or larger are oval in
shape. (dark shaded area).

Ultima® Macro 6-11/Rev 5

Dimensions for Lap Back Seam Seal (MM)

DIMENSIONS FOR LAP BACK SEAM SEAL (MM)

Packaging Material Width Appropriate Width of

Forming Tube OD
(Including Overlap) Finished Package
32mm 116mm 52mm

35 127 57

38 137 62

41 144 67

48 167 76

51 178 83

57 198 92

64 219 102

67 229 106

70 238 111

73 249 116

76 259 122

79 281 133

86 291 137

89 303 141

92 313 146

98 333 157

102 343 162

105 352 167

108 362 171

114 383 181

121 403 192

127 422 202

133 X 133 443 211

140 X 133 462 222

149 X 133 508 241

NOTE:
• A twin tube machine is limited to the dimensions shown within the
lightly shaded area of this table
• For a foldover/lap seam combination, the width of the packaging
material is 2X the width of the finished package, plus 25mm.
• Formers for tubes with an outside diameter of 133mm or larger are
oval in shape. (dark shaded area).

6-12/Rev 5 Ultima®Macro
 7
CHAPTER 7: REGISTRATION ROLLERS
IMPORTANT:
The terms "measuring roller" and "registration roller" refer to the
same component and are used interchangeably.

1 2 8 9 6 4

3
Figure 1: Registration Roller Assembly

Registration rollers unwind a precise length of packaging material. The

registration roller assembly consists of an electric clutch/brake module,
bottom roller, and upper pressure rollers.
The continuously running transmission drives the registration rollers
through a timing belt and an electric clutch/brake.
Upon receiving a signal from the control panel, the clutch energizes
and the brake de-energizes. This causes the bottom roller (2) to turn,
which also turns the upper pressure rollers (4) and feeds the film.
Upon receiving another signal, the clutch de-energizes and the brake is
energizes. This stops the rollers. Between these signals, the pressure
rollers measure a precise length of film.

REGISTRATION ROLLER COMPONENTS

The registration roller assembly consists of a bottom roller, upper pres-
sure rollers, a clutch/brake, and the printed film registration (eyespot)
detector assembly. Some machine models have an auxiliary brake on
the opposite side of the registration roller from the clutch/brake.
Measuring roller tension springs are located on the top of the measur-
ing roller center support. The nuts on the tension spring shaft are
Ultima® Macro 7-1/Rev 5
Registration Roller Spacing

turned counterclockwise so the upper pressure rollers fit snugly against

the measuring roller. Do not allow a gap between the measuring roller
and the upper rollers.

REGISTRATION ROLLER SPACING

The registration roller spacing is set at the factory before the machine
ships. Adjustment is not usually required.

Super CMB The pressure rollers directly against the center bearing block should
Models 12-16, always remain tight against the spacers. The next rollers are typically
12-19, & SF spaced ½ in. apart. The outside rollers are spaced 1 in. from the outside
bearing blocks.
A fixed spring pressure nut applies pressure to the bearing blocks. By
spacing the blue rollers as indicated, uniform pressure is distributed
across the entire web. This eliminates uneven pressure that may cause
premature part failure.

ADJUSTMENT PROCEDURE

Floating Bearing Block Pressure Roller Floating Bearing Block

Spacer

Figure 2: Registration Roller Adjustment Procedure

1. Remove machine power

2. Loosen the setscrew
3. Position the roller
4. Tighten the setscrew and restore power

PRINT REGISTRATION
The bagmaking cycle time is synchronized by registration marks (eye-
spots) on the succession of bags. Print registration is the reference
between the location of a registration mark to the cutoff location on the

7-2/Rev 5 Ultima®Macro
 7
bag. Print registration is maintained by the registration mark scanner,
which senses the registration mark on the film.

IMPORTANT:
False registration mark triggers may cause erratic machine opera-
tion. If this occurs, troubleshoot the film and registration assem-
blies.

When the registration mark scanner senses an eyespot, a signal is sent

to the controller. The controller starts the registration rollers, feeding
the packaging material through the machine for a programmed length
of time. The registration rollers stop, as programmed, to end the cycle.
The controller begins the next cycle upon receipt of a signal from the
scanner.

Figure 3: Scanner Control Unit (top)

The print registration scanner system detects registration marks (eye-

spots) on the following materials:
• Transparent Material
• Foil
• Opaque, Non-foil Material
The scanner is located on a bracket below the film back-up plate at the
registration roller assembly. It is moved to either side by turning the
handwheel located next to the control unit. The sensor can be adjusted
to detect the registration mark over a range from a straight-on 90° posi-
tion to a 45° angle to the film. Signals travel from the registration mark
sensor through a fiber optic cable to a control unit.

Ultima® Macro 7-3/Rev 5

Registration Scanner Components

REGISTRATION SCANNER COMPONENTS

• registration scanner control unit - mounted to the machine
frame inside the front door.
• anti-flutter ski
• scanner pick-up unit - located below the film back-up plate
on the registration roller assembly and connected to the con-
trol unit by a cable.
• scanner pick-up mounting bracket
• packaging material back-up plate

EDR Indicator Offset Adjustment

Trigger Point

Registration Mark
Indicator

Background
Selector
Switch

Contrast Level Indicator

Figure 4: Scanner Control Unit

Scanner Control OFFSET ADJUSTMENT POT

Unit Components
The offset adjustment pot calibrates the registration scanner to the
reflected light level from the packaging material background.

EYE SPOT INDICATOR

The eye spot indicator illuminates when the registration scanner detects
a registration mark.

7-4/Rev 5 Ultima®Macro
 7
BACKGROUND SELECTOR SWITCH
The background selector switch sets the scanner unit to look for either
light or background. The position of the switch is set to the background
color of the packaging material. Select dark when a light registration
mark is printed on a dark background. Select light when a dark regis-
tration mark is printed on a light background.

CONTRAST LEVEL INDICATOR

The contrast level indicator displays the amount of light the registra-
tion scanner receives. The indicator consists of a row of vertically
arranged LEDs, numbered 1 through 10 from top to bottom.
For a black or dark registration mark, adjust the contrast indicator for a
reading of “10“. For a white or light registration mark, adjust the con-
trast indicator for a reading of “1“. When the light level is high, a low
numbered LED illuminates; when the light level is low, a high num-
bered LED illuminates.
The Mark Indicator LED displays ON to indicate that an registration
mark has been detected.

OFFSET CONTROL
The offset control adjusts the amount of light needed to turn the mark
indicator LED on or off.

IMPORTANT:
The offset control is not a sensitivity control; the sensitivity of the
scanner is fixed at maximum.

Ultima® Macro 7-5/Rev 5

Registration Scanner Components

Registration Mark OPAQUE (NON-FOIL) MATERIAL

Sensor Setup
Before proceeding, verify the machine is in plain film mode.
1. Position the background sensor to view the film from a
straight on position
.

Registration Mark Sensor

Film
Backup

1/4” Minimum Gap

Film

90

Fiber Optic Cable

Figure 5: Registration Mark Sensor Positioned “Straight On” to Film

2. Move the film so light reflects off the background

IMPORTANT:
If the surface of the film is extremely glossy, placing the sensor at
a 45° angle to the film provides more accurate performance.

3. Adjust the offset as follows:

a. For a dark registration mark on a light background,
adjust the contrast indicator for a reading of “10"
b. For a light registration mark on a dark background,
adjust the contrast indicator for a reading of "1"
4. Position the light/dark switch so the indicator turns Off
5. Move the registration mark under the sensor and note the
contrast reading
Verify the reading moves at least six to eight bars

FOIL MATERIAL
1. Set the background selector switch as follows:
a. If registration mark is black or darker than foil, set the
selector switch to light
b. If registration mark is white or lighter than foil, set the
selector switch to dark
7-6/Rev 5 Ultima®Macro
 7
2. Position the registration mark sensor:
a. For a black or dark registration mark, position the sen-
sor straight to the film
b. For a white or light registration mark, position the sen-
sor at a 45° angle
3. Move the film to reflect light off the background.
4. Adjust the offset as follows:
a. For a black or dark registration mark, adjust the con-
trast indicator for a reading of "10"
b. For a white or light registration mark, adjust the con-
trast indicator for a reading of "1"
5. Position the light/dark switch so the indicator turns OFF
6. Move the registration mark under the registration mark
sensor and note the contrast reading
Verify the reading moves at least six to eight bars

TRANSPARENT MATERIAL
1. Position the registration mark sensor perpendicular to the
film
2. Move the film so that light reflects off the background
(transparent area) of the film
3. Adjust the offset to indicate a reading of "9" or "10" on
the contrast indicator
4. Set the light/dark switch in the position that turns the indi-
cator OFF when the background is in view
5. Move the registration mark into view and note the con-
trast reading
Verify the reading moves at least six to eight bars

IMPORTANT:
• If additional contrast is needed, place a sheet of white
paper between the film and the film backup for use as a
background.
• To ensure accuracy, order registration mark scanners or
replacement parts ONLY from Hayssen.

Printer Printers are used to print information on the bag concerning time, shift
line number, and/or date. The bagger transmit a signal during the cycle
to trigger the printer. Inputs are available in the bagger to stop the
machine if the printer has a fault.
Film tracking, as well as registration and sealing problems, can result
from film movement drag caused by incorrect timing or faulty printer
operation. If the printer operates too early, it makes contact with the
Ultima® Macro 7-7/Rev 5
Registration Scanner Components

film while it is still moving. If it retracts too late, it remains in contact

with the film too long. Either condition causes the printer to snag the
film and stretch or tear it. This interference can result in tracking, regis-
tration, and possible sealing problems.
This condition can be detected by observing printer operation. To
check, enable the printer in the program and run continuous empty
bags. Verify the printer operates and makes contact with the film only
while the film is stationary. Also, verify the printer is not touching the
film when the next pull begins.

Printer Take-Up The printer take-up roller is mounted on the rear of the registration
Roller roller assembly frame. It diverts the film path by adding to the distance
from the printer. This allows a physical adjustment to position the print
on the bag. Turning the knob pulls the film out of the dancer rollers
without affecting film location with respect to the registration roller
and eyespot detector.

Figure 6: Horizontal Printer Take-Up Roller

7-8/Rev 5 Ultima®Macro
 7

Figure 7: Vertical Printer Take-Up Roller

ELECTRICAL
The clutch/brake assembly provides a signal to start and stop the mea-
suring rollers to control the length of the film pull. Two different ver-
sions of the clutch/brake board are used. Early model Micro-logic
machines use a board with analog outputs; later versions of the
clutch/brake board use a pulse width modulated output. Macro-logic
machines also use the pulse width modulated signal.
The clutch/brake operate as a pair; when the clutch is On, the brake is
Off, and vice versa. The clutch turns On and the armature plate trans-
fers from the brake to the clutch and the rollers turn. When the voltage
to the clutch is Off, the brake hold voltage turns Off. The cycle repeats
itself for the next bag making cycle.

Accu-Track Photo-eye sensors located along the film travel path continuously mon-
itor the position of the film edge. If the film starts to move in one direc-
tion or the other, the control system activates the unwind tracking
motor, which moves the unwind assembly left or right to correct it.

Ultima® Macro 7-9/Rev 5

Maintenance

MAINTENANCE
Pressure Roller When loading film or performing maintenance on the registration roll-
Adjustment ers, it may be necessary to release the pressure roller.
1. Turn the valve control to the far right to close the pressure
roller
2. Turn the valve control to the far left to open the pressure
roller
3. The pressure belts can be rolled from groove to groove on
the pressure roller to clean or adjust for film width

Cleaning It is extremely important for correct operation of the Hayssen bagmak-

ing machine that the registration roller and upper feed roller assembly
be clean and free of dirt and contamination. Clean the rollers frequently
with soap and water. Install new rollers when wear is evident.

Lubrication No lubrication is required.

Miscellaneous 1. Tighten the drive pulley belt to allow approximately 3/8 in.
Adjustments deflection
2. There are three pressure nuts in the upper support plate
a. Back out the two outside nuts so the dimension from
the plate to the top of the nuts is 5/8 in.
b. Lock the inside nut down tightly to the plate

Clutch/Brake This procedure tests the repeatability of the clutch/brake assembly that
Repeatability Test controls registration roller operation. Use any program stored in the
machine to perform this test.
1. Establish a match mark between the registration roller and
the Ultima frame
IMPORTANT:
Use tape to prevent permanent marking or scoring of the registra-
tion roller.

a. Place a piece of tape on the end of the registration

roller
b. Place another piece of tape on the machine frame adja-
cent to the tape on the registration roller
c. Draw a horizontal line on both pieces of tape to signify
the match mark
2. Turn off all degree and time functions in the production
program except for the registration roller

7-10/Rev 5 Ultima®Macro
 7
3. Remove the film by cutting it behind the registration
roller.
4. Set the registration roller dwell time for 62°
The FROM/TO value is not important as long as the dwell time is set
at 62°.

IMPORTANT:
• This is a starting dwell time. On some models, adjust-
ments may be necessary to ensure the registration roller
rotates on full revolution per cycle.
• The empty bag rate may need adjusting to aid in
viewing the alignment match marks during operation.

5. Set the machine speed to 10 bags per minute

6. Select Empty Bag, Continuous Cycle
7. Touch Start
Ensure the match mark stops at the same place on every cycle.

IMPORTANT:
Ultima programming does not allow for half degree settings
(62.5°). This may cause the alignment of the match marks to vary
slightly. This variation is normal as long as the difference in align-
ment is always the same amount on each cycle. A different varia-
tion on each cycle in the alignment of the match marks indicates a
bad clutch/brake assembly.

Burnishing Burnishing, a procedure performed on new units to correct minor

mechanical binding or misfit of parts internal to the clutch/brake unit,
can also be performed to aid in correcting a repeatability issue.
1. Repeat the Clutch/Brake Repeatability Test with these
changes:
a. Set platen FROM value at 0 and TO value at 50.
This forces the bagger into a double pull mode causing the clutch brake
to engage two times per cycle.
b. Set the empty bag rate at 120.
This causes the clutch brake assembly to act 240 times per minute.
2. Allow bagger to cycle for 15-30 minutes.
3. Repeat the Clutch/Brake Repeatability Test.
4. If consistent repeatability is not obtained, replace the
clutch/brake assembly.

Clutch/Brake
Pressure Roller CAUTION:
Replacement Hayssen recommends lock-out, tag-out be completed on the bag-
ger before starting this procedure to prevent personal injury and
equipment damage.

Ultima® Macro 7-11/Rev 5

Maintenance

IMPORTANT:
• Do not lose parts when completing this procedure.
• Install new clutch/brake units during reassembly.

1. Remove machine power

2. Tag out the circuit breaker
3. Measure or scribe the existing measuring roller positions
and note the stagger pattern of set screws that secure pres-
sure rollers to the shaft

threaded
studs

bearing
blocks

pressure rollers
threaded
studs
clutch/brake w/housing

auxiliary brake
bearing
blocks

4. To remove the clutch:

IMPORTANT:
As parts from the clutch/brake are removed, stack them in order.
This makes reinstallation quicker and/or shows the correct order
for installing a new clutch/brake.

a. Remove the two hex screws that mount the outer end
cap to the clutch/brake housing
b. Remove end cap
IMPORTANT:
Some older machines do not have a 2-piece end cap.

c. Loosen the belt take-up and remove the timing belt

from the pulley

7-12/Rev 5 Ultima®Macro
 7
d. Remove the small bronze thrust washer from the shaft
e. Being careful not to touch the clutch contact surfaces,
remove the pulley and armature from the shaft
f. Remove the large nylon thrust washer from the shaft
g. Disconnect the electrical wires from the clutch field
h. Loosen the two set screws holding the brake hub and
clutch rotor on the shaft
i. Loosen approximately ½ turn by using a long Tee han-
dle 3/32 in. Allen wrench through the access hole in the
clutch/brake housing.
IMPORTANT:
One of the set screws is found when the shaft is rotated so the
keyway is at the top or bottom, depending on the access hole
being used. The other set screw is found when the shaft is rotated
with the keyway opposite the access hole.

j. Before removing the clutch assembly, rotate the shaft

so the keyway is at the top
This prevents the key from falling out of the keyway.
k. Slide the clutch assembly from the shaft
If necessary, use a puller.
5. To remove the brake and housing:
a. Remove the key
b. Inspect the keyway and key to verify they are in good
condition
c. Add 5/16 nuts on the threaded studs on the pressure
bearing blocks of the registration roll assembly
d. Tighten the nuts to take the pressure off the rollers
e. Remove the two hex screws that hold the housing to
the side plate
f. Slide the housing and the brake magnet from the shaft
It may be necessary to tap lightly with a soft-faced hammer on both sides
of the housing to loosen it.
g. Remove the small bronze thrust washer from the mea-
suring roller
h. If not replacing the brake, skip to step 6
i. Remove the four hex screws from the brake magnet
then remove the brake magnet from the housing
j. Disconnect the electrical connections from the brake
magnet

Ultima® Macro 7-13/Rev 5

Maintenance

6. Remove the auxiliary brake:

IMPORTANT:
Not all machines have an auxiliary brake.

a. Remove two 8/32 screws from the cover of the auxiliary

brake
b. Using a 3/32 in. Allen wrench, loosen the two set screws
holding the brake to the shaft
c. Slide the brake armature off
d. Remove the key
e. Slide the measuring drive roller free from the assem-
bly
f. If not replacing the auxiliary brake, skip to step 7
g. Remove the four hex head screws to remove the brake
magnet from the housing
h. Disconnect the electrical connections to the brake
magnet
IMPORTANT:
Before proceeding, obtain assistance for step 7.

7. While supporting the pressure roller assembly, remove the

5/ nuts from the threaded studs then remove the pressure
16
roller shaft from the machine
8. Loosen the pressure rollers and slide them off the shaft
9. Install the new pressure rollers on the shaft in the same
position as the old pressure rollers
10. Tighten the set screws on the rollers ensuring the stagger
pattern previously noted for the set screws
11. Inspect springs and bearings and replace as needed
IMPORTANT:
Before proceeding, obtain assistance for step 12.

12. Reinstall the pressure roller assembly

• Install and tighten the 5/16 nuts to the threaded studs
on the bearing blocks to secure the pressure roller
assembly in place
13. Install the auxiliary brake and measuring drive roller
a. If not replacing the auxiliary brake, skip steps b and c
b. Attach the brake magnet to the housing with the four
hex head screws
c. Make the electrical connections to the brake magnet
7-14/Rev 5 Ultima®Macro
 7
d. Reinstall the measuring drive roller
• Mesh drive gears
• Position key-way at the top
e. Put a small amount of Loctite 242 on the bottom of the
key and install the key in the key slot
f. Slide the brake armature onto the shaft
g. Using a 3/32 in. Allen wrench, tighten the two set
screws that secure the brake to the shaft
h. Secure the auxiliary brake cover with the two 8/32
screws
14. Install the brake clutch assembly
IMPORTANT:
Do not use anti-seize compound or apply lubricant to any part of
the clutch/brake assembly as this causes slippage.

a. If not installing a new brake clutch assembly, skip to

step d
b. Make the electrical connections to the brake magnet
c. Attach the brake magnet to the housing using 4 hex
screws
d. Slide the bronze thrust washer onto the measuring
roller shaft
e. Apply approximately one drop of Loctite 242 to the
shaft and install the housing and brake magnet to the
side plate
f. Ensuring pins are aligned, attach the housing to the
side plate using 2 hex head screws
g. Put a small amount of Loctite 242 on the bottom of the
key and install in key slot with the raised end up and
toward the brake magnet
h. Being careful not to touch the contact surfaces, align
the brake armature to the splined clutch hub assembly
On a non-ceramic brake, verify the sharp edge of the armature is against
the magnet.
i. Slide the clutch assembly onto the shaft, verifying the
alignment tab slides onto the alignment pin in the
housing, and the keyway aligns with the alignment
mark on the clutch assembly
j. Attach the electrical wires
k. Line up the set screws with the access hole in the
housing and tighten
l. Slide the large nylon thrust washer onto the shaft

Ultima® Macro 7-15/Rev 5

Maintenance

m. Apply approximately one drop of Loctite 242 to the

shaft so that all bearings that come in contact with the
shaft are correctly retained
This assures the bearing inner races turn with the shaft
n. Being careful not to touch the contact surfaces, align
the clutch armature to the splined pulley hub and
assemble and slide on the shaft
On a non-ceramic clutch, ensure the sharp edge of the armature is against
the rotor.
o. Slide the small bronze thrust washer onto the shaft
p. Reinstall the timing belt but do not tighten
q. Secure end cap on with two hex head screws
r. Tighten the timing belt tensioner so that there is ½ in.
belt deflection on the side opposite the tensioner
s. Remove the 5/16 nuts placed on the threaded studs on
the pressure bearing blocks of the registration roller
assembly
t. Ensure the measuring rollers are clean and free of
grease or oils
IMPORTANT:
• Wait at least one hour for the Loctite to set up before
operating the machine.
• There should be no visible space between the pressure
roller and the measuring roller

15. Restore power to machine

7-16/Rev 5 Ultima®Macro
 8
CHAPTER 8: PULL BELT ASSEMBLY
The pull belts, working in conjunction with the measuring rollers,
advance a predetermined length of film over the forming tube and into
the jaw area. The pull belt assembly consists of a drive shaft, drive pul-
ley, idler pulley, and belts.
There are two different kinds of pull belt arrangements available on the
Ultima. One type is the non-continuous motion belt (non-CMB) that
only turns when the machine controller directs a film pull. This belt is
always in contact with the film/forming tube surface.
The other type of pull belt is the continuous motion belt (CMB) that
turns continuously. CMB pull belts remain in a ready position until
receiving a signal to pull film. A solenoid valve opens and directs air-
flow to operate air cylinders that move the pull belts into contact with
the film/forming tube surface.

Figure 1: Non-CMB Pull Belts

Ultima® Macro 8-1/Rev 5

Pull Belt Operation

Figure 2: CMB Assembly

1. Belt Actuating Roller Assemblies 7. Brake Lockout Knobs

2. Drive Pulleys 8. Fingers

3. Driven Pulleys 9. Centering Locking Knob

4. Pull Belts 10. Centering Starwheel

11. Pressure Adjustment Hand-

5. Auxiliary Film Brakes
wheel

6. Bumpers 12. Alignment Screws

PULL BELT OPERATION

Pull belts are turned by a transmission through drive shafts. CMB
machine drive shafts turn continuously at a rate determined by the bag-
ger speed. Non-CMB belts only turn when a signal is received from the
clutch/brake drive board.
The pull belts pull the advancing film from the measuring roller down
the side of the forming tube and feed it into the jaw area. After pulling
a predetermined length of film, the drive signal from the machine con-
troller is removed. On CMB machines, the pull belts retract and wait
for the next signal. On non-CMB machines, the pull belts stop turning.
The pull belts pull at the same time as the measuring rollers. In most
circumstances, the machine is programmed to have the pull belts begin
the film pull before the measuring rollers to compensate for slip. On
CMB belts, there is additional time required for the belts to move into
contact with the forming tube. A typical pull belt FROM value is 10°.
The TO value always has to be the same as the measuring roller TO
value.

8-2/Rev 5 Ultima®Macro
 8
The mechanical design of the Ultima provides for a 5% increase in pull
belt speed over the measuring roller. This prevents looping (slack in
the film) between the measuring roller and the forming tube. Looping
can cause varying bag lengths or registration loss.
Models with an auxiliary film brake use air exhausted from the sole-
noid-operated valve to operate a small air cylinder mounted on top of
the pull belt assembly. The cylinder grips the film tightly against the
forming tube between pulls to minimize the effects of film stretching.
When using poly, thin, or fragile film, the film brake is essential to pre-
vent bag lengths from varying as the film stretches during the pull and
snaps back when the pull is complete. At very high speeds, the auxil-
iary film brake may hinder the film pull.

PULL BELT PERFORMANCE

Pull belts have to overcome the friction between the inside of the film
and the forming tube. Pull belts also have to overcome slip characteris-
tics on the outside of the film when the belt grips the film.
Some film types require a better gripping surface for pull belts to over-
come high film friction against the forming tube. To solve this issue,
inserts are fitted on the forming tube where the pull belts touch the for-
mer. The inserts have a dimpled surface that assists the pull belts in
overcoming friction between the film and the forming tube.
Angle, pressure, and left to right adjustment are critical for tracking the
film at the seam seal area. On a correctly adjusted machine, the pull
belts contact the forming tube in the center of the insert. In a few cases,
the top of the assembly may have to be tilted toward the rear of the
machine in order to get a good seam seal.
Removing forming tube inserts usually results in premature pull belt
wear. Pull belt wear is dependent on many variables including film
composition, packaging speed, programming, physical condition of the
pull belt assembly, pressure, lubrication, and operator set up. In
extreme conditions, pull belts can last only a few hours. In other situa-
tions with a different combination of variables, pull belts may last for
many months.
CMB pull belts advance a length of film over the former and into the
jaw area. The programmable controller sends a signal to two pneu-
matic actuators inside the CMB assemblies. These actuators extend the
belt actuating assemblies which bring the belts into contact with the
film.
The belts pull the selected length of film over the former into the jaws.
At the end of the pull, the controller signals the actuators which move
the belts away from the film.
Ultima® Macro 8-3/Rev 5
Pull Belt Performance

As the pull belts are moving away from the film, the auxiliary film
brakes extend and press the bumper against the film on each side of the
forming tube.
The bumpers hold the film in position while the bottom seal is made
and the bag is filled with product.
To assist in threading new film it is necessary to lock the bumpers in
place. The following steps set up this procedure:
1. Pull the brake lockout knob out
2. Press a finger down
3. Release the brake lockout knob and the finger is locked in
place
This provides room to pull new material around the tube. When the
machine is started, the bumper resumes normal operation automati-
cally.

Pull Belt Centering To adjust the pull belt pressure and alignment:
and Pressure
Adjustment - Non 1. Open the front doors
CMB 2. Turn pressure handwheel counter-clockwise to move belts
away from former
3. Turn pressure handwheel clockwise to move belts toward
former until both belts are approximately ¼ in. from the
table
4. Examine the belts for centering on the former
a. If they are not centered, loosen the centering starwheel
b. Turn top of starwheel toward the operator to move the
CMB assembly right; away from the operator to move
the CMB assembly left
5. Turn pressure handwheel to move belts toward former
6. Examine gap between belts and former
It may be necessary to adjust again after running the machine. If more
or less pressure is required the pull belts and film, adjust accordingly.
7. Use centering starwheel to fine tune centering
8. When the appropriate settings are achieved, lock the cen-
tering locking knob

Pull Belt Pressure The recommended pull belt air pressure is 30 PSI (2 bar). Minor adjust-
Adjustment on ments can be made in the 28-32 PSI (1.9 - 2.2 bar) range by turning the
CMB Machine pressure adjust knob on the pull belt regulator. Turn the regulator knob
counter-clockwise to decrease pressure and clockwise to increase pres-
sure. The pressure adjustment for the cylinders must close the belts

8-4/Rev 5 Ultima®Macro
 8
evenly on the former. The pull belt assembly automatically adjusts to
any size forming tube.

Figure 3: Pull Belt Pressure (CMB)

If the air pressure is too low, irregular bag lengths can result because
the pull belts cannot grip the film tightly. Too much air pressure can
lead to premature pull belt wear and possible overheating of the step-
per motors.

