FCG-380 rotary pleating equipment

Customer Product Manual

Issue 01/18

This document contains important safety information

Be sure to read and follow all safety information in
This document and any other related documentation.

Shanghai Feng Cheng Machinery Manufacturer Co.,Ltd

www.shfcme.com.cn
 Table of Contents
Chapter One
Ø Preface……………….……………………..…….……2
Chapter Two
Ø Safe
Requirements.…………………….………….……3
Ø General Description………………………..……………3
Ø Safety Rule……………………………………………….4
Ø Safety Alert Symbols…………………………………….4
Ø General Safety Warnings and Cautions………....….5-7
Ø Safety Rules For Operators………………………...…..8
Ø Safety Rules for Maintenance………………………..8-9
Ø Operator’s Working and
Operation Position……………………………….….10-11
Chapter Three
Ø Specifications and Installation…………………….12-13
Ø Installation………………………………………………14
Chapter Four
Ø Adjustment and Operation……………………….……15
Ø Basic Principle and Production
Process Flow of Pleating machine………………..15-17
Ø Operation Procedure of Pleater……………………17-21
Ø Adjustment of Pleater……………………………….21-22
Ø Adjustment of Pleater Width……………………….…..23
Ø Adjustment of pleating Height……………………...23-24
Ø Operation Notice of Pleater………………………...24-26
Ø
1. Safety Notices……..…………………………………………………3
2. Safety Signs…..………………………………………………………4
3. Distribution Diagram of Safety Signs………………………………5
4. Safety Rules for Operators…….……………………………………6
5. Safety Rules for Maintenance………………………………………6
6. Operator’s Working and Operation Position………………………7
7. Safety Rules for Installation…………………………………………7
Chapter Three Specifications and Installation………………………………………8
I. Nameplate…….……………………………………………………………8
II. Specifications………………………………………………………………8
III. Machine Outline and Installation Dimension……………………………9
IV. Installation……...…………………………………………………………..9
V. Power
Supply..……………………………………………………………..9
VI. Air Supply…………………………………………………………………10
Chapter Four Adjustment and Operation..…………………………………………11

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 I. Basic Principle and Production Process Flow of the Machine………11
II. Operation and Adjustment………………………………………………12
III. Electric Operation System………………………………………………17
Chapter Five Maintenance and Troubleshooting………………………………….24
I. Daily Maintenance……………………………………………………….24
II. Periodic Maintenance……………………………………………………24
1． Check Items…….…………………………………………………..24
2． Periodic Lubrication Maintenance………………………………...24
III. Common Troubles and Solutions………………………………………25
Chapter Six Appendixes….………………………………………………………….26

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 Chapter One
Preface
Welcome to use our Company’s FCG-380 rotary pleating equipment.

Only proper operation can fully realize the performance of the machine
and produce high-quality products. Therefore, relative personnel using
the machine should read this operation manual carefully and fully
understand it to run the machine in the optimum state and obtain the
maximum benefit.
At the same time, please also be sure to pay great attention to the safe use
of the machine.
When you read this manual, you have become our customer or service
target, and we will take the responsibility to provide technical help for the
use of the machine. Here is the contact method of our Company:
Tel: +86-21-64483305 +86-21-64483306
Fax: +86-21-64483329
Website: www.shfcme.com.cn
E-mail: info@shfcme.com.cn
Please confirm the detailed model number of the machine you purchase.
The number of mini pleating machine is as follows:
FCG -- XXXX

Model Effective pleating width

Please understand that sometimes there are some differences between the
detailed specifications of delivered machine and the specifications in this
operation manual due to the design alteration or other special reasons.
Our Company will not bear the responsibility for any trouble or damage
arising from not operating the machine according to the instructions in the
operation manual or altering the parts of the machine without authorizati

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 Chapter Two
Safety Requirements
Read this chapter Before using the equipment. This section contains
Recommendations and practices applicable to the safe installation,
operation, and use of product described in this document. Additional
safety information , in the form of task-specific safety alert messages.
appears as appropriate throughout this document.

WARNING! Failure to follow the safety messengers, recommendations,

And hazard avoidance procedures provided in this document can result
in personal injury, including death ,or damage to equipment or property.

