manual palletizer 825pa001

BOATO INTERNATIONAL S.p.A. a s.u. Via Chico Mendes n. 7 34074 Monfalcone (GO) Italy Tel. +39 0481711811 Fax +39 0481482360 www.boato.com - [email protected]

modif ied bitumen membrane plants

Soggetta alla direzione e coordinamento di Boato Holding S.p.A. Cap. Soc. € 520.000,00 i.v. - C.F. - P.IVA - Reg. Imp. GO 00402880314

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Automatic palletising sections for

existing production lines

and

Automatic trolley for the full pallets

transport from the palletizers to the

automatic stove mod. FT50

Customer : BITUPLAST C.A.

PROJECTS: 825.000 – 825.100

USE AND MAINTENANCE MANUAL

(ORIGINAL INSTRUCTIONS)

(ref. 825PA001.pdf)




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General information All the operations described or shown in this manual are to be considered as correct, however Boato

International S.p.A. a s.u. will not be held responsible for those operations carried out and not

reported in this manual.

Boato International s.p.a. a s.u. will not be held responsible for any accident or damage to persons

or things due to the non-observance of the safety rules. The safety rules described in this manual

integrate but do not replace the safety rules locally in force that the operators must comply with.

For clearness purposes, the instructions contained in this manual do not include any instruction not

connected to the reasonable use the machine and all its components have been manufactured for.

The instructions in this manual do not include those details that must be part of the average cultural

and technical knowledge of a machine operator. However particular features have been adopted to

prevent residual risks due to a reasonably foreseeable misuse.

Before an intervention as membrane passage, removing of the membrane roll not ejected, etc. on the

winding machine, it is highly recommended that the main switch on the power board if “OFF” or at

least the emergency push button is activated (pressed).

Before removing any mechanical and/or electrical protection make sure that the main switch on the

power board is “OFF”. Besides, make sure that the position “OFF” of the main switch is pointed out

by an apposite warning sign or key-locked.

All and any checking and/or maintenance operations that require the SAFETY PROTECTIONS TO

BE REMOVED are done under the complete responsibility of the user. It is recommended that such

operations are done by qualified and authorised personnel.

Do NOT carry out any intervention not foreseen and described in this manual. Any careless or

temporary repairs could damage to the safety and operations of the machine.




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The machines are not dangerous for the operator if it used according to the instructions supplied by

Boato and in condition that the safety devices be maintained constantly in function.

This sheet has the purpose to attest that at the receipt of the machine:

the safety devices are efficient

that the machine is supplied with the use and maintenance manual

that the operators get the responsibility to follow it step by step

note:

if our machine has small anomalies we kindly request to you to lay off the utilization and to

inform us tempestively, this will permit us to improve your production and our service

this manual does not contain detailed descriptions for those procedures, safety principles and

maintenance operations considered as standard procedure in your factory.

It is important to notice that this manual contains some directions that must be strictly followed

to avoid injury to persons, or damage to the machinery thus making it a non-save equipment.




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Premise

Kind customer premised that for this kind of machinery does not exist specific legal norms, in any

case these machines have been designed and manufactured according to the Machinery Directives

and in particular according to the following:

Machinery Directive 2006/42/EC (ex Machinery Directive 98/37/EC) and following

modifications

Directive 2006/95/CE, Low Voltage, and following modifications

Directive 2004/108/CE, Electromagnetic Compatibility

Directive 97/23/CE (PED - Pressure Equipment Directive), if applicable

besides the following harmonise/national standards have been applied:

Standard UNI EN ISO 12100: 2010 Safety of machinery. General principles for design – Risk

assessment and risk reduction

Standard CEI EN60204-1 Safety of machinery. Electrical equipment of machinery.

Part 1.

Standard UNI EN ISO 13857: 2008 Safety of machinery. Safety distances to prevent hazard

zones being reached by upper and lower limbs

Standard UNI EN ISO 13732-1: 2009 Safety of machinery - Ergonomics of the thermal

environment - Methods for the assessment of human

responses to contact with surfaces - Part 1: Hot surfaces

Standard EN ISO 13849-1:2008 Safety of machinery - Safety-related parts of control

systems - Part 1: General principles for design




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Aim of the manual

This manual is intend as a guide for the correct and use in safety of the machine, and for its rational

maintenance. Also general instructions for the demolition and elimination are included in this

document.