CMB Assembly to This alignment is factory set. If realignment becomes necessary:

Tube Alignment
1. Remove machine power
2. Loosen the four alignment screws in the side frame
3. Move the assembly so that the belts are in the center of
and parallel to the tube
4. Tighten the alignment screws
5. Restore power

MAINTENANCE
Cleaning Pull Belts Periodically check the belts for tears, excessive wear, slack and con-
tamination. To clean pull belts:
1. Turn all power to machine Off
2. Clean the belts and pulleys with water and soap or a mild
detergent

Ultima® Macro 8-5/Rev 5

Maintenance

3. If the buildup is not removable with soap or mild deter-

gent, use isopropyl alcohol
After using alcohol, immediately rinse to remove any excess alcohol
on belt or pulleys. If the alcohol is not completely rinsed off, it dries
out the belts and shortens their life.
IMPORTANT:
Air pressure to CMB cylinders need to be set at 12 psi to start the
machine.

Replacing Pull Install red pull belts with the arrow pointing in the direction of travel. If
Belts installing red pull belts and the arrow is worn off, install belts so that
the splice is angled up toward the forming tube assembly.
IMPORTANT:
Always change the pull belts in pairs.

Forming
Tube

Splice

Pull Belt

Figure 4: Pull Belt Replacement

Replacing Upper Install new pulleys when they are worn. Always replace top pulleys
Pulleys and bottom pulleys in pairs. To replace the top pulleys:
1. Remove machine power
2. Remove the belts from the pulleys
3. Remove the hex head screw in the upper pulley
4. Remove the pulley with the ball bearings
5. Install the new pulley with two new bearings and tighten
with the hex screw
Verify the new pulley turns freely.
6. Reinstall the belts
7. Restore power.

8-6/Rev 5 Ultima®Macro
 8
Replacing Bottom To replace the bottom pulleys:
Pulleys
1. Remove machine power
2. Remove the belts from the pulleys
3. Loosen the setscrew in the bottom pulley and remove the
pulley
4. Install the new pulley
5. Tighten the setscrew on the flat of the shaft
6. Reinstall the belts
7. Restore power

Pull Belt Drive To lube the universal joint:

Shaft Universal
Joint Lubrication 1. Remove machine power
2. Loosen the set screw on the drive shaft side of the trans-
mission end universal joint
3. Push the driver shaft into the transmission end universal
joint hub to gain clearance and remove the drive shaft
4. Pack both universal joint hubs with food grade grease
5. Mark the drive shaft with a file stroke 13/16 in. (30mm)
from the end
6. Insert the marked end of the drive shaft into the transmis-
sion end universal joint hub and reinstall the drive shaft
IMPORTANT:
Verify the plugged hole of the pull belt universal joint and the set
screw of the transmission end universal joint are in line with each
other and on the same flat of the hex-drive shaft.

7. Position the drive shaft so the 13/16 in. (30mm) mark is just
visible at the transmission end universal joint hub
8. Tighten the set screw of the transmission end universal
joint hub
9. Restore machine power

Ultima® Macro 8-7/Rev 5

Maintenance

8-8/Rev 5 Ultima®Macro
 9
CHAPTER 9: FORMING SYSTEM
The forming system converts flat film into a tube. As the pull belts pull
film over the forming shoulder and onto the forming tube, film is
shaped into a cylinder. The film edges overlap into position to create
one of several types of seam or back seal.
The forming system consists of a former, tube/funnel (2), last roller(s)
(3), support brackets (4), and tube inserts (5). Repair or install a new
former as required. The tube/funnel is made of stainless steel and fits
inside the former. It is supported by brackets (4) that are attached to the
former mounting plate. The last roller(s) guides the packaging material
onto the former. It is mounted directly to the former assembly. The
tube inserts serve as a back-up for the pull belts and prevent wear on
the tube/funnel surface.

A
1. Last Rollers
Top View 2. Hex Head Screws
3. Tube/Funnel
4. Support Brackets
5. Tube Inserts
6. Hex Head Screws
A. Last Roller must be parallel to rear edge of former.
B. Last Roller must be parallel to bottom of former.
C. Last Roller must be tangent to this line.

6
3

5
Bottom View C

Figure 1: Forming System

Ultima® Macro 9-1/Rev 5

Forming Tube Assembly Components

FORMING TUBE ASSEMBLY COMPONENTS

Former The former is the shoulder or wing at the top of the tube. Film travels
onto the shoulder. As the film moves across the former it is shaped into
a tube.
The former is made of sheet steel and is subject to ear and damage from
the film. Textured metal is used for the shoulder to reduce friction. The
edge of the forming tube is subject to excessive wear from constant
rubbing of the film. The edge is coated with a finish for protection.
Inspect the tube for wear and damage on a regular preventive mainte-
nance schedule.
Extra plating is required for protection from film wear when packaging
with paper/poly and paper/foil/poly laminations in excess of four mils
thick. Some tubes used to package abrasive materials have a ceramic
coating.

Forming Tube The tube is made of stainless steel and fits inside the former. Brackets
attached to the former mounting plate support the tube.
Round tubes are most common. Packages more that 10 in. wide require
an oval tube. The oval shape ensures the diameter of the package does
not exceed the distance between the machine jaws to prevent interfer-
ence and jamming. Film selection is critical with an oval tube. Softer
films are required to prevent the film from cracking. Flat bottom bags
are produced with rectangular tubes, some with rollers installed to pro-
duce precise corner creases. Careful attention to film structure is
important when using anything other than round tubes.
Double wall tubes may be used in applications when packaging frozen
products or other situations where condensation is a problem. It con-
sists of a tube fitted inside a tube to provide an insulation space. Dou-
ble wall tubes have also been used to insert gas into a package. The gas
is introduced between the tube walls. The gas pressure directs the gas
downwards into the package.

Last Roller The last roller provides a transition onto the forming shoulder and
serves to guide the film onto the former. A correctly adjusted last roller
ensures the film travels down the tube evenly without unacceptable
twisting or shifting too far to either side.
Adjust the last roller so there is no bend or curve in the film between
the last roller and the edge of the forming tube shoulder.

Tube Stop Located behind the forming tube is a tube stop. Its purpose is to limit
the front to back travel of the forming tube caused by the platen. When
the platen strikes the front of the tube, the back presses against the tube

9-2/Rev 5 Ultima®Macro
 9
stop. This limits forming tube travel and prevents bending from the
constant platen strikes. A bent forming tube prevents even platen pres-
sure on the back seals and can cause the pull belts to pull unevenly. A
correctly adjusted tube stop is as close to the film as possible without
interfering with film travel.

Inserts Two kinds of friction exist between the film and the forming tube. One
is surface area friction created by the contact area between the film and
the tube. The other, startup friction, is caused when the film begins to
move and friction resists the startup movement.
Tube inserts have been developed to address the problem of both types
of friction. Using textured materials of various configurations reduces
surface area and helps prevent premature wear on the tube. The reverse
dimple concept eliminates both markings and surface jaw block effect.
Special coatings reduce friction and provide excellent abrasion resist-
ing characteristics.
Tube inserts also aid the pull belts by helping maintain film tension.
Without inserts, the pull belts may slip on the film and cause tension
loss in critical areas of the machine. This results in looping and poor
tracking on the forming tube and shoulder. Poor tracking may result in
premature pull belt wear and polishing. Forming tube assembly polish-
ing in film contact areas increases friction and reduces slip between the
film and the forming tube, causing looping and poor tracking on the
forming tube and shoulder.
The most common types of forming tube inserts are made of Teflon or
ceramic. Ceramic inserts have a very long life, but they are fragile.
Rough handling can cause them to chip and tear the films. Teflon
spreaders do not chip, but they have a much shorter life.

Spreaders Spreaders are attached, one on each side, to the bottom of the tube and
protrude into the unfinished bag. They serve to eliminate wrinkles and
pleats on end seals. The operator bends the spreaders by hand to pro-
duce the needed effect on the package end seals.
Some inserts are designed with spreaders at the bottom. Spreaders are
made of either Teflon, ceramic, or steel. Teflon and ceramic spreaders
are an extension on the bottom of tube inserts. Like the inserts, they are
removable and can be replaced when they become worn by constant
exposure to film induced friction. Teflon spreaders have a high wear
rate from constant contact with the moving film. Ceramic spreaders
last much longer, but rough handling can cause sharp edges that can
tear the film.
Some applications use steel spreaders welded to the inside of the form-
ing tube. Tubes with steel spreaders usually do not have inserts.

Ultima® Macro 9-3/Rev 5

Forming Tube Assembly Components

Sponge Tape Sponge tape provides a surface to absorb the force of the platen striking
the forming tube. This allows for even pressure along the entire length
of the back seal. The sponge tape is covered with Teflon tape to ensure
a smooth back seal surface. Teflon tape also insulates the sponge tape
from excessive heat from the platen.

Open Back Some snack food machines use open back forming tubes to prevent
Forming Tubes jamming by an irregular shaped product. The open back allows the film
tube to flex as the product presses against it. Open back tubes may
cause the bottom of the forming tube to be pushed toward the rear of
the machine. This results in uneven pull belt tracking along the side of
the tube and could produce a poor back seal. Open back forming tubes
do not use a tube stop.

Tube Air Tube air is blown into the throat of a forming tube in order to prevent a
bridge of product from forming. A product bridge can build up across
the opening of the tube if the product falls too fast, is lightweight, or
irregular shape. Air is injected into the throat of the forming tube to
assist product fall.
Tube air operates on a time-based output triggered from the dump sig-
nal. The operator enters a FROM value in milliseconds to set how long
after the dump signal the output turns on. A TO value, also in millisec-
onds, determines when the tube air turns off.

Air Displacement Dusty products dropping through the forming tube create a cloud of
System contaminants that can settle onto operating components of the bagger.
The contaminants can cause the machine to jam, damage moving parts,
or interfere with the sealing process. To eliminate the effects of product
dust, a vacuum pump is attached to the forming tube to draw the dust
cloud away from the effected areas.

Baffles Some products have a tendency to swirl in the forming tube funnel
rather than fall directly through the tube and into the bag. Swirling
causes the product to string out instead of falling in a compact mass. A
strung out product does not always fall into the bag in time for the jaws
to close and make the top end seal. Product can string out so far that it
may not all get in the correct bag. This condition causes underweight or
overweight packages.
To correct this problem, baffles are installed in the forming tube funnel.
Baffles are vertical barriers that force the product to travel downward
and do not allow swirling.

9-4/Rev 5 Ultima®Macro
 9
BACK SEAL TYPES
As the film is pulled over the forming shoulder it is formed into a tube
with overlapping edges. Several different types of overlap allow a vari-
ety of back seals.

Lap Seal

Fold-over Seal

Fin Seal

Figure 2: Back Seal Types

The difference between the lap and fold-over seal is dependent on the
amount of overlap designed into the neck of the forming tube. The
edges of the forming tube must be close together to create a lap seal.
For a fold-over seal, the edges at the throat are further apart. The fin
seal requires a special platen assembly with two opposing heaters and
platen bars.

Packaging Material Type of Seal

Cellophane Lap
MS-Pouch Paper Lap
Polyethylene Lap
Poly-Cel Fold-over/Fin
Poly-Mylar Fold-over/Fin
Poly-Paper Fin

ADJUSTABLE FORMING TUBES

Some models of forming tubes have an adjustment to allow different
types of back seals. The throat has a moveable tip that changes the gap
distance between the edges of the crossover to change between a lap
seal and a foldover seal.

Ultima® Macro 9-5/Rev 5

Film Width Calculation

Figure 3: Adjustable Forming Tube

FILM WIDTH CALCULATION

Film width is determined by forming tube geometry. This determines
bag width and the amount of film required for the appropriate back
seal. The bag width is stamped on the front of Hayssen forming tube
assemblies. Use the formula to determine film width:
2F + 1in. = FW
F = Forming tube size
FW = Required film width
1in. = Amount of film necessary to accommodate the back seal.
IMPORTANT:
Not all commercially available forming tubes have the same num-
bering system as used on Hayssen equipment.

Bag Size
Stamped Here

9-6/Rev 5 Ultima®Macro
 9
STORAGE AND HANDLING
Forming tubes are delicate and must be handled with care. If they are
damaged, the tube can bend and cause the pull belts to pull unevenly.
Bent forming tubes can also make the film twist on the former and pro-
duce bags with uneven and weak back seals.
Store forming tubes in a protected location away from traffic. Never
lay forming tubes on the floor or store them where they can be dam-
aged. Exercise care when transporting a forming tube. Carry forming
tubes by the funnel supports it in an upright position. Never carry the
former by the tube.
Store extra forming tubes on racks designed for that purpose. Both
wall mounted and freestanding models with add on modules are avail-
able from Hayssen. A Pro-Former transport cart is also available to
move a heavy forming tube.
MAINTENANCE AND ADJUSTMENTS
Seam Seal Sponge Sponge tape needs to have a soft but firm feel throughout its length.
Tape Replacement Press a thumb against the sponge tape and rub from top to bottom.
Install new tape if there are hard spots.

IMPORTANT:
Use plastic banding material to remove splice tape from the form-
ing tube.

Use only one piece of tape on the forming tube. Cover the sponge tape
with a piece of Teflon tape. Slices in Teflon tape cause weak seam
seals and leakers.
Tube Stop To adjust the tube stop:
Adjustment 1. Feed film through the former and down the tube
2. Turn the tube stop until the anvil barely touches the film
3. Back the anvil away from the film
A correctly adjusted tube stop is as close to the film as possible with-
out interfering with film travel.

Tube and Former Center the tube/funnel inside the former so the packaging material can
Concentricity pass through easily. This adjustment is performed at the factory and
Adjustment usually is not required. If this adjustment needs to be made, do the fol-
lowing:
1. Turn all power to machine OFF.
2. Loosen hex head screws (6).
3. Center the tube/funnel (2). Retighten screws.
4. Restore power.

Ultima® Macro 9-7/Rev 5

Maintenance and Adjustments

Last Roller The packaging material contacts the last roller before it enters the for-
Position mer. The last roller must be parallel to the rear edge and to the bottom
Adjustment surface of the former. It must also be tangent to the rear slope of the
former.
To adjust the last roller:
1. Turn all power to machine OFF.
2. Loosen two hex head screws (7).
3. Align the roller and retighten the screws.
4. Restore power.

Forming Assembly To remove the forming assembly:

Removal
1. Turn all power to machine Off.
2. Loosen the threaded hand knobs that clamp the assembly
in place.
3. Carefully slide forming assembly away from machine.
4. Slide new forming assembly in place.
5. Tighten the threaded hand knobs.
6. Restore power.

Removal, Cleaning To replace the pull belt inserts on the sides of the tube:
and Installation of
the Pull Belt 1. Turn all power to machine OFF.
Inserts 2. Slide the old inserts up and away from the tube/funnel (2).
3. Clean the tube/funnel and install new inserts. Restore
power.

9-8/Rev 5 Ultima®Macro
 10
CHAPTER 10: PLATEN ASSEMBLY
The platen makes the vertical seam (back seal) that seals the edges of
the tubular-shaped film to produce a continuously sealed tube. The
platen assembly consists of a heater body, heater body linkage, car-
tridge heater, temperature probe, air cylinder, platen housing, and a
hand wheel. The platen assembly components are contained in the
platen housing which swings out-of-the-way for easy access to the
forming tube assembly.
The actual platen is a rectangular aluminum bar used as a heated die
that seals the two edges of film on the back of the package to one
another. Hayssen uses two variations of platen, depending on the type
of film. The resistance platen has a flat ½ in. (13mm) sealing surface
that is used to activate film sealant and create a seam seal. The poly or
Quali-Seal platen has a ½ in. (13mm) radius surface that creates a seam
seal by melting or welding unsupported poly film structures.
To make a vertical seal, a signal from the control panel extends the air
cylinder, moving the heater body linkage, and pressing the heater body
against the packaging material and the tube/funnel. Heat to make the
seal comes from a cartridge heater that is regulated by a separate tem-
perature controller through a temperature probe. After a predetermined
length of time, the signal retracts the air cylinder and the assembly is
ready for the next cycle.

Figure 1: Platen Assembly

The platen has two adjustments. A front to back adjustment sets the
distance between the platen and forming tube assembly. A lateral
adjustment aligns the platen striking surface to the center of the form-
ing tube to ensure even film overlap.

Ultima® Macro 10-1/Rev 5

Platen Operation

PLATEN OPERATION
When adjusting for normal platen operation, it is important to remem-
ber the four sealing factors:
• sealing time
• sealing temperature
• pressure
• seam seal cooling
The four sealing factors are adjusted until the best quality seal is
achieved. Always try to operate with the minimum sealing temperature
necessary to make acceptable seals. If adjustments are necessary, start
by changing the dwell time or the distance from the forming tube
before changing the temperature.

PLATEN CUSHION INSPECTION

Inspect the seam seal cushion on the forming tube for tears, contamina-
tion on tape, and permanent indentations on the cushion. If Teflon tape
becomes damaged or torn, or if rubber becomes permanently indented
and no longer cushions the sealer bar, replace the tape or rubber as
required.

POLYETHYLENE PLATEN AIR COOLING SYSTEM

Ultima HP or HPR machines are equipped with an air-cooling tube to
enhance cooling when running unsupported polyethylene film struc-
tures. This directs a stream of air at the hot seam seal. This air is sup-
plied through a tube which runs parallel to the sealer bar insert.
Air flow begins as the sealer bar completes its function and starts to
retract from its contact with the forming tube. The flow continues until
the seam sealer starts the next cycle.
These start and stop positions are controlled by the machine micropro-
cessor.

IMPORTANT:
Air for this function needs to be dry, not lubricated.

10-2/Rev 5 Ultima®Macro
 10
PLATEN ADJUSTMENTS
WARNING:
The platen is extremely hot. Remain alert when working in the
platen area to avoid burns.

Centering To center the platen:

Adjustment
1. Loosen the centering lock knob
2. Use the starwheel to move the platen
• turn toward the operator to move to the right
• turn away from the operator to move to the left
3. Tighten the lock knob

Figure 2: Platen Centering Adjustment

IMPORTANT:
Actual location of the lock knob and centering starwheel may
vary depending on the machine model.

Distance To adjust the distance between the platen and the forming tube:
Adjustment
1. Loosen the distance handwheel jam nut
2. Move the platen using the handwheel:
• turn the handwheel clockwise to move the platen
away from the forming tube
• turn the handwheel counter-clockwise to move the
platen towards the forming tube

Ultima® Macro 10-3/Rev 5

Platen Adjustments

3. Tighten the distance handwheel jam nut

IMPORTANT:
• This adjustment is very important. If the gap is too
small, the film may stick to the platen and not flow
smoothly over the forming tube. If the gap is too large,
the back seal is weak or missing.
• The centering handwheel and lock knob are located in
back of the distance handwheel and housing
• Adjust the gap to ¼ in. to 3/8 in. (6mm - 10mm).

Figure 3: Platen Distance Adjustment

Speed Adjustment Flow control valves on the air cylinder control sealer speed. To adjust
the speed of the seam seal bar, do the following:
1. Remove machine power
2. Turn the flow controls on the air cylinder to provide just
enough speed to make an acceptable seal
3. Restore power

10-4/Rev 5 Ultima®Macro
 12
CHAPTER 12: END SEAL ASSEMBLY
The end seal assembly seals the top of one package and the bottom of
the next package while a knife separates the two.
The major components of the end seal system are a jaw actuator
assembly, drive linkage and shafts, jaw carriers, sealing jaws (resis-
tance or Quali-Seal), and a knife assembly.

Figure 1: End Seal System

1.Jaw Actuator Air Cylinder 6.Carrier Shafts 11. Knife Air Cylinder

2. Crank Linkage 7.Front Jaw 12.Pressure Adjusting Nuts

3.Actuator Shafts 8.Rear Jaw 13.Deflection Collars

4.Compression Springs 9.Knife 14.Hex Bolts

5.5. Proximity Switch 10.Knife Linkage

Ultima® Macro 12-1/Rev 5

How the End Seal System Works

HOW THE END SEAL SYSTEM WORKS

When the settle timer times out, the PLC signals the jaw solenoid
valve. This valve shifts and causes the jaw cylinder (1) to retract, clos-
ing the front and rear jaws (7 and 8).
When the jaws are closed and locked, the proximity switch (5) sends a
signal to the PLC. At this point the knife (9) extends and cuts the film,
separating the packages.
During the time the jaws are closed, they apply pressure and heat to the
film to seal the package. After the programmed sealing time, the jaw
cylinder extends and the jaws open.

WARNING:
Be careful when working near the end seal jaws to avoid crushing
injuries, painful cuts and burns. Be careful when replacing the
knife because the edge is very sharp.

ABC JAW OPENING ADJUSTMENT

The ABC jaw opening allows the end seal jaw open distance to be var-
ied. It is used to select the correct jaw opening to suit the bag width for
optimum end seal performance and repeatability.

Figure 2: ABC Jaw Opening Adjustment

12-2/Rev 5 Ultima®Macro
 12
The jaw opening must be wide enough to allow the maximum width
bag to pass through. The machine is able to run smaller bags at much
higher speeds.
Position A is used when the bagger runs large bag widths. Position A
must also be used when the machine is equipped with bag strippers.

Position A has an opening of:

Maximum
Machine Jaw
Pillow Bag
Model Opening
Width

15-22 75/8 in. 15 in.

All other models ~ 7 in. 12 in.

Position B has an opening of:

Maximum
Machine Jaw
Pillow Bag
Model Opening
Width

15-22 51/16 in. 61/8 in.

All other models ~ 45/8 in. 5½ in.

Position C has an opening of:

Maximum
Machine Jaw
Pillow Bag
Model Opening
Width

15-22 35/16 in. 45/8 in.

All other models ~ 3 in. 4 in.

Bag widths that pass through position C normally run at a high rate of
speed. By using this position, the jaws run quieter and with a higher
degree of repeatability. This produces a better quality end seal.

IMPORTANT:
• When film is very light or product is very bulky or
heavy, the bag shape may get wider when traveling
from the forming tube through the jaws, thus hitting the
jaw faces. If this happens, change to the next largest
opening. Some timing functions may need to be reset
when openings are switched.
• Machines equipped with bag strippers must use posi-
tion A.

Ultima® Macro 12-3/Rev 5

ABC Jaw Opening Adjustment

Change Jaw 1. Remove machine power

Opening Position 2. Loosen the two pin clamping screws
3. Remove clevis pin assembly from the existing position
and insert into required position
IMPORTANT:
Thrust washers (7) fall free when the clevis pin assembly is
moved. Put them back before inserting the clevis pin assembly
into the new position.

4. Tighten both pin clamping screws

5. Replace all guards and close doors
6. Restore power and run the machine
7. If the filled bag does not easily pass through the fully open
jaws, shut machine Off and set jaw to the next largest
opening
8. Note the appropriate setting on the timing chart

Jaw Face Pressure Jaw face pressure adjustment may be required to correct faulty seals or
Adjustment for compensate for film gauge thicknesses. The following information is
Resistance Jaws for resistance jaws only.

12-4/Rev 5 Ultima®Macro
 12

Figure 3: End Seal System with Jaw Actuator Cylinder

1. Jaw Actuator Cylinder 8. Rear Jaw 15. Pneumatic Cushion

2. Crank Linkage 9. Knife 16. Cylinder Rod

3. Actuator Shafts 10. Knife Linkage 17. Clevis

4. Compression Springs 11. Knife Air Cylinder 18. Clevis Clamp Screws

12. Pressure Adjusting

5. Proximity Switch 19. Drive Link
Nuts

6. Carrier Shafts 13. Deflection Collars 20. Drive Shaft

21. Drive Link Clamp

7. Front Jaw 14. Hex Bolts
Screws

IMPORTANT:
For the most accurate adjustment, the jaws should be hot.

Ultima® Macro 12-5/Rev 5

ABC Jaw Opening Adjustment

1. Remove machine power and air supply

2. Remove the knife
3. Clean the jaw faces with a brass brush
4. Push the jaws closed by hand
5. Loosen the drive link on the drive shaft
6. Back off the pressure adjustment nuts until the compres-
sion springs are free
7. Loosen the deflection collars and turn until they are at
least ¼ in. away from the front jaw casting
8. Lock the crank linkage parallel with the special clamp
block
9. Push jaw cylinder rod back until it bottoms out
10. Tighten the drive link on the drive shaft
IMPORTANT:
Tighten the drive link clamp evenly. Keep the clamp parallel to
the drive link. The clamp must not contact the drive link.

11. Verify the jaw cylinder rod is fully threaded into the clevis
12. Tighten the clevis clamp screws
13. Turn the pressure adjusting nuts clockwise to compress
the springs to 111/16 in. (43mm) as measured between the
inside surfaces of the washers
14. Turn the deflection collars toward the front jaw casting
until they just touch and lock in place
15. Turn the pressure adjusting nuts clockwise to 19/16 in.
(40mm) as measured between the inside surfaces of the
washers.

Jaw Closed
Proximity Switch IMPORTANT:
Adjustment The proximity switch is factory set and only requires adjustment
if the original setup is disturbed.

1. Keep machine power On

2. Loosen the two hex bolts that attach the bracket and move
the bracket away from the shaft end until the LED de-illu-
minates
3. Move the bracket toward the shaft end until the LED illu-
minates
4. Tighten the two hex bolts

12-6/Rev 5 Ultima®Macro
 12
Jaw Open and The jaw open and close speed controls and cushions are factory set for
Close, Speed, and maximum speed with minimum bounce.
Cushion Controls

Figure 4: Jaw Cylinder

If adjustment is necessary:
1. Remove machine power
2. Open the jaw open speed control by turning counterclock-
wise
3. Open the jaw close speed control by turning counterclock-
wise
4. Close the jaw open cushion and then open ¼ turn
5. Set the jaw close cushion at the 0 position
6. Restore power to the machine
7. Set the jaw close timing from 150° to 330° and the speed
to 60 bags per minute
8. If the machine has a stager or stripper, set the timing at 0°
to 359°
9. Turn all other functions off
10. Touch Reset and run several single cycles and observe the
jaws
11. Turn the jaw open and jaw close flow controls clockwise
to slow the cylinder down
IMPORTANT:
The jaws should not slam or have excessive bounce in either
direction. A slight bounce when the jaws open is normal.

12. If there is too much bounce on the jaw open, make small
adjustments to the jaw open cushion until only a slight
bounce is detected

Ultima® Macro 12-7/Rev 5

Knife Adjustments

• Turn clockwise to increase the cushion and lessen

the bounce; counter-clockwise for less cushion and
more speed

IMPORTANT:
Generally, if there is bounce with little noise, there is too much
cushion. If there is slamming, more cushion is needed.

13. After making an adjustment, allow the machine to com-

plete several cycles and check the results
The jaw close point on the display should consistently show 240° ±
5°.
14. Adjust the jaw close cushion, one number at a time, to
obtain a consistent jaw close point
15. If the jaw close point is too high the flow controls need to
be opened slightly for correct operation
IMPORTANT:
A typical jaw close cushion setting is 4. The higher the number,
the more cushion is obtained.

KNIFE ADJUSTMENTS

Figure 5: Knife Adjustments and Replacement

7. Shaft 12. Knife Air Cylinder 16. Cushion Control

8. Front Jaw 13. Flow Control 31. Jam Nut

9. Rear Jaw 14. Flow Control 32. Rod End

10. Knife 15. Cushion Control 33. Knife Retainer

11. Knife Linkage

12-8/Rev 5 Ultima®Macro
 12

WARNING:
Be careful when working in the knife area. The knife edge is very
sharp and cuts even when brushed against.

