Robopac ROTOPLAT 108-308-508-708, Use And Maintenance Manual

Page 1: ...ROTOPLAT 108 308 508 708 ROTOPLAT LP 308FR 508PDS 708PVS ROTOPLAT TP 108 308 508 708 USE AND MAINTENANCE MANUAL ENG ...

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

Page 3: ...E 27 3 3 SAFETY DEVICE DESCRIPTION 28 3 4 DESCRIPTION OF ELECTRICAL DEVICES 31 3 4 1 REMOTE CONTROL SOFTWARE 33 3 5 DESCRIPTION OF PNEUMATIC DEVICES 34 3 6 DESCRIPTION OF ACCESSORIES ON REQUEST 35 3 7 ROTOPLAT 308 508 708 TECHNICAL DATA 39 3 7 1 MACHINE AND PALLET DIMENSIONS 39 3 7 2 MACHINE TECHNICAL FEATURES 40 3 7 3 PRESSER TECHNICAL FEATURES 40 3 7 4 PNEUMATIC CREASING HEAD TECHNICAL FEATURES ...

Page 4: ... ADJUSTMENT 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 3 1 NUMERICAL AND ALPHANUMERICAL KEYBOARD 81 6 3 2 PROGRAMMING WINDOW 82 6 4 HOME PAGE 83 6 5 MANUAL HANDLING PAGE 85 6 5 1 MANUAL REINFORCEMENT FUNCTION 86 6 6 RECIPES PAGE 87 6 7 WRAPPING CYCLE PAGE 88 6 8 GENERAL PARAMETERS PAGE 89 ...

Page 5: ...ACING MACHINE PARTS 112 9 2 REPLACING THE ROTARY TABLE WHEELS 113 9 3 REPLACING THE ROTARY TABLE ROLLERS 114 9 4 REPLACING THE GUIDING ROLLERS 115 9 5 REPLACING THE ROTARY TABLE GEAR WHEELS 116 9 6 RECOMMENDED SPARE PARTS LIST 117 9 7 MACHINE DECOMMISSIONING AND SCRAPPING 117 9 7 1 MACHINE DECOMMISSIONING 117 9 7 2 MACHINE SCRAPPING 117 10 ANNEXES 118 10 1 WARRANTY CONDITIONS 118 10 2 PRESSER PNEU...

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 Rotoplat 308 508 708 Rotoplat TP3 308 508 708 Rotoplat LP 308 508 708 ...

Page 23: ... 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 Rotoplat 308 508 708 Rotoplat TP3 308 508 708 Rotoplat LP 308 508 708 ...

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: ...n 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 Rotoplat 308 508 708 Rotoplat TP3 308 508 708 Rotoplat LP 308 508 708 ...

Page 26: ...of PVS type Table Spool carriage features Spool carriage type General features FR Spool carriage of FR type with friction roller electromagnetic brake and film stretch adjustment from control panel PDS Spool carriage of PDS type with motorised pre stretching rollers and electronically controlled film tensioning Pre stretch can be adjusted from the control panel 0 25 PVS Spool carriage of PVS type ...

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: ...e 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 ramp stopping the table ro...

Page 29: ...29 TECHNICAL INFORMATION ENG Rotoplat 308 508 708 Rotoplat TP3 308 508 708 Rotoplat LP 308 508 708 ...

Page 30: ...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 8 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 31: ...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 32: ...ENG TECHNICAL INFORMATION 32 Rotoplat 308 508 708 Rotoplat TP3 308 508 708 Rotoplat LP 308 508 708 ...

Page 33: ...G 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 34: ...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 35: ...troke 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 Mechanical presser electrically controlled device for load stabilisation it is not necessary to adjust the height according to the size of the product to be wrapped 3 Pallet loading unloading ramp it facilitates these operations through fork lifting devic...

Page 36: ...unloading operations it is recommended not to get on the ramps with the forklift truck Rotoplat LP 308 508 708 Rotoplat LP with 270 ramp 5 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 Slide shaft 2400 2800 3...

Page 37: ...d to obtain a correct tensioning of the mesh Slide shaft 2400 2800 3100 mm it is used to wrap pallets which are higher than the standard ones Automatic cutting device it automatically cuts the film at the end of the cycle Only for machines Rotoplat Rotoplat TP3 508 708 7 Creasing device it is used during wrapping to gather the film in one point providing the package with a reinforcement point Roto...