It is therefore aimed for the following:

- operators, the manual is intend as the most complete possible guide with instructions on

machine operation and how to carry out simple checks and how to operate in compliance with

accident-prevention regulations

- maintenance staff, the manual provides a detailed programme and instructions of which

interventions are needed to ensure better and long-lasting working period

- anyone who has to work with the machine in order to guarantee to him the best safety

conditions.

Use and preservation of the manual

This manual must be considered an integral part of the machine, and must accompany it in the event

of sale.

It must be kept in a place where it can be easily available for consultation.

In case of loss, please promptly contact the manufacturer, who will be glad to supply another copy.

The manufacturer reserves the right to carry out changes to the production and to the manual,

without any obligation to update the previous products and manuals.

No part of this publication can be re-produced without a manufacturer’s authorisation in writing.

Important warnings for safety

Scrupulously observe the following warning indications:

!CAUTION

Means the possibility of injuries to persons or damage to the machinery if the

instructions given are not totally observed

DANGER

Means high possibility of serious injury or death to persons if the instructions

given are not totally observed

NOTE :

provides useful information

It is assumed that the supplied machine will have to be installed in an electromagnetic environment

of industrial type, complying with the emission and immunity values in accordance with the rules in

force.




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Reference data

Sections of machinery: Automatic palletising sections for existing production lines

Job numbers: 825.000 – 825.100

Serial numbers: Palletizers: 825.005 – 825.102

Automatic trolley: 825.103

Year of manufacturing: 2013

Customer: BITUPLAST, C.A.

Venezuela

Technical assistance requests

In case you need more information, or if you have problems to realise some matters of this manual,

please contact the customer assistance office at the following address and telephone/fax number:

Boato International S.p.A. a s.u.

Via Chico Mendes, 7 - Zona Industriale Schiavetti -

34074 Monfalcone (GO) - Italy –

Telephone +39 0481/711811, Fax +39 0481/482360

U.R.L.: http://www.boato.com

EMAIL: [email protected] (Technical Department)

[email protected] (General Information)

http://www.boato.com/

mailto:[email protected]

mailto:[email protected]




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Transport, lifting and storage

General instructions

In case Boato doesn’t carry out the assembly of the machinery, the customer has to define with

Boato the manovering operations. The personnel performing these operations must be equipped

with helmet, gloves, and quick release footwear type complete of protection reinforced metal toe,

anti perforation and anti-slip sole, and complete overalls (individual protection equipment).

Moreover, anyone handling equipment for moving it, for example cranes, fork-lift trucks, bridge

cranes, must be qualified for this job.

All the accident-prevention and safety regulations in force in the country and place of work where

the machine works must be scrupulously observed.

The number of the persons necessary to guarantee that these operations are performed in absolute

safety, must never be less than two.

Before any handling, always make sure that the lifting devices and their accessories (cables, hooks

forks etc.) are suitable for such operation.

Keep a safe distance from suspended loads and make sure that the lifting cables and ropes are in

perfect condition and correctly inserted in their appropriate hooks.

DANGER

Skilled personnel, with suitable equipment, scrupulously respecting the safety

rules must carry out the transport and lifting operations.

Transport

In case the machine have to be transported by sea, the packing consists of a first wrapper of plastic

material containing salts against humidity, and on the outside a specially designed wooden packing

case.

When necessary the machine can be divided into parts for the transport.

In case of transport by truck, the machinery may be loaded onto the bed of the truck fixed to it by

means of tie rods and clamps.

The machine can be also loaded directly onto the truck bed, placing it on a wooden pallet, in such a

way as to allow its movement by forklift trucks.

Lifting

The machinery can be lifted by means of fork-lift, inserting the forks under the base of the machine,

in such a way as to balance the weight or by means of a crane or overhead crane pay attention to

hook the machine properly in order to balance its weight.