Knife Position 1. Remove machine power

Adjustment 2. Inspect the position of the knife
Verify the knife is fully retracted and the knife air cylinder is fully
extended. Knife position is correct when the tips of the blade are flush
with or 1/32 in. inside the front jaw face.
3. If the knife blade is incorrect:
a. Loosen the jam nut on knife air cylinder shaft
b. Turn the shaft into, or out of the rod end until the knife
blade is in the correct position
c. Tighten the jam nut
4. Restore machine power

Knife Speed 1. Press the reset button, but do not cycle the machine
Adjustment 2. Press the manual operator on the knife control valve to
actuate the knife
3. Observe the knife action
It should be swift and smooth, but not bang.
4. If the knife action is not acceptable, make an adjustment
to the flow controls or the cushion controls or both on the
air cylinder
The flow control adjustments are located on the outboard sides of the
cylinder.

• Flow control adjusts the speed when the knife is

extending
• Flow control adjusts the speed when the knife is
returning
Cushion adjustments are located on the inboard sides of the cylinder.
Cushion protects the knife assembly against shocks when the knife
extends and retracts.

PRELIMINARY KNIFE SETTING

1. Turn flow controls counterclockwise, then clockwise 1½
turns
2. Turn the cushion controls clockwise, then counterclock-
wise ½ turn

Ultima® Macro 12-9/Rev 5

Combination End Seal System - Resistance Sealing System

3. Use the manual operator on the knife control valve to

actuate the knife
4. Check the knife action and make small adjustments as
needed
Knife Blade
Replacement WARNING:
Be extremely careful. The knife edge is extremely sharp.

1. Remove machine power

2. Lift knife retainer off pin and swing aside
3. Lift knife blade off pin and slide out of jaw
4. Re-assemble new knife in reverse order
COMBINATION END SEAL SYSTEM - RESISTANCE
SEALING SYSTEM
Removing and
Installing Sealing
Jaw Faces

Figure 6: Resistance Sealing System for Cellophane

REMOVING THE FRONT OR REAR JAW FACE

1. Remove machine power
2. Lift up the knife blade retainer and remove the cutoff knife
(front jaw only)
3. Remove nuts and slide jaw faces out of housings
12-10/Rev 5 Ultima®Macro
 12
INSTALLING THE FRONT OR REAR JAW FACE
1. Remove machine power
2. Slide the jaw face into its housing and tighten nuts
3. Restore power
4. Turn each jaw temperature controller On and set to 300°F
(149°C)
Jaw faces must be at this temperature or normal operating tempera-
ture before alignment.

WARNING:
To avoid crushing injuries and painful burns and cuts, be careful
when working in the end seal area. Use care when replacing the
cutoff knife because the knife edge is very sharp. The jaws open or
close upon actuation of the jaw open or close key.

5. Loosen nut and manually close the jaw carriers until jaw
faces start to mesh
6. Close and lock the jaw carriers
7. With jaw faces meshed tighten nut

REPLACING SEALING JAW HEATERS

IMPORTANT:
The following steps require heat sink compound.

The entire front or rear jaw assembly carrier has to be removed to

replace heaters. To remove jaw assembly:
1. Remove machine power
2. Remove the knife by lifting the tabs on the ends of the
knife holder and sliding the knife out
3. Disconnect the heater and probe wires from the terminal
strip mounted in the jaw carrier (or wiring box on wash-
down models)
4. Loosen cap screws and remove jaw assembly from carrier
5. Loosen setscrews (1 setscrew per heater) and pull out old
heaters
6. Apply heat sink compound to the new heaters and slide in
place
7. Remove setscrews and apply heat sink compound
8. Put setscrews in place and tighten carefully

Ultima® Macro 12-11/Rev 5

Combination End Seal System - Resistance Sealing System

To install jaw assembly:

1. Mount jaw assembly to the carrier
Note the pin must engage locating slot and that groove in mounting
block must engage locating tongue in carrier. This ensures correct
alignment between front and rear jaw faces.
2. Remove cap screws and apply heat sink compound
3. Put cap screws in place and tighten
4. Restore power

Front and Rear

Sealing Jaw Face
Alignment

Figure 7: Jaw Face Alignment

WARNING:
To avoid crushing injuries and painful burns and cuts, be espe-
cially careful when working in the end seal area. Use care when
replacing the cutoff knife because the knife edge is very sharp.
The jaws open and close upon actuation of the jaw open or close
key.

The jaw faces must be meshed and aligned to produce even end seals.
Jaw face alignment is adjusted by means of spring washers (6) and
adjusting screws. Turning these screws causes the jaw faces to move.

12-12/Rev 5 Ultima®Macro
 12

IMPORTANT:
Primary adjustment should be made on the front (knife side) jaw
face. If correct alignment cannot be achieved, the rear jaw can be
adjusted in the same manner.

Turning the screw in a counterclockwise rotation causes the jaw face to

move outward. By turning one or all of these screws, in any combina-
tion, the jaw faces can be positioned to achieve full contact.
To align the front and rear faces of the resistance sealing jaws:
1. Remove machine power
2. Loosen guard mounting screws and remove guard
3. Loosen setscrew at each adjusting screw
4. Turn adjusting screws clockwise until tight and spring
washers are fully compressed
5. Run sample bags and note areas on end seals that require
more jaw face contact to equalize the seal
This can also be determined with the power Off, by inserting a single
sheet of aluminum foil between the front and rear jaw face and manu-
ally closing and locking the jaw carriers.
6. If adjustment is necessary, turn appropriate adjustment
screw to eliminate gap between the jaw faces
IMPORTANT:
1
/8 or 45° of screw rotation results in approximately 0.005 in. (0.13
mm) of jaw face movement.

7. Tighten setscrews
8. Replace and tighten guard screws

RESISTANCE HOLE PUNCHES

Heated ProPunch The heated ProPunch uses heat and a punch to make a hole in a pack-
age. The system maintains a steady temperature even when there is a
change in speed. This eliminates the possibility of burnout due to over-
heating.

Ultima® Macro 12-13/Rev 5

Resistance Hole Punches

Figure 8: Heated Hole Punch

The punch assembly consists of a heater and cutting tip with a built-in
sensor in the heater. The heater is mounted in a retainer that is attached
to a holding plate. The entire assembly is clamped to the guide shafts.
The entire punch assembly is mounted to the jaw face mounting plate.
The cutting tip on the end of the heater produces the hole. A spring
built into the unit is used to align and adjust the punch.
A temperature control and the On/Off switch are located inside the
electrical enclosure.
The ProPunch is intended for use on polypropylene film and may not
work on other types of films.

HEATED PROPUNCH ADJUSTMENTS

The tip of the heater should protrude approximately 3/32 in. (2.4 mm)
beyond the front sealing jaw face.
To adjust:
1. Turn all power to machine Off and lock out
2. Turn adjusting nut to obtain 5/8 in.
3. Loosen the two clamp screws and slide punch mounting
plate until 3/32 in. is obtained
4. Tighten clamp screws

12-14/Rev 5 Ultima®Macro
 12

IMPORTANT:
32 in. can be changed by turning the adjusting nut.
3/

• To move punch tip towards jaw face, turn nut clock-

wise
• To move punch away from jaw face, turn nut coun-
terclockwise
To adjust the heat control:
1. Open electrical enclosure
2. Turn the temperature controller On
3. Adjust the temperature control by turning the potentiome-
ter to the required temperature on the indicator dial
4. Close the electrical enclosure
5. Wait a few minutes and check the temperature by using a
pyrometer.
Product can be run when the require temperature is reached.
6. If the punch tip becomes contaminated with product, film,
or other foreign substances, clean immediately with a
brass brush.
When running bags without a hole punch, do the following:
1. Turn the hole punch heater Off
2. Remove machine power
3. Loosen the two clamp screws
4. Slide the punch mounting plate back until punch tip is
approximately 1/8 in. inside the sealing jaw
5. Tighten the two clamp screws

Round Mechanical The hole punch assembly consists of a punch rod actuated by an air
Hole Punch cylinder. A steel bushing is fixed in the rear jaw face and a
spring-loaded bushing is retained in the front jaw face.
As the jaws close, these bushings grip the film and seal a ring around
the hole that is produced as the punch rod is actuated. The remaining
tab stays attached to the bag.
The punch air cylinder is actuated through a separate timing function
set in the machine controller.

Ultima® Macro 12-15/Rev 5

Resistance Hole Punches

Figure 9: Round Mechanical Hole Punch

HOLE PUNCH ALIGNMENT

The punch rod must slide freely through the guide bushings in both the
front and the rear jaw face. To do this:
1. Remove machine power
2. To move the punch horizontally, loosen nuts and slide
mounting plate
3. To move punch vertically, loosen screws and slide guide
bars up or down
4. Tighten mounting screws and/or nuts
5. Restore power

CHANGE HOLE SIZE

The number of degrees of circle the hole is cut, can be changed from 0°
to approximately 270°. This cut area is determined by the distance the
punch rod extends beyond the sealing surface of the rear jaw face with
the air cylinder fully extended.
To adjust the position of the punch rod:
1. Remove machine power
2. Loosen adjusting screws
3. Manually extend the punch rod to its maximum out posi-
tion

12-16/Rev 5 Ultima®Macro
 12
4. Slide the cylinder mounting plate until punch rod extends
beyond rear jaw face to location that produces the
required hole
5. Tighten the adjusting screws
6. Restore power

SEALING PRESSURE ADJUSTMENT

Adjust the gripping pressure of bushings as follows:
1. Remove machine power
2. Adjust spring pressure:
a. to increase spring pressure, loosen jam nut and turn
back-up screw clockwise
b. to decrease pressure, loosen jam nut and turn back-up
screw counterclockwise
3. Tighten jam nut
4. Restore power

Punch Rod To remove punch rod for cleaning and/or sharpening:

Removal
1. Remove machine power
2. Loosen the setscrew
3. Slide the punch rod out of the mounting block and
through the rear jaw face
4. Install new or sharpened punch rod
5. Restore power

Punch Cylinder Set the timing of the punch cylinder to stroke out the punch rod just
Timing after the jaws have closed. The rod should be held out only long
enough to cut the hole. If it is held out too long, sealant may build up
on the rod and bushings, causing erratic operation. Timing is done in
the machine controller.

Running Bags To run bags without the hole punch, turn the punch cylinder timing Off
Without Punch on the machine controller and do the following:
1. Remove machine power
2. Loosen adjusting screws and slide punch assembly back
until punch rod is inside jaw housing
3. Restore power

Ultima® Macro 12-17/Rev 5

Combination End Seal System - Quali-Seal System

IMPORTANT:
If jaw faces are also changed, front bushing and spring are loose
pieces and need to be stored in a suitable place to prevent damage
or loss.

Rod and Bushing If the punch rod becomes contaminated with product, film, or other for-
Maintenance eign substances, remove machine power and clean immediately with a
brass brush or knife blade.
The punch rod must be sharp to produce a clean cut hole. To sharpen,
grind bevel on rod until edges are sharp. If the front or rear guide bush-
ings become contaminated with product, film, or other foreign sub-
stances, clean immediately with a brass brush or knife blade.

IMPORTANT:
The rear bushing is fixed in position but the front bushing must be
kept free to slide.

COMBINATION END SEAL SYSTEM - QUALI-SEAL

SYSTEM
Quali-Seal is a precise, temperature controlled end seal system. It is
designed specifically for polyethylene sealing.

12-18/Rev 5 Ultima®Macro
 12

Figure 10: Quali-Seal End Seal System

How Quali-Seal 1. Product is released from the feed system into the bag
Works 2. The pull belts advance the bag to the correct length
3. The bag rests on the bag support
4. The jaws close, and the heated quali-seal bars seal the film
5. An orbital motion knife separates the top of one bag from
the bottom of the next bag
6. The jaws open and air from the stager cools the end seals
7. The filled and sealed bag is ejected
8. The cycle is repeated
Temperature Three separate, solid state, time proportioning temperature controllers
Controllers are mounted on the front panel. They control the heat for the front jaw,
rear jaw, and seam seal.
Teflon Fiberglass Teflon fiberglass tape should be placed on the faces of the Quali-Seal
Tape bars. This helps to prevent film sticking and burn-through problems.
The most commonly used teflon tape is ¾ in. wide. Tape 1 in. wide
and 1½ in. wide is also available.

Ultima® Macro 12-19/Rev 5

Combination End Seal System - Quali-Seal System

IMPORTANT:
Replace the teflon tape from below the jaws rather than removing
the top gripper plate. This eliminates the possibility of the jaws
becoming misaligned during reassembly.

Jaw Set-Up

WARNING:
Verify the main electrical box disconnect is in the Off position
before making adjustments to avoid serious injuries.

1. Remove the knife by lifting the tabs on the ends of the

knife blade retainer and sliding the knife out
2. Locate the edge of the top and bottom rear grippers and
verify the edges are flush against the mounting plate
3. Remove the top and bottom front grippers
IMPORTANT:
A thin, 7/16 open end wrench is required to access bolt heads adja-
cent to the knife blade retainer bar.

a. Loosen the two gripper mounting bolts on the top front

gripper
b. Slide top front gripper off
c. Loosen the two gripper mounting bolts on the bottom
front gripper
d. Slide bottom front gripper off
4. Loosen the hexhead cap screws on the clamping blocks
5. Turn spring housing on each side until a gap appears
between the spring plunger and the jaw actuator rod
6. Retighten cap screws on spring housing clamping blocks
7. Loosen the pressure adjusting and jam nuts on each side
until all tension is taken off springs
8. Loosen both 3/16 in. Allen head screws on deflection collars
9. Turn both deflection collars out of carrier ¼ in.
10. Push the jaws closed and lock on center using the jaw
linkage clamp block
11. Push the front jaw carrier until it just touches the deflec-
tion collars on both the left and right ends
12. Turn both deflection collars into carriers until 2.590 in.
(±0.005 in.) is obtained between the finished surfaces of
the front and rear carriers on both the left and right ends
A Vernier Caliper is used to measure this.

12-20/Rev 5 Ultima®Macro
 12
13. Tighten all four Allen head screws on the deflection col-
lars
14. Turn pressure adjusting nuts 3½ turns beyond the point
where they just contact the springs
This compresses the springs 3/16 in.
15. If necessary, re-adjust deflection collars to 2.590 in. on
both ends of carrier to ensure that the carriers are parallel
and slide freely
16. Turn pressure adjusting nuts until springs are compressed
to a length of 19/16 in.
17. Using a 3/16 in. allen wrench, loosen both spring adjusting
screws
IMPORTANT:
Both the jam nuts and the screws back out when loosened.

18. Turn screws in by hand until contact is made and resis-

tance is just felt
19. From this point, turn screws an additional two turns
IMPORTANT:
Ensure each screw is adjusted the same.

20. Tighten jam nuts on the spring adjusting screws

Hold the position of the screws while tightening the nuts.
21. Loosen the four outer and two center jack screws (square
heads) on the jaw face mounting plate
22. Verify all eight face mounting screws are tight
23. Verify the jaws are still closed and locked on center
24. Loosen cap screws on clamping blocks
25. Turn both spring housings, simultaneously forcing the
rear jaw out until it contacts the front jaw along the full
length of the jaw faces
26. Place a mark on the spring housing to use as a guide
27. Remove jaw linkage clamp block to unlock jaws
28. Turn each spring housing an additional ½ turn
29. Tighten the cap screws on the clamping blocks until the
housings are tight
30. Push the jaws closed until front and rear sealing faces
touch

Ultima® Macro 12-21/Rev 5

Combination End Seal System - Quali-Seal System

31. Push the jaw linkage to final closed position, noting move-
ment of rear sealing jaw. Rear jaw should deflect from 1/32
in. to 1/16 in.
IMPORTANT:
Maximum allowable deflection is 1/16 in.

32. Adjust spring housings if necessary to obtain correct

deflection
33. Turn machine power On
34. Turn on jaw heat and allow jaws to heat up to 220°F
35. Place one piece of carbon paper against one piece of white
paper and tape to front jaw face, the stager, or the bottom
of the forming tube
36. Turn Off all functions except jaws and stager
37. Run one cycle, then check seal impression for even pres-
sure on top and bottom seals
38. If pressure is not even, adjustment can be made to the
front jaw through spring washers
The rear jaw cannot be adjusted.
39. To adjust the front jaw:
a. Remove machine power
b. Loosen setscrews A on top or bottom
CAUTION:
When making adjustments, turn 1/8 turn (45°) at a time. 1/8 turn is
approximately 0.005 in.

c. To increase pressure on top sealing surface, use a ¼ in.

long handled allen wrench to loosen upper adjusting
screws 1/8 turn forcing top of jaw out
d. Turn power On and check seal impression with carbon
paper
e. If pressure is not even, turn power Off and repeat steps
b and c after each 1/8 in. turn until even pressure is
obtained
f. Once even pressure has been obtained and power has
been turned Off, retighten setscrews A
40. Push the jaws closed and lock on center using the jaw
linkage clamp block
41. Install top front gripper with rubber cushion inserted in
slot
42. Turn both top gripper jack screws, forcing gripper out
until rubber cushion contacts rear gripper and a 0.020 in.
gap between front and rear gripper is obtained on both the
left and right ends
12-22/Rev 5 Ultima®Macro
 12
43. Tighten the gripper mounting bolts
44. Repeat for bottom gripper
45. Lock down all four gripper jack screws by turning the jam
nuts until contact is made with jaw face back-up plate
46. If necessary, sealing pressure can be increased from initial
set-up by turning the spring adjusting screws
WARNING:
Maximum number of additional turns are:
• 4 (6 total) for Model 12-16
• 3 (5 total) for Model 15-22
• One turn (360°) adds approximately 20 pounds force
(per side) on Model 12-16 or 30 pound (per side) on
Model 15-22.

47. Reinstall the knife

48. Adjust the knife linkage, so the tip of the cutting blade is
1/ in. below the sealing surface of the front jaw on the
16
right end of the jaw assembly:
a. loosen knife adjusting jam nut at end of knife air cyl-
inder rod
b. turn rod in or out of rod end to adjust the blade
c. tighten jam nut
49. After all adjustments have been made and set-up is com-
plete, loosen setscrews B
50. Turn back-up screws out until contact with carrier is made
51. Tighten setscrews B
IMPORTANT:
The back-up screws are to restrict jaw face deflection and are not
to be used as jack screws to force jaw face out.

52. Restore machine power

Additional Jaw Be sure all power to machine is Off.

Face Adjustment
WARNING:
The following procedure is not usually required and should only
be performed when additional front jaw face pressure is needed
for even sealing across the length of the jaw face.

Ultima® Macro 12-23/Rev 5

Combination End Seal System - Quali-Seal System

Additional adjustment is made with the four outer and two center jack
screws (square head).

CAUTION:
Turn jack screws in 10° increments. Each 10° of rotation yields
approximately 0.001 in. jaw movement. Maximum amount of
adjustment is 0.010 in. or 100° of rotation.

To increase pressure on the ends of the jaw face, loosen outer jaw face
mounting screws and turn top and bottom outer jack screws forcing jaw
face out. Tighten outer jaw face mounting screws.
To increase pressure in center of jaw face, loosen center mounting
screws and turn top and bottom center jack screws forcing jaw face out.
Tighten center jaw face mounting screws.
After all adjustments have been made and set-up is complete, loosen
setscrews B. Turn back-up screws out until contact with carrier is made
and re-tighten the setscrews and restore machine power.

IMPORTANT:
The back-up screws are to restrict jaw face deflection and are not
to be used as jack screws to force jaw face out.

Timing The timing specifications listed below should be used as guidelines.

Considerations The exact timing for each machine may vary depending on machine
speed and film.
• jaw open should occur no later than 300° to minimize the
sealing time and optimize cooling
• set the timing for the knife from 50° to 350°
• after the Quali-Seal jaws open, the stager remains closed;
this requires a 359° setting on stager open
EXAMPLE: FROM: +20of registration roller and pull
belt stop time and TO 359°
• time the bag eject system to eject the bag as late as possible
to allow for cooling and top seal set-up
• discharge the bag gently so the bottom of the bag leads the
top and is discharged without tipping
Additional Checks • end seal cooling air should remain on as long as possible
after the jaws open and be set for the maximum speed
• check the knife and die slot alignment to prevent the knife
from running into the die face
• inspect for and remove any polyethylene or product
build-up in the rear knife slot
• verify the heater wires are correctly clipped, looped, and
supported so they do not interfere with the knife

12-24/Rev 5 Ultima®Macro
 12
Wiring to Hayssen Quali-Seal jaws comes protected by heat resistant
flexible electrical tubing and is secured by clips to prevent wire break-
age at the terminals.

Wire Clips

Figure 11: Correctly Secured Quali-Seal Wiring

4-Sealing Rib On machines with four sealing ribs (two seals on top and two seals on
Variations bottom of bag), set up the sealing jaws as follows:

WARNING:
Verify the main electrical box disconnect is in the Off position
before making adjustments to avoid serious injuries.

1. Remove the knife by lifting the tabs on the ends of the

knife holder and sliding the knife out
2. Locate the edge of the top and bottom rear grippers and
verify the edges are flush against the mounting plate
3. Remove top and bottom front grippers
IMPORTANT:
A thin, 7/16 open end wrench is required to access bolt heads adja-
cent to the knife blade retainer bar.

a. Loosen the two gripper mounting bolts on the top

front gripper
b. Slide top front gripper Off
c. Loosen the two gripper mounting bolts on the bottom
front gripper
d. Slide bottom front gripper off
4. Loosen the hexhead cap screws on the clamping blocks
5. Turn spring housing until a gap appears between the
spring plunger and the jaw actuator rod
There is one on the right and one on the left
6. Retighten cap screws on spring housing clamping block

Ultima® Macro 12-25/Rev 5

Combination End Seal System - Quali-Seal System

7. Loosen the pressure adjusting and jam nuts on each side

until all tension is taken off springs
8. Loosen both 3/16 in. Allen head screws on deflection collars
9. Turn both deflection collars out of carrier ¼ in.
10. Push the jaws closed and lock on center using the jaw
linkage clamp block
11. Push the front jaw carrier until it just touches the deflec-
tion collars on both the left and right ends.
12. Turn both deflection collars into carriers until 2.590 in.
(±0.005 in.) is obtained between the finished surfaces of
the front and rear carriers on both the left and right ends
Use a Vernier Caliper to measure this.
13. Tighten all four Allen head screws on the deflection col-
lars
14. Turn pressure adjusting nuts 3½ turns beyond the point
where they just contact the springs
15. If necessary, re-adjust deflection collars to 2.590 in. on
both ends of carrier to ensure that the carriers are parallel
and slide freely
16. Turn pressure adjusting nuts until springs are compressed
to a length of 19/16 in.
17. Using a 1/16 in. Allen wrench, loosen both spring adjusting
screws
IMPORTANT:
The jam nuts on these screws back out with them.

18. Turn screws in by hand until contact is made and resis-

tance is just felt
19. From this point, turn screws an additional ½ turn
IMPORTANT:
Verify each screw is adjusted the same.

20. Tighten jam nuts on the spring adjusting screws

Be sure to hold the position of the screws while tightening the nuts.
21. Verify all eight jaw face mounting screws are tight
22. Verify the jaws are still closed and locked on center
23. Loosen cap screws on clamping block
24. Turn both spring housings simultaneously forcing the rear
jaw out until it contacts the rubber cushions along the full
length of the jaw face

12-26/Rev 5 Ultima®Macro
 12
25. Place a mark on the spring housing to use as a guide
26. Remove jaw linkage clamp block to unlock jaws
27. Turn each spring housing an additional ½ turn
28. Tighten the capscrews on the clamping blocks until the
housings are tight
29. Push the jaws closed until front and rear sealing faces
touch
30. Push the jaw linkage to final closed position noting move-
ment of rear sealing jaw
Rear jaw should deflect from 1/32 in. to 1/16 in.

IMPORTANT:
Maximum allowable deflection is 1/16 in.

31. Adjust spring housings if necessary to obtain correct

deflection
32. Turn power to machine On
33. Turn on jaw heat and allow jaws to heat up to 220°F
34. Place one piece of carbon paper against one piece of white
paper and tape to front jaw face, the stager, or the bottom
of the forming tube
35. Turn Off all functions except jaws and stager.
36. Run one cycle and check seal impression for even pres-
sure on top and bottom seals
37. If pressure is not even, adjustment can be made to the
front jaw through spring washers.
38. To adjust the front jaw:
a. remove machine power
b. loosen setscrews A on top or bottom

CAUTION:
When making adjustments, turn 1/8 turn (45°) at a time. Each turn
is approximately 0.005 in.

c. to increase pressure on top sealing surface, use a ¼ in.

long handled allen wrench to loosen upper adjusting
screws 1/8 turn forcing top of jaw out
d. to increase pressure on bottom sealing surface, use a
¼ in. long handled allen wrench to loosen lower
adjusting screws 1/8 turn forcing bottom of jaw out
e. Turn power On and check seal impression with carbon
paper

Ultima® Macro 12-27/Rev 5

Combination End Seal System - Quali-Seal System

f. If pressure is not even, turn power Off and repeat steps

c and d after each 1/8 turn until even pressure is
obtained
g. when even pressure is obtained and power is Off,
re-tighten setscrews A
39. Push the jaws closed and lock on center using the jaw
linkage clamp block
40. Install top front gripper with rubber cushion inserted in
slot
41. Turn both top gripper jack screws, forcing gripper out
until rubber cushion contacts rear gripper and a 0.020 in.
gap between front and rear gripper is obtained on both the
left and right ends
42. Tighten the gripper mounting bolts
43. Repeat for bottom gripper
44. If necessary, sealing pressure can be increased from initial
set-up by turning the spring adjusting screws
IMPORTANT:
Maximum number of additional turns is: 2 ½ (3 total).

• One turn (360) adds approximately 110 pounds of

force (per side)
45. After adjusting sealing pressure, the gripper pressure must
also be increased
a. loosen jam nuts on pressure adjusting nuts
b. Turn adjusting nuts to compress springs to final length
of 1¼
46. Reinstall the knife
47. Adjust the knife linkage, so the tip of the cutting blade is
3
/32 in. below the sealing surface of the front jaw on the
right end of the jaw assembly
a. loosen knife adjusting jam nut at end of knife air cylin-
der rod
b. turn rod in or out of rod end to adjust the blade
c. tighten jam nut
48. After all adjustments have been made and set-up is com-
plete, loosen setscrews B
49. Turn back-up screws out until contact with carrier is made

12-28/Rev 5 Ultima®Macro
 12
50. Tighten setscrews B
IMPORTANT:
These screws are to restrict jaw face deflection and are not to be
used as jack screws to force jaw face out.

51. Restore power to machine

Optional Round The hole punch assembly consists of a serrated tooth punch rod actu-
Sealed Hole Punch ated by an air cylinder. As the hole is being punched, film is gripped
between the punch guide block on the rear jaw and spring loaded
back-up block on the front jaw.
For sealed punches, these blocks are heated by a solid state tempera-
ture control which also regulates the temperature. The punch air cylin-
der is actuated through a timing function set on the machine controller.
The remaining tab stays attached to the bag.

Figure 12: Quali-Seal Jaws with Heated Hole Punch

SET-UP
Follow jaw set-up procedure. When locating grippers, locate both the
standard (non-hole punch) grippers and the hole punch grippers.

IMPORTANT:
Only one set of bottom grippers is installed on the machine at any
one time.

