AETNAGROUP ROBOPAC STARBOX 50, Use And Maintenance Manual

Page 1: ...StarBOX 50 StarBOX 65 serial n GB USE AND MAINTENANCE MANUAL Translation of the original instructions Carton erecting machine Instructions manual code 3709300424 English Edition 0 0615 ...

Page 2: ......

Page 3: ...Council Directive 2004 108 EC dated December 15 2004 European Parliament and Council Directive 2006 95 EC dated December 12 2006 Reference to harmonised standards and relevant annexes in 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 INDIVIDUAL AUTHORISED TO DRAFT THE TECHNICAL BOOKLET IS Mr Pierangelo Laghi R D Manager Via Fabrizio da Mo...

Page 4: ......

Page 5: ...or handling and loading 27 4 2 Packaging and unpacking 27 4 3 Transport and handling 28 4 4 Machine Installation 29 4 5 Installation of roller conveyor 31 4 6 Recommendations for connections 31 4 7 Pneumatic connections 32 5 Information on adjustments 5 1 Recommendations for adjustments 33 5 2 Ejector stoke adjustment 34 5 3 Adjusting the chain for moving the flap closing sheets 35 6 About the use...

Page 6: ... 2 2 English English Page deliberately empty Summary ...

Page 7: ...ell known and easy to access place available for reference any time the need should arise Refer to the table of contents and the analytical index 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 manuf...

Page 8: ...ectly on the machine It contains references and indispensable operating safety indications A Machine model B Machine s serial number C Year of manufacture D Power supply voltage E Power supply frequency F Power supply phases G Electrical power consumption H Total installed power L Air consumption M Max air supply pressure N Machine weight P Manufacturer s name ...

Page 9: ...use and ordinary maintenance of the machine Maintenance technician A person authorised and chosen among those who have the requirements skills and information necessary to perform ordinary and extraordinary machine maintenance He is expected therefore to possess precise information and skills with particular expertise in the field of intervention Format Change series of operations to carry out on ...

Page 10: ...ds ROBOPAC SPA VIA FABRIZIO DA MONTEBELLO 81 47892ACQUAVIVAGUALDICCIOLO REPUBBLICAS MARINO RSM Phone 0549 international 378 910511 Fax 0549 908549 905946 http www aetnagroup com 1 5 Attached documentation The machine is provided with the documentation listed below in the absence of a different trade agreement CE statement of conformity Warranty conditions included in this booklet Instructions for ...

Page 11: ...ator Usually it is too late to remember what should have been done when the accident has already happened 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 information The manufacturer has designed the machine observing all the good manufacturing regulations...

Page 12: ... temperature during transport and or storage must fall within the range allowed in order to prevent damaging the electrical components Install the machine ONLY in spaces free of explosion and or fire risks Avoid the spaces exposed to atmospheric and corrosive agents Assess prior to installation if it is necessary to draw up a safety plan in order to protect the safety of the personnel involved Pro...

Page 13: ...test that the machine can be commissioned without any risk for the operator Dismantle all the packaging components in compliance with the standards in force in the country of installation Non compliance with the instructions given may cause risks for safety and health of the persons and economic damages ...

Page 14: ...t use the machinery with the safety devices not properly installed and efficient Alwaysweartheindividualsafetydevicesindicatedinthe instructions for use and provided by the standards in force regarding the safety at workplace Always keep the surrounding areas in suitable conditions and free of obstacles in order to minimise the risks especially near the control station The machine must be used by ...

Page 15: ...al conditions of use have been restored Never carry out an intervention with the machine enabled but only after having stopped it properly under safety conditions Never use the machine without wearing the personal protective devices indicated by the manufacturer and required by current workplace laws Never use the machine if the scheduled maintenance interventions have not been carried out accordi...

Page 16: ...standing the user manual and must easily identify the safety signs Make sure the machine is ONLY used by adequately trained documented and authorized operators The employer must draw up the documentation of the specific training carried out by the operators in order to exhibit it in case of litigation ...

Page 17: ...safety and health of the operators The residual risks are all the risks that persists although all safety solutionshavebeenappliedandintegratedduringmachinedesign The list specifies the residual risks specific for this type of machine Danger of crushing The machine is not protected against the involuntary starting of the actuating sheet with a consequent starting of the cycle and crushing of the u...

Page 18: ...manufacturer Do not use products that contain corrosive toxic and inflammable substances Wear the individual protection devices provided by the laws on workplace safety and indicated in the instructions for use and or affixed to the machine Replace the components only with original pare parts or with similar design and functional features The use of similar but non original spare parts may lead to...

Page 19: ...he possible adjustments of the machine B Information sign Indicates the points for lifting with a hook device C Information sign Controls plate D Mandatory sign Indicates the obligation to read the entire documentation before using the machine E Information signal Identifies the pneumatic disconnecting switch Important Check that the plates are clearly readable and if necessary replace them with n...

Page 20: ...in 1000 English English Chapter 2 Safety information 2 8 Surrounding areas The illustration depicts the perimeter work areas of the machine A Operator s working area B Box exit zone C Sorrounding area Min 1000 Min 1000 Min 1000 ...