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Storage

If the machine remains inactive for a long period, it is advisable to proceed as follows:

- if it is packed in a wooden case or in a container with internal protection against humidity, this

will be sufficient for long period of storing;

- if the machine is not packed or has been already used for a periods, before to be stored has to be

cleaned and protected by coating before with a special protective oil and then wrapping it with

sheets of plastic containing salts against humidity.

Machine noise The machine has been designed and built in such a way as to reduce noise at source.

However, if this machine is installed in reverberated environment or in presence of other noise

sources, and the level of daily exposure of the operator, if continuously exposed, is higher than 80

dB, than risk conditions can occur.

In this case the employer is obliged to provide the workers with individual suitable protection

devices (earmuffs, ear plugs).

Safety analysis

The customer will choose the machine’s operators and the personnel indicated for the maintenance

operations and for any other interventions on the machine.

The customer has to inform its personnel regarding the possibility of risks during the working

operations and which individual safety protections have to be adopted during the production.

Personnel instructions

The personnel indicated for the use of the machinery must:

- know what mentioned in the manual;

- observe the suggestions regarding the individual safety protections to be adopted.

Only this personnel can approach to the machine only after to have consulted the use and

maintenance manual in order to observe all the safety instruction described.

The manual has to be always at their disposal and has to be acquainted to the new personnel in case

of substitution of the same.




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Individual protection equipment The personnel assigned has to be equipped with the following individual protection equipment:

- quick release footwear type complete of protection metal toe,

anti perforation and slip sole EN 20345

- complete overalls manufactured in order to avoid that the clothes

get caught on the movable parts EN340

- helmet with glasses for head and eyes protection EN 397

- protection gloves (for thermal risks) EN407

- other if necessary

- adequate fire extinguishers always available

The above individual protection equipment has to be supplied from the customer to the personnel

assigned for the use, maintenance or any other intervention on the machine.

IMPORTANT: in case of emergency situations, the operator presses the push-button “EMERGENCY

STOP” in the control board.

Pushing this push button the machine or any of its part is not in operation and all the electrical

devices on the machine are turned off.

For the start up of the machine again it is necessary to rotate the "EMERGENCY STOP" push button

in order to release it.

Before to start to carry out any operation make sure that the main switch on the power board is

“OFF”.

CAUTION: please pay the maximum attention to the interventions on pneumatic acted movements

due to the risk of residual energy. Before to carry out any intervention on pneumatic movements, to

disconnect the pipes of compressed air.

DANGER

In case of ordinary/extraordinary maintenance ensure to switch OFF the

main switch on the electric power board.




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Fire prevention

It is forbidden to work near to machine utilising welding machine or grinders or any other tools

which can produce flames or localised heating. In case it is necessary to utilise these tools for

maintenance or any other intervention, it is obligatory to follow strictly the following:

- take off the electricity to the machinery

- protect the parts of machinery from the fall of sparks and hot chips by apposite shields non-

flammable

- to have available a fire extinguishers

This personnel instructed and authorised from the customer have to be equipped with the above

mentioned individual protection equipment.

In any case, these jobs have to be done always in the presence of the personnel assigned for the fire

prevention equipped with fire extinguishers.

General notes for a proper utilisation of the unit

The customer will choose the personnel indicated for the management and maintenance operations

and for any other interventions on the machine.

All the fonts of danger have to be illustrated to the personnel by the customer.

Only this personnel can approach to the machine and has to be protected with the individual safety

protections.

This manual has to be always at their disposal and have to be acquainted to the new personnel in

case of substitution of the same.

All the operations for the maintenance, extraordinary intervention for reparation or modification,

cleaning operation must be carried out strictly with the machinery stopped with the electric voltage

supply taken off.

In case it is necessary to use welding machine or any other tools, which can produce flames or

localised heating, they have to know all the residual risks due to the use of these tools (see the

chapter “Fire prevention”).

These jobs have to be done with the presence of the personnel assigned for the fire prevention

equipped with fire extinguishers.

