Robopac Masterplat FREEZER Use And Maintenance Manual Download Page 3

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Index

ENG

Index
1. GENERAL INFORMATION ................................................................................................................................. 6

1.1.

PURPOSE OF THE MANUAL ............................................................................................................................. 6

1.2.

MANUFACTURER AND MACHINE IDENTIFICATION ....................................................................................... 7

1.3.

TERMS AND DEFINITIONS ................................................................................................................................ 8

1.3.1.

PICTOGRAMS INDICATING DANGER ....................................................................................................... 9

1.3.2.

PICTOGRAMS INDICATING PROHIBITION ............................................................................................. 10

1.3.3.

PICTOGRAMS INDICATING OBLIGATION ............................................................................................... 11

1.4.

HOW TO REQUEST ASSISTANCE .................................................................................................................. 12

1.5.

ATTACHED DOCUMENTATION ....................................................................................................................... 12

1.6.

HOW TO READ THE INSTRUCTIONS FOR USE ............................................................................................ 12

2. SAFETY INFORMATION................................................................................................................................... 13

2.1.

GENERAL SAFETY WARNINGS ...................................................................................................................... 13

2.2.

SAFETY WARNINGS FOR HANDLING AND INSTALLATION ......................................................................... 14

2.3.

SAFETY WARNINGS FOR USE AND OPERATION ........................................................................................ 15

2.4.

SAFETY WARNINGS RELATED TO MISUSE .................................................................................................. 16

2.4.1.

REASONABLY FORESEEABLE MISUSE ................................................................................................. 16

2.4.2.

EMPLOYER OBLIGATIONS ...................................................................................................................... 16

2.5.

SAFETY WARNINGS ON RESIDUAL RISKS ................................................................................................... 17

2.6.

SAFETY WARNINGS FOR ADJUSTMENTS AND MAINTENANCE ................................................................ 20

2.7.

SAFETY WARNING FOR THE ELECTRICAL EQUIPMENT ............................................................................ 20

2.8.

INFORMATION AND SAFETY SIGNS .............................................................................................................. 21

2.9.

PERIMETER AREAS ......................................................................................................................................... 23

3. TECHNICAL INFORMATION ............................................................................................................................ 24

3.1.

MACHINE GENERAL DESCRIPTION ............................................................................................................... 24

3.1.1.

MACHINE MODELS DESCRIPTION ......................................................................................................... 26

3.2.

DESCRIPTION OF THE OPERATION CYCLE ................................................................................................. 27

3.3.

SAFETY DEVICE DESCRIPTION ..................................................................................................................... 28

3.4.

DESCRIPTION OF ELECTRICAL DEVICES .................................................................................................... 30

3.4.1.

REMOTE CONTROL SOFTWARE ............................................................................................................ 32

3.5.

DESCRIPTION OF PNEUMATIC DEVICES ..................................................................................................... 33

3.6.

DESCRIPTION OF ACCESSORIES ON REQUEST ......................................................................................... 34

3.7.

"MASTERPLAT PLUS” TECHNICAL DATA

...................................................................................................... 38

3.7.1.

"MASTERPLAT PLUS FRD" MACHINE AND PALLET DIMENSIONS ...................................................... 39

3.7.2.

"MASTERPLAT PLUS PGS" MACHINE AND PALLET DIMENSIONS...................................................... 39

3.7.3.

"MASTERPLAT PLUS PGS USA" MACHINE AND PALLET DIMENSIONS ............................................. 40

3.7.4.

MACHINE TECHNICAL FEATURES .......................................................................................................... 40

3.7.5.

PRESSER TECHNICAL FEATURES ......................................................................................................... 40

3.7.6.

“MASTERPLAT PLUS FRD” AND "PGS” SPOOL CHARACTERISTICS

.................................................. 41

3.8.

“MASTERPLAT PLUS LP FRD” AND “PGS” TECHNICAL DATA

..................................................................... 42

3.8.1.

"MASTERPLAT PLUS LP FRD" MACHINE AND PALLET DIMENSIONS ................................................ 43

3.8.2.

"MASTERPLAT PLUS LP PGS" MACHINE AND PALLET DIMENSIONS ................................................ 43

3.8.3.

"MASTERPLAT PLUS LP PGS USA" MACHINE AND PALLET DIMENSIONS ........................................ 44

3.8.4.

MACHINE TECHNICAL FEATURES .......................................................................................................... 44

3.8.5.

PRESSER TECHNICAL FEATURES ......................................................................................................... 44

3.8.6.

“MASTERPLAT PLUS LP FRD” AND "PGS” SPOOL CHARACTERISTICS

............................................. 45

3.9.

“MASTERPLAT PLUS TP3 FRD” AND “PGS” TECHNICAL DATA

.................................................................. 46

3.9.1.

“MASTERPLAT PLUS TP3 FRD" MACHINE AND PALLET DIMENSIONS

.............................................. 47

3.9.2.

“MASTERPLAT PLUS TP3 PGS" MAC

HINE AND PALLET DIMENSIONS .............................................. 47

3.9.3.

MACHINE TECHNICAL FEATURES .......................................................................................................... 48

3.9.4.

PRESSER TECHNICAL FEATURES ......................................................................................................... 48

3.9.5.

“MASTERPLAT PLUS TP3 FRD” AND "PGS” SPOOL CHARACTERISTICS

........................................... 49

3.10.

NOISE LEVEL ................................................................................................................................................ 50

3.11.

INSTALLATION ENVIRONMENT CHARACTERISTICS .............................................................................. 50

4. INFORMATION ON HANDLING AND INSTALLATION ...................................................................................... 51

4.1.

RECOMMENDATIONS FOR HANDLING AND LOADING................................................................................ 51

4.2.

PACKING AND UNPACKING ............................................................................................................................ 51

4.3.

