INTRODUCTION

The AS (A-Series) is a uniform, automatic carton sealer designed to operate in high-speed, automated production lines. Its primary function is to receive, seal, and discharge cartons efficiently. To ensure smooth operation within integrated systems, the AS is equipped with relay outputs and photo sensors that allow upstream and downstream conveyors to communicate directly with the machine.

SYSTEM INTEGRATION OVERVIEW

How Conveyors Control the AS Machine

To coordinate box flow and prevent jams or misfeeds, the AS provides upstream and downstream conveyors with the ability to monitor and respond to the machine's status. This is achieved via:

• Dry Relay Contact (Relay #2 - R2):
  Located in the AS electrical tray, Relay #2 outputs a dry contact signal that indicates when the machine is ready to accept the next carton.

• Control Wiring for Integration:
  Wires #9 and #10 transmit the R2 signal to upstream equipment. When R2 is “ON,” the upstream conveyor can release a new box. When R2 turns “OFF,” the conveyor holds the next box until signaled again.

• Photo Sensors (Optional):
  Additional upstream and downstream sensors can be installed to further enhance system control.

What We Provide to Assist Conveyor Control

To assist with setup and ensure seamless integration, BestPack provides:

• Wiring Schematics:
  Available inside the electrical cabinet, within the machine manual, or by request via technicalsupport@bestpack.com.

• Prewired Terminal Blocks:
  Terminals #9 and #10 provide simple wire connection points for upstream relay signals.

• Green LED Indicator on R2:
  Built-in visual feedback confirms when R2 is active (ON) or inactive (OFF), aiding in troubleshooting.

• HMI Carton Spacing Timer:
  A configurable delay ensures optimal timing between boxes (default: 250 ms; range: 150–5000 ms).

OPERATION

Production Cycle & Interlocks

• Box Entry & Spacing:
  When a new box blocks photo sensor PH1, R2 turns OFF, preventing additional boxes from entering. After the spacing delay, R2 turns back ON to signal readiness.

• Cycle Fault Protection:
  If boxes arrive too close together, the AS will fault with alerts like:

  • "Box Jam"

  • "Carton Spacing Error"

Downstream Control

• “Ready-to-Receive” Interlock (Optional):
  A downstream sensor can pause the machine if the exit is blocked. Once clear, the AS resumes.

OBSERVATION CHECKLIST

ADVANCED OPTIONS

• Upstream “Box Incoming” Photo Sensor:
  Automatically restarts conveyor motors after idle time.

• Motor Timeout Feature:
  Pauses conveyor motors when idle, saving energy and reducing wear.

• Downstream Full Signal:
  Pauses upstream operation if boxes back up beyond the AS discharge point.

TROUBLESHOOTING & PROCEDURE

Step-by-Step Relay Test

1. Verify Wiring:

   • Confirm wires #9 & #10 are connected to upstream logic.

2. Check LED Indicator:

   • R2 ON = Green LED illuminated = Ready for box

   • R2 OFF = PH1 blocked or machine faulted

3. Relay Testing:

   • Swap relay with a known working one

   • Confirm coil is 24VDC

   • Confirm contacts pass 120VAC when powered

4. Power Cycle Logic:

   • Reset circuit breaker if mismatch between machine and conveyor states (e.g., AS stops but R2 remains ON)

5. Carton Spacing Tuning:

   • Use HMI to fine-tune the delay to match upstream conveyor speed

6. Upstream Functionality:

   • Adjust conveyor flow to ensure consistent spacing and maximum throughput

7. Downstream Signal Check:

   • Ensure the “Ready-to-Receive” sensor is functioning and not blocked

CONCLUSION

Integrating the AS with upstream and downstream conveyors ensures a reliable, automated sealing process. The AS machine's relay logic, photo sensors, and adjustable timing empower conveyors to intelligently control box flow and avoid costly jams or stoppages.

Maintain proper carton spacing, monitor system feedback through R2’s LED, and leverage BestPack’s wiring resources to optimize your production line.

If assistance is needed, contact us at technicalsupport@bestpack.com for schematics, parts, or expert help.

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