At the end of the shift or therefore at the end of the working day, the following components have to

be cleaned:

- all the photocells (transmitter and receiving)

- check and eventually clean all the transmissions on the machine

At the end of the week the following components have to be checked:

- the proper functioning of the EMERGENCY STOP on the machine and its relative control board

- the proper functioning of the limit switches and safety switches




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The control and power board during the normal functioning of the line has to be always closed.

Only the authorised personnel can approach to the control board with its relative key.

In order to allow reaching easily the EMERGENCY STOP, do not leave any objects close to control

boards that can cause encumbrance.

For modifications to the machine, which can modify the functioning concept of the machinery,

and/or structural modification on the same, we suggest consulting the manufacturer before.

After to have utilised the fire extinguishers take care to substitute the same immediately.

DANGER

In case of ordinary/extraordinary maintenance and/or

ordinary/extraordinary intervention or reparations ensure to switch OFF the

main switch on the electric power board.

!

ATTENTION

All the maintenance operations, reparations, or intervention for putting in

operation the machinery, cleaning operation and functioning control of the

components of the machinery have to be performed strictly by authorized

personnel instructed by the customer and must know what is mentioned in

this manual.

!

ATTENTION

Pay attention when active the pneumatic manual valves. Keep your hands

away from the component pneumatically acted.

DANGER

It is strictly forbidden any intervention of reparation, modification etc. on

the electric control and power boards if they are supplied by electric

current.

Any type of intervention on the electric control and power boards has to

be done by skilled personnel and authorized by the customer




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Machinery demolition instructions

For the demolition and scrapping of the machinery, please consider the following information:

- the operation of disassembling and demolition have to be carried out by qualified personnel

- disconnect all cables and wires for the current supply of the machinery before to start to

disassembly the machinery

- discharge, storage and consequently eliminate the special substances of “special type” or

“toxic- injurious” as oil on the gearboxes, compound, residue of compound in the tank,

electronic components in the control and power boards. These operations have to be done

according to the standard rules in your country.

- disassemble the machinery taking care to separate the different materials in consideration of

their chemical composition (steel, aluminium, plastic et cetera).

All of these operations have to be done in consideration of your safety standard rules of your

country

Safety norms adopted

On the engineering and manufacturing of the machinery the following norms have been considered:

- for the platform, parapet and staircase prEN547-3

- for the control/power boards CENELEC file EN60204-1

- for the safety distance UNI EN 294

The platforms, protection guards, parapets have been

painted with the colour: yellow RAL 1007

The mobile parts of machinery which may cause risks,

have been painted with the colour: orange RAL 2010




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Risks residual - prevention

The personnel indicated for the use of the plant, for the maintenance operations and for any other

interventions must:

- know what mentioned in the above paragraphs

- observe the suggestions regarding the individual safety protections to be adopted

Only this personnel instructed and authorised from the customer can approach to the working area.

In any case all the working operations such maintenance operations, reparations or other can be

done with the machinery stopped and without electricity.

In case it is necessary to use welding machine or any other tools, which can produce flames or

localised heating, they have to know all the residual risks due to the use of these tools.

These jobs have to be done with the presence of the personnel assigned for the fire prevention

equipped with fire extinguishers.

!

CAUTION

In case of maintenance or any other intervention on the machinery (less

than those of normal operation of the machine during production), we

recommend to take off the electricity to the machinery.

These jobs have to be done with the presence of the personnel assigned for

the fire prevention equipped with fire extinguishers

!

CAUTION

For any cleaning or maintenance operations advise the operators that work

in the area where the machine is installed at the beginning and at the end

of these kind of works

Risks residual - localisation

Even if the personnel utilised for operating on the machinery (and for any other intervention like

maintenance etc.) is qualified, instructed and equipped with the individual protection equipment

notice that even if on the machinery are installed safety protections there are risks residual due to

the following factors:

Parts in motion

Closed the area where are installed the movable parts of the “Automatic palletising unit” with

fixed protections (protection nets) to avoid the access of the operator into the dangerous area of

this section when the machine is in production.

The access in the are closed by the protection nets is allowed through safety doors. If one of the

doors is opened, all the operations of the area are stopped. To restore the operation it is necessary

to act on the apposite reset push-button.