TRANSPORT AND HANDLING ......................................................................................................................... 53

Summary of Contents for Masterplat FREEZER

Page 1: ...MASTERPLAT PLUS FRD PGS MASTERPLAT PLUS LP FRD PGS MASTERPLAT PLUS TP FRD PGS USE AND MAINTENANCE MANUAL ENG ...

Page 2: ...ENG 2 Page left blank intentionally ...

Page 3: ...DEVICES 33 3 6 DESCRIPTION OF ACCESSORIES ON REQUEST 34 3 7 MASTERPLAT PLUS TECHNICAL DATA 38 3 7 1 MASTERPLAT PLUS FRD MACHINE AND PALLET DIMENSIONS 39 3 7 2 MASTERPLAT PLUS PGS MACHINE AND PALLET DIMENSIONS 39 3 7 3 MASTERPLAT PLUS PGS USA MACHINE AND PALLET DIMENSIONS 40 3 7 4 MACHINE TECHNICAL FEATURES 40 3 7 5 PRESSER TECHNICAL FEATURES 40 3 7 6 MASTERPLAT PLUS FRD AND PGS SPOOL CHARACTERISTI...

Page 4: ...STING THE TABLE GUIDE WHEELS 75 6 INFORMATION ABOUT THE USE 76 6 1 RECOMMENDATIONS FOR OPERATION AND USE 76 6 2 DESCRIPTION OF THE CONTROLS 77 6 3 DESCRIPTION OF USER INTERFACE 78 6 4 MAIN MENU PAGE 79 6 4 1 WRAPPING CYCLE 80 6 4 2 TABLE ROTATION SPEED rpm 81 6 4 3 CARRIAGE SPEED 82 6 4 4 WRAPPING END DELAY PALLET HEIGHT 83 6 4 5 MANUAL CONTROLS 84 6 4 6 FILM TENSIONING 85 6 4 7 OTHER 86 6 4 8 SET...

Page 5: ... 9 2 REPLACING THE ROTARY TABLE WHEELS 115 9 3 REPLACING THE ROTARY TABLE ROLLERS 116 9 4 REPLACING THE GUIDING ROLLERS 117 9 5 REPLACING THE ROTARY TABLE GEAR WHEELS 118 9 6 RECOMMENDED SPARE PARTS LIST 119 9 7 MACHINE DECOMMISSIONING AND SCRAPPING 120 9 7 1 MACHINE DECOMMISSIONING 120 9 7 2 MACHINE SCRAPPING 120 10 ANNEXES 121 10 1 WARRANTY CONDITIONS 121 10 2 PRESSER PNEUMATIC DIAGRAM 122 ...

Page 6: ... the message Translation of the original instructions Refer to the table of contents in order to easily identify the subjects of interest Some information may not correspond completely to the actual configuration of the machine delivered Any additional information does not affect the readability of the text and the safety level The Manufacturer reserves the right to modify the contents of the manu...

Page 7: ...ontains references and indispensable operating safety indications 1 Machine model 2 Machine serial number 3 Year of manufacture 4 Power supply voltage 5 Power supply frequency 6 Power supply phases 7 Absorbed electric current 8 Installed power 9 Air consumption 10 Air supply max pressure 11 Machine weight 12 Manufacturer s identification 13 Name ...

Page 8: ...e Therefore the technician must have accurate information and competences with particular skills in the field of intervention Format changeover Set of operations to carry out on the machine before starting to work with characteristics other than the previous ones Training Training process aimed at transferring to the new operator the knowledge skills and behaviours required to operate the machine ...

Page 9: ...a risk of electric shock ATTENTION DANGER DUE TO FLAMMABLE MATERIAL ATTENTION DANGER DUE TO MOVING PARTS ATTENTION DANGER DUE TO HIGH TEMPERATURES ATTENTION DANGER DUE TO SUSPENDED LOADS ATTENTION DANGER DUE TO CONTACT WITH OVERHEAD OBSTACLES ATTENTION TRIPPING OR FALLING DANGER ATTENTION TANGLING DANGER It signals to the concerned personnel that the device bearing this pictogram features parts wh...

Page 10: ... FLAMES This symbol prohibits the use of naked flames near the machine or parts of it to prevent a fire hazard NO PEDESTRIANS Pedestrians are not allowed to pass through the area where this signal is located DO NOT EXTINGUISH WITH WATER Any fire that may occur near the machine or parts of it must NOT be extinguished with jets of water DO NOT INSERT YOUR HANDS DO NOT PUSH DO NOT SEAT DOWN DO NOT CL...

Page 11: ...ATION TO WEAR PROTECTIVE GOGGLES The presence of the symbol next to the description requires the use of safety goggles by the operator since the risk of injury is implicit OBLIGATION TO WEAR A PROTECTIVE HELMET The presence of the symbol next to the description requires the use of a protective helmet by the operator since the risk of injury is implicit OBLIGATION TO WEAR A PROTECTIVE MASK The pres...

Page 12: ...lled commercial devices if necessary for machine use Unpacking and installation instructions Quick guide for quick start USB pendrive containing the information listed below Use and maintenance manual translated into various languages Spare parts catalogue Machine programming software Wiring Diagrams 1 6 HOW TO READ THE INSTRUCTIONS FOR USE The manual is divided into chapters each of which describ...

Page 13: ...ents can be caused by a careless use of the machine by the operator Usually it is too late to remember what should have been done when the accident has already happened Caution warning Preserve the readability of the information signs and observe the indications given The information signs may have different shapes and colours indicating hazards obligations prohibitions and indications Tampering w...

Page 14: ...mplement a safety plan in order to protect the safety of the personnel involved Provide proper safety conditions when operating in high areas that are dangerous or hard to access Install the machine according to the minimum perimeter spaces indicated by the Manufacturer and the surrounding working activities Prepare a machine installation project if the machine is to interact directly or indirectl...