General Description
Rotary pleating equipment is applicable to the pleating the panel air
filter, the embossing roller makes the embossing on the filter media to
improve the dust holding capacity of filter and decrease the resistance
of the filter media. This equipment is fully automatically designed.
The customer can produce different product by easily changing the
embossing roller.
Rotary pleating equipment consists of decoiler, paper connecting table,
slitting system, feeding system, paper storing box, heating system,
embossing roller, marking system, hot melt dispensing system,
collecting roller, conveyor, cooling system, auto cross cutting system,
pleated paper collecting table. The feeding system is powered by one
1.1 kw inverter motor. The embossing roller and collecting roller is
powered by two 1kw servo motor. The gluing position is controlled by
four 0.4 kw servo motor. The conveyor is powered by one 0.4kw servo
motor. The cross cutting system is powered by 0.6mpa compressed air.

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Safety Rules
WARNING! Safety Notices:
Read and understand the whole contents of this manual;
There should be no unsafety factors around the machine before it starts.
Do not run the machine until closing the protective hood.
Main power supply should be turned off when maintaining or adjusting
the machine. Never adjust the machine in the starting condition;
Power switch should be turned off when power is off or leaving the
machine for a while;
Do not open the movable door and protective hood on the machine
when the machine is in working condition;
Working on electrical units had better be operated by electrical
technicians. After turning off the power, in order to prevent residual
voltage, you should carry out repair and maintenance work after 15
seconds;
No smoking, no fire.

Safety Alert Symbols

The following safety alert symbol and signal words are used
throughout this documents to alert the reader to personal safety hazards
or to identify conditions that may results in damage to equipment or
property. Comply with all safety information that follows the signal
word.

WARNING! Indicates a potentially hazardous situation that, if not

avoided, can result in minor or moderate personal injury.

CAUTION: Indicates a potentially hazardous situation that, if not

avoided, can results in minor or moderate personal injury.

CAUTION:(Used without the safety alert symbol) Indicated a

potentially hazardous situation that, if not avoided, can results in
damage to equipment or property.

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 General Safety Warnings and Cautions
Warning safety signs for accident prevention have been pasted on the
essential places of the machine. Please be sure to follow the notice
matters of the signs.
Safety signs include: DANGER, WARNING and CAUTION.
The meanings of safety signs are as follows:
DANGER: result in the possibility of death if not following this safety
requirement.
WARNING: result in the possibility of serious injury if not following
this safety requirement.
CAUTION: result in the possibility of personal injury or machine
damage if not following this safety requirement.
Table 1-1 contains the general safety warnings and cautions that apply
to FCME equipment. Reviews the table and carefully read all of the
warnings or cautions that apply to the type of equipment described in
the manual.

Warning signs Warning or Caution

WARNING: Risk of electrocution! Even when switched off and

electrically isolated at the disconnect switch or circuit breaker, the
equipment may still be connected to energized auxiliary devices.
De-energize and electrically isolate all auxiliary devices before
Danger! Electric
shock servicing the equipment. Failure to properly isolated electrical
power to auxiliary equipment before servicing the equipment can
results in personal injury, including death.
WARNING: Risk of fire or explosion! FCME equipment is not
rated for use in explosive environments.

Caution! Scald!

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 To avoid hand injury, please pay attention to the sharp knife
during machine running.

Caution! Injure hand

WARNING: Moving parts hazard, can cause severe injury. Keep

away from moving parts. Do not wear gloves or loose clothing. Do
not operate without doors, covers and guards in place. Don not
approach moving parts, can cause severe compression injury and
Caution! Mechanical scratch.
injury!

Safety Rules for Operators

Ø The operation and maintenance of the machine should be
carried out by the personnel with professional training and
actual operation training;
Ø In order to avoid being entangled into the running section of the
machine, please coil long hair in the working hat;
Ø When cleaning the machine, please be sure to switch off power
supply. Do not use solvent to clean the machine. Clean the
housing components with neutral soap liquid, and use 10# oil to
clean the metal components;
Ø When finding any abnormal sound, switch off the machine
immediately and ask for the repair worker to check the machine.
The machine can’t run until removal of the trouble and
installation of the protective hood;
Ø In order to avoid hand injury, do not put hands on running parts,
rollers or heating parts when the machine is running;
Ø Never use hands to touch the injecting nozzle of hot-melt glue
unit in order to avoid hand scalded by high temperature of the
surface;

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 Ø The melted hot-melt glue has quite high temperature. So, do not
touch it until fully cooling;
Ø When meeting some sudden accidents, press emergency stop
switch, cut off the power supply and remove the troubles.

