AETNAGROUP ROBOPAC COMPACTA 400 Use And Maintenance Manual Download Page 1

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COMPACTA

400 - 620 - 960 M

Serial number

USE AND MAINTENANCE MANUAL

ROTATING RING BAND WRAPPING MACHINE

Instructions manual code 3710305395

English Edition November 2007

Summary of Contents for ROBOPAC COMPACTA 400

Page 1: ...COMPACTA 400 620 960 M Serial number GB USE AND MAINTENANCE MANUAL ROTATING RING BAND WRAPPING MACHINE Instructions manual code 3710305395 English Edition November 2007 ...

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Page 3: ...Ș ıİ ıȣȝȝȩȡĳȦıȘ ȝİ ĲȚȢ ȕĮıȚțȑȢ ĮʌĮȚĲȒıİȚȢ ĮıĳĮȜİȓĮȢ țĮȚ ʌȡȠıĲĮıȓĮȢ ĲȘȢ ȣȖİȓĮȢ ȩʌȦȢ İʌȚȕȐȜȜİĲĮȚ Įʌȩ ĲȚȢ ȅįȘȖȓİȢ 98 37 ǼȀ 73 23 ǼȅȀ 89 336 ǼȅȀ țĮȚ ʌİȡĮȚĲȑȡȦ ĲȡȠʌȠʌȠȚȒıİȚȢ I NL EG Verklaring van overeenstemming Richtlijn 98 37 EG bijlage II type A ROBOPAC s a verklaart dat de machine die bedoeld is voor ambachtelijke en industriële omgevingen met de hierbij vermelde identificatiegegevens voldoet aan ...

Page 4: ...e uvedených údajov v záhlaví prehlasuje že strojné zariadenie urþené pre remeselné a priemyselné použitie je v súlade so základnými bezpeþnostnými predpismi a s požiadavkami na ochranu zdravia v zmysle ustanovení smerníc 98 37 ES 73 23 EHS 89 336 EHS I SL Izjava CE o ustrezanju Smernica 98 37 CE priloga II tip A ROBOPAC s a izjavlja da naprava izdelana za uporabo v industrijskih postopkih razpozna...

Page 5: ...ack of production or injuries to per sons or damage to things caused by malfunctions or forced suspension in using the machine covered by the warranty The warranty does not cover Non sono coperti da garanzia damage caused by transport damage due to incorrect installation improper use of the machine or negligence tampering or repairs by unauthorised personnel lack of maintenance parts subject to no...

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Page 7: ...ȞĲȒȡȘıȒ ĲȠȣ ȉȠ įȓțĲȣȠ įȚĮȞȠȝȒȢ ĲȘȢ ROBOPAC İȓȞĮȚ Įʌȩ ĮȣĲȒ ĲȘ ıĲȚȖȝȒ ıĲȘ įȚȐșİıȒ ıĮȢ ȖȚĮ ȠʌȠȚȠįȒʌȠĲİ ʌȡȩȕȜȘȝĮ ĲİȤȞȚțȒȢ ȕȠȒșİȚĮȢ țĮȚ ĮȞĲĮȜȜĮțĲȚțȫȞ țĮȚ ȖȚĮ ȠʌȠȚĮįȒʌȠĲİ ȞȑĮ ĮʌĮȓĲȘıȘ ʌȠȣ ȝʌȠȡİȓ ȞĮ İȓȞĮȚ țĮĲȐȜȜȘȜȘ ȖȚĮ ĲȘȞ İʌȚȤİȓȡȘıȒ ıĮȢ ȀȐșİ ʌĮȡĮĲȒȡȘıȘ ıȤİĲȚțȐ ȝİ ĲȠ ʌĮȡȩȞ İȖȤİȚȡȓįȚȠ İȓȞĮȚ ȝȚĮ ıȣȝȕȠȜȒ ȖȚĮ ĲȘ ȕİȜĲȓȦıȘ ĲȦȞ ȣʌȘȡİıȚȫȞ ʌȠȣ Ș ROBOPAC ȑȤİȚ ıțȠʌȩ ȞĮ ʌȡȠıĳȑȡİȚ ıĲȠȣȢ ʌİȜȐĲİȢ ĲȘȢ NL NEDERLANDS De v...

Page 8: ...vilno in varno uporabo stroja ter za smotrno naþrtovanje vzdrževalnih del na njem Distribucijska mreža proizvajalca ROBOPAC Vam je v vsakem trenutku na razpolago pri tehniþni podpori nadomestnih delih ter pri vseh novih rešitvah ki lahko dodatno pripomorejo k izboljšanju postopkov v Vaši dejavnosti Vsaka pripomba bo dobrodošla saj je pomembna za razvijanje in izboljšave storitev ki jih želi proizv...