Page 15: ...ective Equipment indicated in the Instructions for use in particular safety shoes and that provided for by the laws in force on matter of safety in the workplace Always keep the perimeter areas in suitable conditions and free from obstacles in order to minimise the risks for the operator especially near the control station The machine must be used by one operator only that must be appointed and au...

Page 16: ...ntended by the Manufacturer Do not use or let the machine be used with defective deactivated and or incorrectly installed safety devices Do not continue to use the machine if malfunctions have been detected Stop the machine immediately and restart it only after the normal conditions of use have been restored Never carry out an intervention with the machine in operation but only after stopping it p...

Page 17: ... operators The residual risks are all the risks that persists although all safety solutions have been applied and integrated during machine design The list specifies the residual risks specific for this type of machine Risk of slipping Do not climb on machine parts during its operation Risk of impact Do not approach machine parts during its operation Risk of shearing upper limbs Do not insert your...

Page 18: ...ENG SAFETY INFORMATION 18 Risk of body crushing Do not stand in the machine operating area Risk of crushing upper limbs Do not insert your hands inside moving parts ...

Page 19: ...ing machine operation Risk of falling or ejected objects Do not use the machine at a speed which is not suitable for the type of product to be wrapped If the packages to be wrapped contain unstable and dangerous elements it is necessary to implement appropriate safety measures e g perimeter protections to avoid risks of injuries to persons ...

Page 20: ...ccordance with the applicable laws All the extraordinary maintenance interventions shall be carried out only by authorised personnel with experience and expertise in the field of intervention Important Non compliance with the instructions given may cause risks to the safety and health of people as well as economic damages 2 7 SAFETY WARNING FOR THE ELECTRICAL EQUIPMENT The electrical equipment has...

Page 21: ...cution 2 Prohibition sign Do not climb on the ramp with the forklift truck 3 Information sign It indicates the lifting points with hook device 4 Information sign It indicates the lifting points with fork device 5 Information sign It indicates the rotary table rotation direction 6 Prohibition sign Do not act on the component with your hands 7 Danger sign Hand crushing danger Important Make sure tha...

Page 22: ...ENG SAFETY INFORMATION 22 Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP ...

Page 23: ...ON ENG 2 9 PERIMETER AREAS The illustration shows the perimeter working areas of the machine 1 Operator standing area 2 Pallet loading unloading area 3 Perimeter area Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP ...

Page 24: ...hine consists of a rotary table which makes the pallet turn and a spool carriage which unwinds and stretches the film The machine is equipped with a series of safety devices designed to avoid any injuries to the operator or other persons using the machine It comes in different models to satisfy different market needs Stretch film spools commonly available on the market are used for load wrapping T...

Page 25: ...formation purposes only the machine models and the legend lists the parts Legend 1 Slide shaft 2 Table motor 3 Rotary table 4 Carriage motor 5 Control panel 6 Spool carriage 7 Base 8 Loading unloading ramp Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP ...

Page 26: ...tem to protect devices against low temperatures Masterplat INOX Maintaining the same features as the standard machine this model is made of stainless steel to allow working in particular environments On request it can feature a control panel with heating system to protect devices against low temperatures In this case the machine can operate at an ambient temperature of 30 40 C Table Spool carriage...

Page 27: ...limbs Do not insert the film in the gripper by hand Phase 2 Once the cycle has started the rotary table starts to turn while the spool carriage unwinds the film for the entire height according to pre set parameters Phase 3 Once the wrapping phase has ended the machine stops and film hot cutting and welding are automatically performed CW version Phase 4 The operator unloads the pallet The cycle is ...

Page 28: ... fall of the spool carriage in case of accidental breakage of the lifting chain 3 Main switch it enables and disables the power supply It can be locked to prevent unauthorised persons from enabling it during machine adjustment and maintenance phases 4 Acoustic signal it signals the wrapping cycle start 5 Fork infeed safety photocell it detects the presence of forks on the pallet loading unloading ...

Page 29: ...he button in the direction indicated by the arrow Danger warning When the emergency button is pressed the terminals of the motors may still be powered 7 Key operated switch it overrides the emergency condition of the spool carriage If it is kept turned it allows to activate the carriage upstroke with the user interface manual controls ...

Page 30: ...roswitch it stops the downstroke if there are obstacles under the spool carriage 5 Photocell it detects the height and the presence of the load to be wrapped 6 Load cell sensor it detects the film tensioning and enables the variation of the pre stretching roller speed 7 Electric motor it powers pre stretching rollers 8 Sensor it enables the synchronised stop of the rotary table 9 Carriage lifting ...

Page 31: ...31 TECHNICAL INFORMATION ENG Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP ...

Page 32: ...2 3 4 1 REMOTE CONTROL SOFTWARE The Machine features a remote control Software 1 Through a sensor on the roller 2 the system controls film use end of the spool and general info Important For further details see the wiring diagram ...

Page 33: ...s the position of the devices on the machine 1 Pressure regulator with filter and pressure gauge To adjust the general pressure of the pneumatic system Turn the knob to change the pressure values indicated on the pressure gauge Important For further details see the pneumatic diagram ...

Page 34: ...ontrolled device for load stabilisation It is supplied with pneumatic cylinder with rod Max stroke 800 mm The height must be adjusted according to the size of the product to be wrapped An air supply system is required for its operation 2 Pallet loading unloading ramp it facilitates these operations through fork lifting devices hand pallet trucks Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS ...

Page 35: ...at PLUS LP Masterplat PLUS LP with 270 ramp 4 Lifting frame Structure which allows lifting the machine from the ground when the floor must be washed or for loading with electric hand pallet trucks Underground installation template profiled structure for base underground installation Rotary table ø1800 it is used to wrap pallets with a size greater than the standard one Brake shaft for mesh only fo...

Page 36: ...t tool it is used to create a film reinforcement on the base of the product or on the pallet 6 Spool shaft D 50 and D 76 for coreless spools Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP ...