Installed safety ropes in correspondence of the connection benches of the existent machinery. If

one of the safety barriers is activated, all the operations which involve dangerous movements of

the components in the related areas are stopped, as in emergency condition.




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Installed a safety barrier with muting system in correspondence of the outlet of the “automatic

palletising unit” in order to avoid the access of the operator in the area where the dangerous parts

of the palletiser are moving.

Automatic trolley for full pallets transport equipped with safety laser scanner to stop the

translation movement in case of detection of obstacles in the way of the trolley.

Cylinders/rollers in motion The cylinders during the production turn and have to be observable from the operators during the

membrane production.

Even if during the production it is not necessary to approach these cylinders, during the design and

manufacturing of them we have

applied the following safety standards:

reduction of the cylinders/rollers revolutions as much as possible

elimination of rotating projecting parts

installation of protections, guards on the cylinders/rollers transmissions

DANGER

Do not remove the safety devices.

DANGER

Do not work on moving members

It is compulsory that only qualified personnel approaches and controls

the machinery




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DANGER

Pay attention to the hands

DANGER

In case of malfunctioning of the machinery or emergency situations

push the button “Emergency stop” installed in the control board of the

section.

After having solved the problem, in order to start the machine again,

push-button has to be rotated to be released.

This push-button stops any operation of the machine.




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EC Declaration of Conformity of the Machinery (within the meaning of Machinery Directive 2006/42/EC)

(see the separated documents)




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Identification label on the machine The identification plates shown here below are fixed on the machinery frames:

Automatic palletising unit complete of empty

Serial number:

via Chico Mendes, 7 - Z.I. Schiavetti - 34074 Monfalcone (Italy)

tel. +39 0481 711811 - fax. +39 0481 482360 - www.boato.com

Job number: 825.100

by Boato International S.p.a. a s.u.

S.L. 825


825.102

Plant andmodel type:

pallets feeding unit and connection benches

Automatic palletising unit complete of empty

Serial number:



Job number: 825.000


S.L. 825


825.005


pallets feeding unit and connection benches

Automatic trolley for the full pallets transport

Serial number:



Job number: 825.100


S.L. 825


825.103





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Working area and Overall dimensions

Refer to the drawing 825.PF.002_01, extracted hereinafter:

Center shaft

1410 mm. from

the floor

A

A

Enrrolladora-2

Enrrolladora-1

Plataforma

de

Enrrollador

Center shaft

1410 mm. from

the floor Plataforma

de

Enrrollador

1.1

1.2

1.3

2.2

2.3

3.1

4.1

2.1

- Automatic palletising unit with Empty pallets loading system and connection benches: refer

to this manual

- Automatic trolley for the full pallets transport from the palletizers to the automatic stove

mod. FT 50: refer to this manual

- Automatic stove mod. FT 50 operating by thermoretractable film (with manual application

of the plastic hood): refer to the Operating and Maintenance Manual from Company Bocedi

AUTOMATIC

PALLETIZER P2 AUTOMATIC

PALLETIZER P1

AUTOMATIC

TROLLEY




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Technical description of the equipment and functioning description

Two connections benches are provided for each of the two Automatic palletising unit sections:

- the first connection bench consists of a frame completely welded supporting a motorized

belt conveyor for transferring the roll coming from the existent winder to the next rollers

connection bench. In case of change of production with finished membrane rolls with

different diameter, to avoid the jump of the membrane rolls ejected from the winder to this

bench, two idle rollers vertically adjustable are provided;

- the second connection bench consists of frames supporting a set of motorized transporting

rollers to move the roll of finished product to the next inclined belt transport conveyor. This

bench is provided with a pivoting movement pneumatically acted in order to allow the

discharge of the roll onto the mentioned inclined belt transport conveyor.

The roll of membrane is transported by the inclined belt transport conveyor and then is released

with a lifting system onto the palletiser turning table.

The lifting system is moved by a pneumatic cylinder acting softly with a mechanical leverage to

permit the correct positioning of the roll onto the turning table as well as its compactness with

respect to the other rolls already on the turning table.

When a prefixed number (complete row) of rolls are set on the turning table, it rotates automatically

by 90°, thanks to an inverter controlled AC motor, and releases the row of rolls in a vertical position

on the pallet.