Page 38: ...e 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 Rotoplat TP3 308 508 708 Rotoplat LP 308 508 708 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 Rotoplat TP3 308 508 708...

Page 39: ...hnical data 3 7 1 MACHINE AND PALLET DIMENSIONS Description Rotoplat Standard Optional Optional Optional Shaft height A 2350 2550 2950 3250 H 2200 2400 2800 3100 B 2560 2760 3160 3460 Load overall dimensions 1650 1800 C 1650 1800 2200 2400 D 2755 2835 3535 3635 E 2313 2313 2446 2546 L 1000 1200 1400 1400 W 1200 1200 1600 1600 Weight kg 2000 2000 2000 200 ...

Page 40: ...1800 C 2200 2400 rpm 5 12 5 11 5 8 Carriage upstroke downstroke speed m min 1 5 5 5 Maximum capacity kg 2000 Overall weight kg 395 455 Ambient operating temperature C 0 40 3 7 3 PRESSER TECHNICAL FEATURES Description Value Working pressure 6 1 bar 0 6 0 1 MPa Pneumatic cylinder with rod H 2200 2400 2800 3100 Air consumption 11 Nl min 3 7 4 PNEUMATIC CREASING HEAD TECHNICAL FEATURES Description Val...

Page 41: ...er 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 Bubble wrap spool dimensions 3 Maximum outer diameter D mm 1000 Spool height H mm 500 Internal diameter d mm 76 Max weight kg 12 ...

Page 42: ...ne dimensional specifications and technical data 308 508 708 3 8 1 MACHINE AND PALLET DIMENSIONS Description Rotoplat LP Standard Optional Optional Optional Shaft height A 2350 2550 2950 3250 H 2200 2400 2800 3100 B 2532 2732 3132 3432 Load overall dimensions 1650 C 1732 D 2802 E 1826 L 1000 W 1200 F 3126 Weight kg 1200 ...

Page 43: ...00 C 2200 2400 rpm 5 12 5 11 5 8 Carriage upstroke downstroke speed m min 1 5 5 5 Maximum capacity kg 1200 Overall weight kg 470 580 Ambient operating temperature C 0 40 3 8 3 PRESSER TECHNICAL FEATURES Description Value Working pressure 6 1 bar 0 6 0 1 MPa Pneumatic cylinder with rod H 2200 2400 2800 3100 Air consumption 11 Nl min 3 8 4 PNEUMATIC CREASING HEAD TECHNICAL FEATURES Description Value...

Page 44: ...f 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 Bubble wrap spool dimensions 2 Maximum outer diameter D mm 1000 Spool height H mm 500 Internal diameter d mm 76 Max weight kg 12 ...

Page 45: ...hnical data 3 9 1 MACHINE AND PALLET DIMENSIONS Description Rotoplat TP3 Standard Optional Optional Optional Shaft height A 2350 2550 2950 3250 H 2200 2400 2800 3100 B 2560 2760 3160 3460 Load overall dimensions 1650 1800 C 1650 1800 2200 2400 D 2755 2835 3535 3635 E 2313 2313 2446 2546 L 1000 1200 1400 1400 W 1200 1200 1600 1600 Weight kg 2000 2000 2000 200 ...

Page 46: ...5 11 Carriage upstroke downstroke speed m min 1 5 5 5 Maximum capacity kg 1500 Overall weight kg 525 530 Rotoplat TP3 108 308 550 560 Rotoplat TP3 508 708 Ambient operating temperature C 0 40 3 9 3 PRESSER TECHNICAL FEATURES Description Value Working pressure 6 1 bar 0 6 0 1 MPa Pneumatic cylinder with rod H 2200 2400 2800 3100 Air consumption 11 Nl min 3 9 4 PNEUMATIC CREASING HEAD TECHNICAL FEAT...

Page 47: ...iption 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 48: ...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 49: ...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 50: ...ENG INFORMATION ON HANDLING AND INSTALLATION 50 Package with cardboard box Package in cage ...

Page 51: ...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 52: ...y 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 Important To handle the TP3 version machine the brackets must be installed as indicated in the figure Rotoplat 308 508 708 Rotoplat TP3 308 508 708 Rotoplat LP 308 508 708 ...

Page 53: ...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 54: ...c 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 Rotoplat 308 508 708 Rotoplat LP 308 508 708 Rotoplat TP3 308 508 708 ...