Page 37: ...mp type is the one indicated in the figure 270 Important If the Roll container stop device 3 is used set the film stretch 4 to low intensity to avoid load overturning Masterplat PLUS TP3 Masterplat PLUS Roll container insertion Insert Roll container 1 as follows A Insert a fixed wheel 6 inside area 5 as indicated B Rotate Roll container 1 until bracket stops 3 as indicated Masterplat PLUS TP3 Mast...

Page 38: ...ENG TECHNICAL INFORMATION 38 3 7 MASTERPLAT PLUS TECHNICAL DATA The illustration and the table include the machine dimensional specifications and technical data FRD PGS ...

Page 39: ...rall dimensions 1650 1800 C 1650 1800 D 2760 5 2835 5 E 1715 1790 F G N L 1000 1200 W 1200 1200 Weight kg 2000 2000 3 7 2 MASTERPLAT PLUS PGS MACHINE AND PALLET DIMENSIONS Description Masterplat PLUS PGS Standard Optional Optional Optional Shaft height 2200 2400 2800 3100 A H 2865 3065 3465 3765 B 2560 2760 3160 3460 H1 2200 2400 2800 3100 M 77 5 77 5 77 5 77 5 Load overall dimensions 1650 1800 C ...

Page 40: ... 220 240 1Ph 220 240 3Ph 380 415 3Ph N 120 1Ph for USA Power supply frequency Hz 50 60 60 for USA Installed power kW 1 5 Masterplat PLUS FRD 1 9 Masterplat PLUS PGS Table rotation speed C 1650 rpm 5 12 C 1800 5 11 Carriage upstroke downstroke speed m min 1 4 4 Maximum capacity kg 2000 Overall weight kg 395 455 Ambient operating temperature C 0 40 Ambient operating temperature FREEZER model C 30 40...

Page 41: ...plat PLUS FRD Description Unit of measurement Value Film spool dimensions 1 Maximum outer diameter D mm 300 Spool height H mm 500 Film thickness μm 17 35 Internal diameter d mm 76 Max weight kg 20 Mesh spool dimensions 2 Maximum outer diameter D mm 300 Spool height H mm 500 Internal diameter d mm 76 Max weight kg 20 ...

Page 42: ...ENG TECHNICAL INFORMATION 42 3 8 MASTERPLAT PLUS LP FRD AND PGS TECHNICAL DATA The illustration and the table include the machine dimensional specifications and technical data FRD PGS ...

Page 43: ...400 2800 3100 M 31 31 31 31 Load overall dimensions 1650 C 1650 D 2801 5 E 1826 F G N L 1000 W 1200 Weight kg 1200 3 8 2 MASTERPLAT PLUS LP PGS MACHINE AND PALLET DIMENSIONS Description Masterplat PLUS LP PGS Standard Optional Optional Optional Shaft height 2200 2400 2800 3100 A H max 2837 3037 3437 3737 B 2532 2732 3132 3132 H1 2200 2400 2800 3100 M 31 31 31 31 Load overall dimensions 1650 C 1650...

Page 44: ...V 220 240 1Ph 220 240 3Ph 380 415 3Ph N 120 1Ph for USA Power supply frequency Hz 50 60 60 for USA Installed power kW 1 5 Masterplat PLUS FRD 1 9 Masterplat PLUS PGS Table rotation speed C 1650 rpm 5 12 C 1800 5 11 Carriage upstroke downstroke speed m min 1 4 4 Maximum capacity kg 1200 Overall weight kg 470 580 Ambient operating temperature C 0 40 Ambient operating temperature FREEZER model C 30 4...

Page 45: ...rplat PLUS LP FRD Description Unit of measurement Value Film spool dimensions 1 Maximum outer diameter D mm 300 Spool height H mm 500 Film thickness μm 17 35 Internal diameter d mm 76 Max weight kg 20 Mesh spool dimensions 2 Maximum outer diameter D mm 300 Spool height H mm 500 Internal diameter d mm 76 Max weight kg 20 ...

Page 46: ...ENG TECHNICAL INFORMATION 46 3 9 MASTERPLAT PLUS TP3 FRD AND PGS TECHNICAL DATA The illustration and the table include the machine dimensional specifications and technical data FRD PGS ...

Page 47: ...0 1650 1800 D 2625 2775 2850 E 1650 1725 1800 F 1645 1765 1950 G 620 620 620 N L 800 1000 1200 W 1200 1200 1200 Weight kg 1200 1500 1500 3 9 2 MASTERPLAT PLUS TP3 PGS MACHINE AND PALLET DIMENSIONS Description Masterplat PLUS TP3 PGS Standard Optional Optional Optional Shaft height 2200 2400 2800 3100 A H 2875 3075 3475 3775 B 2570 2770 3170 3470 H1 2200 2400 2800 3100 M 77 5 77 5 77 5 77 5 Load ov...

Page 48: ...50 rpm 5 12 C 1800 5 11 Carriage upstroke downstroke speed m min 1 4 4 Maximum capacity kg 1500 Overall weight kg 525 Masterplat PLUS TP3 FRD 550 Masterplat PLUS TP3 PGS Ambient operating temperature C 0 40 Ambient operating temperature FREEZER model C 30 40 1 1 On request also the INOX model can operate at this temperature 3 9 4 PRESSER TECHNICAL FEATURES Description Value Working pressure 6 1 ba...

Page 49: ...erplat PLUS TP3 FRD Description Unit of measurement Value Film spool dimensions 1 Maximum outer diameter D mm 300 Spool height H mm 500 Film thickness μm 17 35 Internal diameter d mm 76 Max weight kg 20 Mesh spool dimensions 2 Maximum outer diameter D mm 300 Spool height H mm 500 Internal diameter d mm 76 Max weight kg 20 ...

Page 50: ...e installed must be carefully selected taking into account the environment conditions in order to have correct and risk free operating conditions Therefore we suggest to take into account the following prerequisites An appropriate ambient temperature see Technical data A perimeter area that must be left around the immediate working area also for safety reasons see Perimeter areas A flat surface st...