Safety Rules for Maintenance

Ø The machine should be maintained by professional personnel
only after they deeply understand the principle and performance
of the machine;
Ø Stop running the machine when maintaining or cleaning it;
Ø Please run the machine after putting the hood, cover and other
units removed during the maintenance back to the original
positions;
Ø When replacing any electrical part, it is necessary to cut off
power supply. Replace it with the same one or the one with
equivalent specifications.

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Operator’s Working and Operation Position
See the figure below for operator’s working and operation position
The whole rotary pleating equipment

Safety Rules for Installation

Ø The ground for installation should be flat;
Ø The inlet wire of power supply should be complying
with the power of the machine, and the power line
should be fixed well;
Ø The machine must be with grounding protection.
The ground wire should be connected on the mounting
bolt of machine foundation, and zero line cannot be
used as ground wiring;
Ø Please ensure the way of installation position
unobstructed and prepare the forklift with load capacity

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 of 1 ton above;
Ø The distance between two sides of the installation
position of the machine and walls should be larger than
1m. Adjust the foundation of the machine to keep the
machine horizontal;
Ø The machine should be fixed with foundation bolts. It
also can be placed on the ground with antiskid sizing
mats;
Ø The machine is powered by 380V 50Hz. Install safety
device and switch with proper capacity in front of the
power socket outside the machine.

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 Chapter Three
Specifications and Installation
The rotary pleating machine is produced by Shanghai Feng Cheng Machinery
Engineering Co., Ltd. There are two machine nameplates, one is on the pleater and
the other is on the slitting conveyor.

I. Nameplate

People’s Republic 0f China

Shanghai Feng Cheng Machinery Engineering CO., Ltd

Name Model Weight

Rotary pleating machine FCG-380 XXXkg

Manufacturing Date Series No

XXXX/XX/XX XXXXXX

II. Specifications:
Maximum pleating height: 65 mm
Minimum pleating height: 17mm
Maximum width for filter paper passing through: 246 mm
Pleating speed: 70m/min
Power of motor:
Servo motor: 1.5+0.4+0.4kW
Air pressure: 0.6 Mpa
Power supply: 380V, three-phase
2. Specifications of hot-melt unit (two unit):
Glue melting capability: 10 Kg/hr

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 Glue barrel capacity: 10Kg
Rate voltage: 240V (one phase)
Power:16.5 KW
² Machine Outline and Installation Dimension

L×W×H：8532mm×1208mm×2250mm

Installation
The machine should be placed on the suitable position of the
proper working site with sufficient space.
Line out the installation central line in the workshop
according to the installation position.

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After removing the outer packing box and dustproof film,
place the machine on the fixed position or the installation
position of production line by a forklift. The distance between
two sides and walls must be larger than 1.5m.
Calibrate the level of the machine.
V. Power Supply
The inlet wire of power supply wire should be equivalent to
the power of machine.
Power supply is 380V 50Hz. Please check whether the power
supply configuration conforms to the nominal in the manual.
The machine must be with grounding connection. The ground
wire should be connected on the mounting bolt of machine
foundation.
VI. Air Supply
When connecting air supply, please check whether the air
supply meets the requirements of the machine. The air supply
pressure of the machine is 0.6MPa. It is not allowed to
connecting the air supply if it does not meet the requirements.

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 Chapter Four
Adjustment and Operation
I. Basic Part of the equipment
Ø Decoiler

Decoiler is used to holding the filter media. This equipment

consists of two decoiler. Due to time saving propose, please put
the filer media on both decoiler. Decoiler consists of conical,
main roller, product block parts. Please pay attention, the left side
of equipment is base line. Two conical is used to holding the core
of paper. Product block parts is used for different product.
Now there is two piece of product block parts in the equipment
for two different wide filter meida.

Ø Paper connecting table

The paper connecting table to used to join two rollers of media
together. The usually paper connecting time is 45s. The paper
connecting table consists of base, paper holding tool, tape holder.

Ø Heating system
Heating system is used to heating the filter media, heated paper is
easy to pleat and make the embossing on it. Heating system is
used the IR technology, and includes the top and bottom heating
section. Each section has 6 IR light. Each IR light is 500W. The
two heating section is controlled by two individual temperature
controller. Max heating temperature is 250C.

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Ø Embossing system
Embossing system includes embossing roller, pulling roller two section.
These two sections are controlled by 1kw servo motor. Embossing roller
includes, top embossing roller, bottom embossing roller, bearing, base,
center correcting system, paper thickness adjusting section, gear. Pulling
roller includes top pulling roller, bottom pulling roller, movable bearing,
bearing, gear.