Page 9: ...NUAL 11 ASSEMBLY INSTRUCTIONS 26 ATTACHED DOCUMENTATION 12 BAND WRAPPING 42 BLOCKING THE FILM IN THE CLAMP 39 CLEANING THE FILTER 44 CONDENSATE DRAINAGE 44 CONTINUOUS WRAPPING 42 CONTROL DESCRIPTION 36 DEMOLITION AND DISPOSAL 45 DESCRIPTION OF THE ELECTRICAL DEVICES 16 ELECTRICAL CONNECTIONS 29 ELECTRIC BLACK OUT STOP 41 EMERGENCY STOP 42 FILM CUTTING BLADE REPLACEMENT 47 FILM SPOOL LOADING 38 FIL...

Page 10: ... OPERATION AND USE NORMS 20 PACKAGING AND UNPACKING 23 PNEUMATIC CONNECTIONS 28 PNEUMATIC DIAGRAM 48 POSITION ONLY ON THE INFEED PRESSURE UNIT 32 PRESSURE UNIT ADJUSTMENT OPTIONAL 31 PRODUCTION END STOP 41 PUTTING THE ROTATING RING IN PHASE 37 RECOMMENDATIONS FOR CONNECTIONS 27 RECOMMENDATIONS FOR HANDLING AND LOADING 23 RECOMMENDATIONS FOR USE AND FUNCTIONING 35 REPLACEMENT INSTRUCTIONS 47 RESIDU...

Page 11: ...ady available in the event consultation is required The manufacturer reserves the right to carry out modifications without obligation of prior notice To better stress the importance of some passages or to indicate important specifications symbols whose meanings are described as follows have been adopted Danger Attention Indicates critically dangerous situations that if neglected can result in seri...

Page 12: ...y maintenance group of functions necessary to maintain suitable machine operations and efficiency Normally the manufacturer who defines the necessary skills and intervention procedures plans these operations Extraordinary maintenance group of functions necessary to maintain suitable machine operations and efficiency These operations are not planned by the manufacturer and must be carried out by th...

Page 13: ...ture of the machine B Control panel to activate machine functions C Infeed and outfeed roller surface conveyor unit they hold the product to be wrapped and tran sport it to operations they are equipped with width adjustable roller guides D Rotating ring unit made up of a rotating ring with a transmission belt driven by an electric motor guided by an inverter E Reel Carriage unit made up of a quick...

Page 14: ...rapping the product performing the number of preset wraps at the last wrap of the rotating ring the clamp comes out to hook the film terminated the wraps counting the rotating ring stops while the clamp re entering blocks and cuts the film The machine is ready for a new wrapping cycle If the operator keeps the START pedal pressed the rotating ring continues rotating hence wrapping the product when...

Page 15: ... Fixed safety guard prevents access to moving parts C Main switch cuts off the power supply to the machine and can be locked to prevent use by unauthorised people D Emergency buttons when pressed they immediately stop the machine in the emergency conditions To reset rotate the button in the direction indicated by the arrow E Bi stable solenoid valve blocks all pneumatically driven movements when e...

Page 16: ... if necessary replace them with new ones that shall be positioned in the same places as pre viously 07080303 2 6 DESCRIPTION OF THE ELECTRICAL DEVICES The figure shows the positioning of the devices on board of the machine A Safety switch SQ1 the machine stops when the safety cover is opened B Phase sensor SQ2 detects the rotating ring in the start cycle position machine in phase C Electric motor ...

Page 17: ...uct size Dimensions width and height of the cross sections of the products to be wrapped must stay within the frame traced on the sketch Such data is valid in case the cross section is kept constant on all the length of the product For best quality results the production cross section should be as close as possible to the machine diameter For products that intersect the sketched areas contact the ...

Page 18: ...200 mm d internal reel diameter 76 mm d optional 50 mm L width 50 125 mm film thickness 17 50 m Machine dimensions 07080305 W L H H Machine 400 620 960 L 980 980 980 W 1000 1206 1546 H 1353 1564 1868 H 850 850 815 Solenoid valves Y1 controls clamp ope ning and closing Y1 07080306 ...

Page 19: ...shown in the table Acoustic power measured during working according to ISO 3746 79 ISO CD 11202 1997 standards ISO 3746 79 ISO CD 11202 1997 Lm Lw Lop dB A dBw A dB A Functioning in working conditions 62 8 80 6 69 2 Lm Average level of pressure on the measurement surface Lw Acoustic power output Lop Level at the operator s place Danger Attention Prolonged exposure over 85 dB A may cause health pro...