Ultima® Macro 12-29/Rev 5

Combination End Seal System - Quali-Seal System

ADJUST GRIPPING PRESSURE

To adjust gripping pressure on the back-up block:
1. Loosen the jam nuts
2. Turn adjusting screws to provide only enough pressure to
adequately grip the film while hole is being punched
IMPORTANT:
For sealed punches, adequate pressure must be obtained to seal
film in area around hole. Use Teflon Tape over sealing surfaces of
guide block and back-up block.

PUNCH ROD LOCATION ADJUSTMENT

1. Manually extend the punch rod holder to its maximum out
position
2. Loosen the clamp screws
3. Slide cylinder mounting plate until teeth on the punch rod
extend 5/16 in. beyond the guide block
4. Tighten the clamp screws

HEAT CONTROL ADJUSTMENT

1. Turn hole punch heater switch On
2. Adjust temperature controller to produce required seal
around hole
This setting varies depending on the type of film and machine speed.

IMPORTANT:
Adjust the heat to produce the seal around the hole and not the
hole itself.

TO RUN BAGS WITHOUT A HOLE PUNCH

IMPORTANT:
This is for sealed hole punches only.

1. Turn punch heat control Off

2. Remove machine power
3. Disconnect punch cylinder air lines at stopcocks
4. Loosen the clamp screws
5. Slide punch assembly off of glide bars
6. Loosen the two gripper mounting bolts on the bottom rear
gripper

12-30/Rev 5 Ultima®Macro
 12
7. Slide bottom rear gripper off with hole punch parts
attached
8. Loosen the two gripper mounting bolts on the bottom
front gripper
9. Slide bottom front gripper Off
10. Remove the two adjusting screws, and jam nuts from the
jaw mounting plate
11. Remove the two guide block mounting bolts
12. Remove the insulators, springs, back-up block, and guide
block from the jaw mounting plate
13. Slide standard front and rear bottom grippers On
14. Tighten the gripper mounting bolts
15. Restore machine power
16. Turn hole punch cylinder timing Off on operator interface

PUNCH CYLINDER TIMING

Set the timing of the punch cylinder to stroke out the punch rod just
after the jaws have closed.
The rod should be held out only long enough to cut the hole and pro-
duce a good seal around it. If it is held out too long, poly sealant may
buildup on the punch tip, causing erratic operation. Also, a hole may
be burned into the bag.

HOLE PUNCH MAINTENANCE

If the punch tip becomes contaminated with product or film do the fol-
lowing:
1. Press the Stop button and open the guard doors
2. Use a soft brass scouring pad or a soft dry cloth to wipe
clean
3. Check for wear and replace as required

CHANGING END SEAL SYSTEMS

To change sealing systems, the front and rear sealing jaw assemblies
have to be removed from the carriers.

Change from Poly To change from polyethylene film to cellophane film:

to Cellophane
1. Remove machine power
2. Unplug electrical disconnect for the sealing jaw

Ultima® Macro 12-31/Rev 5

Changing End Seal Systems

3. If the machine is not equipped with an electrical discon-

nect, undo the terminal strip in the carrier
4. Carefully remove the cutoff knife
5. Loosen cap screws and remove the sealing jaws for poly-
ethylene from the carrier
6. If jaws have a hole punch, disconnect the airline at stop-
cocks and turn stopcocks Off
7. Mount resistance jaws to carrier.
The pin must engage locating tongue in carrier to ensure correct align-
ment between front and rear jaw faces.
8. If equipped with a hole punch, connect air lines at the
stopcocks and turn On
9. Tighten cap screws
10. Install cutoff knife

WARNING:
Use caution when handling the knife. The knife edge is very sharp
and causes injuries if used incorrectly.

11. Install guards

12. Connect electrical lines for heaters
13. Restore power

Change from To change from cellophane film to polyethylene film:

Cellophane to Poly
1. Remove machine power
2. Unplug electrical disconnect for heater wires
3. If the machine is not equipped with an electrical discon-
nect, undo the terminal strip in the carrier
4. Loosen guard mounting screws and remove guards
5. Remove cutoff knife
6. Loosen capscrews and remove sealing jaws from carrier
7. If equipped with a hole punch, disconnect air lines at stop-
cocks and turn stopcocks to Off
8. Mount sealing jaws for polyethylene to carrier.
The pin must engage slot and that groove in mounting block must
engage locating tongue in carrier to ensure correct alignment between
front and rear jaw faces.
9. If equipped with a hole punch, connect air lines at stop-
cocks and turn stopcocks to On
10. Tighten capscrews
11. Carefully install cutoff knife
12-32/Rev 5 Ultima®Macro
 12
12. Install guards
13. Connect electrical line for sealing jaws (and hole punch, if
applicable) at main electrical enclosure
14. Restore power
IMPULSE SEALING SYSTEM

Figure 13: Impulse Sealing System for Polyethylene

A. Counterclockwise rotation 1. Spring washers 3. Cap screws

B. Direction of sealing jaw 2. Adjusting screws 4. Pin

movement when adjusting
screw is turned counterclock- 1. Setscrew at end of each adjust- 5. Mounting block
wise. ing screw

2. Guard mounting screws 6. Chilled water lines

Sealing Jaw To produce good end seals, even pressure must be maintained between
Alignment the sealing ribbons and backup rubbers in the front sealing jaw.
Even pressure is obtained by means of spring washers (1) and adjust-
ing screws (2). Turning these screws causes the sealing jaw to move at
the point of each screw (A). The sealing jaw moves in direction (B).
By turning one or all of these screws, in any combination, the sealing
jaws can be positioned to achieve even pressure across the entire
length of each sealing ribbon.

Ultima® Macro 12-33/Rev 5

Impulse Sealing System

Begin by adjusting the front (knife side) sealing jaw; if correct adjust-
ment cannot be achieved, adjust the rear jaw in the same manner. To
adjust the sealing jaws.
1. Padlock electrical disconnect in the Off position
2. Loosen setscrew at each adjusting screw
3. Loosen guard mounting screws on machines with
impulse/resistance combination sealing only
4. Turn adjusting screws clockwise until tight and spring
washers are fully compressed
5. Run sample bags and check end seals
6. If seal is uneven, turn appropriate adjusting screw to
achieve an even seal
IMPORTANT:
A 45° turn of the screw results in approximately 0.005 in.
(0.13mm) of sealing jaw movement.

7. Tighten setscrews (3) and mount screw (4).

Changing End To change sealing systems (polyethylene to cellophane and cellophane
Seal Systems to polyethylene) remove the front and rear sealing jaw assemblies from
the carriers.
POLY TO CELLOPHANE
To change the sealing system from polyethylene to cellophane, use the
below figure and follow the instructions.

Figure 14: Water Line Connections for Polyethylene (Impulse Jaws)

F. From water chiller 1. Front jaw

T. To water chiller 1. Rear jaw

U. Upper port 2. Mounting storage bracket

12-34/Rev 5 Ultima®Macro
 12
1. Remove machine power
2. Unplug electrical disconnect for the sealing jaw
3. Remove water cooling lines
4. Remove cutoff knife
5. Loosen cap screws and remove the sealing jaws for poly-
ethylene from the carrier
6. If jaws have a hole punch, disconnect air lines at stop-
cocks and turn stopcocks to Off position
7. Mount resistance jaws to carrier
The pin must engage locating tongue in carrier to ensure correct
alignment between front and rear jaw faces.
8. If equipped with a hole punch, connect air lines at stop-
cocks and turn stopcocks to On position
9. Tighten cap screws
10. Install cutoff knife
WARNING:
Use care when replacing the knife.

11. Install guards

12. Connect electrical lines for heaters
13. Restore power

CELLOPHANE TO POLY
To change from cellophane to polyethylene end seal system, use these
instructions.
1. Remove machine power
2. Unplug electrical disconnect for heater wires at the main
electrical enclosure
3. Loosen guard mounting screws and remove guards
4. Remove cutoff knife
5. Loosen capscrews and remove resistance sealing jaws
from carrier
6. If equipped with a hole punch, disconnect air lines at stop-
cocks and turn stopcocks to Off position
7. Mount sealing jaws for poly to the carrier
The pin must engage the slot and the groove in mounting block must
engage locating tongue in carrier to ensure correct alignment between
front and rear jaw faces.

Ultima® Macro 12-35/Rev 5

Optional Accessories Poly Impulse Sealing

8. If equipped with a hole punch, connect air lines at stop-

cocks and turn stopcocks to On position
9. Tighten cap screws
10. Install cutoff knife
11. Install guards
12. Connect electrical line for sealing jaws (and hole punch, if
applicable) at main electrical enclosure
13. Restore power

OPTIONAL ACCESSORIES POLY IMPULSE

SEALING
First Bag SCR The first bag sealing system maintains constant sealing temperatures
Sealing System by automatically controlling the impulse power applied to the sealing
load (sealing ribbons). The degree of compensation is determined by
the continuous sensing of the current and voltages of the sensing load.
.

Figure 15: Control and Calibration Areas

CONTROLS AND CALIBRATION

The first bag SCR has the following controls and calibrations:
• 50/60 Hertz - this is the first of four dip switches on the
printed circuit board of the control unit. This dip switch is
used for frequency selection.
• 2.5/0.45 Seconds (A) - this is the second of four dip
switches on the board. This switch permits one of two maxi-
mum impulse times (450ms or 2.5s) without replacement of
the external potentiometer.

12-36/Rev 5 Ultima®Macro
 12
• 21/29 Amperes (A) - this is the third of four dip switches on
the board. This switch permits maximum impulse current of
21 or 29 amperes.
• R - ON/ - Off - this is the fourth of four dip switches on
the board. This switch permits operation with or without
temperature compensation. R - Off = without compensa-
tion.
• LED1(B) - one of three LEDs on the printed circuit board of
the control unit. This red LED illuminates only if an
over-current condition occurs, indicating that the SCR pulse
generator is Off.
IMPORTANT:
To reset this condition, the power supply must be turned Off.

• LED2(B) - the second of three LEDs on the board. This red

LED illuminates only if the load resistance is higher than
the reference value.
• LED3 (B) - the third of three LEDs on the board. This green
LED illuminates if the load resistance is lower than the ref-
erence value.
• Trimmers - there are 11 trimmers on the control unit printed
circuit board, 8 of which are preset. Three remaining trim-
mers (C) are identified as reference element, preheat maxi-
mum, and preheat minimum. Preheat minimum and preheat
maximum trimmers are designed for independent mini-
mum/maximum settings for the preheat. The reference ele-
ment trimmer is used to calibrate the control unit for a
specific load.
• 200 Milli-amp fuse on the printed circuit board of the con-
trol unit provides on-board protection for the incoming
power supply.
• 30 Ampere Semiconductor Fuse (E) - this fuse protects the
SCR output device and is mounted on the main body of the
control unit along with a spare.
• Input/Output Terminations - power terminals 1 and 2 are
used for sealing load connection. Terminals 3, 4, and 5 are
used for input control power.

Ultima® Macro 12-37/Rev 5

Optional Accessories Poly Impulse Sealing

SETUP AND CALIBRATION EXAMPLE

Terminal Usage
Terminals 3 and 4 115V

Terminals 3 and 5 230V

Terminals 6, 7, and 8 Preheat potentiometer connection

points (5 k ohm)

Terminals 9, 10, and 11 Impulse magnitude connection points

(5 k ohm)

Terminals 12, 13, and 14 Preheat and impulse control

Continuity between 12 and 13 turns
on preheat
Continuity between 12 and 14 turns
on impulse

Terminals 13 and 14 Positive in reference to terminal 12

Terminals 15 and 16 Impulse time potentiometer connec-

tion points (50 k ohm)

Terminals 17 and 18 Reference connection points across

the load

Terminals 19 and 20 Connection points for an auxiliary

impulse contact. These contacts are
closed for the impulse duration.

Use the following steps as an example for setup and calibration.

1. Set dip switch 50/60 Hertz to line frequency
2. Set dip switch 0.45/2.5 seconds to 0.45 seconds
3. Set dip switch 21A/29A to 21A
4. Set dip switch R-Off/R-On to R-Off
5. Set all external potentiometer controls to minimum
6. Adjust preheat minimum trimmer for some negligible
value or zero (observe light)
7. Adjust preheat maximum trimmer for a convenient value,
allowing the necessary range on external control
a. Set external potentiometer controls for correct sealing
(bagger to run continuously at the lowest cycle rate for
normal production running)
b. With the bagger running as in step 8, adjust reference
element trimmer so LED2 and LED3 are off or both
blinking

IMPORTANT:
Allow time for stabilization. 15 to 20 bags is typical.
12-38/Rev 5 Ultima®Macro
 12
c. Set dip switch R-Off/R-On to R-On
IMPORTANT:
• Re-calibration may become necessary with any signifi-
cant change in the sealing system, such as a major
difference in potentiometer settings, film gauge, or
cooling system.
• LED 1 is an over-current indicator as set in Step 3.
When an over-current occurs, the output shuts down
and LED 1 turns On. To reset, turn sealers Off.

Change To change sealing system from cellophane to polyethylene, use the fol-
Cellophane to Poly lowing procedure:
1. Remove machine power
2. Unplug electrical disconnect for heater wires at the main
electrical enclosure
3. Loosen guard mounting screws and remove guards
4. Remove cutoff knife
5. Loosen capscrews and remove resistance sealing jaws
from carrier
6. If equipped with a hole punch, disconnect air lines at stop-
cocks and turn stopcocks to Off position
7. Mount impulse sealing jaws to carrier
The pin must engage the slot and the groove in the mounting block
must engage locating tongue in carrier to ensure correct alignment
between front and rear jaw faces.
8. If equipped with a hole punch, connect air lines at stop-
cocks and turn stopcocks to On position
9. Tighten cap screws
10. Install cutoff knife
11. Install guards
12. Connect electrical line for sealing ribbons (and hole
punch, if applicable) at main electrical enclosure
13. Connect water lines, if applicable, at front and rear sealing
jaw

Ultima® Macro 12-39/Rev 5

Water Cooling Unit

Figure 16: Water Line Connections for Polyethylene (Impulse Jaws)

F. From water chiller 1. Front jaw

T. To water chiller 1. Rear jaw

U. Upper port 2. Mounting storage bracket

12. Restore power

WATER COOLING UNIT

The TempriteModel TR4-14 water cooler has been modified to circu-
late either cool or warm water through impulse sealing jaws as an
optional accessory. A pump at the bottom of the cooler circulates water
through the system. When the chiller switch on the chiller unit is in the
Off position, no water is circulated.
When the chiller switch is in the cold position, water at 50-60 °F
(10-15 °C) is circulated. In the hot position, water at 90-106 °F
(33-41°C) is circulated.

Filling the System The system is filled through the bottle reservoir.
1. Open stopcock
2. Fill through reservoir until water comes out of stopcock
3. Close stopcock
4. Fill reservoir to top
5. Operate pump and sealing jaws for 5 minutes to remove
air from the lines
6. Repeat steps 1 through 4

12-40/Rev 5 Ultima®Macro
 12
Replacing the If the temperature controller requires replacement, use the following
Temperature procedure:
Controller
1. Install new controller (set adjusting screw to full counter-
clockwise position)
2. To determine when heater is On, connect ammeter to hot
wire of heater
Ammeter should read 5-6 A when heater is On.

IMPORTANT:
Compressor and heater cannot be on at the same time.

3. Turn chiller switch to hot position

4. Observe temperature rise at upper gauge on connection
block
5. Set heater control to turn heater Off at 98 °F (37 °C)
IMPORTANT:
Heater should turn Off at 98 °F (37 °C) and turn On at 93 °F (34
°C).

Replacing the If the temperature controller requires replacement, use the following
Temperature procedure:
Controller at the
Compressor 1. Install the new controller (set adjusting screw to full coun-
terclockwise position)
2. Install a jumper wire to bypass the heater temperature
controller
This allows water to be heated above 98 °F (37 °C).
3. Turn chiller switch to hot position
4. Observe temperature rise at upper gauge on connection
block
5. Set compressor temperature control to turn compressor
On at 106°F (41°C)
IMPORTANT:
Compressor should turn on at 106 °F (41 °C) and OFF at 101 °F (38
°C).

6. Disconnect jumper wire installed during step 2

Ultima® Macro 12-41/Rev 5

Water Cooling Unit

12-42/Rev 5 Ultima®Macro
 12
CHAPTER 12: TRANSMISSION & ENCODER
The transmission provides separate and continuous drives for the regis-
tration rollers, pull belts and encoder. A variable speed DC motor
drives the spur gears. These gears, through bearing-mounted shafts,
drive gears that turn the registration roller output shaft, pull belt output
shafts, encoder drive gear and encoder.

Encoder Rotary
Motor Drive
Gear Encoder
Output
Shaft

Registration
Roller
Output
Shaft

Pull
Belt
Output Shaft

Figure 1: Transmission

Long/Short Lever The transmission lever must be placed in either the short bag (usually
shorter than 12 in.) or long bag (usually longer than 12in.) mode. In the
short bag mode, 1° of machine time is equal to 0.105 in. of film pull or
10° of machine time is equal to approximately 1 in. of film pull. In the
long bag mode, 1° of machine time is equal to 0.164 in. of film pull or
7° of machine time is equal to approximately 1 in. of film pull.

Motor A ½HP 90 VDC motor drives the transmission. A drive signal is trans-
mitted from the motor drive board in the electrical cabinet.
New brushes in the motor are ¾ in. (19mm) long. Brush wear is nor-
mal in constant speed DC motors. Replace the brushes when they wear
to 3/8 in. (10mm) or half of their original length. Because the motor
housing is sealed to protect from moisture and product debris, the car-
bon from the brush wear has no way to escape. On some motors, the
carbon build up can create short circuits that cause the windings to
burn out. To prevent this, it is a good idea to blow the motor housing
out with low pressure air on a regular basis.

Ultima® Macro 12-1/Rev 5

Encoder

ENCODER
Operation The rotary encoder is driven continuously. With each 360° revolution,
it sends out 360 pulses that provide timing signals for all machine func-
tions.
Upon receiving a signal from the feed system, the machine controller
begins to count these pulses. It compares them to the digital settings
and issues commands to the required functions.
At the end of the packaging cycle, (though the encoder continues to
rotate and send pulses) the machine controller stops counting and issu-
ing commands until it receives another signal from the feed system.

MAINTENANCE
The transmission is normally a low maintenance component. Routine
preventative maintenance checks should be performed to increase
transmission life and ensure lasting performance.
Periodic oil changes help to prevent rust, corrosion, and pitting. Clean
oil reduces internal friction and can reduce power costs. Best perfor-
mance occurs when the transmission oil is drained and refilled every
six months.

Changing Drain and fill the oil in the transmission every 6 months. Remove the
Transmission Oil cover or open the filler cap to fill the housing.
Use two (2) quarts of USDA approved HI (AA) rated SAE oil. The
drive gears for the pull belts need to be immersed approximately ½ in.
(13 mm). Replace the cover using LocTite 515.
1. Remove machine power
2. Drain the old oil through the drain tube on the rear of the
transmission
3. Wipe the drain tube plug clean before reinserting into the
housing
4. Remove the cover or open the filter cap to fill the housing
IMPORTANT:
Filling the transmission without the filter screen in place can
allow contaminants to enter the transmission housing.

12-2/Rev 5 Ultima®Macro
 12
5. Fill the housing until the oil level is approximately ½ in.
(12.5 mm) over the drive gears for the pull belts
Use two quarts of USDA H1 approved SAE 30 non-foaming food
grade oil.

CAUTION:
Do not overfill. There is no seal around the motor shaft. Overfill-
ing the housing allows oil to seep into the motor and cause dam-
age.

6. Reinstall the filter cap

7. If the transmission cover was removed, use LocTite 515
8. Restore electrical power

Encoder Removal 1. Lock out electrical power to the machine

and Replacement 2. Remove connector from the encoder
3. Loosen the allen head set screw in the rubber coupling
4. Remove the four mounting screws which secure the plate
with the encoder to the transmission bracket
5. Remove the encoder from the plate
6. Inspect the rubber coupling and replace if it is hard and
brittle
IMPORTANT:
The rubber coupling must be soft and pliable. If it is hard and brit-
tle, it can create radial thrust that leads to early encoder failure
and timing errors.

7. Attach encoder to the plate using the four screws removed

in step 5.
8. Attach encoder and plate to the transmission bracket using
the four screws removed in step 4.
9. Tighten the allen head set screws in the rubber coupling.
10. Restore electrical power.

Motor Inspection Inspect the motor every six months or 2000 hours of operation.
Replace brushes that are worn to one half of their original length or to
3/ in. (10 mm).
8

Carbon from normal brush wear accumulates inside the motor housing
and can cause low resistance paths for circulating current on the motor
windings. Open both brush covers and blow the carbon dust out of the
motor using low or medium pressure air.

Ultima® Macro 12-3/Rev 5

Maintenance

12-4/Rev 5 Ultima®Macro
 13
CHAPTER 13: PNEUMATIC SYSTEM
The pneumatic system directs airflow for package seal cooling and
lubricated air for the valves and air cylinders. The system consists of a
filter, regulator, pressure gauge, oil line lubricator, and a smooth start
or dump valve. The factory default air pressure is set at 65 PSI. For
greater efficiency, use incoming air pressure of more than 65 PSI. An
air pressure switch stops the machine if the air pressure falls below 40
PSI. The major components of the pneumatic system are accessible by
opening the side doors.

Figure 1: Pneumatic System Components

The pneumatic system consists of two sections. The first is the air
input system. It provides conditioned air to the various machine func-
tions. The second section is the air manifold and valve system. It
switches the air On or Off in the correct sequence with the machine
cycle.
Ultima® Macro 13-1/Rev 5
Air Input System

AIR INPUT SYSTEM

IMPORTANT:
Clean, dry air must be supplied to the machine.

Filter Regulator The incoming air is filtered to remove particles and moisture. The reg-
with Gauge ulator is factory set at 60 - 65 psig for correct operation of the machine
functions. This regulator has no adjustment.
The filter unit must be periodically emptied and cleaned to remove the
collected moisture and dirt. Refer to the manufacturer's information for
maintenance procedures.

CMB Regulator This regulator controls the force with which the CMB's extend. Adjust
with Gauge the regulator to approximately 30 psig.

Dataweigh The Dataweigh regulator supplies air to the trap door actuators. Set the
Regulator with regulator to approximately 40 psig.
Gauge

Lubricator The lubricator adds a light oil mist to the air to lubricate the air cylin-
ders. Use a non-detergent oil of SAE 10. Set the oil flow for approxi-
mately 1 drop every 4 cycles. Fill the lubricator when it is below ¼ full.

Shut Off and This valve is solenoid operated. When energized, it allows air to flow
Dump Valve to the machine functions. When de-energized, it stops the air flow and
removes air pressure on the cylinders.

CAUTION:
The shut off and dump valve does not control the air to the CMB
cylinders. The air supply to the machine MUST be removed
before doing any maintenance in this area.

Air Pressure This switch is located in the electrical cabinet. It detects when the air
Switch pressure is not adequate for correct machine operation. If the pressure
drops below 40 psi the machine stops and the visual display reads
"Low Air Pressure".

Flow Control Flow control valves meter the flow of compressed air in one direction
Valves while allowing free flow in the reverse direction. By adjusting the con-
trol knob on the valve, the speed of the air-operated components on the
machine can be regulated.
Record correct setting number. If the valve does not function correctly,
remove and clean it. If this does not help, replace it.

13-2/Rev 5 Ultima®Macro
 13
Air Valve and The air valve and manifold assembly is made up of the valves needed
Manifold for the machine functions. They are mounted on a segmented base.
Assembly
The valves are 4-way, 2 position, solenoid pilot operated. They plug
into the base which permits easy maintenance.

Figure 2: Manifold Assembly and Function Decal

Valves 1, 2, and 3 pass clean, non-lubricated air. The other valves pass
clean lubricated air. The valve receives a signal from the machine con-
troller to energize and actuate a particular function. When completed,
the controller de-energizes the valve and exhausts the air.
The functions performed by the valves are listed on the function decal
on the side of the manifold. An alternate list is on an assembly drawing
in the manual.
The standard valve functions are end seal air, knife, jaws, and platen.
Optional valve functions are Quali-Seal, hole punch, air tuck, seam
seal air, tube air, bag eject, poker, tucker, stager, shaker, shaker jaws,
pre-tuck, stripper, flap deflector, and printer.

Exhaust Silencer The exhaust silencer separator is located in the center of the bottom of
Separator the manifold. It must be kept clean to avoid any back pressure. Inspect
weekly and clean as required. If the muffler shows any damage replace
it.

Optional This unit has sensing elements in the filter and lubricator containers. If
Maintenance Alert the filter has too much water, the sensor reports this to the controller.
and Prevention The machine stops and the display reads "Fill Lube Oil/Empty Water."
System (MAPS)
If the lubricator is low on oil the machine stops and the display reads
Fill Lube Oil/Empty Water.

Ultima® Macro 13-3/Rev 5

Pneumatic System Maintenance

PNEUMATIC SYSTEM MAINTENANCE

Air Drain water as necessary.
Filter/Regulator
IMPORTANT:
Inspect the air filter/regulator if the air supply has a high mois-
ture content.

1. Place a container under the filter/regulator

2. Open the stopcock and drain the water into the container
3. Close the stopcock

Exhauster/Silencer 1. Remove the rubber cap on the drain outlet to allow accu-
mulated oil/moisture to drain
2. Remove the screw inside bottom of the exhauster/silencer
3. Pull downward to remove the plastic bowl
4. Clean the plastic bowl with soap and water and wipe dry
5. Wash the filter using soap and clean water
6. Rinse and dry before re-installing
7. Reassemble the exhauster/silencer

Lubricator Add oil if the level falls below ¼ of the minimum level.
1. Remove machine power
2. Bleed air from the system by pressing the E-Stop button
3. Open the fill port on top of the lubricator
4. Fill with SAE 10, clean non-detergent oil
5. Close fill port
6. Restore air pressure to 65 PSI

Oil Delivery Rate Use a screwdriver to turn the adjusting screw located on the top of the
lubricator. Turn the screw clockwise to decrease the oil delivery rate or
counterclockwise to increase the oil delivery rate.

Lubricator Bowl 1. Tag out air pressure to machine

2. Bleed air from system by pressing E-Stop button
3. Remove bowl
a. Press downward on latch
b. Twist metal bowl guard slightly in clockwise direction
c. Pull metal bowl guard down
4. Pull plastic bowl down with a twisting motion

13-4/Rev 5 Ultima®Macro
 13
5. Drain any contaminates that may have collected in the
bottom of bowl into an approved container
6. Clean plastic bowl with soap and water
7. Wipe dry
8. Clean the siphon tube by removing and blowing low pres-
sure air through it
9. Re-install plastic bowl by pressing firmly into position
with a slight twisting motion
WARNING:
Do not operate the machine without the metal bowl guard in
place.

10. Re-install metal bowl guard

11. Restore air pressure at 65 PSI

Ultima® Macro 13-5/Rev 5

Pneumatic System Maintenance

13-6/Rev 5 Ultima®Macro
 14
CHAPTER 14: TROUBLESHOOTING
CAUTION:
When performing any troubleshooting task, refer back to the indi-
vidual chapters in this manual for safety guidelines for the area of
the machine in which work is being performed..