Ø Marking system
Marking system includes two EFD 781S spray gun, movable
supporting, ink tank. One spray gun is used to mark the point on
the paper, the marking point is used to be detected for the auto
cross cutting system. The other spraying guns is used to mark on
the point or line on the bad product.

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Ø Main control panel
Main control panel is on the top of the equipment. The main
control panel can be turned. It includes the supporting arm,
operating box, touch screen, operation buttons.

Ø Dispensing System
The dispensing system is used to form the pleated paper
with glue. It consists of hot melt applicator, glue guns, glue hoses,
gun movement system and etc. Glue gun is fixed on the movable
base, and connected to two sets of hot melt applicator is put at the
side of machine, hot melt applicator is connecting to the
dispensing gun by hose. The dispensing volume can be adjusted
by the pump setting on the hot melt applicator touch panel .When
the machine stop, the hot melt dispensing system will also stop
automatically.
The dispensing position is be set on the touch screen of the main
control panel. The dispensing volume also automatically matches
the pleating speed. The detail of how to set the hot melt applicator,
please read the nordson applicator manual.

Ø Collecting system

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The collecting system is used to pleat the paper media from the
horizontal to vertical. The special collecting screw is controlled by the
servo motor, set the zero point and it will match the speed of
embossing roller and pulling roller. The collecting system includes
base (No.1), horizontal adjusting screw(No.2), gear box(No.3), top
press adjusting system(N0.4), servo motor(No.5), collecting
screw(No.6), vertical adjusting screw(No.7). Balance adjusting screw
(No.8). Horizontal adjusting system can adjust the left and right screw
separately, and also can adjust both, which is used to make the
distance from two screws are same.

Ø Cooling system
Cooling system is equipped upper the coveyor belt and used to
cooling the dispensed glue. According to actual situation, user can
open or adjust fan amount.

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Ø Cross cutting system
It’s used to cross cut the pleated paper according to the required
pleat number. It consists of rodless cylinder, knife, lifting handle
arm and etc.

Ø Safety cover
All the aluminum frame, transparent glass safety cover is consists
of slitting& feeding roll part, main unit cover, conveyor cover,
cross cutting cover, output cover and other safety covers.

Ø Collect table
It’s used to put the pleated filter element or element non-good
products.

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 II. Adjustment of pleat unit

1. Roller distance adjustment

The distance between two rollers is adjusted according to different
thickness of filter media. Feeding roller, paper drawing roller’s upper
and bottom distance is according to their thickness. Corrugation
roller’s distance is according to paper thickness and pleat loc height.
If the distance is too small, it will damage the rollers. Via adjust two
knurl hand knobs upper the roller, when rotate clockwise, the
distance will be smaller, vice verse. Upon adjusted, fix the dial
indicator to be 0 for later use. Both sides have the dial indicators
which can guarantee the distance of two sides are same, otherwise
the paper will go off tracking. After distance adjustment, adjust the
gear to eliminate distance of transition gear and lock the screw of
hand knob.

3． Centering adjustment of corrugation roller

Centering the convex knife of upper roller and flat knife of
bottom roller or centering the flat knife of upper roller and the
convex knife of bottom roller, otherwise the paper’s verticality after
pleat is not good. Via adjusting the screws on the pedestal of upper
roller can rotate the upper roller microscale, but the position of
bottom roller and gear is fixed, the upper roller and red shaft cover is
connected by key. After adjust, lock two screws two side. After
adjustment of roller, then adjust the distance of gears, finally lock the
fixed screw of yellow adjustment gear.

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III. Electric control system
Ø electric system
The machine uses three-phase, four-wire, 220V 50Hz. The control system is
consists of PLC, touch screen, converter, servo motor controller,
temperature controller, relay, power switch, button and etc. The machine’s
electric controller parts. Indicator are equipped on the electric box and
operation manual
Ø operation manual
1. main control panel: OP-1

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Ø Electric Operation procedure and notice
1. Preparation
Close the power switch (if with host-machine hand-cranking handle, take out it),
close the electric cabinet door, release the self-locking function of the emergent stop
button, turn on power control switch, and the working indicator light will be on.
2. Installation and maintenance notices