The number of rows as well as the number of rolls per row can be set into the touch panel HMI

located on the control board of the machine, described further on in this manual. The software of the

HMI shows graphically the pallet pattern so as to give an immediate sight of the recipe to the

machine operator.

The pallet is situated on a motorized trolley, which is able to move from its loading position

(creation of the pallet) to its unloading position (full pallet unload and empty pallet loading).

During the loading phase, the trolley is moved progressively until it is completely loaded.

Automatically, from the empty pallet section (10 pallet capacity), an empty pallet is loaded onto the

trolley during the unloading (full pallet) phase.




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The HMI (human-machine-interface), located on the electrical control board of the machine, is of

the touch screen type has a graphic display LCD colours and where all the parameters and cycle

values are viewed and controlled. All these parameters are recordable.

With the HMI it is possible to set the graphic layout of the pallet, named Pallet Recipe (PR). The

PR consists of the following parameters:

- Number of rows on the pallet.

- Number of rolls for each row.

- Disposition (rectangular or staggered arrangement) of the rows in the pallet:

During the setting of the recipe the display shows in real time the layout of the pallet while being

created, so that the operator can appreciate what is the result of the setting.

In this phase there is also an automatic control of the numbers of rolls per row being input by the

operator so as to avoid impossible configurations and human mistakes.

The PR can be saved in order to be easily recalled at any time according to the membrane being

manufactured and the rolls geometry for them.

During the loading of the rolls in the palletiser, in the home page of the display there is a drawing of

the pallet with circles that represent the rolls. A circle in white colour indicates that the roll is not

placed in the pallet. As soon as the rolls are positioned in the pallet, the colour of the circles

becomes green, and when a row of rolls is completed on the pallet, all the circles of that row

become black. When the pallet is completed, all the circles are black in the display.

40,2

15

405

In case of manual positioning or removing of rolls

in the pallet by your personnel, those physical

operations must be reported in the HMI by the

operator, in order to have in the display the

correct situation of the pallet in the machine.

RECTANGULAR STAGGERED




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The display can also show:

- The weight of the rolls (if rolls weighing unit is installed in the machinery).

- The partial counting of the finished rolls fabricated.

- The total counting of the finished pallets fabricated.

Protection for every operation (motor) is given by thermal magnetic relays. On the instrument

board there are all the control buttons and warning lights to control each phase of the palletising

cycle. The electrical components are SIEMENS.

The electrical power board is contained in a RITTAL cabinet and is built according to

CENELEC standards.

All the functions are controlled by a PLC (programmable logics controller).

The safety protections are the following:

- Set of security light barriers with emitter and receiver at the entrance and exit of the

machine operating area.

- Set of net fence guard to install all around the line

- Set of key limit switches for fence guard openings for operators access (maintenance).

The Automatic trolley is composed of a tubular frame completely welded supporting a belt of

metallic tubular motorised by a gearmotor assembled on a trolley driven by a second gear motor,

foreseen for running on runways.

It is used for transferring the full pallets coming from the two new palletizing sections to the

automatic stove. Runways, supports for the festoon cable are provided for the control of the

machine. The length of the runways is 8mt approx. designed for running with high speed for

servicing the two production lines (according to this runways length).




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Mechanical features:

Standard pallets EUR and EUR2: 1)

1200x800mm - 1200x1000mm

Pallet minimum height: 1)

120mm

Pallet maximum height: 1)

160mm

Pallet maximum height with rolls: 1500 mm

Maximum weight of the pallet: 1200 kg

Compressed air: 6 bar

Electric voltage: 440 V, 3 phases – 60 Hz

Auxiliaries voltage: 24 VDC

1) In case different Customized pallet sizes are required, the approval from Boato

International technical department is necessary.




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Adjustments and preparatory operations

DANGER

Before any preparatory operation is carried out in the machine

switch OFF the main switch on the power board.

!

ATTENTION

All the maintenance operations, reparations, or intervention for

putting in operation the machinery, cleaning operation and

functioning control of the components of the machinery have to

be performed strictly by authorized personnel instructed by the

customer and must know what is mentioned in this manual.