TROUBLESHOOTING GUIDELINES
1. Search the Problems and Solutions tables in this chapter,
or applicable vendor literature, for the specific issue.
a. If the problem is not listed, proceed to step 2.
b. If the problem is listed, follow the possible solutions
to resolve.
• If the problem is not resolved using the possible
solutions, proceed to step 2.
2. Gather the following information, before calling Hays-
sen’s Technical Support
a. Instruction Manual for the equipment.
b. Parts Manual for the equipment.
c. Detailed description of the problem, and corrective
actions taken to this point.
Include such information as error codes and symptoms.
d. Parts on hand.
e. Machine serial number.

The placard with the machine

serial number is normally
mounted on the outside of the
electrical cabinet.

Machine serial number

3. Call Hayssen’s Technical Support at (864) 486-4111 and

select Option 3.
Other Hayssen contact information is listed in the How to Use the
Parts Manual to Order Replacement Parts section of the Instruction
Manual and the Parts Manual.

Ultima® Macro 14-1/Rev 5

Basic Troubleshooting For Operators

BASIC TROUBLESHOOTING FOR OPERATORS

The bagger is divided into two systems for easier troubleshooting. Sys-
tem I consists of the unwind stand to the registration rollers. System II
consists of the registration rollers to the end seal jaws.
Cleaning with soap and water often solves many major problems.
Always install new parts when any assembly is broken. Use this four
step procedure when troubleshooting:
4. Check for dirt.
5. Check for correct setup by operator and mechanic.
6. Be sure the packaging material is within specifications.
7. Check the machine for mechanical or electrical assembly
failure.

Figure 1: Troubleshooting Diagram

1. Roll of film 6. Printer 11. Back seal bar

2. Stationary rollers 7. Registration rollers 12. Forming tube
3. Dancer rollers 8. Registration mark scanner 13. Pull belt
4. Tension assist spring 9. Last roller 14. End seal jaws
5. Leaf spring 10. Forming tube assembly

14-2/Rev 5 Ultima®Macro
 14
PACKAGING MATERIAL FEED SYSTEM

Problem Probable Cause Corrective Action

• Clean the roll brake and drum with solvent
Roll brake and drum dirty
brake cleaner.

Roll not tight on spindle • Tighten the roll.

• Reposition the roll (refer to Packaging

Roll is misplaced on spindle
Material Unwind Stand chapter).

Roll is unevenly wound or telescopes on • Replace the roll.

core

• Check specifications of the packaging

Too much friction
material.

• Re-thread (refer to Packaging Material

Packaging material incorrectly threaded
Unwind Stand Chapter).

Packaging material is Packaging material is stretched exces- • Inspect, clean or replace the film feed
sively or its motion is restricted roller bearings.
not tracking correctly
(System I) • Replace the roll.
• Check storage procedures and stock
Edges of packaging material curl
• Refer to Packaging Material Unwind
Stand Chapter.

• Inspect the stock.

• Consult manufacturer for storage / techni-
Moist packaging material cal advice
• Refer to Packaging Material Unwind
Stand Chapter.

Tension assist springs not hooked • Re-adjust springs.

evenly

Leaf springs or coil springs on shock • Re-adjust or replace.

roller are broken or adjusted incorrectly

Packaging material is • Clean with soap and water. Use Scotch-

Pull belts dirty
not tracking correctly brite on red pull belts only.
(System II) Incorrect timing • Check settings on machine controller. Pull
[loss of tension or loop- belts start prior to registration rollers by
ing between registra- about 5° to 20° on CMBs.
tion rolls and former]

NOTE:
Some films can cause excessive
pull belt wear. To remedy this,
decrease pull belt timing but not
to the point where the packag-
ing material begins to loop.

Pull belts not centered to tube and • Refer to Machine Setup

former

• Make sure there is a maximum gap of 1/16

Pull belt pressure set incorrectly
in. between casting and pressure washers.

Ultima® Macro 14-3/Rev 5

Print Registration

Problem Probable Cause Corrective Action

Nicked, dented, or badly worn edges on • Repair or replace forming shoulder and
Torn packaging material forming tube.
forming shoulder and forming tube

Foreign particles on packaging material • Protect packaging material against con-

cause it to bind between forming shoul- tamination.
der and forming tube
Torn packaging material
(continued) • Replace with roll of correct width (refer to
packaging material size chart supplied
Packaging material is too wide
with machine and to Packaging Material
Unwind Stand).

• Adjust the seam sealer so it is ¼ in. to 3/8

Seam sealer is too close to the tube
in. (6 to 9.5mm) from the tube

Packaging material • Adjust temperature. Typical temperature

Incorrect temperature
sticking to tube, bunch- settings are 275 to 325° (135 to 163°C).
ing at bottom, not feed- Incorrect timing • Check settings on the machine controller.
ing or being pulled
incorrectly Spreaders too far apart • Move spreaders closer together.

Packaging material sticking to backup • Remove 1 in. of rubber at bottom of tube.

rubber

PRINT REGISTRATION

Problem Probable Cause Corrective Action

• Wash with soap and water. Use Scotch-
Dirty pull belts or registration rollers
brite on red pull belts only.

• Inspect light source and sensor of scan-

ner for dust or other obstructions.

• Check the eye scanner position

• Check the eyespot size and contrast.

• Spots may be dark enough, but too

Eyespots are not reliably registered or
Faulty registration small.
are not registered at all
• Red eyespots, although large and dark,
cannot be sensed reliably.

• Reset the eye sensitivity.

• Refer to the print registration setup pro-

cedure.

Bag length in plain film mode not equal • Increase the registration roller From
to the final cutoff + 3/8 in. value.

14-4/Rev 5 Ultima®Macro
 14
REGISTRATION ROLLER CLUTCH/BRAKE
PROBLEMS
1. Using an oscilloscope, check the registration roller brake
voltage while the machine is idling.
2. Check the registration roller clutch voltage by pressing
Continuous Tube to generate a steady clutch voltage sig-
nal at the circuit board.
IMPORTANT:
To avoid wasting packaging material, do not thread the machine.

3. Connect the oscilloscope to the clutch and brake terminals

on the circuit board. Set the oscilloscope sweep time to 2
ms/div. at 5 VDC/div. (0.5 Vdc with 10X probe).
4. Examine voltage trace. A single 40 ms overexcite pulse
occurs and then the pulses are as shown below.

Ultima® Macro 14-5/Rev 5

Registration Roller Clutch/brake Problems

30V
10 ms *1.2 ms for brake
* 1.5 ms for clutch
25V

20V

15V

10V

5V

0V

0 2 4 6 8 10 12 14 16
ms
• The brake voltage shows 24 VDC pulses, approximately 1.2
ms wide at 10 ms intervals.
• The clutch voltage shows 24 VDC pulses, approximately
1.5 ms wide at 10 ms intervals.
5. If the trace is different than this:
a. Turn all power OFF
b. Disconnect the wires of the circuit under test.
c. Restore power
6. Examine the voltage trace
a. If the trace is correct, troubleshoot the coil circuit.
b. If the trace is incorrect, replace the circuit board.

14-6/Rev 5 Ultima®Macro
 14
SEAM SEAL SYSTEM

Problem Probable Cause Corrective Action

Dirty sealing bar • Clean with a soft cloth.

Platen set incorrectly • Refer to the Seam Seal System chapter.

• Reduce seam seal temperature until no

seal is obtained. Gradually increase the
Seam seal temperature is too high
temperature as required to produce an
acceptable seam seal.

Packaging material sticks to sealing • Check Teflon® tape or insert on the

area of forming tube tube. Replace if necessary.
Weak seam seal
• Increase the seam seal temperature and
Seam seal temperature is too cool wait for heaters to reach operating tem-
perature.

No cooling air • Open the air valves for the seam sealer.

• Increase the air volume and decrease

Insufficient cooling
the seam seal temperature, if possible.

Incorrect setting of last roller on former • Refer to the Forming System chapter

Back stop set incorrectly • Set back stop 1/32 in. from tube.

• Check the width of the packaging mate-

rial and the diameter of the tube (refer
Insufficient lap
to the packaging material size chart
Seam seal is too narrow supplied with the machine).

• Decrease the pull belt stop time until

Pull belts running too long looping occurs, then increase approxi-
mately 5%.

BAG CUTOFF

Problem Probable Cause Corrective Action

• Check machine timing. The knife starts
Knife is not timed correctly
at the same time as the jaw open/close.

• Check if proximity switch is sending

Proximity switch requires adjustment
signal to machine controller.

Flow controls and cushions require • Adjust the knife cylinder flow controls
Knife does not cut adjustment and cushions.

• Increase the dwell time of the jaw

Insufficient dwell time
open/close and knife.

• Reverse the knife in the jaw (flip over).

Knife dull
• Sharpen the knife with a fine stone.

Ultima® Macro 14-7/Rev 5

End Seal System

END SEAL SYSTEM

Problem Probable Cause Corrective Action

Dirty jaws • Clean with a brass brush

WARNING:

110 VAC present. Turn Off

the temperature controllers

• Adjust jaw and seam seal temperatures

Temperature is too hot or cold to the lowest temperatures that produce
Weak end seal strong seals.

• Set bag eject so it supports filled pack-

Bag eject set incorrectly (poly)
age.

Timing incorrect • Start jaw timing 10 - 30° earlier.

Inocorrectly set speed, linkage, and • Refer to the End Seal System chapter.
pressure-last number on jaw close dis-
play varies more than ±1°.

Jaw is closed too long • Decrease jaw close dwell time.

• Increase sealing temperature on con-

trollers
Heat is too low
• Check for low voltage
End seal burned on
resistance seal Sealing temperature too high • Reduce heat.

• Readjust jaw pressure and compression

travel (refer to Maintenance).
Uneven jaw pressure
• Check packaging material specifica-
tions.

Spreaders too close together • Readjust the spreaders.

Bag eject too high • Lower the bag eject.

Wrinkles in end seals
Stager / shaker or jaws / strippers clos- • Close flow controls in 1/2 to 1 turn
ing too fast

14-8/Rev 5 Ultima®Macro
 14

Problem Probable Cause Corrective Action

Incoming air line undersized or remote • Air line must equal or exceed size of
from compressor inlet on air regulator

• The recommended pipe size is for a

Various other machines are connected short line connected directly to the
to air line between bag making machine main supply. Additional connections
and compressor cause a pressure drop which stops the
machine.

Frequent machine stop- Use a high volume cleanup nozzle con- • Same as previous corrective action
pages nected to the same line as the bag described.
maker

Dirty air filter • Remove filter and clean.

• Drain water on a predetermined sched-

Water not drained from filter bowl ule (filter is ineffective once water level
reaches filter element).

Frequent water accumulation in bowl • Add after cooler to compressor.

Plugged filter • Clean or replace filter.

Defective diaphragm • Replace diaphragm

No air from regulator
Defective adjusting screw • Replace adjusting screw.

Defective seals • Replace the seals

• Check voltage and Hertz at the coil lead

Solenoid valve coil terminals.
Wrong line voltage or frequency
buzzes
• Review nameplate data.

• Check for current flow at coil lead ter-

Solenoid coil is not energized
minals
Solenoid valve does not • Use a test lamp and test for coil conti-
move when solenoid is nunity.
energized Solenoid coil is burned out
• Check for magnetism of activated coil.

• Repair or replace parts as necessary.

• Tap lightly to release plunger.

Solenoid plunger is stuck in its guide
• Check for rust or burns.
Solenoid valve does not
move when solenoid is Worn or damaged parts in valve • Repair or replace.
de-energized
• Check air filer.
Contaminated valve seating parts
• Repair or replace parts as required.

Solenoid valve opera- Foreign matter contamination • Clean filter and valve.
tor vent leaks air when it
is energized Defective parts • Replace parts as necessary.

Solenoid valve opera- Foreign matter contamination • Clean filter and valve
tor vent leaks air when it
is de-energized Defective parts • Renew parts as necessary.

Ultima® Macro 14-9/Rev 5

Error Messages

Problem Probable Cause Corrective Action

Foreign matter contamination • Clean filter and valve.
Continuous air leak from Defective parts • Renew parts as necessary
valve exhaust port of sole-
noid valve • Check cylinder.
Defective cylinder piston cups
• Replace cups and packing

Piston cups are worn • Use repair kit to rebuild cylinder.

Air cylinder leaks at ports
Rod seals are worn • Use repair kit to rebuild cylinder.

Misalignment between piston rod and work • Disconnect piston rod and check align-
piece connection ment throughout length of stroke.

• Check cylinder for undue wear.

Worn parts
Air cylinder jerks or hesi- • Repair internal parts.
tates while piston rod is
moving Foreign matter contamination • Check filter and clean as required.

Air pressure too high or too low; incorrect • Run a systems and flow check.
size air lines

Flow control clogged • Replace flow control

Air cylinder pounds or Piston rod cushion is worn out • Replace internal parts.
hammers at end of stroke Flow control adjusted incorrectly • Adjust flow control

Loose packing gland • Tighten packing.

Air cylinder leaks at pis-
Worn piston rod • Repair or replace piston rod.
ton rod
O-rings worn • Replace O-rings.

Piston cup worn • Replace piston cup.

Loosened piston rod nut • Tighten piston rod nut.

Dirt or rust in cylinder • Clean or replace cylinder.

Air cylinder does not Worn clevis and pins • Replace clevis and pins.
extend or retract com-
pletely • Clean or replace
Dirty regulator
• Check the air filter.

Air line plugged • Clean out air line.

Flow control adjusted incorrectly • Adjust flow control.

ERROR MESSAGES
Display Messages There are three types of messages that display at different times during
operation:
• Information
• Error messages that display when a controlled shutdown
occurs
• Error messages that display when an immediate shutdown
occurs
14-10/Rev 5 Ultima®Macro
 14
Information Information messages are normal and may occur in any mode. They do
Messages not cause a shutdown.

Message Definition
Cut Tube - Press Reset Displays during a clean out cycle after the bagger creates a tube of film.

Bag In Position Displays after a film setup when an eyespot is detected.

Eyespot Not Detected Displays after a film setup when no eyespot is detected.

Out Of Registration Displays while operating in filled bags mode and an eyespot is not
detected within the registration window. In empty bag mode, this mes-
sage appears without a shutdown.

Registration Restored Displays when an eyespot has been detected following an out of registra-
tion condition. When a filled cycle goes out of registration, the bagger
continues to make bags as long as product is discharged. If an eyespot is
detected, "Registration Restored" displays and the system continues to
run. If no eyespot is detected, the system shuts down.

Undefined Command - MDT Indicates the Ultima received a command that was not defined in the pro-
gramming.

Defective Output K/F Ultima The output did not turn On or Off. Possible causes are a defective output
module, bad fuse, broken wire, loose terminal, or a defective load.

Defective Htr Output - Ultima One of the heaters did not turn On or Off. Possible causes include a
defective output module, tripped circuit breaker, broken wire, loose termi-
nal, or a defective load.

Premodule Fault P* B* Indicates an output did not turn On or Off and the error occurred before
the output module.
P*=Output port
B=Bit number within port
This is usually caused by a defective board mounted device such as a
driver or latch and is generally not repairable in the field.

Bad Safety Input - Ultima Indicates the safety string input is down but the master relay still func-
tions. This message appears if the wiring from the external switch to the
processor is defective.

Defective Input - Ultima Indicates one of the inputs has failed.

******Temp Is Too Low - Ultima The actual temperature is below the setpoint for the zone displayed.

******Temp Is Too High - Ultima The actual temperature is above the setpoint (from 5° to 20°) for the zone
displayed.

Auto Program Not Loaded - MDT Displays if the MDT cannot accept the auto program or if a checksum
error is detected.

Web Guide Sensor Error - Displays when the inside sensor detects no film and the outside sensor
Ultima detects film.

External Enable - Ultima Displays in filled bags mode when the external enable input activates.

Ultima® Macro 14-11/Rev 5

Error Messages

Controlled The following errors cause a controlled shutdown, where the system
Shutdown Error stops after completing is current function.
Messages

Message Definition
Low Oil Detected - Ultima Oil level is too low.

Water Level Exceeded - Ultima The bowl used to collect the water from the air lines is full.

Terminal Count - Ultima The bag stop = 0 in filled bags mode.

Feed Rate Exceeds Ultima The feed system is discharging product faster than the bagger is making
Speed bags while in filled bags mode.

Low Film - Ultima The film roll is low.

Start Delay Too Long - Ultima The next product discharge was received but the current bag cycle has
not started.

Shorted RTD An RTD has shorted out.

Open RTD An RTD is not connected

Illegal Temp - Ultima The temperature is set too high.

Temp Overrange - Ultima The actual temperature is above the high limit (550°).

Replace Printer Ribbon - Ultima The printer ribbon input is Off.

Invalid Placement ***.5 To ***.5 The placement value is not valid for a double pull program.

14-12/Rev 5 Ultima®Macro
 14
Immediate Safety errors cause the machine to shut down immediately.
Shutdown Error
Messages

Message Definition
No +24V Supply - Ultima The Ultima has lost its +24V.

Right Door Open - Ultima The right guard door is open.

Left Door Open - Ultima The left guard door is open.

Low Air Pressure - Ultima The air pressure has dropped below the limit set on the pressure switch.

Master Stop Pushbutton - Ultima The E-Stop pushbutton is pressed and locked in.

Aux Stop Pushbutton - Ultima The auxiliary stop button is pressed.

Press Reset Button - MDT The display’s master relay has dropped.

Master Relay - Ultima The Ultima’s master relay has dropped.

Metal Detected - Ultima The metal detector has detected metal.

Watchdog - Ultima There is a problem with the processor and processing has stopped. The
processor attempts to reset and restart. If it fails, board replacement is
probably necessary.

Shutdown Timer - Ultima The machine has been idle longer than the shutdown time (approx 30
min.)

No Encoder - Ultima The encoder pulses are not detected by the processor board.

Jam Detected - Ultima The jaws have jammed for the second consecutive cycle.

Communication Error - MDT The display did not acknowledge one of the commands from the Ultima.

CPU Block Error - Ultima One of the areas of the Ultima control boards did not initialize correctly at
power-up or Restart.

Ouch Error - Ultima The control boards fail and processing stops.

Enable Level Error - Ultima One or more of the CPU board enable levels are lost during operation.

Ultima Shutdown: Press Reset This is a twin tube message. It is displayed when one side of the machine
is shut down.

Ultima® Macro 14-13/Rev 5

Error Messages

14-14/Rev 5 Ultima®Macro
 16
CHAPTER 16: OPTIONAL ACCESSORIES
This chapter contains various accessories that may be used with certain
applications. The machine probably has some of the accessories
described in the following pages. Options available on the machine
include, but are not limited to, those described in this chapter.

BAG SUPPORT AND EJECT

The bag support and eject assembly supports the filled bag and ejects it
horizontally onto a takeaway conveyor. By removing product weight
from the end seals it allows stronger seals infeed
The assembly is located directly below the end seal jaws. The assem-
bly consists of: support plate (1), ejector plate (2), air cylinder (3),
locking handle (4), support shafts (5), locking collar (6), handwheel
(7), hexnuts (8), support block (9), and handle (10).

3
8

1
9

10

7 4

Figure 1: Bag Support and Eject Assembly

Assembly To adjust the assembly:

Adjustment
1. Remove machine power
2. Position support plate (1) ¾ in. (19 mm) less than one bag
length from the cutoff knife

Ultima® Macro 16-1/Rev 5

Flat Bottom Bag

3. Loosen handle (4) and lift or lower unit on its support

shafts (5)
4. To fine-adjust the unit up or down, loosen locking collar
(6) and turn hand wheel (7) until the correct position is
achieved
5. Restore power

Eject Air Cylinder Set the timing of the eject air cylinder (3) on the control panel so the
Timing cylinder actuates after the jaws open, ejecting the bag from the support
plate (1). To adjust the timing:
1. Remove machine power
2. Adjust the flow control settings located on the cylinder
3. Restore power

Ejector Plate The ejector plate (2) may have to be changed to accommodate different
Changeover package sizes. To do this:
1. Remove the two hex nuts (8) from the back of the ejector
plate (2)
2. Remove the plate from the support block (9)
3. Attach new plate by reversing the procedure

Ejector Plate The ejector plate can be located front-to-back by:

Positioning
1. Loosen the handle (10) and move the air cylinder (3)
2. Lock the handle in the appropriate position
3. Restore power

FLAT BOTTOM BAG

The flat bottom bag accessory is used in applications where a bag with
a flat bottom, rather than a standard pillow bag, is needed.
A special rectangular forming tube assembly and two tucker arms form
the flat bottom of the bag. Two air cylinders, mounted below the jaws,
assist in tucking the sides of the bag into the correct position.
Optional bag creasers, which mount to the forming tube assembly, may
be used to help shape the bag depending on the type of film being run.
An optional bag support/eject system may be added when it is neces-
sary for the bags to be delivered onto a conveyor in an upright position.

16-2/Rev 5 Ultima®Macro
 16
Adjustments Adjustment to the flat bottom bag assembly is required when changing
bag size.
When changing the forming tube assembly it is very important to align
the centerline of the forming tube with the centerline of the jaws when
they are in the closed position (as viewed from side of machine). The
forming tube should be mounted 1/8 in. to ¼ in. above the top surface of
the end seal jaws.
The front guide plate and rear guide plate requires adjustment for the
new size bag. To do this:
1. Loosen the bolt that holds the rear guide plate in position
2. Move the guide in the slotted hole until a gap of 1/8 in.
between guide plate and package is obtained and retighten
the bolt
3. Loosen the ratchet handle and move the front guide plate
until a gap of 1/8 in. between plate and package is obtained
4. Re-tighten the ratchet handle
To adjust the distance of the two tucker arms:
1. Open the jaw assembly
2. Loosen the ratchet handle
3. Turn the hand knob until the correct setting is achieved
4. Tighten the ratchet handle.
5. Repeat as necessary to obtain correct tuck depth
Adjust the air cylinders for adequate, even tuck to the top of the bag.
1. Loosen hand knob
2. Slide the cylinder to the correct position
3. Re-tighten the hand knob

Ultima® Macro 16-3/Rev 5

Stager/cooler

STAGER/COOLER
The stager/cooler assembly is located above the end seal jaws to stage
product drops. It supports product above the seals while the seals are
cooling. It also eliminates product bounce.

Figure 2: Stager/Cooler

1. Front cross plate 4. Air cylinder 7. Flow control fittings

2. Rear cross plate 5. Pivot arms 8. Cushion

3. Air blast tubes 6. Adaptor blocks

The stager/cooler consists of two cross plates (1 and 2) above the end
seal jaws. The plates are actuated by two air cylinders (4)
Attached to the cross plates (1 and 2) are air blast tubes (3) which
direct compressed air to cool the end seals. The air cools the seals when
the cross plates (1 and 2) are in the closed position and the end seal
jaws are in the open position
When the stager/cooler is used in conjunction with the Quali-Seal poly-
ethylene sealing system, adapter blocks (6) are installed between pivot
arms (5) and cross plates (1 and 2). The purpose of these blocks is to
lower the air blast tubes (3) as close as possible to the end seal, thus
maximizing the cooling effect.

16-4/Rev 5 Ultima®Macro
 16
When the stager/cooler is used in conjunction with the resistance seal-
ing system, the adaptor blocks are not used as they interfere with the
resistance jaws.

CAUTION:
The adaptor blocks must be removed when using resistance jaws
on combination Quali-Seal and resistance sealing machines

Sequence of After the product reaches the bottom of the tubular shaped package
Operation (the bottom must be sealed), a signal from the machine controller
indexes the film to the correct length. Another signal causes the stager
air cylinder (4) to extend, causing the pivot arms (5) to close the cross
plates (1 and 2).
The cross plates, mounted on the pivot arms, flatten the lower portion
of the package (pre-shaping the final package). Another signal from
the machine controller causes the end seal jaws to close, making the
top seal on one bag and the bottom seal on the other.
When the end seal jaws actually close, product falls onto the stager
plates. At the same time, the machine controller signals the knife to cut
the top seal from the bottom seal. Another signal causes the end seal
jaws to open and the air blast tubes (3) blow air on the hot seal to cool
it.
Another signal stops the cooling air and actuates the air cylinders to
open the cross plates. This allows the product to reach the bottom of
the bag. The machine is now ready to begin another cycle.

Speed Adjustment Cylinder speed can be adjusted as follows:

1. Remove machine power
2. Adjust the cushions (8) by turning the adjustment screws
all the way in (clockwise) and then back them out ½ turn
Fine adjustment may be required for quiet operation.

IMPORTANT:
Cushions are only used on model 15-22 machines.

3. Adjust the flow control fittings (7) by turning the adjust-

ment screws all the way in (clockwise) and then back
them out four (4) turns
Fine adjust the screws in or out until the pivot arms (5) open and close
smoothly

IMPORTANT:
Adjusting the rod end cushion and flow control affects the stager
closing. Adjusting the cap end cushion and flow control affects
the stager opening.

Ultima® Macro 16-5/Rev 5

Linear Stager

4. Restore power
5. Check operation and repeat steps 1 - 4 if necessary to
achieve efficient operation.
CAUTION:
To avoid damage to the pivot arms and cross plates, the cushions
and flow controls must be set the same on both cylinders.

LINEAR STAGER
The linear stager assembly is located above the end seal jaws to stage
product drops. It supports the product above the seals while the seals
are cooling.
The linear stager has two stager plates located above the end seal jaws.
These plates are actuated by an air cylinder.
Attached to the stager plates and below the jaws are deflators which
force air out of the bag before the jaws close.
Air cooling tubes direct compressed air to cool the end seals. This air
cools the seals when the stager plates are closed and the end seal jaws
are opening. The amount of air flow is adjusted with a flow control
valve.

Air Cylinder Flow Control for Cooling Air

Stager Open Speed Control Stager Close Speed Control

Cushion Adjustment Cushion Adjustment

.040” gap when

cross plates are closed Stager Plates

Figure 3: Linear Stager Assembly (top view)

16-6/Rev 5 Ultima®Macro
 16
Sequence of As product is discharged from the feed system, a signal from the
Operation machine controller indexes the film to the correct length.

IMPORTANT:
The timing of the product drop in relation to the bagmaking cycle
is controlled by the start delay.

Another signal causes the air cylinder to actuate, closing the stager
plates. The stager plates move on guide rails and flatten the lower por-
tion of the package while the deflators force air out of the bag about to
be sealed.
At this point, the end seal jaws close making the top seal of one bag
and the bottom seal of the other.
When the end seal jaws close, the product falls onto the stager plates.
At the same time, the knife cuts the top seal from the bottom seal.
Another signal causes the end seal jaws to open.
Air cooling tubes direct air on the hot seal to cool it. The cooling air
turns off after the programmed time.
Another signal causes the stager plates to open. This allows the prod-
uct to reach the bottom of the bag. The machine is now ready to begin
another cycle.

Speed Adjustment 1. Remove machine power

2. Adjust the cushions by turning the adjustment screws all
the way in (clockwise) and then back them out ½ turn
Fine adjustment may be required for quiet operation.
3. Open the speed controls completely and then close 1 turn
• If fine adjustment is required, turn the controls in or
out until the stager plates open and close smoothly
4. Restore power
5. Check operation and repeat steps 1 - 4 as needed to
achieve efficient operation

Stager Plate Gap A 0.040 in. gap between the closed stager plates is factory set and does
Adjustment not normally require adjustment. Thicker films and some types of
products may require this gap to be slightly modified.

IMPORTANT:
Verify the timing is set correctly before adjusting the gap.

Ultima® Macro 16-7/Rev 5

Product Stripper

To adjust the gap:

1. Loosen the adjustment screws on the stager plates
2. Slide the plates on the slotted holes
3. Re-tighten the screws
IMPORTANT:
The centerline of the closed stager plates must match the center-
line of the closed end seal jaws. Use the end seal jaws as the refer-
ence centerline.