Page 55: ...orrespondence with the hinge 2 Insert the screws L into the hinge without tightening them Rotoplat 308 508 708 Rotoplat TP3 308 508 708 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 Rotoplat 308 508 708 Rotoplat TP3 308 508 708 ...

Page 56: ...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 Rotoplat LP 308 508 708 7 Loosen the screws G 8 Remove the bracket H Rotoplat LP 308 508 708 ...

Page 57: ... the screws L and remove the brackets M Rotoplat LP 308 508 708 Important Store the components for lifting handling 4 5 4 LOADING UNLOADING RAMP ASSEMBLY Assemble the pallet loading unloading ramp Y and connect the power connector Z Rotoplat TP3 308 508 708 ...

Page 58: ... 4 that 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 Rotoplat 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 59: ...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 60: ...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 61: ...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 62: ...t 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 Rotoplat 308 508 708 Rotoplat LP 308 508 708 Rotoplat TP3 108 308 508 708 ...

Page 63: ...TIONAL 1 Remove the spool carriage U 2 Fit the frame V on the slide shaft 3 Fit the rollers W on the frame V with the suitable screws X 4 Fit the spool carriage on the frame V Rotoplat 308 508 708 PLURIBALL Rotoplat LP 308FR 508PDS 708PVS PLURIBALL Rotoplat TP3 308 508 708 PLURIBALL ...

Page 64: ...ide 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 connections have already been performed by the Manufacturer if the presser is delivered with the machine Rotoplat 308 508 708 Rotoplat LP 308 508 708 Rotoplat TP3 308 508 708 ...

Page 65: ...e floor Depending on the floor type it may be necessary before laying the machine to lay foundations in correspondence 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 Rotoplat 308 508 708 Rotoplat LP 308 508 708 Rotopla...

Page 66: ...cknowledged in the specific sector must perform the connection in accordance with the best practice and take into account all the 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 ...

Page 67: ... 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 Rotoplat 308 508...

Page 68: ...the Instructions for use Activate all the safety devices provided stop the machine and assess whether there is any 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 ...

Page 69: ...he tensioner B 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 stretc...

Page 70: ...atio 16 Fit the gear N of the new transmission gear set 17 Position the gear with the disc side P coupled with the clutch Q 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 phases make sure that coupling tabs are correctly inserted 23 Rest the plate F on the stud bo...

Page 71: ...mounted on the carriage later on This option allows the system to use a mesh spool with an FR 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 Rotoplat 308 Rotoplat TP3 308 Rotoplat LP 3...

Page 72: ...I 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 torq...

Page 73: ...y 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 Rotoplat TP3 308 508 708 ...

Page 74: ...otor 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 Rotoplat LP 308 508 708 ...

Page 75: ...ghten 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 Rotoplat TP3 308 508 708 5 8 BUBBLE WRAP SPOOL BRAKING ADJUSTMENT 1 To tension the film correctly work on the handwheel L which adjusts the spool braking Rotoplat 108 308 508 708 BUBBLE WRAP ...

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: ...ser interface 3 Cycle start button it is used to start the wrapping automatic cycle 4 Cycle stop button it is used to stop the wrapping automatic cycle 5 Reset button it is used to reset the machine before restarting it after an emergency stop or after a shut down due to the disconnection of the power supply 6 Emergency override key operated switch it is used to temporarily bypass the carriage eme...

Page 78: ...The page is displayed upon the activation of the control on the right of the various recipes from the recipes page The page displays the wrapping values currently in use and gives access to the other pages 2 Manual handling page The page displays the controls to activate the handling of functions in manual mode 3 3 1 RECIPES page The page displays the controls to activate the concerned recipe 4 Wr...

Page 79: ...79 INFORMATION ABOUT THE USE ENG ...

Page 80: ...ENG INFORMATION ABOUT THE USE 80 ...

Page 81: ...in the selected area No Name Description of the function A Display area The area displays the numerical and alphabetical characters entered B Button Activating the control will close the page and the values entered will not be saved C Button Activating the control will delete the selected character D Button Activating the control will delete one character at a time starting from the last one on th...

Page 82: ...iption of the icons Icon Description of the function 1 Lower wrapping 2 Reinforcing wrapping 3 Upper wrapping 4 Film stretch 5 Film pre stretch 6 Carriage upstroke speed 7 Carriage downstroke speed 8 Table rotation speed B Button it is used to close the programming window C Bar it is used to quickly increase or decrease the value displayed in the area E D Buttons they are used to increase or decre...