Page 21: ...requirements Refer to table 3 1 machine type The packs that contain liquids or insubstantial materials must be suitable for the product and must be perfectly closed and tight in order to prevent any leaks of the content It is equipped with a series of safety devices designed to avoid anyharm befalling the operator or other persons who come into contactwith the machine in any way The machine is pro...

Page 22: ...e box towards the machine downstream C Guide bars Continually operated they keep the cardboard box in the guide D Flap folding sheet steel panel Operated pneumatically they close the four lower flaps E Sheet steel sensing panel Operated by the flaps of the box it enables the flap closing sheets to go up and the pipe guides to close F Carton hopper G Outfeed roller conveyor Optional H Foot control ...

Page 23: ...rements this machine can be supplied in different models and configurations Starbox 50 to erect boxes wide up to 500 mm and long up to 650 mm Starbox 65 to erect boxes wide up to 650 mm and long up to 800 mm The machine is designed just for one operator and requires his constant presence ...

Page 24: ... the carton tilted press downwards until the carton leans on the work table 2 Direct the box towards outfeed until it reached the sheet steel sensing panel L In this way the work cycle begins 3 Close the two bars that block the carton the two sheet steel panels start and close the side flaps Theoperatormustkeepthecarton pressed on the work table If the flaps are very precise lengthwise they gaze t...

Page 25: ...ress the pedal control starting the ejector The machine completes the cycle and is ready for the next cycle Automatic cycle Ejectionisperformedautomatically without any further consent Danger Warning The automatic cycle must be used with a taping machine that closes only the bottom part of the box 4 At this point according to the position of the operating selector there are two types of cycles ...

Page 26: ...e china A Main electrical knife switch with padlock to activate and deactivate the power supply It comes with a padlock to prevent unauthorised personnel from activating the power supply B Emergency button the machine stops immediately when this button is pressed in emergency situations To reset rotate the button in the direction indicated by the arrow ...

Page 27: ...n of accessories on request To enhance the performance and to increase the versatility of the machine the manufacturer furnishes the accessories listed below A Product outfeed roller conveyor Can be connected to the downstream machine usually a taping machine B Casters ...

Page 28: ...ons Machine model A mm B mm C mm D mm E mm F mm G mm STAR BOX 50 1740 740 610 890 700 975 250 STAR BOX 65 1890 890 Table 3 2 Product size Description Machine model STARBOX 50 STARBOX 65 L min See taping machine downstream L max 650 mm 800 mm W min 230 mm 300 mm W max 500 mm 650 mm Note You can reach minimum measurements in smaller widths W with favourable thickness and box creasing but never less ...

Page 29: ...hapter 3 Technical information Table 3 3 Machine technical specifications Description Description STAR BOX 50 STAR BOX 65 Air consumption Nl cycle 8 5 9 Operating pressure 6 1 bar 6 1 bar Total weight 115 kg 120 kg ...

Page 30: ...asily operated without creating any unnecessary risks for personnel Therefore we suggest the following prerequisites suitable room temperature A suitably aired place so that when the machine is working the degree of humidity is not unpleasantly high low from the point of view of the operator A sufficient lighting in order that a pleasant relaxing working environment is created for the operator a b...

Page 31: ... the possible RESIDUAL RISKS 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 especially electric equipment are protected with anti moisture nylon covers The cases are marked with ...

Page 32: ...oidsuddenmovements adequately anchor the machinery to the means of transportation Important For further transportation recreate the initial packaging conditions for transport and handling The machine can be handled with a fork or hook lift truck having adequate capacity Position a lifting device as indicated in the figure Caution Warning Before lifting the machine check for centering position of t...

Page 33: ...en to install dismantled parts Proceed as indicated 1 Lift the machine See 4 3 transport and handling 2 If the machine is equipped with swivel wheels F screw them onto the feet 3 Mount the rods H of the box magazine and fix with the nuts L 4 If necessary identify the exact position and trace the co ordinates to correctly place the machine ...

Page 34: ...formation on handling and installation operations 5 Operate screws E to move feet D and level the machine 6 Remove the lifting bars M Important Conserve the bars for the consequent lifting of machine 7 Ifmachineissuppliedwithcasters block them ...

Page 35: ...es and have acquired certified experience in the specific field and must perform connections professionally taking into account all the regulative and legislative requirements When connections are completed make sure these requisites were observed by performing a general inspection before making the unit operative 4 5 Installation of roller conveyor In the case of a former equipped with idle rolle...

Page 36: ...e 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 6 bar and use the knob C to compensate any pressure differences Repeat this operation when the machine is running 4 7 Pneumatic connections Proceed as indicated ...

Page 37: ...intervention activate all the safety de vices provided stop the machine and assess if any residual energy is still present 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 use the machine for unspecified purposes and assess the possible Chapter 5 Information on adjustments ...

Page 38: ... knob A and moving the ejector B in the different positions these positions depend from the box s length Caution Warning In the event the former is used without an idle roller do not use the last holes F on the sheet in order to avoid operating problems With ejector totally out guide shoe C on sheet steel plate D must remain leaning on guide E ...