Page 51: ...suse the machine and assess the possible residual risks 4 2 PACKING AND UNPACKING The packing is realised keeping the overall dimensions limited 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 especially electrical equipment are protected with anti moisture nylon co...

Page 52: ...ENG INFORMATION ON HANDLING AND INSTALLATION 52 Package with cardboard box Package in cage Package in cage Masterplat PLUS LP ...

Page 53: ...he destination can be performed with different vehicles The diagram represents the most used solutions During transport in order to avoid sudden movements adequately anchor the machine to the vehicle Important For further transportations recreate the initial packaging conditions for transport and handling ...

Page 54: ...e moved with a forklift truck with suitable load capacity by inserting the forks in the points indicated directly on the machine Transport and lifting means must be operated by personnel authorised and qualified for the use of such means Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP ...

Page 55: ...personnel must perform installation and assembly operations Proceed as follows 1 Insert the forklift truck forks in the specially designed spaces provided in the base 2 Lift the machine from the pallet if any Danger warning To perform the operation in safety conditions insert some wooden blocks under the forks of the forklift truck and place everything on the floor 3 Place the machine in the area ...

Page 56: ...ers the electric cables 2 Remove the mounting brackets B 3 Route the electric cables C inside the slide shaft 4 Lift the electric box D 5 Fasten the electric box to the slide shaft with the screws E 6 Close the cover F of the electric box D with the suitable key G Masterplat PLUS LP Masterplat PLUS TP3 ...

Page 57: ...table in correspondence with the hinge 2 Insert the screws L into the hinge without tightening them Masterplat PLUS Masterplat PLUS TP3 3 Connect the lifting device hook in the bracket M of the slide shaft and tension 4 Lift the slide shaft H 5 Fasten the slide shaft to the machine body with the screws N 6 Tighten the screws of the hinge L Masterplat PLUS Masterplat PLUS TP3 ...

Page 58: ...nect the hook of the lifting device to the bracket C of the slide shaft and tension Only for slide shaft with a height of 2200 2400 mm 4 Lift the slide shaft D 5 Fasten the slide shaft to the machine body with the screws E 6 Tighten the screws of the hinge F Masterplat PLUS LP 7 Loosen the screws G 8 Remove the bracket H Masterplat PLUS LP ...

Page 59: ...G AND INSTALLATION ENG 9 Loosen the screws L and remove the brackets M Masterplat PLUS LP 4 5 4 LOADING UNLOADING RAMP ASSEMBLY Assemble the pallet loading unloading ramp Y and connect the power connector Z Masterplat PLUS TP3 ...

Page 60: ...hat cover the loading ramp photocell by loosening the fastening screws 5 B Disconnect the cable of photocell 6 and 7 for the emitter and the receiver Masterplat PLUS TP3 308 508 708 C Insert the supporting knobs 8 and move the upstroke ramp 9 D Remove one of the two upper LH 10 or RH 11 guards and one of the two upper connection guards 12 or 13 by loosening the fastening screws 14 ...

Page 61: ...onnection guards 12 F Slide the photocell receiver connector cable 16 out from the opposite side of the ramp position G Remove the guard 10 from the initial position and reposition it on the front side fastening it with the screws 14 H Reposition the photocell receiver connector cable 16 in the guard 10 and in the connection guard 12 ...

Page 62: ...cable inside it J Refit the upper guard 10 and the upper connection guard 12 with the fastening screws 14 K Position the upstroke ramp 9 on the side and screw the supporting knobs 8 L Recover the cable in excess 16 17 using a tie connect the connector 6 7 to the photocell receiver and position the photocell guard 3 ...

Page 63: ...e guard 1 that covers the base N Unscrew the reflector 18 O Turn the plate clockwise until the reflector 18 is positioned on the opposite side of the loading area P Press the Home position button to turn the plate clockwise and position it in the loading point ...

Page 64: ...slide shaft with the suitable screws Q 2 Fit the arm R on the guide and fasten it with the screws S 3 Fit the presser plate T on the arm Important The pneumatic connections have already been performed by the Manufacturer if the presser is delivered with the machine Masterplat PLUS Masterplat PLUS LP Masterplat PLUS TP3 ...

Page 65: ...e of the various supporting legs Laying the foundations and fixing the machine is essential to ensuring the machine stability and functionality Important Should it be necessary insert metal pates A between the screws and the floor Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP 4 7 MACHINE UNDERGROUND INSTALLATION Dig a pitch in the floor to insert the template C and fix it with a concrete ...

Page 66: ...regulatory and legislative requirements Once the connection has been completed before commissioning the machinery it is necessary to perform an overall check to verify if said requirements have been complied with 4 9 PNEUMATIC CONNECTION 1 Insert a flexible hose in the end of the hose barb fitting and fasten it with a metallic screw clamp A 2 Check that the valve B is in the OPEN position 3 Activa...

Page 67: ...diagram 2 Turn main switch to pos 0 OFF 3 Connect the power cable if supplied to the socket A as shown in the figure in accordance with the mains supply 4 The earth wire yellow green must be connected to its earth terminal PE 5 Power the machine using the main switch 6 Press the Reset button 7 When the Start button is pressed the plate should turn anticlockwise 8 Provided by the customer Masterpla...

Page 68: ...ny residual energy before carrying out the operations Provide suitable safety conditions in compliance with the regulations on workplace safety to prevent and minimise the risks Pay attention to the safety warnings do not misuse the machine and assess the possible residual risks 5 2 FILM STRETCH ADJUSTMENT 5 2 1 SPOOL CARRIAGES OF FRD TYPE 1 Use the lever A to lock and unlock the roller B 2 Use th...