Page 20: ...iate signals 3 3 OPERATION AND USE NORMS In addition to being competent on machine use the operator must possess the skills and acquired profi ciency suited to the type of work to be accomplished Even after an opportune documentation at first utilisation if necessary simulate some tests to identify command and their main functions in particular those concerning the starting and stopping operations...

Page 21: ...is invaluable Safety is also in the hands of all the operators who interact with the machine 1 Danger on infeed roller conveyor The roller conveyor is able to hold products up to a certain length approximately 700 mm Longer or in any case unbalanced products could fall on the operator after being placed on the conveyor When these types of products require wrapping arranging a support that can sust...

Page 22: ...ignal position for their position Explanation can be found next to each one of them It shows the insertion points for the lifting forks Electrical shock danger do not access within elements under tension Cutting hazard Danger Do not operate in the film cutting and clamping area while the ma chine is running Ring rotation sense ...

Page 23: ...e for lifting and transportation operations must decide which are the most suitable means according to the machine s destination 4 2 PACKAGING AND UNPACKING The packing is realised keeping the overall dimensions low also in consideration of the transport chosen To facilitate transport shipping can be performed with some components disassembled and appropriately protected and packaged Some parts th...

Page 24: ...e performed by different vehicles The diagram represents the most popular solutions During transport in order to avoid inopportune movement adequately secure the load to the tran sportation vehicle Important For further transportation recreate the initial packaging conditions for transport and han dling 2412370080 ...

Page 25: ...g the degree of humidity is less than 95 Room lighting must be normal recommended 250 650 lux also in order to create a pleasant and relaxing condition for machine operators a boundary area around the immediate working area for safety reasons as shown in fig a flat surface steady and without vibrations with adequate weight supporting capacity The area must be equipped with a power supply socket an...

Page 26: ...tructions Danger Attention Authorised technical service personnel must perform installation and assembly operations Proceed as indicated Remove the screws that block the machine frame to the wooden pallet Insert the fork lift s forks in the specially designed spaces provided in the base Lift the machine from the pallet Insert supporting legs in the place of the blocking screws Danger Attention To ...

Page 27: ...rformed following the manufacturer s indications in the enclosed dia grams Personnel authorised to perform this operation must possess technical skills abilities and have acquired certified experience in the specific field and must perform connections pro fessionally taking into account all the regulative and legislative requirements When connections are completed make sure these requisites were o...

Page 28: ...he rubber fitting and fasten it with a metallic screw clamp A Check that the valve B is in the OPEN position Turn on the power supply line Check that the pressure gauge indicates at least 6 bar bar bar and use the knob C to compensate any pressure differences repeat this operation when the machine is running 07080314 A B C ...

Page 29: ...ch to 0 OFF Connect the power cord as illustrated according to the network mains Important The earth wire yellow and green must be con nected to its earth terminal PE Use the main switch to start the machine Press the START pedal 3PH 400V N T N L PE T S R PE N L PE N T S 230V 1PH 3PH R PE 07080315 Important EXCLUSIVELY reserved for Technical Service personnel Press the START pedal even without pro...

Page 30: ...In particular adequately mark the surrounding areas and prevent access to all devices that could if activated cause unexpected personal safety hazards 5 2 INFEED ROLLER SURFACE ADJUSTMENT Danger Attention Perform this operation with the machine isolated from energy sources Based on the width of the film used adjust the infeed roller surface position using the screws A Between the film end and the ...

Page 31: ...ve 1 3 cm between the product and the guides on each side 07080317 A A 5 4 PRESSURE UNIT ADJUSTMENT OPTIONAL 5 4 1 Height Danger Attention Perform this operation with the machine isolated from energy sources According to the product to be packed regulate the height of the pressure units by adjusting knobs A as to block the product to be wrapped without forcing it 07080318 A ...

Page 32: ...h the machine isolated from energy sources According to the position of the infeed roller con veyor Î Position only on the infeed conveyor egulate the position of the infeed pressure unit by adjusting screws B Caution Warning The infeed pressure unit must remain comple tely INSIDE the infeed roller conveyor 07080320 07080319 B B ...

Page 33: ... film during the cycle respect to the necessary quantity The optimum adjustment must be performed with the heaviest spool available that is the one with greater inertia and must guarantee that the film always remains well compact on the spool Open the mobile guard A Adjust spool carriage roller friction using the knob B turn clockwise to increase the braking effect 07080321 A B ...

Page 34: ...The tension obtainable during wrapping also depends on the material and thickness of the film as well as to its width Open the mobile guard A Use knob B on the friction roller to adjust film tension the roller is equipped with mechanical friction turn clockwise to increase the braking effect and film pull 07080322 B A NOTE Also check the adjustment compatibility with the specifications of the prod...