Page 39: ...o put the machine in safety conditions 2 Dismantle the fixed protections D 3 Loosen the nuts E 4 Operate nuts F to adjust chain tension 5 Tighten the nuts E Important To check chain tension use the method indicated in the illustration The resulting shift R should be 10 15 mm Caution Warning Before re starting the machine check that no tools or other equipment has been left near the moving parts ...

Page 40: ...ne for the first time the operator must read the manual and identify the controls and simulate some operations especially the start up and shutdown Check that all safety devices are installed correctly and in good working order Only implement the uses intended by the manufacturer and do not tamper with any device to obtain performances different from the intended ones Chapter 6 About the use ...

Page 41: ...et turn the knob in the direction indicated by the arrow found on the button D Repositioning button Button must be pressed to bring into the cycle start position the various machine components E Work speed regulators The individual speeds of the flap folding sheet steel panels of the guide bars and of the ejector are adjusted at testing by the servicing personnel however some adjustments might be ...

Page 42: ...ate main inlet on 0 to close pneumatic circuit and stop machine eventually locking the inlet 6 4 Emergency stop and restart Press the EMERGENCY button Machine operation stops immediately After having normalized the working conditions unblock the emergency stop button to allow machine operation For the consequent restart simply insert a new carton in the machine ...

Page 43: ...ntions with all the safety devices enabled and wear the DPI provided Mark the intervention area and prevent access to the devices that if activated may cause unexpected hazards and jeopardize the safety level DO NOT carry out any intervention that is not described in the manual but contact an Assistance Service authorised by the manufacturer DO NOT damp in the environment materials pollutant liqui...

Page 44: ...lean with a cloth of air jet Reducer filter Condensation control Condensation discharging See 7 5 Condensate drainage Every 200 hours Reducer filter Cleanliness Clean with a blast of air and alcohol See 7 6 cleaning air filter Safety devices Efficiency control Replace the damaged components Slide guides General inspection Cleaning and lubrication See 7 3 Lubrication point diagram Shifting chains G...

Page 45: ...ain components and the frequency of the lubrication interventions Symbol and Description Smear with grease Keep to the recommended lubrication frequency to get top machine performances and a longer operating life Use lubricants oils or grease recommended by the manufacturer or with similar chemical physical features ...

Page 46: ...N EP 460 ESSO BLASIA 460 AGIP MOBILGEAR 634 MOBIL OMALA EP 460 SHELL ENERGOL GR XP 460 BP Grease TELESIA COMPOUND B IP Gear and worm gear motor STRUCTOVIS P LIQUID KLUBER TOTALCARTER SYOO TOTAL Synthetic oil TELESIA OIL IP SYNTHESO D 220 EP KLUBER BLASIA S 220 AGIP Lithium grease ALVANIA R2 SHELL Bearings with support HL 2 ARAL ENERGREASE LS2 BP BEACON 2 ESSO MOBILIX MOBIL Synthetic oil 5 C 5 C VG...

Page 47: ...ntrol the level of condensation in the container B Push the valve C up until all condensation is removed 7 6 Cleaning the air filter Proceed as indicated Loosen the cup B with the specific key Detach the filter and clean with compressed air and wash if necessary with petrol or trichloroethylene Reassemble the filter and tighten the container B ...

Page 48: ...and solutions Table 8 1 List of problems Problem Cause Remedy The main drawbacks are principally relatedtothesomeofthepneumatic parts breaking Breakage or malfunction of pneumatic components Have an expert technician check with the help of the pneumatic diagram the component s to be replaced Chapter 8 Troubleshooting ...

Page 49: ...t is not described in the manual but contact an assistance service authorised by the manufacturer Do not damp in the environment materials pollutant liquids and the residues created during the interventions but dispose them according to the standards in force Replace the components only with original pare parts or with similar design and functional features The use of similar but non original spar...

Page 50: ...le the fixed protections D 3 Unscrew the nuts Q to loosen chains R completely 4 Remove the chain links T and remove chains R 5 Install the new chains and lock them with the chain links 6 Adjust chain tension See 5 3 Adjusting the chain for moving the flap closing sheets 7 Restart the machine and check that it functions correctly Caution Warning Before re starting the machine check that no tools or...

Page 51: ...nnot be restarted and position it in a place not easy to access Empty in ad adequate way the systems containing damaging substances and do it in accordance with the current laws in force at workplaces and those regulating environmental protection Machine scrapping Scrapping must be entrusted to authorized centres having the adequate skills and equipment to operate in safety conditions Those who ca...

Page 52: ...f production or injuries to persons or damage to things caused by malfunctions or forced suspension in using the machine covered by the warranty The warranty does not cover 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 normal wear and tear For purchased co...

Page 53: ... 49 English Chapter 10 Enclosed documentation 10 2 Pneumatic system ...

Page 54: ...gle valve B Unidirectional flux regulator C Automatic end stop D Selector valve E Unidirectional flux regulator F Monostable valve G Monostable valve H Roller end stop I Monostable valve L Monostable valve M Cylinder N Cylinder O Cylinder P Pneumatic soft starter ...