Line 6 Douglas Caser Settings explained

Remove the chain from the PLS encoder and turn the encoder input shaft until the PLS and the mechanical timing dial match positions. A one or two degree difference in not critical so you don’t have to be exact. The caser has a 360º encoder, counter clockwise.


PLS-1: Glue flap settings


With a tray in the main flights jog the machine until the tray is positioned where you want the glue to begin applying on the first end flap. Check the display position on the PLS and program the PLS-1 to turn on at this time. Jog the machine to where you want the first glue strip to stop and program the off setting for channel 1. Continue jogging and set the On/Off pulse for the second strip.


PLS-1 On _100_ PLS-1 Off _125_ PLS-1 On _265_ PLS-1 Off _290_


PLS-1 Compensation _300_


PLS-2: Vacuum enable


Jog the machine until the vacuum cups are just about to make contact with the tray magazine. Set PLS 2 to turn on at this time. Continue jogging the machine with the tray on the vacuum cups until you want the vacuum to let go. Set PLS-2 to turn off at this time.


PLS-2 On __4__ PLS-2 Off _14_ PLS-2 On _128_ PLS-2 Off _325_


PLS-1 Compensation _300_


PLS-3: Machine cycle stop


Actual cycle stop position of for your machine typically should be 0. Set the PLS 3 for a 10 window to turn on at about 355. Check to see if it stops within a couple of degrees of 0. It doesn’t have to be perfect just close.


PLS-3 On _350_ PLS-3-Off _359_ PLS-3 Compensation __0__


PLS-4: Product out of position


On the machine PE-2 is looking across the Infeed close to the loader. Jog the machine until PE-2 starts to look across the beginning of the gap between product groups. PLS 4 should be set to turn on at this time. Continue jogging until PE-2 is about to see the next product group. Set PLS-4 to turn off at this time. Under normal circumstances PE-2 should not see anything during the time that PLS-4 is turned on. If it does, the “Product Out Of Position” is triggered.


PLS-4 On _230_ PLS-4 Off _302_ PLS-4 Compensation __0__


PLS-5: Misplaced case


PE-3 and PE-4 are looking down at the major flap hold-down decks. The bottom major flaps of the tray should be under these decks after the tray is setup. If either of these photo sensors fails to detect their respective reflectors then the machine assumes that the tray flaps are on top of the deck and this is not desirable. Jog the machine until the tray is in position such that a flap on top of the deck would be blocking the photo sensor. To allow for different tray sizes in direction of travel it is advisable to jog the machine until the photo sensors are looking at the last couple inches of the tray flap. The trailing edge of the tray is fixed and when different tray sizes are used only the leading edge is adjusted in the flights. PLS-5 should be set with about a 10 window to turn on at this time.


PLS-5 On _60__ PLS-5 Off _70__ PLS-5 Compensation __0___


PLS-6: Check for tray at Product Loader


The logic suggests that PE-2 and PE-5 are located in close proximity to each other. PE-2 is looking for product and PE-5 is looking for trays. When PLS 6 turns on, these two photo sensors are checked to determine if both are detecting their respective targets (tray and product). If one of the photo sensor inputs is on and the other is off then a problem exists. Jog the machine until both sensors are looking at the last couple inches of their respective targets.

PLS-6 should be set to turn on for about a 10 window at this time.

PLS-6 On _20__ PLS-6 Off _21__ PLS-6 Compensation __0___

PLS-7: Tray at Seal Bar

The logic suggests that PE-9 is located to look for a tray just as it enters the seal bar on the wrapper. When PLS 7 turns PE-9 is checked to determine if a tray is entering the wrapper. If it is the seal bar will be enabled to be brought up into position to seal and cut the film. Jog the machine until PE-9 is looking at about midway on the shortest tray in the direction of travel that you use. PLS-7 should be set to turn on for about a 10 window at this time.

PLS-7 On _80__ PLS-7 Off __88_ PLS-7 Compensation __0___

PLS-8: Seal Bar Clamp/Unclamp

PLS-8 is used to control when the seal bar is brought up to clamp position for sealing and cutting. To save wear on the seal bar and stripper bars we only clamp when a package is to be sealed. PLS-8 should be set to turn on for about a 10 window when the last inch or two of the tray is on the stripper bar. Make sure the sealing bar is fully up and stable before it contacts the film for sealing.

PLS-8 On _341_ PLS-8 Off __4__ PLS-8 Compensation _200_

PLS-9: Seal Bar Closed

PLS-9 is used to control the seal bar closed warning pilot light. If the machine is stopped in a position where the top of the seal bar is rotated to its upper quadrant this pilot light is turned on so the operator knows this and can take action. The reason for this is that the knife is close enough to the stripper bar, even when it is clamped, that some heat transfer can occur causing the stripper bar to get hot. This will cause problems with the film sticking to the stripper bar. Jog the machine until the knife-edge of the seal bar is at about horizontal on its way towards the sealing position. PLS-9 should be turned on at this time. Continue jogging until the knife is again horizontal on its way out of the stripper bar and set PLS-9 to turn off at this time.

PLS-9 On _110_ PLS-9 Off _320_ PLS-9 Compensation __0___

The last thing to do is program speed compensation into the appropriate channels. Reaction time for electronics, solenoids, valves, airflow, etc. is relatively constant. The machine speed however, changes from low to high. As a result some settings, such as the glue pattern control need to be advanced as the machine increases in speed to compensate for the reaction time. Without compensation the glue strips will be too late at high speeds because the tray is moving faster while the glue system reaction is not.

The Electro Cam PLS is able to accept a speed compensation value for each channel independently. This is good because the reaction time of the glue gun system may differ from the vacuum system. The values entered represent how many degrees/thousand rpm to advance the channel settings. Typical settings on our machine range from about 200 to 400. Refer to your PLS manual or call Bob Thielen at Douglas for assistance regarding this setting. The channels recommended for compensating are channels 1, 2, and 8. Without getting into complicated mathematics the values determined are trial and error.