Page 83: ... it is used to program the number of wrappings at the base of the pallet The displayed number indicates the programmed value H Button it is used to program the film stretch value The displayed number indicates the programmed value L Button it is used to program the film pre stretch value only for PDS PVS carriages The displayed number indicates the programmed value M Button it is used to program t...

Page 84: ...played in the area Button it is used to display the recipes page The displayed number indicates the active recipe Area it displays the name of the active recipe Button jog it is used to move the carriage back to the lower limit switch When the carriage is at the lower limit switch the button is not displayed Press the cycle stop button to stop the movement Button it is used to display the manual h...

Page 85: ...utton hold to run it is used to activate the table counter clockwise rotation Button hold to run it is used to activate the presser arm upstroke Button hold to run it is used to activate the presser arm downstroke Button hold to run it is used to activate the creasing head upstroke Button hold to run it is used to activate the creasing head downstroke Button hold to run it is used to activate the ...

Page 86: ... pallet or at its upper end it is possible to manually perform intermediate wrapping by pressing the button A with two different modes Keep the button A pressed to stop the carriage performing reinforcement wrapping until the button is released Repeatedly press the button A to make the carriage perform as many reinforcement wrapping turns as the times the button has been pressed 1 9 turns Importan...

Page 87: ...kground function enabled B Buttons they are used to program the recipe name C Area it displays the preview of the selected pallet wrapping cycle D Buttons on the RH they are used to activate the layered cycle E Button it is used to copy the data from one recipe to another F Button it is used to display the next recipe page G Button it is used to display the previous recipe page ...

Page 88: ...ry to set a height greater than that of the product to be wrapped E Button it is used to program the delay of the stopping point of the spool carriage during the upstroke phase only with automatic stop F Button it is used to enable and disable the programming of the distance from the ground offset at the beginning of wrapping Blue background Function enabled Grey background Function disabled G But...

Page 89: ...PARAMETERS PAGE The page is used to program the machine operating parameters A Button it is used to display the production counters pallets page B Button it is used to display the H M I settings page C Button it is used to display the service page ...

Page 90: ...ounter total of the wrapping cycles performed by the machine B Area it displays the counter partial of the wrapping cycles performed by the machine C Button it is used to reset counter B The function is active only if the system is accessed by a machine operator user see the enter password page user login D Area it displays the machine operating time in days hours minutes and seconds ...

Page 91: ...n it is used to display the change password page C Button it is used to enable and disable the recipe programming mode The function is active only if the system is accessed by a machine operator user see the enter password page user login D Button it is used to display the page with the software version E Button it is used to select the language F Button it is used to display the page for setting ...

Page 92: ...B Area it displays the entered characters C Numerical keyboard D Button it is used to confirm the entered values The activation of the control is signalled by the animation of icon G E Button it is used to save the password The control is enabled only if the animation of icon G is active F Button it is used to reset the entered values The activation of the control disables the animation of icon G ...

Page 93: ...the machine operator user Icon A2 it is used to select the service support user Icon A3 it is used to select the software administrator user B Area it displays the entered characters C Numerical keyboard D Button it is used to confirm the entered password login To prevent another type of user from accessing the protected functions use one of the following procedure to perform the user logout at th...

Page 94: ...lay the status of the various electronic components of the electric control panel B Button it is used to display the MODBUS status C Button it is used to display the load cell offset D Button it is used to display the status of motors E Button it is used to update the software F Button it is used to display the machine set up general parameters G Button it is used to display the alarm log ...

Page 95: ...ess the home 1 1 page 4 If necessary press the button E to copy the data from one recipe to another 5 Select the concerned recipe 6 Set the recipe name 7 Press the button B to display the home page 1 8 Press the button C to display the wrapping cycle page 4 9 Set the recipe parameters The area D displays the preview of the selected pallet wrapping cycle 10 Press the button B to display the home pa...

Page 96: ...rop down window E where the new value can be set 6 16 MACHINE SWITCHING ON AND OFF 1 Turn the main switch A to I ON to activate the power supply The display shows RES 2 Press the Reset button B The display goes into standby mode 3 Set the cycle parameters See Cycle parameters setting 4 Perform the cycle starting operations see Cycle start and stop 5 Turn the main switch A to 0 OFF to switch the ma...

Page 97: ...l carriage starts moving from the pallet base and stops when it reaches the upper end after having performed the required number of wrapping turns at the base and at the upper end of the pallet Press the START button again to perform a second single wrapping cycle which starts from the top and goes down until reaching the pallet base See Paragraph Wrapping cycle page Rotoplat LP 308 508 708 Rotopl...