Page 69: ... 4 Slide the belt out of the pulley D 5 Loosen the screws E 6 Remove the plate F with motor and bearings 7 Remove the retaining ring G 8 Remove the pulley D 9 Remove the retaining ring H 10 Remove the gear L 11 Remove the retaining ring M 12 Remove the gear N 13 Loosen the screws and remove the disc P from the gear N 14 Select the set of gears L N relating to the concerned pre stretch rate see tab...

Page 70: ...gear set 16 Fit the gear N of the new transmission gear set 17 Position the gear with the spacer P facing the carriage 18 Fit the retaining ring M 19 Fit the gear L of the new transmission gear set 20 Fit the retaining ring H 21 Fit the pulley D 22 Fit the retaining ring G Important During reassembly make sure that coupling tabs are correctly engaged 23 Rest the plate F on the stud bolts paying at...

Page 71: ...n the carriage later on This optional allows the system to use a mesh spool with an FRD std carriage Important For a correct tensioning of the mesh adjust the braking effect so that the outfeed roller G is more braked than the infeed roller H moreover it is necessary to avoid braking the stretching rollers too much to prevent the mesh from slipping Masterplat PLUS FRD Masterplat PLUS LP FRD Master...

Page 72: ...UNI 5739 not supplied with a torque wrench not supplied to the torque of 3 Nm 7 Screw the nuts C again until reaching the chain tensioner E level 8 Loosen the screw D 9 Refit the guard B 10 Place the pole back in its vertical position and tighten the screws A 5 4 ROTARY TABLE CHAIN ADJUSTMENT 1 Remove the cover A 2 Loosen the fastening screws B of the reduction unit 3 Tighten the screw C with a to...

Page 73: ...ly 2 Remove the cover A 3 Loosen the fastening screws B of the reduction unit 4 Tighten the screw C with a torque wrench not supplied to the rated torque of 3Nm 5 Tighten the reduction unit screws B when adjustment is completed 6 Loosen the screw C completely and refit the guard A Masterplat PLUS TP3 ...

Page 74: ...rmotor gear wheel 3 Loosen the fastening screws D of the gear wheels B and C 4 This adjustment must be performed at the operator s discretion by using the proper tools Danger warning Any maintenance operation in this area must be carried out with machine stopped with electric switch set to OFF and with no other operator near the machine Masterplat PLUS LP ...

Page 75: ...E WHEELS 1 Remove the cover A 2 Loosen the fastening nuts B 3 Loosen the screw E 4 Tighten the screw D so that the wheel C is pressed against the rotary plate by approximately 4 mm 5 Tighten the screw E 6 Tighten the nuts B 7 Refit the guard A Masterplat PLUS TP3 ...

Page 76: ...acle in front of the machine at a distance of approximately 20 cm Important The frequency of the accidents derived from machine use depends on many factors that cannot always be foreseen and controlled Some accidents may be caused by unpredictable environmental factors others are mainly due to users behaviours On first use and if required in addition to being authorised and appropriately informed ...

Page 77: ... is used to temporarily bypass the carriage emergency When the key is turned to position I hold to run the user interface screen will display the page emergency override and this allows by pressing the start button 7 to lift only the carriage 7 Multi function selector it allows activating and setting machine functions Turn the selector clockwise or counter clockwise and release it when the concern...

Page 78: ...eviation R turn the control to access the views or to modify the values To modify the values press the control turn it until the concerned value is displayed and press it again to save it Abbreviation P press the control to activate the selected function Abbreviation PH it indicates a long pressure of the multi function selector 1 which allows accessing the second level functions Colours of page e...

Page 79: ...l Controls Menu 6 Access to Film Tensioning Menu See Film tensioning menu 7 Access to Other Menu See Other Menu 8 Intermediate wrapping turns 9 Intermediate and upper wrapping turns 10 Access to Settings Menu See Settings Menu 11 Synchronisation of the machine table in initial position carriage down presser up If JOG is pressed again movements will stop 12 Access to the Recipe Menu See Recipe Menu...

Page 80: ...ENG INFORMATION ABOUT THE USE 80 6 4 1 WRAPPING CYCLE Activation mode abbreviation Button Description R Double wrapping cycle R Single wrapping cycle R Double wrapping with feeder cycle ...

Page 81: ...81 INFORMATION ABOUT THE USE ENG 6 4 2 TABLE ROTATION SPEED rpm Activation mode abbreviation Button Description P Display the table rotation speed rpm ...

Page 82: ...NG INFORMATION ABOUT THE USE 82 6 4 3 CARRIAGE SPEED Ref Activation mode abbreviation Button Description A P Display carriage speed B P Display carriage upstroke speed P Display carriage downstroke speed ...

Page 83: ...LLET HEIGHT Ref Activation mode abbreviation Button Description A P View the distance of the wrapping end delay in cm P View the dimension of the offset from the ground in cm B P View the set pallet height P View the dimension of the offset from the ground in cm ...

Page 84: ...ge hold to run rises until reaching the upper limit switch R If JOG is pressed the presser hold to run rises until reaching the upper position R If JOG is pressed the table hold to run turns until reaching the initial position R If JOG is pressed the presser hold to run moves down until reaching the lower position R If JOG is pressed the carriage hold to run moves down until reaching the lower lim...

Page 85: ... version only Ref Activation mode abbreviation Button Description A P View the film tensioning value B P View the lower film tensioning value P View the film upstroke tensioning value P View the upper film tensioning value View the film downstroke tensioning value ...

Page 86: ...tton 7 to access the Other Menu Activation mode abbreviation Button Description R Presser function enabling R Ergonomic upstroke function R Phase angle adjustment function R Copy recipe data function R Return to the Home page Icon ref Code activation mode Page Description R Presser enabled R Presser disabled ...

Page 87: ...e phase angle height R Selection of the recipe to copy 6 4 8 SETTINGS Activation mode abbreviation Button Description P Press the button 10 to access the settings Menu Activation mode abbreviation Button Description R Cycle counter R Acoustic signal R User Page alternative options depend on the login status R Panel lock ...