PRODUCT STRIPPER
The product stripper removes any product in the end seal area before
the jaw carriers close.

Figure 4: Product Stripper Assembly

A. Adjust this gap between the stripper bars to 0.035” (0.9mm) across the entire length of the stripper
bars.

3. Air cylinder, bore and stroke (2)

11. Adjusting Screw 25. Left Hand Jam Nut
1.125” by 1.75” (28.6 by 44.5mm).

4. Clevis (2) 13. Cam 26. Right Hand Jam Nut

6. Proximity Switch 16. Clamp Collar 27. Internal Cushion

7. Stripper Arm 20. Aircraft Nut 1/4-20 31. Proximity Switch for Stripper

8. Adjusting Block, RH thread (4) 21. Aircraft Nut 5/16-18 33. Cam Follower 1”

9. Adjusting Block, LH thread (4) 23. Hold down Bar 34. Cam

10. Cam Roller 24. External Flow 41. Stripper Bars

16-8/Rev 5 Ultima®Macro
 16
A signal from the machine controller causes the air cylinder (3) to
retract causing the stripper arms (7) to close. The stripper bars (41) are
now 0.035 in. (0.9 mm) apart with the packaging material between
them. As the jaw carriers come together to make the end seal, the cam
followers (33) allow the vertical motion cam (13) and the entire assem-
bly to move down on the shafts (12). The stripper bars (41) strip the
product from the end seal area.
Sealing jaws contact the film to make the seal. A signal from the
machine controller actuates the knife which cuts the packaging mate-
rial between the top seal of the filled bag and the bottom seal of the
empty bag.
After the bag is cut, the jaw signal reverses, causing the jaws to open.
As the jaw carriers open, the cam (13) moves the assembly up to its top
position. While the jaws are opening, the air cylinder (3) opens the
stripper bars (41).

Electrical and Timing the opening of the stripper bars is very critical.
Pneumatic Speed
Adjustment CAUTION:
Do not allow the stripper bars to contact the safety cams.

The stripper bars can be controlled by and electrical adjustment and a

pneumatic adjustment.

Stripper Proximity The stripper proximity switch (31), at the rear of the machine, protects
Switch Electrical the stripper arms by delaying arm opening in respect to the jaw open-
Adjustment ing. This prevents the stripper arms from opening prematurely if incor-
rect timing is entered in the machine controller.
The proximity switch senses when the jaw carriers are open an allow-
able distance. It then lets the stripper arms open regardless of the TO
setting in the machine controller.
To adjust the proximity switch:
1. Turn the strippers On using the operator interface
2. Set the TO setting at 358°
The strippers need to open at the end of the bag making cycle to pre-
vent damage to the stripper/jaw assembly.
3. Turn the external flow controls (24) and internal cushions
(27) counterclockwise
4. Set the main pressure regulator to 60 psi (4.1 bar)
CAUTION:
Do not exceed 65 PSI (4.5 bar) or long-term damage to the
machine can occur.

Ultima® Macro 16-9/Rev 5

Product Stripper

5. Power up the machine and enter the fastest empty bag pro-
gram stored in the memory
The machine must be timed in the fastest cycle to operate correctly at
slower speeds. Jaws should be timed to open at 350°.

IMPORTANT:
It is unnecessary to setup machine timing at fast speeds unless
actually running faster speeds.

6. Cycle machine in continuous cycle empty bags

7. If stripper bars are contacting the white safety cams (34)
on the way open
a. shut down the machine
b. remove the left side guard and move bottom of the
proximity switch (31) 1/8 in. (3 mm) toward the front of
the machine
c. continue to repeat this cycle until the stripper bars
open freely without hitting the white safety cams (34)
IMPORTANT:
Insufficient proximity switch adjustment (towards the rear of the
machine) results in damage to the stripper jaw area. Too much
proximity switch adjustment (toward the front of the machine
results in bags catching on the stripper bars during the next bag
making cycle.

Stripper Cylinder Cylinder speed can be changed by adjusting the external flow controls
Pneumatic Speed (24) on the air cylinder.
Adjustment
CAUTION:
Before operating the machine the cushions and flow controls must
be set the same on both cylinders to avoid damage to the stripper
arms and bars.

Adjust flow controls at the fastest bag making cycle. It is unnecessary

to setup at 100 cycles per minute when the maximum running speed is
80 cycles per minute.
When adjusting flow controls and cushions, verify both cylinders are
adjusted equally so they operate in synchronization with each other.
1. Coarse adjust external flow controls by turning clockwise
until fully closed; then turn 4 turns counterclockwise
2. Coarse adjust the cushions by turning clockwise until fully
closed; then ½ turn counterclockwise
3. Adjust the top flow control (24) by cycling the machine

16-10/Rev 5 Ultima®Macro
 16
4. If strippers contact white cams (34) (located in the jaw
carrier) on the open cycle, turn the top flow controls
clockwise until contacting is eliminated
IMPORTANT:
Too little flow control adjustment results in bags catching on the
stripper bars during the next bag making cycle. Too much flow
control adjustment results in damaged parts in the stripper/jaw
area. Periodically maintain this flow control adjustment to ensure
a reliable unit.

5. Adjust the bottom flow control (24) by cycling the

machine
• If strippers close extremely fast, turn bottom flow
control clockwise until correct speed is achieved
6. Cushion (27) the adjustment
• If loud noise is heard when opening, adjust top flow
controls (24)
• If loud noise is heard when closing, adjust bottom
flow controls
• Turn clockwise until noise is eliminated

IMPORTANT:
Flow controls must be adjusted equally.

7. Recheck and tighten all nuts and bolts

Stripper Bar For efficient operation, the gap between the stripper bars must be
Adjustments adjusted:
1. Remove machine power
2. Retract air cylinder (3) until clevis stops perpendicular
with adjusting screws (11)
3. Loosen jam nuts (25 and 26) and turn adjusting screws
(11) on both sides of the machine until a gap of 0.035 in.
(0.9 mm) is obtained across the length of the stripper bars
(41)
4. Verify the adjusting screws (11) on both sides of the clevis
(4) move
The stripper bars (41) must be level on top and parallel with each
other and must also be centered with the jaws
5. Tighten the jam nuts (25 and 26)
6. Restore machine power

Ultima® Macro 16-11/Rev 5

Product Stripper

The product stripper removes any product in the end seal area before
the sealing jaws close.

Figure 5: Product Stripper Assembly (side view)

After the stager/shaker jaws close, the stripper arms close with the film
between them. The stripper bars should now be 0.035 in. apart.
At this point, the sealing jaws close to make the end seal driving the
stripper assembly down on the shafts. The stripper bars strip product
from the end seal area forcing it down into the bag.
After the jaws close, the knife cuts the film between the top seal of the
filled bag and the bottom seal of the next bag.
After the bag is cut, the jaws open. As the jaws open, the linkage
moves the stripper assembly to its top position and the air cylinders
open the stripper arms. The stager also opens at this time to allow the
next bag to move into position.

Stripper Bar Gap For maximum stripping action the gap between the stripper bars must
Adjustment be set correctly:
1. Remove machine power
2. Pull down on the clevis until both air cylinder rods are
fully retracted
3. Loosen the eight jam nuts (four on each side of stripper
assembly)
4. Turn the four stripper bar gap adjustment screws evenly
on both sides until a gap of 0.035 in. is obtained across the
length of the stripper bars
16-12/Rev 5 Ultima®Macro
 16
5. Check the centerline of the stripper bars against the cen-
terline of the jaws:
a. push the jaws together leaving a small gap
b. insert a steel rule through the jaw and stripper gap
c. look up from the underside to verify that the rule is
straight
d. make small turns, if needed, to the correct stripper bar
gap adjustment screws to match the centerlines
e. re-tighten the jam nuts.
6. Restore machine power

Stripper Cylinder The speed of the stripper arms should be set for maximum speed with
Pneumatic Speed smooth and quiet operation. To adjust:
Adjustment
1. Remove machine power
2. Loosen the four jam nuts on the open stripper and close
stripper speed controls
• Coarse adjust by turning clockwise until fully closed
and then four turns counter-clockwise
3. Coarse adjust the internal cushions by turning clockwise
until fully closed; then ½ turn counterclockwise
4. Restore machine power
5. Turn all functions except the stripper Off
6. Set the stripper timing FROM 130° TO 345°
7. With empty bags selected, cycle the machine and observe
the action of the stripper bars
8. Turn the power Off and fine adjust the close stripper
speed controls for maximum speed without noise
• If the strippers close extremely fast, turn the controls
clockwise
9. Turn the power and the jaws On
10. Set the timing FROM 150° TO 330°
11. Cycle the machine and observe the action of the stripper
bars
12. Turn the power Off and fine adjust the open stripper speed
controls
13. If the stripper bars contact the cams when opening, turn
the speed controls clockwise to correct
14. Turn the power On and make several empty bags

Ultima® Macro 16-13/Rev 5

Product Stripper

15. Observe the action of the stripper bars and fine adjust the
speed controls as needed
• If the stripper action is too slow and bags are
catching on the stripper bars, turn the stripper open
flow controls counterclockwise
• If the stripper action is too fast parts may be
damaged in the stripper or jaw area. Turn the stripper
close speed controls clockwise
The flow controls must be adjusted equally on both air cylinders.

Stripper Proximity The proximity switch, in the slotted hole, at the rear of the machine,
Switch Adjustment protects the stripper arms by sensing the position of the jaws. This pre-
vents premature opening of the stripper arms if incorrect timing is
entered into the machine.
The stripper arms are only allowed to open when the jaws have already
opened to approximately 1 in. to ensure there is no contact with the
jaws as the stripper arms open.
The proximity switch is factory set. Before adjusting, verify the speed
controls and cushions are set correctly.
1. Set the main air pressure regulator is at 60 - 65 PSI
2. Turn the strippers On
3. Set the timing FROM 130° TO 358°
4. Cycle the machine in empty bags
5. If the stripper bars are contacting the cams as they are
opening
a. stop the machine
b. remove the switch guard and move the proximity
switch 1/8 in. toward the front of the machine
c. Continue to move it until the stripper bars open with-
out contacting the cams
d. Replace the guard.

IMPORTANT:
If the proximity switch is set too far toward the rear of the
machine, damage to the stripper bars and jaw assembly may
occur. If the proximity switch is set too far toward the front of the
machine, bags catch on the stripper bars.

16-14/Rev 5 Ultima®Macro
 16

Stripper bar

Jaw actuator
pinch clamp

Outside Stripper actuator Outside

pinch clamp pinch clamp pinch clamp

Figure 6: Product Stripper (front view)

Stripper Linkage
Adjustment IMPORTANT:
The stripper linkage is set at the factory before your machine is
shipped. Adjustment is not normally required.

1. Remove machine power

2. Loosen the two outside pinch clamps by loosening the
eight bolts
3. Loosen the stripper actuator pinch clamp (four bolts)
4. Loosen the jaw actuator pinch clamp (four bolts)
5. Push the jaws closed and lock on center using the jaw
linkage clamp block
6. Measure the distance between each end of the stripper
bars to the jaws
It should be equal on both sides.
7. If the distance is not equal, raise the side that is further
from the jaw, by pushing up on the air cylinder, until they
are equal
8. Tighten the two outside pinch clamps to the stripper actu-
ator shaft
Tighten each bolt the same amount to ensure an even gap on each side
of the pinch clamp.

Ultima® Macro 16-15/Rev 5

Product Stripper

9. Turn the jaw actuator pinch clamp and adjust so the actua-
tor link is at approximately a 30° angle from the floor and
tighten the clamp
10. Push upward on the bottom of the air cylinders until there
is approximately 1/8 in. between the stripper bars and the
jaws
11. Hold this position and tighten the stripper actuator pinch
clamp to the shaft
12. Unlock the jaws and pull them open
The strippers rise to the top position.
13. Verify the strippers move up and down freely
14. In the top position the stripper bars should not contact the
shaker cylinders
When the bars are opening they should clear the stripper cams.
15. If the stripper bars rise too high and contact the shaker cyl-
inders, open the jaws and loosen the jaw actuator pinch
clamp
16. Keep the jaws fully open and move the arm up until clear-
ance is achieved and tighten the clamp
17. If the stripper bars are not rising high enough and are con-
tacting the jaw carrier stripper cams, open the jaws and
loosen the stripper actuator pinch clamp
18. Move the arm down until clearance is achieved and
tighten the clamp
19. Restore machine power
20. Cycle the machine in empty bags and check to verify the
stripper moves without interference through the entire
cycle
If it does not, turn power Off and repeat steps 13 or 14 and 15 and 16
until clearance is achieved

16-16/Rev 5 Ultima®Macro
 16
POKER
The poker prevents product from bridging in the tube and funnel.

Flow Control Adjustment Screws

Poker Arm

Air Cylinder Mounting Brackets

Figure 7: Poker

After the last piece of product enters the tube/funnel, a signal from the
machine controller forces the air cylinder to extend. This makes the
poker arm pivot in the mounting brackets.
If there happens to be product bridging or clogging the tube or funnel,
the poker arm breaks it up, allowing the product to flow freely down
the tube.
Another signal forces the air cylinder to retract and the assembly waits
for the next cycle.

IMPORTANT:
Do not force the poker to clear a jam.

Air Cylinder Speed 1. Remove machine power

Adjustment 2. Turn the flow control adjustment screws (7) on the cylin-
der inward to decrease and outward to increase speed
Fine adjustment may be required for smooth, quiet operation.
3. Restore power, check operation, and repeat the procedure
to achieve correct operation

Ultima® Macro 16-17/Rev 5

Film Splicer Instructions

FILM SPLICER INSTRUCTIONS

Figure 8: Film Splicer Assembly

The film splicer assembly makes replacing rolls of film quicker and
easier. Follow the procedure as shown below:
1. Remove machine power
2. Raise the dancer roller and lock it in the up position

3. Raise the depletion detector arm up until it locks in the

ball detent

16-18/Rev 5 Ultima®Macro
 16
4. Clamp web of depleted roll
5. Rotate handle #2, located on side of film unwind, until it
locks into position on web

6. Trim depleted web at slot #1 (Slot nearest back of

machine)
7. Remove depleted roll from machine

8. Install new roll of film

9. Feed new film through machine under clamping bar #1

10. Lift old web while still clamped under clamp #2

11. Run new web underneath to clamp bar #2

Ultima® Macro 16-19/Rev 5

Film Splicer Instructions

12. Clamp in position using handle #1

New web lies under old web.

13. Trim new web off through slot #1

IMPORTANT:
Do not trim old web. Lift out of way when trimming.

14. Reposition trimmed end so new web lies over top of old
web
IMPORTANT:
Film does not go through former if it is not in this position.

16-20/Rev 5 Ultima®Macro
 16
15. Remove length of tape (width of web) from tape dispenser
located on unwind side plate

16. Tape the webs together

17. Lower the dancer roller

18. Lower the depletion detector
19. Unclamp the webs on the splicer
20. Restore power to the machine

ACCU-TRACK AUTOMATIC UNWIND EDGE

ADJUSTMENT
The Accu-Track system automatically controls the position of the
unwind stand and maintains tracking at the forming shoulder to ±1/16 in.
(1.6 mm) in most cases.
Lateral movement of the unwind is made through a synchronous motor
with push buttons located on the front panel.

Operation Adjust the edge of the packaging material as shown under motorized
unwind edge adjustment.
When bags are correct, push the toggle switch to Automatic. The sen-
sors and microprocessor control the edge of the film.

Ultima® Macro 16-21/Rev 5

Accu-Track Automatic Unwind Edge Adjustment

Eye Control Box

Synchronous Motor

Front
Operator
Panel

Figure 9: ACCU-TRACK Automatic Unwind Edge Adjustment

The system has two modes, manual and automatic.

In manual mode, the operator controls the direction and the time to
shift the film. Pushing the left button moves the film to the left. Push-
ing the right button moves the film to the right.
In auto mode, monitoring is done by two photosensors. They check the
edge of the film and send this information to the controller, which
sends a signal to the motor to move the film in the correct direction.
The auto control, when located on the right side, makes the correction
for the sensors tracking the right side of the film. The registration eye
has to be set up to be looking for a registration mark on the right side of
the film. If both sensors are uncovered, the film has to move to the
right to put it into a location where one sensor is covered and the other
is not covered.
If the registration eye and photosensors are on the left side of the pack-
aging material, the auto control makes the corrections tracking the left
edge.
The sensors, switch and registration eye are normally mounted at the
factory before the machine ships.

16-22/Rev 5 Ultima®Macro
 16
Positioning the The required position is where there is one photosensor covered and
Sensor Guide one not covered by the film. Both sensors have an LED that illumi-
Assembly nates when the sensor is covered. This also shows on the right and left
push buttons on the operator panel.
The rear sensor is on a slotted bracket and can be adjusted from 0 to 3/16
in. A separation of 0 causes a constant correction. The best gap to start
with is 1/16 in. to 3/32 in. This may need to be adjusted later.
The sensor guide assembly with the registration eye may be located on
either the right or left side of the packaging material.
A toggle switch is used to indicate right or left edge tracking.
Sensitivity The sensors are a diffuse reflection type and have a 10 cm detecting
Adjustment distance. They can detect transparent, opaque and translucent materi-
als.
To adjust the sensitivity on the amplifier, place the photo sensors and
film where they are normally located. The setting needed is when the
sensor detects the film but not the background. To do this:
1. With a small screwdriver, turn the sensitivity up gradually
until the sensor detects the film
This is point A.
2. Remove the film and turn the sensitivity up until it detects
the background
This is point B.
3. Turn the dial so that it is halfway between point A and
point B
To test the setting:
1. Place the film in the normal position
2. Verify the sensor is illuminated and detecting the film
3. Move the film away
4. Verify the sensor stops detecting
Basic Function of The machine controller:
the Controller
• Receives a signal from the photo sensor, through the ampli-
fier
• Processes the signal per the built in program
• Activates the motor to move the film to the correct position
• A correction is necessary if both sensors are covered; The
controller sets a delay for ten knife counts and then checks
the sensors to see where the packaging material is. The
material is covering both sensors so the controller starts a
counter (with a maximum of 3) and indexes to one.
Ultima® Macro 16-23/Rev 5
Accu-Track Automatic Unwind Edge Adjustment

With the next knife cycle, the sensors are still covered, so the counter
indexes to two. After the third knife cycle, the sensors are still covered
and the counter indexes to three.
Now a correction is necessary. The controller sends a signal to the
motor to move the unwind to the left or right as needed.
After the correction has been made, another counter starts with a count
of one. It has a maximum of 20. This counter is cleared when a correc-
tion needs to be made in the opposite direction, or no correction is
needed.
If the maximum count is reached, the program stops moving the motor.
To correct this you must switch to manual control and center the
unwind using the push buttons in the front panel.

16-24/Rev 5 Ultima®Macro
 16
SHAKER JAW ASSEMBLY
The shaker jaw assembly is used on snack food machines. It is located
just above the end seal jaws and is sometimes referred to as the stager
assembly. The unit is removable and is held in place by either two
ratchet handles or two bolts, one on each side of the assembly.

Pneumatic Shaker Actuator Pneumatic Shaker Actuator

Setscrew Setscrew
Shaker Smoothness Flow Control Clamp Release
Clamp Release Flow Control
Flow Control

Ratchet Handle Jaw Carriers Ratchet Handle

Shaker Jaws

Shaker Jaw Cylinder

Shaker Adjust Controls

Figure 10: Shaker Jaw Assembly

The falling product lands on the shaker jaws just after they have
closed. This keeps the product off the cooling end seal until the seal
has set and is strong enough to receive the weight of the product.
The falling product lands on the shaker jaws just after they have
closed. This flattens and pre-forms the bag and protects the cooling
end seal from the impact of the product until the seal has set and is
strong enough to receive the weight of the product.
The shaker jaws become the stage fro the product which transfers into
the bag after the seal has sufficiently cooled and the shaker jaws open.

Ultima® Macro 16-25/Rev 5

Shaker Jaw Assembly

When the shaker jaws are fully closed, and the shaker function has
been turned on, the clamps of the two pneumatic shaker actuators grip
the shaker jaws holding the filled bag. Air flows through the valves
which are mounted directly on the actuator assembly. This air flow
moves the shaker pistons up and down which vibrates the shaker jaws
and extends the clamps of the actuators which grip the closed shaker
jaws. As the clamps are holding the shaker jaws, the pneumatic shaker
actuators begin to vibrate the shaker jaws. This clears any product out
of the sealing area and settles it toward the bottom of the bag.
This shaker action starts automatically when the shaker jaw proximity
switch signals that the shaker jaws have closed on the bag. The vibra-
tion clears any product out of the sealing area and settles it toward the
bottom of the bag. The vibration stops when the jaw close proximity
switch is detected.

Operation To use the shaker, the following functions must be enabled:

• Registration rollers
• Pull belts
• Jaw close
• Shaker jaws
• Shaker
• Aux. #1
Shaker action starts automatically when the shaker jaw proximity
switch signals that the shaker jaws have closed on the bag.
Air flows through the valves which are mounted directly on the actua-
tor assembly. This air flow:
• moves the shaker pistons up and down which vibrates the
shaker jaws and
• extends the clamps of the actuators which grip the closed
shaker jaws.
Shaker action stops at the TO setting of the function AUX #1.
To time AUX #1 (located in Machine Timed Functions 2 screen):
• FROM: Typically set to 10°
• TO: Observe the JAW CLOSED POINT on the Auto Opera-
tion screen. Subtract 10 to 20 from that value and enter as
the TO value for AUX #1. This stops the shaker action just
before the end seal jaws have fully closed on the bag.
IMPORTANT:
If necessary, the shaking action can be stopped earlier by choosing
a smaller AUX #1 TO value.

16-26/Rev 5 Ultima®Macro
 16
If timing is not set correctly, the shaker action stops when the end seal
jaw proximity switch signals that the end seal jaws have closed.
Frequency and Intensity (Amplitude) are determined by the FROM/TO
values of the shaker function (located in Machine Timed Functions 2
screen).
• Frequency is determined by the TO value in milliseconds
• The TO value determines the shake intervals of the jaw. To
calculate the frequency in Hz, divide 1000 ms by the TO
value:
Example:100 ms = 10 Hz
80 ms = 12½ Hz
• Intensity (Amplitude) is determined by the FROM value in
milliseconds.
• The FROM value determines during how many millisec-
onds of the total shake the output to the valves is OFF.
• Typical settings are shaker FROM 40 TO 100
• The higher the FROM value, the weaker the shake.
(Higher number means shorter shake pulse duration.).
• The higher the TO value, the slower the shake (Higher
number means longer shakes, fewer shakes per minute.)
• To disable the shaking function, turn AUX #1 or Shaker, or
both OFF.
The shaker jaws are timed to open some time after the end seal jaws
open. they help to support the product while the end seal cools.

WARNING:
All adjustments to the shaker jaw assembly must be done with the
power turned OFF. After the adjustment has been made, restore
the machine’s power and check the results.

Shaker Jaw 1. Disconnect the shaker jaw valve airlines at the manifold
Removal 2. Cap or plug the fittings at the manifold
3. Disconnect the electrical control wiring
4. Loosen the ratchet handles or bolts on each side of the jaw
assembly frame
5. Pull the frame forward and upward to remove it from the
machine

Ultima® Macro 16-27/Rev 5

Shaker Jaw Assembly

Shaker Jaw 1. Verify the ratchet handles or bolts are loose

Installation 2. Angle the jaw assembly frame and slide it into position
3. Press the frame as far back as possible and tighten the
ratchet handles or bolts
4. Tighten the ratchet handles while firmly pushing the frame
rearward
5. Connect the airlines
6. Connect the electrical control wiring

Shaker Jaws This setting controls how vigorously the shaker "shakes" the product.
Speed Make this adjustment with the checked flow control valves in the cylin-
der port fittings. For normal operation, the speed adjust controls should
be fully open. Fine adjustment may be required for special applica-
tions.

Jaw Cylinder The cushion adjustment screws are located in the end caps of the jaw
Cushion cylinder. They are adjusted to prevent the shaker jaws from slamming.
Set the cushion adjustment screws by turning them fully clockwise,
then counter-clockwise ½ turn.

Shaker Amplitude The intensity with which the shaker jaws vibrate is adjusted on the
Manual touch screen. Each shaker actuator has an amplitude adjustment knob
Adjustment which is set for maximum amplitude at the factory. Field adjustments
are not required.

Shaker The shaker smoothness flow controls adjust the exhaust air flow from
Smoothness the vibrator piston of the actuator. The valves are located on the back of
Tuning the frame just below and in front of the jaw cylinder.
Observe and listen to the action of the vibrator cylinders; they should
operate smoothly without slamming. Adjust the flow controls to
smooth out the vibrator action without canceling the effect of the vibra-
tors, if necessary.

Clamp Release The clamp release flow controls adjust the exhaust air flow of the
Time shaker jaw clamp. They adjust the speed at which the clamps release
the shaker jaws after the vibrations stop. They should be set at approxi-
mately midpoint. Fine tuning is seldom required and is not critical.

Proximity Switch
Position WARNING:
Do not reset the machine at any time during this procedure. Ver-
ify the safety switches on all guards are functioning correctly
prior to moving the proximity switch.

16-28/Rev 5 Ultima®Macro
 16
1. Leave the electrical power On but disconnect the air from
the machine
2. Open the front doors and manually push the shaker jaws
closed
3. Loosen the proximity switch bracket mounting screw and
move the bracket forward until the LED in the proximity
switch barrel stops illuminating
4. Move the bracket backward until the LED barely turns On
5. Tighten the bracket mounting screw

AUGER FEED SYSTEM

The Macro-Logic servo auger interface offers an auger system inte-
grated into the Macro-Logic display terminal (MDT). A fiber-optic
communication line connects the auger to the MDT which is used for
data entry.
The auger is commanded to fill by the Macro-Logic at the same time
the pacer signals the start delay to begin timing. The start delay is used
to time the fill in relation to the jaw close.
Pulse or RS232 checkweigh feedback may be connected directly to the
auger and selected through the MDT.
The system needs to be set up through the program setup mode as
explained in chapter 5. From the Program Setup screen, select Auger
Setup.

Setup The Feed System Selection screen displays. Three auger selections
exist:
1. Auger - Remote Controlled. The auger is controlled by its
own keyboard/monitor.
2. Auger - System Controlled (Pulse feedback). All auger
functions except checkweigh feedback functions are dis-
played.
3. Auger - System Controlled With Feedback. All functions
are displayed.

Ultima® Macro 16-29/Rev 5

Auger Feed System

Touching the square area next to the word system allows the operator
to scroll through the numbers until the type of system is found. Press
Save and Next to continue setup.

Figure 11: Feed System Selection

If there is an RS232 checkweigh feedback, the screen below appears.

Without RS232 checkweigh feedback, only Turns, Target Weight and
Pulse/Turns displays.

Figure 12: Auger Setup 1

TURNS Indicates the number of auger revolutions that are needed to fill a bag.

TARGET WEIGHT The weight the auger attempts to deliver. All compensations are made
to achieve this weight exactly. Variances in fill weight are ± this value.
This weight is to the nearest 0.01g. However, the program defaults to
whole numbers. Therefore, if the target weight is 5 grams, 5.00 is
entered as the target weight. If the target weight is 5.25, all four digits
including the decimal point should be entered.