Page 98: ...hine features a presser it rises from the load 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 the cycle In this way the position of the covering shee...

Page 99: ... a new cycle Important To temporarily suspend the cycle press the Cycle stop button B Press the Cycle Start button A to restart it Rotoplat LP 308 508 708 Rotoplat TP3 308 508 708 6 20 PRESSER HEIGHT CHANGE Presser unit can be supplied with pneumatic stroke 800 or mechanical cylinder version The illustrations show the machine with the presser unit in the available versions See tables to find the m...

Page 100: ...rsion Slide shaft H mm Arm in normal position H1 mm Arm in normal position H2 mm Pneumatic cylinder with rod 2350 2200 1400 2550 2400 1400 2950 2800 1400 3250 3100 1400 6 21 1 MECHANICAL PRESSER This presser does not need any adjustment for wrapping heights above 750 mm Rotoplat LP 308 508 708 Rotoplat TP3 308 508 708 Presser unit version Slide shaft H mm Arm in normal position H1 mm Arm in normal...

Page 101: ...engraved on the spool 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 Rotoplat LP 308FR 508PDS 708PVS Rotoplat TP3 308 508 708 To allow the unwinding of the film on carriages of PVS type it is necessary to press the roller rotation button C on the sp...

Page 102: ...e spool carriage 2 Unwind the film and insert it between the rollers following the diagram depicted on the specific plate 3 Adjust the spool braking see paragraph Bubble wrap spool braking adjustment 4 Lock the film end into the suitable locking disc A on the rotary table Rotoplat TP3 308 508 708 BUBBLE WRAP ...

Page 103: ...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 104: ...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 105: ...ding 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 12 ...

Page 106: ... The diagram shows the main parts concerned by the lubrication interventions and their intervals Rotoplat 308 508 708 Rotoplat TP3 308 508 708 Spread grease over it Check the lubricant level Do not top up and or change in life lubed reduction units and gearmotors ...

Page 107: ...107 MAINTENANCE INFORMATION ENG Rotoplat LP 308 508 708 Spread grease over it Check the lubricant level Do not top up and or change in life lubed reduction units and gearmotors ...

Page 108: ... C MELLANA OIL 460 IP SPARTAN EP 460 ESSO BLASIA 460 AGIP MOBILGEAR 634 MOBIL OMALA EP 460 SHELL ENERGOL GR XP 460 BP Worm screw reduction unit Grease TELESIA 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 Lithi...

Page 109: ...ds until all condensation is let out 4 Tighten the valve C again Rotoplat LP 308FR 508PDS 708PVS Rotoplat TP3 108 308 508 708 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 Rotoplat LP 308FR 508PDS 708PVS Rotoplat TP3 ...

Page 110: ...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 111: ...ected on the pallet loading unloading ramp Remove the obstacle and press the Reset button E04 Protection alarm Intervention of safety barriers or open door Remove the obstacle and press the Reset button E30 Inverter alarm 1 Table 2 Carriage 3 Stretch 4 Pre stretch 5 Presser POWER DRIVER LOW POWER DRIVER HIGH OVER VOLTAGE MAX VOLTAGE UNDER VOLTAGE HW POWER CURRENT OVER HEAT PHASE FAIL CURRENT MAX C...

Page 112: ... 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 113: ...BLE 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 Rotoplat 308 508 708 Rotoplat TP3 308 508 708 ...

Page 114: ... 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 Rotoplat LP 308 508 708 ...

Page 115: ...emove 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 Rotoplat LP 308 508 708 ...

Page 116: ... 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 Rotoplat LP 308 508 708 ...

Page 117: ...IONING Cut off any supply to the machine power pneumatic etc so that it cannot be restarted and position it in a place that cannot be easily accessed Empty the systems which contain hazardous substances in a proper manner and in compliance with the laws in force at workplaces and with those on environmental protection 9 7 2 MACHINE SCRAPPING Scrapping must be performed by authorised centres with e...

Page 118: ...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 119: ...119 ANNEXES ENG 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 120: ...ENG ANNEXES 120 10 3 CREASING HEAD PNEUMATIC DIAGRAM Legend A Filter regulator unit B Solenoid valve C Flow regulator D Silencer E Unloading regulator F Presser actuating pneumatic cylinder ...

Page 121: ...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...