Page 88: ... panel R Motor parameters Assistance page R Machine parameters Assistance page R Input Output status Assistance page R Load cell settings PGS only R Info Assistance page R Return to the previous menu Icon Ref Activation mode abbreviation Page Description P View counters P Partial T Total H hours R Acoustic signal ON R Acoustic signal OFF ...

Page 89: ...t 9999 to lock the panel When the panel is locked the edge of the screen is yellow P Enter the password to unlock the panel P To change the panel lock password enter a new password and select the checkmark Enter the chosen password again and confirm to update its value P CELL Load cell reading instant value OFFSET Offset value with film tensioning 0 Press and keep pressed for about 3 seconds to se...

Page 90: ...ION ABOUT THE USE 90 6 4 9 RECIPE Activation mode abbreviation Button Description P Programme Icon ref Code activation mode Page Description R Programme 1 Programme 2 Programme 3 Programme 4 Programme 5 Programme 6 ...

Page 91: ...91 INFORMATION ABOUT THE USE ENG R Manual cycle See Manual Cycle ECO cycle See Eco Cycle ...

Page 92: ...cycle menu Home page Set the table rotation speed the carriage upstroke downstroke speed and the film stretch as previously indicated in programmes from 1 to 6 Activation mode abbreviation Button Description R Table rotation speed Carriage speed Manual controls Film stretch for PGS version only Other menu Settings Synchronisation of the machine ...

Page 93: ...ith feeder cycle Film stretch for PGS version only allow to modify the parameters just listed P Carriage downstroke At every pressure the carriage moves down or stops P Carriage upstroke At every pressure the carriage moves down or stops P Table stop in initial position The table stops in the initial position and the cycle ends The cycle ends when the carriage downstroke movement brings it to the ...

Page 94: ...abbreviation Button Description P Press the button 12 to access the self learning cycle Home page Activation mode abbreviation Button Description R Start logging mode Manual controls Film stretch for PGS version only Other menu Settings Synchronisation of the machine ...

Page 95: ... speed and the film stretch as previously indicated in programmes from 1 to 6 Once any of these control buttons has been pressed these values can no longer be modified Activation mode abbreviation Button Description R Table rotation speed Carriage movement speed Film stretch for PGS version only Carriage downstroke Start Stop Carriage upstroke Start Stop Cycle pause Table stop in initial position ...

Page 96: ...ion mode abbreviation Button Description P When the button is pressed the table starts to turn P Use the buttons to perform the required movements P Press the jog button to confirm the selected control Press the STOP button to end the logging ...

Page 97: ...he Reset button 2 Press the Cycle Start button Restart from feeder cycle 3 Home page if the film stretch function is absent 4 Emergency bypassed The carriage can be lifted using the start button even in case of carriage emergency 5 Wrapping cycle in starting phase ...

Page 98: ...For FREEZER and INOX versions it is recommended not to cut off the power supply to the machine Caution warning For LP versions remove the load after the wrapping cycle 2 Press the Reset B button 3 Set the cycle parameters See paragraph cycle parameters setting 4 Perform the cycle starting operations see paragraph Cycle start and stop 5 Turn the main switch A to O OFF to switch the machine off 6 6 ...

Page 99: ...d after having performed the required number of wrapping turns at the base and at the upper end of the pallet See Description of user interface 6 7 2 DOUBLE WRAPPING CYCLE To select the double cycle Turn the jog control to enable the wrapping cycle page Press the jog control and select the double wrapping Press the jog control to confirm The spool carriage starts moving from the pallet base rises ...

Page 100: ...ops in this position If the machine features a presser it rises from the load by approximately 200 mm At this point the operator after placing the covering sheet onto the top of the pallet activates the cycle again by pressing the START button the presser moves down again The carriage rises until reaching the pallet upper end performs the programmed upper wrapping turns and moves down to complete ...

Page 101: ... the packages and the products contained in them 4 Press the Cycle Start button A The machine completes the cycle and stops automatically 5 Cut the film 6 Remove the pallet and position a new pallet to start a new cycle Important To temporarily suspend the cycle press the Cycle stop button B Press the Cycle Start button A to restart it 6 8 1 INFORMATION VALID ONLY FOR FEEDER CYCLE WRAPPING MODE 1 ...

Page 102: ...presser installed on the machine Caution warning For LP versions remove the load after the wrapping cycle 6 10 PNEUMATIC CYLINDER WITH ROD 1 Loosen the screw A 2 Adjust the height of the pneumatic cylinder B on the guide C according to the size of the product to be wrapped 3 Tighten the screw A Masterplat PLUS Masterplat PLUS LP Masterplat PLUS TP3 Presser unit version Slide shaft H mm Arm in norm...

Page 103: ...ol carriage plate 3 Pull the cord outwards The film automatically moves down to the roller and covers it over its entire length 4 Lock the film end into the suitable locking disc A on the rotary table Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP To allow film or mesh routing between rollers and unwinding on carriages of FRD type it is necessary to unlock the brake by turning the handwhee...

Page 104: ...FORMATION ABOUT THE USE 104 To allow film unwinding on carriages of PGS type it is necessary to press the roller rotation button C on the spool carriage Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP ...

Page 105: ...service centre authorised by the Manufacturer Do not dispose of materials polluting liquids and the waste generated during the interventions into the environment but dispose of them according to the standards in force Danger warning Before performing any maintenance operation activate all safety devices provided and evaluate whether it is necessary to inform the personnel operating on the machine ...

Page 106: ...Rubber rollers Cleaning Clean with alcohol Lifting chains Greasing See Lubrication point diagram Tensioning check Adjust See Spool carriage lifting chain adjustment Table rotation chain Greasing See Lubrication point diagram Tensioning check Adjust See Rotary table chain adjustment Reduction units and gearmotors Checking lubricant level1 Top up if necessary with lubricant of the same type See lubr...