MANUAL TARE The weight of the bags being filled. The manual tare weight refers to
WEIGHT the zero equivalent of the bag weight. Enter the tare weight so the tar-
get weight is not affected by the weight of the bag.
16-30/Rev 5 Ultima®Macro
 16
MINIMUM CHECK The lowest allowable weight for a filled bag. All weights below this
WEIGHT are discarded.

MAX. CHECK WEIGHT The maximum weight allowed per filled bag. All weights above this
are discarded.

PULSE/TURNS Do not set. This is the pulse rate of the motor to achieve the number of
auger revolutions.

COMP. ERROR LIMIT The percent of compensated bags allowed. This is set to 0.01%.

COMPENSATION The number of bags counted to compute an average or sample.

SAMPLE

COMP. SAMPLE The number of bags the machine should skip before starting to count
DELAY the next sample.
After the parameters are set, touch Next to display the Auger Setup 2
screen.

Figure 13: Auger Setup 2

SERVO HIGH SPEED Maximum number of auger revolutions per minute during a fill. Do not
adjust. If a fault occurs, consult the auger manual.

SERVO BASE SPEED The minimum number of auger revolutions per minute during a fill. Do
not adjust. If a fault occurs, consult the auger manual.

ACCELERATION Rate of RPM increase per second. Do not set. If a fault occurs, consult
the auger manual.

AGITATOR OFF Allows the agitator to run after the auger stops to prevent certain prod-
DELAY ucts from hanging up in the hopper. This is only valid when Agitator
w/Fill is selected.

LOW LEVEL TIME-OUT Enter the amount of time, in 0.01min. the eye is allowed to detect low
product level before shutting the system down.

Ultima® Macro 16-31/Rev 5

Auger Feed System

CLUTCH DELAY TIME This works in conjunction with an optional accessory that is lifted into
place to prevent product from falling into the seals. The delay time
indicates the amount of time after the accessory is lifted into place
before the clutch is engaged.

AGITATOR Controls the operation of the slow speed agitation system. On runs the
agitator continuously. Off prevents the agitator from running. Agitator
w/Fill runs the agitator only when the auger is engaged.

ACCESSORY An output used to control product drip. The output turns On at fill start
or after lift up switch is made (if lift enabled) and stays On until auger
output goes Off. On enables, Off disables.

CHECKWEIGH BY Option to turn checkweigh feedback by pulse On/Off.

PULSE
Touch Ret to return to the Main Menu. Touch Next to go back to Auger
Setup 1.

Automatic CALIBRATION
Adjustment
The automatic adjustment cycle consists of several steps. The first is
calibration.
This cycle enables the system to be calibrated in weight (grams). In this
way, an adjustment can be entered in grams either manually or by a
checkweigh device through an RS232 communication link.
The object is to relate turns to grams so a calibration factor can be
determined which can be used to convert grams coming into the system
to number of turns needed. To do this:
1. Enter the program to be run
2. From the Main Menu with the key in position 3, touch
Manual Operation
The Ultima Manual Operation screen displays.
3. Run a few empty cycles to check for good bags
4. Once completed, touch Calibrate Auger
This displays the first of the calibration screens. This process goes
through each screen until calibration is complete.
5. Touch Ret from any of the Calibration screens to return to
the Main Menu
6. Touch Manual Screen to return to the Manual Operation
screen

16-32/Rev 5 Ultima®Macro
 16

Figure 14: Auger Calibration 1

Run an empty bag to use as a tare weight. To do this, press

Start/Stop and a single empty bag is produced. The next screen
appears once the bag is made. Save this for use during the
weighing operations.
If the system speed or target weight need to be changed, this can
be done through the display.
The number of auger revs (revolutions) for the calibration sam-
ple can now be entered. Try to enter a number of revolutions as
close as possible to your target weight. Refer to the timing
chart. When the correct value is displayed, touch Ent. Touch
Ent again to advance to the next screen.

IMPORTANT:
If using a large screw and dispensing a small amounts of product,
a lower number of revolutions is desirable. If using a small screw
and dispensing a larger amount of product, a higher number of
revolutions is desirable.

7. Touch Start/Stop to run a sample

This is generally a 2 bag sample and should be used for an average.
When complete, the run stops and the screen changes.
8. Using the empty bag as a tare weight, enter the average
weight
9. When the correct weight is displayed, touch Ent
A delay occurs before the next screen displays because the newly cal-
ibrated auger program is being saved to EEPROM.

Ultima® Macro 16-33/Rev 5

Auger Feed System

Auto Operation The Auto Operation screen displays the target weight of the program.

Figure 15: Auto Operation

The target weight is entered in the Calibration screens as described

above.
The Auto Operation screen displays the number of auger turns. This
enables the operator to view changes made by checkweigh feedback.
The block labeled Filling turns reverse video which the auger screw is
turning.
Auger Setup displays the Auger Setup screen to make adjustments
while the machine is running.
Prog Set displays the Change Setting Value screen to change addi-
tional settings while the machine is running.

Change Setting The Change Setting Value screen is used to modify several auger
Value parameters while the machine is running.

Figure 16: Change Setting Value

16-34/Rev 5 Ultima®Macro
 16
• The system speed can be changed by touching the System
Speed P/M block and the sort blocks. Touch Enter to con-
firm the setting.
The speed can be slowed down to any value required, but can-
not be increased above the programmed speed. This feature
allows the system to operate normally when product supply is
low.
• The actual delivery can be manually trimmed by touching
Auger Trim and sort.
Tens is the default and no reverse video is displayed. Touching
the number next to Auger Trim changes the increment factor to
ones, then tens, then back to tenths. The display turns reverse
video when increments of ones or tens are selected. No more
than 10% of the target weight may be trimmed per entry.
Once the correct value is displayed, touch Enter to set the value
into the program. After entry, the value returns to 00.0.
VOLUMETRIC FEED SYSTEM
Component The volumetric product feed system measures product by volume and
Identification feeds by gravity. The system consists of:
• Feed cups • Trap doors
• Feed plate • Forming tube assem-
• Trap door plate bly funnel
• Servo motor (feed cup • Cam
adjustment) • Volumetric mount-
• Hopper ing plate

Servo Motor Hopper

Handwheel

Volume Adjustment Motor

Trap Doors
Upper Plate

Telescoping
Cups

Lower Plate
Brush Bars Cam Follower
Forming Tube
Figure 17: Volumetric Feed System
®
Ultima Macro 16-35/Rev 5
Volumetric Feed System

Operation The system is mounted on top of the packaging machine. The telescop-
Overview ing cups are mounted on a revolving plate and driven by a DC drive
motor. Each cup has a cam operated trap door on the bottom that
swings open to dump the product down the tube at a preset time in the
cycle.
The height of the cups determines the volume of the product delivered.
The height is controlled by a small DC motor or by a manual hand
crank. The motor provides motorized volume adjustment by raising or
lowering the upper plate without stopping the machine.

Handwheel
Servo Motor

Volume Adjustment Motor

Upper Plate

Lower Plate

Figure 18: Volumetric Feed System

The volumetric feed system consists of a volumetric filler which is

driven by a DC drive motor through a motor control module. These
functions are controlled by electronic modules in the electrical cabinet.
The operating speed is set in the program for the product being run. It
is determined by timing the duration between dumps as sensed by the
dump sensor.

Setup DUMP SENSOR

The dump sensor is a proximity switch. It turns on each time a cup
passes the sensor. There is one sensor marker per cup. The sensor
marker is a metal stud that activates the proximity switch. The dump
sensor generates the go signal that causes the start delay timer to begin
the next cycle.

16-36/Rev 5 Ultima®Macro
 16
The amount of start delay time entered into the program determines the
amount of time the product is allowed to fall before the bagmaking
cycle is started. Delays up to one full cycle are allowed.
The dump sensor signals the end of one cycle and the start of the next.
If the speed is set to 60 dumps/minute, the system is expecting one
dump per second. If the dumps are coming faster or slower than the set
rate, the PLC commands the motor control board to slow down or
speed up.
The volumetric motor drive is turned on each time the bagmaker is
started in filled bags mode.

Volumetric Filler Volumetric System

Dump Sensor
Adjustment Knob Configuration

Dump
Sensor

Volumetric Drive

DC Motor Motor
Control

Motor
Electronic Controller DAC Control

Figure 19: Volumetric System Configuration

In addition to indicating cup position, the dump sensor proximity

switch determines the stopping point of the drive motor when the sys-
tem is brought to a stop.
During a controlled shutdown, the drive motor is turned Off as soon as
the signal from the dump sensor is received. If the system is being run
in a double dump mode, this occurs on the second dump. This assures
no wasted film or product due to jams caused by product leaking
through a partially open cup.
The dump sensor is mounted on a sliding plate which can be moved
relative to the opening of the cups.

PRELIMINARY DUMP SENSOR ADJUSTMENT

To adjust the position of the sensor:
1. Run the feed system at the maximum anticipated speed
and bring it to a stop

Ultima® Macro 16-37/Rev 5

Volumetric Feed System

2. Check the position of the cups after the motor stops

The current cup should be completely open and have totally dis-
charged its product and be in the process of closing. The next door
must be completely closed when the motion is stopped.
3. If the next door is already opening, advance the position of
the dump sensor so the signal is sent to the bagger earlier
in the cycle and starts the shutdown earlier
4. To adjust the dump sensor, turn the dump sensor adjusting
knob to adjust the sensor location
5. Once the correct stopping point is achieved, tighten the
sensor mounting plate
This point should be acceptable for all speeds slower than the maxi-
mum.
6. It may be necessary to re-adjust the start delay timing to
compensate for the adjustment in the sensor position

VOLUME CUP ADJUSTMENT

Volume adjustment is accomplished by moving the feed plate. This is
done through a servomotor controlled by a switch on the operator inter-
face. Moving the plate up increases the cup volume and moving it
down decreases the volume.

IMPORTANT:
When running product, the bottom cups should always overlap
the upper cups by at least ¼ in. (7 mm) or product spills. Cups can
be designed for special applications. Contact Hayssen for more
information.

CAUTION:
Decrease volume adjustment only while product is running. The
mass of product in the cups can restrict movement of the feed
plate. This causes the motor to bind and damage. The volume can
be increased at any time.

TRAP DOOR ADJUSTMENT

Horizontally opening trap doors, operated by the cam follower in a
closed track, assure high speed opening and controlled closing. This
produces a more consistent, timed product discharge. The sliding
motion of the doors provides self-cleaning and more accurate fills. The
trap doors are adjusted using three bolts located on the cam control.
Dump timing is the relationship of the product arrival at the bottom of
the tube to the closing of the end seal jaws. Change the timing when the
trap door opens and closes over the forming tube assembly by relocat-
ing the trap door cam. This adjustment is necessary if the product does
not fall correctly into the funnel.
16-38/Rev 5 Ultima®Macro
 16
To advance or retard the dump:
1. Remove machine power
2. Loosen three bolts in the cam hub
3. Rotate cam to advance or retard dump
4. Retighten the bolts
5. Restore power
IMPORTANT:
The Ultima empty bag speed must be set approximately 10 ppm
faster than fill speed. Failure to do this displays the message Fill
Speed Exceeds Machine Speed.

Correct trap door timing depends upon machine speed, type of product
and product density.

COORDINATION OF DROP TIMING

If the dump timing position is changed, it may be necessary to reset the
pull belts, jaws open-close, bag cutoff, and temperature seal timing to
coordinate drop timing.

BRUSH/SCRAPER ADJUSTMENT
Stationary brush/scraper bars sweep product evenly for a full, level fill
in each cup. The brushes also assist in pre-filling cups prior to the hop-
per filling zone. Adjust the brushes up or down, using the threaded
bolts, to achieve the correct height for product distribution. Inspect
these items periodically for cleanliness and product buildup.

CHANGING SETS OF CUPS

The volumetric feed may have several sets of cups for running various
packages and weights.

IMPORTANT:
Rubber retaining rings are provided on each half set of cups, top
and bottom. These rings lock the cup into position. The same
rings are used for any size cups.

CAUTION:
Retain and use these rings. Do not operate the volumetric feed
without cup O-rings in place on the feed cups.

Ultima® Macro 16-39/Rev 5

Volumetric Feed System

To change cup sets proceed as follows:

1. Remove machine power
2. Empty the cups and spread the feed plate and trap door
plate apart by turning the volume adjustment switch on the
volumetric operator panel
3. Remove the cups to be replaced
Remove upper cups first over the top of the upper plate.
4. Put each new-sized cup back into position
CAUTION:
The cup must seat firmly in its groove or the retaining ring does
not lock.

5. Set the required volume size

6. Restore power

DUMP PLATE HEIGHT ADJUSTMENT

Adjust the dump plate up or down, according to cup size, to allow for
clearance as the plate turns. Most volumetric feed systems allow man-
ual and electric adjustment. The plate is adjusted manually using the
hand crank or electronically using switches located in the operator con-
trols.

CLUTCH ADJUSTMENT (SMALL MOTOR)

The clutch is used as a safety feature to protect the motor from damage
in case of a jam during volume adjustment. The clutch should be
adjusted to allow optimum operation.

CHAIN ADJUSTMENT (SMALL MOTOR)

The chains are used to drive the distribution plate. Loosen the bolts on
the slotted adjustment block and adjust accordingly. Tighten bolts
when the required adjustment is achieved.

BELT ADJUSTMENT (LARGE MOTOR)

Adjust nut on tensioner to achieve optimal tension.

16-40/Rev 5 Ultima®Macro
 16
GAS FLUSH (MODIFIED ATMOSPHERE PACKAG-
ING)
Gas flush is an optional system that has the capability to produce a
vacuum, partial vacuum or inert gas atmosphere in flexible packages
of high barrier construction. The purpose of gas flush is to extend the
shelf life of many foods.

IMPORTANT:
Gas flows only in the Filled Bag Operation Mode. Gas flows
non-stop until the filling process is terminated by the operator.

Flow Meter

Pressure
Regulator

Gas Flow
Solenoid

Gas Inlet

Needle
Valve Gas Lance

The Gas flush system is normally comprised of:

Gas flow solenoid Pressure regulator

Pressure gauge Needle valve

Flow meter Gas lance inside the FTA

Ultima® Macro 16-41/Rev 5

Gas Flush (Modified Atmosphere Packaging)

Pressure
Regulator

Pressure
Gauge

Gas Flow Solenoid

Gas flow is enabled/disabled by the gas flow solenoid.

The gas travels from the solenoid to the adjustable pressure regulator
where the pressure is set. A gauge is connected to the pressure regula-
tors to allow monitoring of the operating pressure. The typical setting
is around 40 PSI. The gas passes from the regulator to the flow meter
through a needle valve. The needle valve is adjustable so that the
desired oxygen level within the package can be obtained and main-
tained. The gas is introduced into the package via the gas lance inside
the FTA.

16-42/Rev 5 Ultima®Macro
 16
SPINACH AGITATOR
The agitator engages product as it drops from the infeed system. There
are two fingers that continuously rotate to disperse product and prevent
clogging on the main feeder. The motor is connected to an 18:1 gear
reducer and a motor speed controller that drives and controls the agita-
tor.

Front View Drive Shaft

Motor Cover
Motor and
Gearhead

Agitator
Fingers

Motor Speed Back View

Controller Box

Figure 20: Spinach Agitator

Ultima® Macro 16-43/Rev 5

Spinach Agitator

Assembly Motor
Components
A 1/8HP, 115/230 VAC, motor drives the agitator.
Gearhead
18:1 ratio gearhead is used to reduce and control the motor speed.
Speed Controller
A potentiometer allows change of speed settings from low to high as
desired to control product disbursement.
Drive Shaft
Connects the drive assembly to the agitator fingers.
Agitator Fingers
Rotate below the infeed system and disperse the product as it falls from
the infeed conveyor.

Installation The agitator assembly is installed on two shafts with four alignment
blocks (two on each side). Assembly is secured in place using four
locking handles.

Spinach Product
Agitator
Infeed

Scale
System

16-44/Rev 5 Ultima®Macro
 16
Motor Settings

Speed
Potentiometer

Run/Stand-by
Switch

MOTOR START/STOP
1. Open flip cover on motor controller box.
2. To start, set Run/Stand-by switch to run.
Motor will start running at speed set on the potentiometer.
3. To stop, set Run/Stand-by switch to stand-by.

MOTOR SPEED ADJUSTMENT

1. Open flip cover on motor controller box.
2. Turn the speed potentiometer dial toward High to increase
speed or toward Low to decrease speed.

Ultima® Macro 16-45/Rev 5

Spinach Agitator

16-46/Rev 5 Ultima®Macro
 17
CHAPTER 17: FEED SYSTEMS
SCALE FEED SYSTEM
The Ultima/scale interface requires two signals:
1. The fill enable signal is generated by the bagger. This is
the ready to make packages signal and it remains On
when the Ultima is in fill mode. It is inhibited only when a
fault message appears in the display, or if the machine is
stopped.
2. The second, generated by the scale, is the go signal. This
is the scale dump signal that initiates a package making
cycle.
Communications between the Ultima and the scale use low level opti-
cal modules, the ODC5 output (fill signal) and the IDC5 Input (go sig-
nal).
The empty bags per minute value entered in the display determines the
base machine rate.

IMPORTANT:
This value must always be higher than the filled bags rate.

Roll the display to Empty Bags = XX Per Minute. Touch the appropri-
ate keypad to increase or decrease the speed as needed.
The speed of the Ultima responds to the command when the Enter pad
is touched and the machine has cycled through several bags for the
speed to achieve the required value.
If registration is missed, the Ultima inhibits the fill enable to the scale,
and displays Out Of Registration. It attempts to regain registration by
making up to two empty bag cycles.

Figure 1: Scale Interface

Ultima® Macro 17-1/Rev 5

Scale/Ultima Timing

If registration is obtained, the fill enable turns On and the Out Of Reg-
istration message is cancelled. If registration is not obtained, the bag
making process stops.
To clear the Out Of Registration message, the Ultima must be run in
setup mode. When registration is achieved, enter filled bags and start
bags.

SCALE/ULTIMA TIMING
The go signal on line 2 is given after the preset start delay. This start
delay has only duration. The Ultima does not start a cycle until the start
delay timer times out. The duration of the delay is entered through the
display using the Start Delay on the rollover. Delay time is entered in
milliseconds and timing is accurate to 1 millisecond.
Line 3 shows the poker delay, which is the amount of time between the
leading edge of the dump signal and the initiation of the valve driving
the poker. This delay enable the product to fall down the tube prior to
advancing the poker.
The poker delay is the FROM setting on the poker 40-character-bar
display. This input is in milliseconds even though it is in the same for-
mat as the machine timing and referenced from the dump signal. Prod-
uct flow determines the length of the delay.
Line 4 shows the amount of time the poker is energized. This duration
is the TO setting of the poker on the 40-character rollover. The timing
is in milliseconds and is independent of machine timing. The TO and
FROM inputs on this line include an ON/OFF option to inhibit the
poker without setting the time to zero.

IMPORTANT:
The timing diagram shown below is only a representative draw-
ing of a typical cycle. The relationship between signals is subject
to product type, machine speed, filled bag rate and other parame-
ters.

Figure 2: Typical Ultima and scale Interface Timing

17-2/Rev 5 Ultima®Macro
 17
AUGER FEED SYSTEM
The auger is controlled and monitored by the Ultima through an incre-
mental encoder. The encoder is gear-driven by the auger. The auger
screw is driven by the main auger screw motor through two pulleys, a
belt and a clutch/brake unit.
The main auger motor starts when the Ultima is reset. The agitator
motor starts only when the Ultima is in one of the following modest
• Filled bags
• Clean out
• Sample
The auger screw turns when the Ultima provides a signal. In filled bags
mode, the Ultima provides a paced signal which energizes the clutch
and counts the pulses of the encoder. When the count is complete it
stops the clutch. This signal can be timed to the bag making cycle to
compensate for product density or the use of free flow auger tooling.
The Ultima can also run in start auger auto mode, where the signal is
timed from the jaw closed point. This helps keep product out of the end
seals by not allowing the auger to start until the jaws are fully closed.
In sample mode, the signal is provided when a set key pattern in fol-
lowed. The auger is stopped at a preset number of revolutions set by
the operator. This provides a sample weight that can be used to cali-
brate the target weight.
In clean out mode, a set key pattern is followed. A key is held and the
auger runs until the key is released. This enables the operator to clean
out the hopper.

IMPORTANT:
Cut the bag open at the bottom of the tube before running clean
out mode.

CAUTION:
Do not run the auger without product or damage to the auger
flights and tube may occur.

Auger Operating
Procedure IMPORTANT:
Read and understand all operating procedures.

1. The Ultima must be reset

Ultima® Macro 17-3/Rev 5

Auger Feed System

2. The auger control box disconnect, located on the back of

the auger mounting plate must be turned On
A message Last Auger Fill Cycle Not Completed displays if the auger
attemps to run with this disconnect turned off.
3. When the machine is installed, check the auger and low
speed agitator for correct rotation
• If rotation is not correct, have a Hayssen service
technician or qualified electrician change the rota-
tion
4. Start the machine and select a program
5. Set the machine to empty bag mode and run several bags
• Check for registration if running printed film
• Verify the bags are sealing correctly
• Retain one bag to be used as a tare weight for the
checkweigh operation
6. Roll the display to Auger Setup-Sample Wt. XXXX
Rev=X
The X's are numbers.
On this line, Rev is the number of revolutions the auger makes
when a sample bag is run. Roll the Rev number between 1 and
5. Select a number that fits in the sample bag. For best accuracy,
use the highest number that fits.

IMPORTANT:
Start with a small number.

7. Touch Enter after the number of revolutions is keyed

8. Dispense a sample bag:
a. Touch Manual
b. Touch Single Cycle
c. Touch Start Bags
The controller activates the auger and dispenses the pre-set number of
revolutions.
9. Dispense sample product into the bag:
a. Touch Empty Bags
b. Touch Single Cycle
c. Touch Start Bags
The sample bag drops from the jaws.
10. Use the bag saved in step 5 to tare the checkweigher
11. Weigh the sample bag
17-4/Rev 5 Ultima®Macro
 17
12. Run several bags and enter the average weight
IMPORTANT:
This weight is the actual weight of the product.

The weight can also be entered as a decimal point. Touch the Key pad
in the third column of the first row. This change is temporary unless
the program is stored into memory. Use the decimal for weights under
100 grams.
13. Roll the display to the next line Target Weight XXX Trim
XX and enter the required value for the final filled bag
14. Touch Enter
At this point the trim is inoperative.
15. Run filled bags:
a. Touch Reset to start the bagger and auger
b. Touch Filled Bags
c. Touch Start Bags to begin running filled bags
16. After cycling, the actual weight may be slightly different
from the required weight as product density varies. If this
is the case, the trim value may be rolled up or down to
adjust the weight. To trim:
a. Turn the trim number positive or negative
b. Touch Enter
This puts the value of the trim in the Ultima and resets the trim value to
zero.
c. Recheck the weight and trim the value as needed
IMPORTANT:
Product level can affect the target weight. If the level becomes too
low, trimming the target weight is useless.

The Stop Bags touchpad stops the auger and the Ultima at the end of
the bagmaking cycle. The E-Stop touchpad stops the auger and the
bagger at any point in the cycle. The weight of the bag in that cycle is
not correct.
17. To clean out the auger, roll the display to Auger Setup
a. Touch Manual
b. Touch Cont. Tube
c. Touch Start Bags
The auger runs while the touchpad is held.

Ultima® Macro 17-5/Rev 5

Volumetric Feed System

18. After entering all the parameters for a program, store it

into memory. This bypasses the setup process next time
the program is loaded.
If the auger cycle is longer than the time allowed for filling, the mes-
sage Last Auger Fill Cycle Not Completed displays. The auger stops.
To correct this
1. Reduce the machine rate or increase the auger rate
2. Touch Start Bags

VOLUMETRIC FEED SYSTEM

The volumetric product feed system measures product by volume and
feeds by gravity. The system consists of:

2
6 1
3

7
8 9

Figure 3: Volumetric Feed Components

1.Feed cups 6.Trap doors

2.Feed plate 7.Forming tube assembly funnel

3.Trap door plate 8.Cam

4.Servomotor (feed cup adjustment) 9.Volumetric mounting plate

5.Hopper

17-6/Rev 5 Ultima®Macro
 17
The system is mounted on top of the packaging machine. The cups are
located between the feed plate and trap door plate. The upper cups
slide within the lower cups to permit changing the volume of the cups.
The plates are continuously rotated by a drive motor mounted to the
volumetric feed system. The plates rotate under the hopper and the
cups fill with product. The product is leveled off by a series of brushes
and/or scrapers. The filled cup passes over the forming tube and the
product is discharged into the forming tube assembly funnel. It then
goes down the forming tube assembly and into the bag.

Operator Panel The volumetric feed system has the following controls"
• START BAGS - activates the volumetric feed drive
motor.

IMPORTANT:
This keypad is operable only if the MODE selector keypad is in
the FILL BAGS position.

• STOP BAGS - deactivates the volumetric feed drive

motor. The motor is deactivated immediately, but the
machine completes its bag making cycle.
• FILL BAG RATE - determines the speed of the volumet-
ric feed drive motor when the machine is in the FILL
MODE.
• VOLUMETRIC INCREASE/ DECREASE - activates
motor to move turret plates apart (to increase) or together
(to decrease) the volume in the feed cups.
• SINGLE DUMP / DOUBLE DUMP - This switch allows
one or two dumps per bag cycle. This is standard on all
volumetric machines.

Volume Cup Volume adjustment is accomplished by moving the feed plate. This is
Adjustment done through a servo motor controlled by a switch on the volumetric
operator panel. Moving the plate up increases the cup volume and
moving it down decreases the volume.

IMPORTANT:
• When running product the bottom cups should always,
overlap the upper cups by at least 1/4" (7 mm) or
product is likely to spill. Cups can be designed for
special applications. Consult with HAYSSEN.
• DECREASE volume adjustment only while product is
being run. You may INCREASE the volume at any time.

Ultima® Macro 17-7/Rev 5

Volumetric Feed System

Trap Door Dump Dump timing is the relationship of the product arrival at the bottom of
Adjustment the tube to the closing of the end seal jaws. You may change the timing
(Timing) when the trap door opens and closes over the forming tube assembly by
relocating the trap door cam (8). This adjustment would be needed if
the product does not fall properly into the funnel.
To advance or retard the dump:
1. Turn all power to machine OFF.
2. Loosen three bolts in the cam hub.
3. Rotate cam (7) to advance or retard dump.
4. Retighten the bolts.
5. Restore power.

IMPORTANT:
The Ultima EMPTY BAG SPEED must be set approximately 10
packages per minute faster than FILL SPEED. Failure to do this
will result in the message "FILL SPEED EXCEEDS MACHINE
SPEED" shown on the display.

"Proper" trap door timing depends upon machine speed, type of prod-
uct and product density.

Coordination of If you change the dump timing position, you may have to reset the pull
Drop Timing belts, jaws open-close, bag cutoff, and temperature seal timing to coor-
dinate drop timing.

Brushes or The volumetric feed system has brushes and/or scrapers. Inspect these
Scrapers items periodically for cleanliness and product buildup. In normal oper-
ation, the brushes level the product in the up and push excess product
to the front of the hopper to fill the cup.

Changing Sets of The volumetric feed may have several sets of cups for running various
Cups on Five, Six packages and weights.
or Nine Cup
Volumetric Feed IMPORTANT:
Rubber retaining rings are provided on each half set of cups, top
and bottom. These rings lock the cup into position. The same
rings are used for any size cups.