Page 35: ...our In addition to being authorised and appropriately informed on first use personnel must simulate some manoeuvres to identify the main commands and functions Only carry out the operations foreseen by the manufacturer and do not tamper with any device to obtain performances other than those provided Before use check that the safety devices are correctly installed and efficient Users in addition t...

Page 36: ...can only be used with the machine on If the machine is not running the pedal must be pressed to run the machine Machine running implements the button that opens and closes the clamping cylinder C Pedal START The machine starts the work cycle when the pedal is pressed if all initial conditions are met rotating ring in phase The machine automatically starts after the work cycle is completed If the r...

Page 37: ...o Î Information about adjustments Wrapping tension Î Informazioni sulle regolazioni Spool carriage clutch Î Information about adjustments Number of overlaps for each operating cycle Î Control description Rotating ring speed Î Control description 6 5 MACHINE STARTING The mobile panel must be closed All safety devices must be integral and efficient The machine must be cleaned and in order Compressed...

Page 38: ... the diagram the dotted line indicates the adhesive side of the film interior or exterior Important The adhesive side of the film must always face the product to be wrapped 1 Spool carriage roller 2 Friction roller 3 Idle rollers 4 Dancing roller R05008028 1 Outside adhesive Inside adhesive 2 1 2 3 3 3 3 If necessary adjust the clutch on the spool carriage roller Î Friction adjustment on reel carr...

Page 39: ...ration can ONLY be run if the rotating ring is in phase Danger Attention The operation is performed with the machine on pay the utmost attention Manually unwind a meter of film and place it in the lower part of the rotor 07080325 Press the button B the clamp has to fully exit 07080329 B 07080326 ...

Page 40: ...o that it rests against the clamp rod and hold it with one hand Danger Attention Do not place hands near the clamp 07080327 Push the button B again the clamp should recede and the film should remain locked in the clamp At this point remove the cut edge of the film 07080328 07080329 B ...

Page 41: ...ediately The electric motors stop and the pneumatically operated components remain still in their position When electric power supply returns the machine does not continue its operating cycle but remains still in the same position To restart operation press the START pedal to bring in phase the various machine members rotating ring pressure units see Putting the rotating ring in phase if necessary...

Page 42: ...ts as to guide the product during the wrapping operation Press the START pedal The machine will perform the wrapping operation with the preset number of rounds 3 4 or 5 as de scribed in paragraph Operating Cycle When the machine stops the operator can move the product forward to perform another wrapping cycle and so on according to the requirements Once the desired wrapping scheme has been perform...

Page 43: ...d their respective tighteners and that they have not stretched to any significant degree Dust and dirt deposits in moving parts do not hinder their movement the rotating ring belt does not present wear or tears in the cloth 7 2 MAINTENANCE PERIOD TABLE Important Keep the machine in maximum working conditions by performing the programmed maintenance operations advised by the manufacturer Good maint...

Page 44: ...re R05008034 7 4 CLEANING THE FILTER Remove the cup and take off the filter Clean it using compressed air and if necessary clean it using petrol or trichloroethylene Replace the cup R05008035 7 5 ROTATING RING BELT ADJUSTMENT Proceed as indicated Loosen the fastening screws A of the gear box use screws B to achieve correct belt tension Tighten the reducer fastening screws A when finished Important...

Page 45: ...tance Service personnel 7 7 DEMOLITION AND DISPOSAL Useful information for the disposal of machines and machine parts Demolition must be performed by qualified personnel Construction material Low density linear polyethylene L L D PE Steel aluminium and cast iron Copper and silver in the electrical electronic components Rubber resins and fibres None of the component materials is harmful or poisonou...

Page 46: ...ched roller Film wraps on product do not overlap much in continuous wrapping Decrease product infeed speed on roller conveyor Film wraps on product overlap too much in continuous wrapping Increase product infeed speed on roller conveyor Wrapping begins too close to the product edge Move the product more forward when the wrapping operation begins Wrapping begins too far from the product edge Move t...

Page 47: ...indicated Remove body cover by unscrewing the four screws D on the support C Loosen the fastening screws A Remove blade B and replace it with a new one Tighten the screws A when finished Reassemble body cover Caution Warning Handle with great care as the blade is very sharp 07080333 A B D C D 9 3 LIST OF ESSENTIAL SPARE PARTS List of the spare parts of easy wear and of which it would be necessary ...

Page 48: ...COMPACTA 400 620 960 M 48 3710305395 10 Enclosed documentation 10 1 PNEUMATIC DIAGRAM 7370303708 07080030 Key A Filter Regulator unit B Solenoid valve C Open close clamp pneumatic cylinder ...

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