Page 107: ...pending on their type Topping up and or change must not be performed in case of life lubed reduction units and gearmotors Cycle timings have been defined on the basis of the standard cycle The standard cycle is the following 500 mm high film spool 1500 mm high pallet pallet weight equal to 1500 kg total wrapping cycle consisting of two turns at the base two turns at the top with rotation speed of ...

Page 108: ...AGRAM The diagram shows the main parts concerned by the lubrication interventions and their intervals Masterplat PLUS Masterplat PLUS TP3 Spread grease over it Check the lubricant level Do not top up and or change in life lubed reduction units and gearmotors ...

Page 109: ...109 MAINTENANCE INFORMATION ENG Masterplat PLUS LP Spread grease over it Check the lubricant level Do not top up and or change in life lubed reduction units and gearmotors ...

Page 110: ... COMPOUND B IP STRUCTOVIS P LIQUID KLUBER TOTALCARTER SYOO TOTAL Gear reduction unit and worm screw reduction unit Synthetic oil TELESIA OIL IP SYNTHESO D 220 EP KLUBER BLASIA S 220 AGIP Gear reduction unit and worm screw reduction unit Lithium grease ALVANIA R2 SHELL HL 2 ARAL ENERGREASE LS2 BP BEACON 2 ESSO MOBILIX MOBIL Bearings with support Synthetic oil 5 C 5 C VG 68 SAE 20 5 C 25 C VG 100 SA...

Page 111: ... upwards until all condensation is let out 4 Tighten the valve C again Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP 7 6 AIR FILTER CLEANING 1 Unscrew the container B with the specific wrench 2 Remove the filter clean it with compressed air and wash it if necessary with petrol or trichloroethylene 3 Refit the filter and tighten the container B Masterplat PLUS Masterplat PLUS TP3 Masterpla...

Page 112: ...rt and foreign bodies The chrome plated shafts must be cleaned with a cloth and slightly lubricated with a cloth soaked in Vaseline oil The parts in plastic material 1 must be cleaned with a slightly damp cloth do not use alcohol petrol or solvents Use only a dry cloth to dust the control panel 2 For the cleaning of the parts inside the machine consult our technical assistance service ...

Page 113: ...n and press the Reset button E02 Carriage emergency An obstacle has been detected along the trajectory during the spool carriage downstroke Remove the obstacle and press the Reset button E03 Hand pallet truck emergency An obstacle has been detected on the pallet loading unloading ramp Remove the obstacle and press the Reset button E04 Protection alarm Intervention of safety barriers or open door R...

Page 114: ... parts or parts with similar design and construction features The use of similar but non original spare parts may result in improper repairs altered performance and economic damage Safety components and or devices must be replaced only with original spare parts to preserve the safety level required Important Before performing any maintenance operation activate all safety devices provided and evalu...

Page 115: ...Y TABLE WHEELS 1 Loosen the screws A 2 Fit the eyebolts B and remove the upper plate C 3 Lift the table and place it on the ground 4 Replace the wheels D 5 Reposition the table on the base and fasten it with the screws Masterplat PLUS LP Masterplat PLUS TP3 ...

Page 116: ...on the ground 4 Replace the rollers D 5 Reposition the table on the base and fasten it with the screws Important Should it not be possible to lift the rotary table using the eyebolts as indicated in point 2 position the support E and screw it into the rotary table central seat using the screws F Lift the rotary table using the fork lifting device Masterplat PLUS LP ...

Page 117: ... Remove the snap ring D 5 Replace the rollers G 6 Reposition the table on the base and fasten it with the screws Important Should it not be possible to lift the rotary table using the eyebolts as indicated in point 2 position the support E and screw it into the rotary table central seat using the screws F Lift the rotary table using the fork lifting device Masterplat PLUS LP ...

Page 118: ...the cover A 2 Loosen the fastening screws D of the gear wheels B and C 3 Replace the gear wheels Danger warning Any maintenance operation in this area must be carried out with machine stopped with electric switch set to OFF and with no other operator near the machine Masterplat PLUS LP ...

Page 119: ...ge supporting wheels No 1 braked roller pad Only for spool carriages of FRD type No 1 driving belt Only for spool carriages of PGS type To order them contact your local dealer and refer to the spare parts catalogue Important Replace worn parts with original spare parts Use oils and greases recommended by the Manufacturer All the above will ensure the proper operation of the machine and the correct...

Page 120: ...E SCRAPPING Scrapping must be performed by authorised centres with experienced personnel and by using the appropriate equipment for safe operating conditions The person who performs the scrapping must identify any possible residual energies and implement a safety plan to eliminate unexpected risks The components must be selected according to the chemical and physical features of the material and d...

Page 121: ...k of production or injuries to persons or damage to things caused by malfunctions or forced downtime of the machine covered by the warranty THE WARRANTY DOES NOT COVER Transport failures Damage due to incorrect installation Improper use of the machine or negligence Tampering with or repairs by unauthorised personnel Lack of maintenance Parts subject to normal wear and tear For purchased components...

Page 122: ...ENG ANNEXES 122 10 2 PRESSER PNEUMATIC DIAGRAM Legend A Filter regulator unit B Solenoid valve C Flow regulator D Silencer E Unloading regulator F Presser actuating pneumatic cylinder ...

Page 123: ...OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 26 February 2014 on the harmonisation of the laws of the Member States relating to electromagnetic compatibility Reference to harmonised standards and their annexes at the applicable points EN ISO 12100 2010 EN 60204 1 2006 A1 2009 EN 415 5 2010 EN 415 6 2013 EN 415 10 2014 THE PERSON AUTHORISED TO DRAFT THE TECHNICAL BOOKLET IS Ing Pierangelo Laghi...

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Summary of Contents for Masterplat FREEZER

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Robopac Masterplat FREEZER, Use And Maintenance Manual, Page: 3 / 123

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Summary of Contents for Masterplat FREEZER

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