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 1) The machine is power by three-phase, four-wire, 380V. User can take maintenance
according to the electric schematic diagram. (See appendixes: wiring diagram and
schematic diagram)
2) The machine should be grounded separately.
3) Except the need of clearing and adjusting, the door of the electric cabinet should be
closed. Please do not open it at discretion.
4) Professional personnel should check the insulation condition of the electric cabinet
and the tightening condition of each electric part periodically.
5) If the running of the machine has some troubles, the maintenance work must be
carried out by the professional electrical technician or electrician.
6) Before operating this machine, it is necessary to read the operation manual and the
operating instruction manual of relative electric parts detaily . Do not operate the
machine at will.
7) The data of converter has been set before leaving factory, if the customer need to
adjust, please refer to the professional person and reading the instruction of
converter, then go on adjustment.
8） Upon press the “Emergency Stop”, the machine will automatically stop
3、electric parts list is as attached
IV. Operation notice
1、Please check if two conical parts of decoiler has clamped the paper core tightly and
the media cannot rotate freely.
2、Please check if the upper and bottom slitting knife is locked tightly. Two sides of
knife should be as close as possible with bit distance.
3、The distance between the upper and bottom roller cannot be too small, otherwise
the paper is easily to be broken
4、The distance between the height of forming collect roller and guide plate should be
adjusted according to different pleat height for easy collecting.
5、The height between upper and bottom heater should be much higher than the pleat
height. The temperature should be adjusted suitable.
Ⅴ. Noise

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 The noise of machine is less than 80dB。

Chapter Five Maintenance and

Troubleshooting
When taking daily servicing and maintenance, stop running the machine and switch
off the power supply.
I. Daily maintenance
1. Keep the oil level height in the oil cup of pneumatic triple-coupling according to
the requirements. Put out the water liquid when the water in the water-filtration
cup is up to the stated capacity.
2. Keep the machine and its surrounding working site clean and unobstructed. Clear
the waste residual paper to the designated place in time.
3. The sliding and rotary parts should be maintained with oil lubricating.
4. Before starting up the pleater for every shift, operator should firstly turn on the
preheating switch to increase the temperature of the heater in the machine to the
setting temperature, and then start pleating the filter paper.
5. When finishing every shift work, take all filter papers out to avoid the possibility
that the heating vapor corrodes the filter-paper tunnel of the machine or the
burning of filter paper.
6. When finishing every shift work, it is necessary to switch off power supply until
the power light of the machine is off.
II. Periodic maintenance

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 Periodic maintenance is to stop running the machine and carry out the check
work (except daily maintenance) with planning according to the specified period. In
general, every month takes a period maintenance to inspect the running condition of
each part, the wearing condition of moving parts and the loose condition of tightening
parts.
1. Check items
1．1 The gears should be meshed well without looseness or tripping.
1．2 Driving mechanism should be run well without any abnormal noise.
1．3 The knife edge of the pleater should be level without any gap or
deformation.
1．4 The cylinder should be run stably with reliable sealing and without any
creeping or impact.
1．5 The tightening parts should be tightened well without the conditions of
looseness and falling off.
2. Periodic lubrication maintenance
2．1 Lubricate the gear meshing places every week.
2．2 Lubricate the movable connecting places every shift.
2．3 Lubricate the designated lubricating places according to the production
condition on time.

1. adding oil for all gear drives 2. adding oil for all reduction box

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 5. Add oil for all gear box of screw

Common Troubles and Solutions

No. Troubles Causes Solutions
1 Paper off tracking Media roll off Adjust the position of media roll
tracking
2 The two sides of Adjust the distance of roller, keep
distance of parallel
Feeding roll,
corrugation roller
or collect roller is
same
3 Stop collar of Adjust the stop collar to the
transition roller correct position

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 4 The edge of slited The knife is not Check if the knife is sharp or not,
paper is burr sharp if not change the knife
5 The air pressure Adjust the pressure of slit knife
of slit knife is too
low
6 Slitting size is not The distance Adjust the distance between
suitable from knife is slitting knives
incorrect
7 Difficult to pleat The press mark is Adjust the upper-bottom roller
too light distance, but it cannot be too
small, otherwise the paper will
broke
8 The collect roller is The distance Adjust the upper-bottom roller
slip during paper between distance
feeding upper-bottom
roller is too big
9 Pleated paper not The distance Adjust the distance between the
go to the forming between the screw and collect port
collect screw screw and collect
port is too big or
too small
10 The speed of belt Belt conveyor is Change the data on the touch
conveyor and main too fast or too screen according to different
unit is different slow product
11 Paper cooling is not Fan cooling is Start the fan cooler
good not enough
12 Heating temperature Heater stop work Check the heater’s wire connect or
is not going on fuse is ok or not
13 Heating temperature Data set is wrong Adjust the set temperature of
is too high or too controller
low

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