CAUTION:
Retain and use these rings. Do not operate the volumetric feed
without cup "O" rings in place on the feed cups.

1. To change cup sets proceed as follows:

2. Turn all power to machine OFF.

17-8/Rev 5 Ultima®Macro
 17
3. Empty the cups (1) and spread the feed plate (2) -and. trap
door plate (3) -apart by turning the volume adjustment
switch on the volumetric operator panel.
4. Remove the cups to be replaced. Remove upper cups first
over the top of the upper plate (2).
5. Put each new-sized cup back into position.

CAUTION:
The cup must seat firmly in its groove or the retaining ring will
not lock.

6. Set the desired volume size.

7. Restore power.

How to Set This is an optional feature.

Software for an
Adjustable Set the software as follows:
Volumetric Feed 1. When the bag setup is correct, run an empty bag for the
System "TARE' weight.
2. Select the SAMPLE WT line on the display be pressing
the bottom row key labeled "C". This will select the TAR-
GET WT line. However, if you hold the key down for a
count of "One Thousand One" the SAMPLE WT line will
appear.
EXAMPLE: SAMPLE WT. WT #1 XXXXg WT #2
XXXXg

3. If program #0 is loaded from EPROM, then the calibra-

tion parameters are at zero and the setup procedure may
begin. If old calibration parameters are present, then try to
change SAMPLE WT. #1. This should result in a BAD
MINIMUM HEIGHT error and clear the calibration
parameters.
At this point the SAMPLE WT line should contain zeros and look like
this:
SAMPLE WT. #1 0g WT. #2 0g
4. Clear the volumetric plate and cups of all product.

Ultima® Macro 17-9/Rev 5

Volumetric Feed System

5. With the cups empty, and EMPTY BAGS selected, press

the ENTER key. The Servo motor will now run the cups a
completely collapsed position of minimum height and vol-
ume. As the motor runs, two numbers will appear on the
left side of the display line. The rightmost number is the
target height and the other is the present position of the
volumetric plate. 'Me two numbers disappear and SAM-
PLE WT. flashes on the display to indicate that the mini-
mum height has been achieved.
6. Select FILLED BAGS on the keyboard. Press START
BAGS and run several bags for a sample of minimum
product bags.
7. Press STOP BAGS when the sample is finished.
8. Weigh the filled bags and determine the "average" weight
of the product (less the empty bag weight) for minimum
height bags.
9. Put this average weight into the WT. #1 position of the
display.
10. Press the ENTER key. -The number just entered will also
appear in the WT. #2 position, since it is the minimum
value that WT. #2 can have.
Again the present and target position, numbers will appear as
the servo motor moves the cups to the 150% height. When it is
reached, and the numbers are equal, the display will flash SAM-
PLE WT. WT.#1.
11. Select FILLED BAGS on the keyboard and press START
BAGS. Run several bags for a sample of maximum prod-
uct bags.
12. Press STOP BAGS when the sample is finished.
13. Weigh the filled bags made and determine the "average"
weight of the product (less the empty bag weight) for
maximum height bags.
14. Put this average weight into the WT. #2 position of the
display.
15. Press the ENTER key. The display will flash SAMPLE
WT., WT #1, and WT. #2.
The volumetric is now calibrated. However, the cups are at their maxi-
mum height and the target weight is defaulted to the minimum value.
You probably want a different weight for your target weight, so select
the TARGET WEIGHT line again. It will read:

17-10/Rev 5 Ultima®Macro
 17
The XXXX is the minimum cup weight mentioned before. The target
weight will roll up to twice the minimum cup weight, except in some
cases of very large cups, where it will only roll to WT. #2.
To enter the target weight, select TARGET WEIGHT on the bottom
row key "C". With the bagmaker in the STOP BAGS mode, put the
desired weight in the TARGET WEIGHT position of the display. Press
the ENTER key. The two numbers will appear at the left of the display
until the target weight is reached, then the display will flash TARGET
WEIGHT.
Now, or after running a few bags, you may want to save the TARGET
WEIGHT and calibration parameters to EEPROM for future reference.
To do so, use the standard "save current program" procedure which is:
1. Select position #2 on the keylock switch. The SAVE
CURRENT PROGRAM line will not appear unless a
valid burn position is selected on the keylock switch.
2. Select the SAVE CURRENT PROGRAM line on the dis-
play.
3. Select program stored as the same one entered, or as a
new program.
4. Put a 143 in the burn code field.
5. Press the ENTER key, the word STORED will flash on
the display. Now all bagmaker and volumetric parameters
are stored.

How to Use the To change the target weight at times other than setup, stop the machine
Operation Modes and follow the procedure previously described. '
After cycling, the actual weight may be slightly different from the
desired weight, as product density varies. If this is the case, the TRIM
value may be rolled up or down to adjust the weight.
A trim adjustment may be made by selecting the TARGET WEIGHT
line, using bottom row key "C". Roll the desired trim in the TRIM field
on the display, and press the ENTER key. Two values will appear until
the trim adjustment is complete, then TRIM will flash on the display.
It is possible to enter a trim value, and not have the cups move. In such
a case, the change was too small for the volumetric to adjust properly.
When the bagmaker is in the STOP BAGS mode, the volumetric plate
and cups may be raised or lowered through a manual mode. To do so,
select the SAMPLE weight line on the display. Press the manual mode
keypad on the keyboard. The display will be "SAMPLE WT. UP" or
"SAMPLE WT. DOWN". To select the direction, the "normal" on/off
keys in the first two rows of the keyboard (third column from the left)
Ultima® Macro 17-11/Rev 5
Volumetric Feed System

will select the words UP or DOWN on the display. Once the desired
direction is selected, use the manual continuous tube mode to change
the cup position.

IMPORTANT:
Remain alert for jamming.

The cups will move as long as the START BAGS key is held down.
When FILLED BAGS are made, the target height is checked upon
pressing the START BAGS key. If the cups are not at the TARGET
height or a trimmed TARGET height, an adjustment will be made
immediately.
Pressing the RED STOP button on the front panel (which drops the
master relay) will automatically stop any movement of the servo motor.
This is consistent with the other bagmaker functions.

Figure 4: Volumetric System Configuration

The operating speed is set in the program for the product being run. It
is determined by timing the duration between dumps as sensed by the
dump sensor.
The dump sensor is a magnetically operated proximity switch. It turns
On each time a cup (magnet) passes the sensor. There is one magnet
per cup. This On signal causes the start delay timer to begin the next
cycle.
The amount of start delay time entered into the program determines the
amount of time the product is allowed to fall before the bagmaking
cycle is started. Delays of up to one full cycle are allowed.

17-12/Rev 5 Ultima®Macro
 17
The dump sensor signals the end of one cycle and the start of the next.
If the speed is set at 60 dumps/minute, the system is expecting one
dump per second. If the dumps are coming faster or slower than the set
rate, the Macro-Logic commands the motor control board to slow
down or speed up.
The volumetric motor drive is turned On each time the bagmaker is
started in auto mode. The height of the cups is then checked against the
programmed value, and if required, an adjustment is made. Once in
position, the cycle is started.
If the automatic height adjustment is to be bypassed, the unit can be
placed in a manual adjustment mode through the Change Setting Val-
ues screen.

Dump Sensor In addition to indicating cup position, the dump sensor determines the
Adjustment stopping point of the drive motor when the system is brought to a stop.
During a controlled shutdown, the drive motor is turned Off as soon as
the signal from the dump sensor is received. If the system is being run
in a double dump mode, this would occur on the second dump. This
assures no wasted film or product due to jams caused by product leak-
ing through a partially open cup.
The dump sensor is mounted on a sliding plate which can be moved
relative to the opening of the cups.
To adjust the position of the sensor:
1. Run the feed system at the maximum anticipated speed
and bring it to a stop
2. Check the position of the cups after the motor stops. The
cup dumping should have fully opened totally discharging
its product and be in the process of closing. The next door
must be completely closed when the motion is stopped.
3. If the next door is already opening, advance the position
of the dump sensor so the signal will be fed to the
Macro-Logic earlier in the cycle, thus starting the shut-
down earlier.
4. Once the desired stopping point is achieved, tighten the
sensor mounting plate. This point should be acceptable for
all speeds slower than the maximum.
5. You may need to readjust the start delay timing to com-
pensate for the adjustment in the sensor position.

Ultima® Macro 17-13/Rev 5

Volumetric Feed System

Calibration MANUAL ADJUSTMENT

In systems which do not have the automatic height adjustment, the
height of the cups is adjusted in the "Change Setting Values" screen
shown below.

Figure 5: Change Setting Value

The VOLUMETRIC MODE block will read MANUAL. Touching the

block will cause it to highlight. At this point, the UP and DOWN keys
will cause the adjustment motor to run up or down while the block is
pressed.
The process can be repeated until the desired height is achieved. It will
have to be repeated from time to time depending on variation in prod-
uct density.

IMPORTANT:
Be careful not to raise the cups so high that they actually come
apart during the adjustment procedure.

AUTOMATIC ADJUSTMENT (OPTIONAL)

The automatic adjustment cycle consists of several steps. The first is
calibration.
This cycle enables the system to be calibrated in weight (grams). In this
way, an adjustment can be entered in grams either manually or by a
checkweigh device through an RS-232C communication link. The cali-
brated height can be repeated before starting any feed cycle to be sure
the cups are properly adjusted.
The object is to relate height to grams so a calibration factor can be
determined which can be used to convert grams coming into the system
into a change in height of the cups. To do this:
1. Enter the program you wish to run.

17-14/Rev 5 Ultima®Macro
 17
2. From the Main Menu with the key in position 3, press
MANUAL OPERATION.

Figure 6: Main Menu

3. The "Ultima Manual Operation" screen will appear. Run a

few empty cycles to check for good bags. Once com-
pleted, press CALIBRATE.

Figure 7: Ultima Manual Operation

4. This brings up the first of the calibration screens. See fig-

ure below. This process goes through each screen until
calibration is complete.

Figure 8: Volumetric Calibration

Ultima® Macro 17-15/Rev 5

Volumetric Feed System

Run an empty bag to use as a TARE weight. To do this, press START

and a single empty bag will be produced. Save this for use during the
weighing operations.
If the SYSTEM SPEED or TARGET WEIGHT needs to be changed,
this can be done through the display.
5. The first step is to run the cups to a minimum height. A
reminder to empty the hopper is displayed on the screen.
See figure below. If you wish to leave the calibration cycle
at any time, press RET.

Once the product has been removed, press START to lowering the
cups. When the cups are at the minimum value, the correction motor
will be turned OFF and the screen will change to the next one in
sequence.
6. In this screen, a twelve bag sample will be run. See figure
below.

Load product into the system and press START. Twelve filled
bags will be run and the system will stop. The first bags will be
empty and should be discarded The last five bags may be used
as samples. When this is completed, the screen will change.

17-16/Rev 5 Ultima®Macro
 17
7. The screen, as shown in the figure below, will appear.

The average weight of the minimum height sample can now be

determined and entered. Make sure the empty bag produced in
step 4 is used as a TARE weight to be sure you are working
with NET weight, not GROSS weight.
Enter the weight in 0.1 gram increments. When the correct
value is displayed, press ENT.
8. Once entered, the screen will change. See figure below.

The cups will run to 150% of minimum height when the

START block is pressed. Once in position, the height adjust-
ment motor will stop and the screen will change.

Ultima® Macro 17-17/Rev 5

Volumetric Feed System

9. The 150% sample is started by the screen shown infigure

below.f

This is also a 12 bag sample, of which only the last five bags
should be used as an average. When complete, the run will stop
and the screen will change.
10. The average weight will be entered in the screen shown in
the figure below.

Using the empty bag as a TARE weight, weigh and average the
last 5 bags run. Enter the weight in 0.1 gram increments. When
the correct weight is displayed, press ENT.
11. The process is now complete.
a. The cups have been run to a known minimum height
and the weight was determined.
b. The cups have been run to 150% and a second sample
weight has been entered.
c. The difference in weight is divided by the difference in
height to come up with the calibration constant of
grams per increment of height. Knowing the calibra-
tion constant, any value of correction entered in grams
can be converted to height

17-18/Rev 5 Ultima®Macro
 17
The screen shown below is used to enter the desired system speed in
order to determine the desired filled bag rate and volumetric motor
speed.

Enter the desired speed in bags per minute. Once displayed, press
ENT.
12. The screen as shown below will appear.

Figure 9:

The screen shown above is used to enter the target weight to be run.
Enter the weight in 0.1 gram increments. Press Ent.
This completes the calibration cycle. At this point the data is automati-
cally saved to the EEPROM for future reference.

Ultima® Macro 17-19/Rev 5

Volumetric Feed System

Auto Operation The Auto Operation screen displays the target weight of the program.

Figure 10: Auto Operation

The target weight is entered in the Calibration screens.

In automatic mode, the fill cycle will not begin until the volumetric is
at the programmed height. As a result, there could be a delay when
loading a new program.

WARNING:
Do not attempt to override or stop the correction process or touch
any part of the machine during this time. The cycle may begin at
any time after the proper height is reached.

Change Setting
Value Screen

Figure 11: Change Setting Value

The Change Setting Value screen can be used to modify several volu-
metric parameters while running.

17-20/Rev 5 Ultima®Macro
 17
1. The system speed can be changed by pressing the System
Speed P/M pad and running the speed up or down by
pressing the Inc or Dec blocks. Press ENT to confirm the
setting.
The speed can be slowed down to any value desired, but cannot
be increased above the programmed speed. This feature allows
the system to operate normally in the event of a low product
supply.
2. The system can be manually trimmed by pressing VOLU-
METRIC TRIM and INC or DEC.
Once the proper value is displayed, press ENT to bring the
value into the program. After entry, the value will return to
0000.
3. If you wish to run an automatic system in a manual mode,
this can be done by first turning the key to position 3. The
height can be adjusted manually by pressing Volumetric
Mode and toggling it to Man. The Inc and Dec can be
used to go to the desired position.
In this mode, the height is ignored and the cycle will proceed in
a normal manner as long as the mode is in MAN and the key is
in position 3.

Ultima® Macro 17-21/Rev 5

Volumetric Feed System

17-22/Rev 5 Ultima®Macro
 Clutch/Brake
A Pressure Roller Replacement 8-11
Repeatability Test 8-10
ABC Jaw Opening Adjustment 12-2 Combination End Seal System
Accu-Track 16-21 Quali-Seal System
Basic Function of the Controller 16-23 4-Sealing Rib Variations 12-25
Operation 16-21 Additional Jaw Face Adjustment 12-23
Positioning the Sensor Guide Assembly 16-23 Adjust Gripping Pressure 12-30
Sensitivity Adjustment 16-23 Heat Control Adjustment 12-30
Air Displacement System 10-4 Hole Punch Maintenance 12-31
Air Input System 14-2 Jaw Set-Up 12-20
Air Pressure Switch 14-2 Optional Round Sealed Hole Punch 12-29
Air Valve and Manifold Assembly 14-3 Punch Cylinder Timing 12-31
CMB Regulator with Gauge 14-2 Punch Rod Location Adjustment 12-30
Dataweigh Regulator with Gauge 14-2 Teflon Fiberglass Tape 12-19
Exhaust Silencer Separator 14-3 Temperature Controllers 12-19
Filter Regulator with Gauge 14-2 Timing Considerations 12-24
Flow Control Valves 14-2 To Run Bags without a Hole Punch 12-30
Lubricator 14-2 Resistance
Optional Maintenance Alert and Prevention Change Hole Size 12-16
System (MAPS) 14-3 Heated ProPunch 12-13
Shut Off and Dump Valve 14-2 Heated ProPunch Adjustments 12-14
Auger 16-29 Hole Punch Alignment 12-16
Auto Operation 16-34 Punch Cylinder Timing 12-17
Automatic Adjustment 16-32 Punch Rod Removal 12-17
Change Setting Value 16-34 Removing and Installing Sealing Jaw Fac-
Setup 16-29 es 12-10
Rod and Bushing Maintenance 12-18
Round Mechanical Hole Punch 12-15
B
Running Bags Without Punch 12-17
Back Seal Types 10-5 Sealing Pressure Adjustment 12-17
Baffles 10-4
Bag Support And Eject 16-1
Assembly Adjustment 16-1
D
Eject Air Cylinder Timing 16-2 Dancer Roll and Brake Adjustment 7-6
Ejector Plate Changeover 16-2 Determining Film Width 7-9
Ejector Plate Positioning 16-2 Double Pull Recipe 6-11
Bar Code Reader Wand 6-2
Modifying Existing Barcodes 6-2
E
C Electrical
Feed System 3-5
Change Jaw Opening Position 12-4 GFCI 3-3
Changing End Seal Systems 12-31 Installation 3-2
From Cellophane to Poly 12-32 Encoder Operation 13-2
From Poly to Cellophane 12-31 End Seal Assembly 12-1
Clutch 8-10 ABC Jaw Opening Adjustment 12-2

1
 G
Change Jaw Opening Position 12-4
How It Works 12-2 Gas Flush 16-41
Jaw Closed Proximity Switch Adjustment 12-6 GFCI 1-2, 3-3
Jaw Face Pressure Adjustment for Resistance Ground Fault Circuit Interrupter 3-3
Jaws 12-4 Guards 1-1
Jaw Open and Close, Speed, and Cushion
Controls 12-7
Error Messages 15-10
H
Heated ProPunch Adjustments 12-14
Hole Punch Alignment 12-16
F
Film Splicer Instructions 16-18
Film Width Calculation 10-6
I
First Bag SCR Sealing System Impulse Sealing System 12-33
Change Cellophane to Poly 12-39 Cellophane To Poly 12-35
Controls and Calibration 12-36 Changing End Seal Systems 12-34
Setup and Calibration Example 12-38 Poly to Cellophane 12-34
Flat Bottom Bag 16-2 Sealing Jaw Alignment 12-33
Adjustments 16-3 Infeed 3-5
Forming Assembly Removal 10-8 Double Dumping 3-6
Forming Tube Assembly Electrical 3-5
Adjustable 10-5 Mechanical Interface 3-6
Air Displacement System 10-4 Product Spacing 3-5
Baffles 10-4 Timing 3-5
Components 10-2 Installation
Former 10-2 Air Devices 3-1
Forming Tube 10-2 Electrical Devices 3-2
Inserts 10-3 Ground Fault Circuit Interrupter 3-3
Last Roller 10-2 Feed System 3-5
Maintenance 10-7 Lifting machine 3-3
Forming Assembly Removal 10-8 Product Feed Interface
Last Roller Position Adjustment 10-8 Double Dumping 3-6
Removal, Cleaning and Installation of the Mechanical Interface 3-6
Pull Belt Inserts 10-8 Spacing 3-5
Seam Seal Timing 3-5
Sponge Tape Replacement 10-7 Product feed interface 3-5
Tube and Former Concentricity Adjust- Site Preparation 3-1
ment 10-7
Tube Stop Adjustment 10-7
Open Back Forming Tubes 10-4 J
Sponge Tape 10-4
Jaw Closed Proximity Switch Adjustment 12-6
Spreaders 10-3
Jaw Face Pressure Adjustment for Resistance
Storage and Handling 10-7 Jaws 12-4
Tube Air 10-4 Jaw Open and Close, Speed, and Cushion Con-
Tube Stop 10-2 trols 12-7

2
 Replacing Upper Pulleys 9-6
K Master Stop 5-1
Messages
Keylock Switch 5-2 Controlled Shutdown Error 15-12
Knife Adjustments 12-8 Display 15-10
Blade Replacement 12-10 Immediate Shutdown 15-13
Position 12-9 Information 15-11
Speed 12-9 Modifying Existing Barcodes 6-2
Motorized Unwind Edge Adjustment 7-9
L
Last Roller Position Adjustment 10-8
O
Lift Machine 3-3 Operator Panel and Controls 5-1
Linear Stager 16-6 Optional Maintenance Alert and Prevention Sys-
Sequence of Operation 16-7 tem (MAPS) 14-3
Speed Adjustment 16-7
Stager Plate Gap Adjustment 16-7
Load a Recipe 6-2
P
Bar Code Reader Wand 6-2 Platen Assembly 11-1
LocTite 4-3 Adjustments 11-3
Fasteners 4-4 Centering Adjustment 11-3
Lubrication 4-1 Distance Adjustment 11-3
lubrication chart 4-2 Speed Adjustment 11-4
Cushion Inspection 11-2
Operation 11-2
M
Polyethylene Air Cooling System 11-2
Machine 5-15 Pneumatic System 14-1
Macro-Logic System 6-1 Pneumatic System Maintenance 14-4
Maintenance Air Filter/Regulator 14-4
belts 4-3 Exhauster/Silencer 14-4
Cleaning 8-10 Lubricator 14-4
Cleaning Pull Belts 9-5 Lubricator Bowl 14-4
Clutch/Brake Pressure Roller Replacement Oil Delivery Rate 14-4
8-11 Pneumatics
Clutch/Brake Repeatability Test 8-10 Installation 3-1
Fasteners 4-4 Poker 16-17
Film Feed Rollers 4-3 Air Cylinder Speed Adjustment 16-17
General Procedures 4-3 Poly Impulse
LocTite 4-3 Optional Accessories
Lubrication 8-10 First Bag SCR Sealing System 12-36
Miscellaneous 8-10 Polyethylene Platen Air Cooling System 11-2
Pressure Roller 8-10 Print Registration 8-2
Pull Belt Drive Shaft Universal Joint Lubrica- Printer 8-7
tion 9-7 Take-Up Roller 8-8
Registration Eye 4-3 Product Jam Detector 1-2
Replacing Bottom Pulleys 9-7 Product Stripper 16-8
Replacing Pull Belts 9-6 Bar Adjustments 16-11

3
 Eye Spot Indicator 8-4
Bar Gap Adjustment 16-12 Offset Adjustment Pot 8-4
Cylinder Pneumatic Speed Adjustment 16-10, Offset Control 8-5
16-13 Removal, Cleaning and Installation of the Pull Belt
Electrical and Pneumatic Speed Adjustment Inserts 10-8
16-9 Removing a Depleted Roll of Film 7-7
Linkage Adjustment 16-15 Replacement Parts
Proximity Switch Adjustment 16-14 Contacting HayssenSandiacre® 0-3
Proximity Switch Electrical Adjustment 16-9 Delivery Of Parts 0-4
Pull Belt How to Order Parts 0-1
Centering and Pressure Adjustment - Non Parts Identification 0-1
CMB 9-4 Reset 5-1
Cleaning 9-5 Resistance Hole Punches 12-13
CMB Assembly to Tube Alignment 9-5 Round Mechanical Hole Punch 12-15
Drive Shaft Universal Joint Lubrication 9-7
Operation 9-2
Performance 9-3 S
Pressure Adjustment on CMB Machine 9-4 Safety Notices
Replacing 9-6 Basic Danger and Warning Notices
Replacing Bottom Pulleys 9-7 Guards 2-1
Replacing Upper Pulleys 9-6 burn, nip, and pinch points 2-3
Electrical 2-3
R installation 2-2
lubrication 2-4
Recipe machine location 2-2
Changing a Parameter Value 6-3 parts replacement 2-4
Chart 6-13 Safety Overview 2-1
Create or Edit 6-3 safety signals 2-1
Degree and Millisecond Range 6-3 Screen
General Information 6-3 Auto Operation 5-7
Saving 6-9 Bagmaker Monitor 5-20
Registration 8-2 Change Setting Value 5-10
Registration Eye Counter and Temperature 5-18
Maintenance 4-3 Date/Time & Print 5-19
Registration Roller Key Position 1 Menu 5-4
Components 8-1 Key Position 2 Menu 5-5
Registration Roller Assembly Machine Timed Functions 1 5-15
Print Registration 8-2 Machine Timed Functions 2 5-16
Scanner Control Unit 8-4 Manual Operation 5-12
Spacing 8-2 Master Relay Troubleshooting 5-23
Adjustment Procedure 8-2 Mechanical Check Troubleshooting 5-31
Super CMB Models 12-16, 12-19, & SF Out of Registration Troubleshooting 5-25
8-2 Power Up 5-2
Registration Scanner Product Designator 5-14
Background Selector Switch 8-5 Program Selection 5-6
Components 8-4 Real Time Functions 5-17
Contrast Level Indicator 8-5 System Error Troubleshooting 5-26

4
 T
Temperature Control Troubleshooting 5-30
Troubleshooting Main Screen 5-22 Threading Film 7-8
Ultima Auto Program 5-21 Timing 6-1
Screen Descriptions 5-2 Transmission & Encoder 13-1
Auto Operation 5-7 Changing Transmission Oil 13-2
Bagmaker Monitor 5-20 Encoder Removal and Replacement 13-3
Change Setting Value 5-10 Long/Short Lever 13-1
Counter and Temperature 5-18 Maintenance 13-2
Date/Time & Print 5-19 Motor 13-1
Key Position 1 Menu 5-4 Motor Inspection 13-3
Key Position 2 Menu 5-5 Troubleshooting
Machine Timed Functions 2 5-16 Bag Cutoff 15-7
Manual Operation 5-12 End Seal System 15-8
Master Relay Troubleshooting 5-23 guidelines 15-1
Mechanical Check Troubleshooting 5-31 Operators 15-2
Out of Registration Troubleshooting 5-25 Packaging Material Feed System 15-3
Product Designator 5-14 Print Registration 15-4
Real Time Functions 5-17 Registration Roller Clutch/brake 15-5
System Error Troubleshooting 5-26 Seam Seal System 15-7
Temperature Control Troubleshooting 5-30 Tube and Former Concentricity Adjustment 10-7
Troubleshooting Main Screen 5-22 Tube Stop Adjustment 10-7
Ultima Auto Program 5-21
Seam Seal U
Type 7-10
Sensor Setup Unwind Assembly 7-1
Foil Material 8-6 Components 7-2
Opaque Material 8-6 Dancer Roll and Brake Adjustment 7-6
Transparent Material 8-7 Dancer Rollers 7-3
Setting the Date and Time 6-9 Determining Film Width 7-9
Shaker Jaw Low Film Bar 7-4
Amplitude Manual Adjustment 16-28 Motorized Unwind Edge Adjustment 7-9
Clamp Release Time 16-28 Operation 7-5
Cylinder Cushion 16-28 Positioning Ruler 7-3
Installation 16-28 Principles of Operation 7-1
Operation 16-26 Removing a Depleted Roll of Film 7-7
Proximity Switch Position 16-28 Roll Brake Mechanism 7-3
Removal 16-27 Roll Locating Collar 7-4
Smoothness Tuning 16-28 Roll Spindle 7-3
Speed 16-28 Spindle Roll Brake Drum 7-4
Site Preparation 3-1 Spindle Support Plates 7-2
Stager/cooler 16-4 Spindle Tube 7-3
Sequence of Operation 16-5 Stationary Rollers 7-2
Speed Adjustment 16-5 Threading Film 7-8
Unwind Motor 7-4

5
 V
Volumetric
Belt Adj. 16-40
Brush/Scraper Adj. 16-39
Chain Adj 16-40
Changing Sets of Cups 16-39
Clutch Adj 16-40
Cup Adjustment 16-38
Drop Timing 16-39
Dump Plate Height 16-40
Dump Sensor Adj. 16-37
General Information 16-35
Setup 16-36
Trap Door Adjustment 16-38

W
Washdown
bagger 4-5
scale 4-6
Water Cooling Unit 12-40
Filling the System 12-40
Replacing the Temperature Controller 12-41
Replacing the Temperature Controller at the
Compressor 12-41