DANGER

Before of any intervention for putting in operation the

machinery after a production stop, cleaning operation or

functioning control of the components of the machinery to be

sure that the main switch on the power board is OFF

DANGER

Before of any ordinary/extraordinary intervention or

reparations on the machinery the machinery must be stopped

and without electricity

!

ATTENTION

Pay attention when active the pneumatic manual valves. Keep

your hands away from the cylinders.

DANGER

It is strictly forbidden any intervention of reparation,

modification etc. on the electric control and power boards if they

are supplied by electric current.

Any type of intervention on the electric control and power boards

has to be done by skilled personnel and authorized by the

customer




- 24 -

Palletizing unit preparatory operations

Before running the palletizing unit for the first time, carry out the following operations:

- Trolley brake adjustment

The trolley brake have to be adjusted acting to the knurled knob pos. A2 (fig.2) in order to

increase or decrease the braking effect considering the requirement.

fig.2

A2




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- Sensors adjustment of the roll lifting arms

The roll lifting arms are foreseen with 2 sensors pos. A3 and B3 (fig.3 – typical picture).

One of these reads the lifting arms position when they are placed in lower position, the other

one reads the lifting arms when they are positioned in the higher position.

- Sensors adjustment of the roll pusher

Two sensors are assembled on the pusher (one limit switch for the return pos. A4 (fig.4) and one

limit switch for the exit pos. B4 (fig.4).

After to have adjusted them the first time it is not necessary to adjust them again.

fig.3 – typical picture


A3

B3

A4

B4




- 26 -


- Adjustment of the flow regulators of the pneumatic cylinder and membrane roll lifting

arms.

Two flow regulators are assembled on the pneumatic cylinder of the membrane roll lifting arms

pos. D5 (fig.5), one for the rise and one for the descent of the arms.

The flow regulators are necessary in order to adjust the lifting and lowering speed of the roll

lifting arms.

- Adjustment of the turning table width

The turning table width is modified

by the opening and closing of the

turning table side.

This movement is performed by

means of a gear-motor.

The sensor pos. A6 fig. 6 are fixed

and the distance from them is set in

the operator panel. When the set

distance is reached, the mentioned

motor is stopped.

In order to move the sensor, the

following operations are necessary:

- loose the relative handles

- move the sensors in the desired

position

- lock the handles


D5 D5

A6 A6




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- Adjustment of mechanical stop

The adjustment of the mechanical stops pos. A8 (fig.8) occurs acting on hand-wheel pos B8

(fig.8). This mechanical stop is for the regulation of the displacement of the first row of rolls

from the edge of the pallet.


B8

A8

A8




- 28 -

- Adjustment of the lower mechanical stops on the trolley

The lower stop of the pallet on the trolley can be moved vertically and toward the palletizer.

For the vertical adjustment:

- loose the two screws pos. C8 (fig.8A)

- move vertically the stop pos. A8 (fig.8A)

- lock the two screws pos. C8 (fig.8A)

For moving the stop toward the palletizer:

- loose the two screws pos. B8 (fig.8A)

- move the stop A8 (fig.8A) toward the palletizer

- lock the two screws pos. B8 (fig.8A)

fig.8A - typical

C8

A8

B8

C8

B8




- 29 -

- Adjustment of the pallet stops under the palletizing unit

Under the palletizing are assembled two stops pos. A9 (fig.9) in order to align and center the

pallet.

It is necessary to adjust these stops every time the pallet dimension are changed.

The transversal adjustment is performed by means of a mechanical block, the longitudinal

adjustment by means of pneumatic cylinders.

In order to adjust the stops, the following operations are necessary:

- switch OFF the main switch on the electric power board;

- loose the fixing screws (to permit the transversal position adjustment) of both stops;

- exclude the trolley exit positioning "EXIT TROLLEY" in "0" position;

- put a empty pallet on the trolley;

- switch ON the main switch on the power board and push the "START-UP MACHINE" (the

ray of action of the machine have to be free from the operators);

- return the trolley manually acting on the "RETURN TROLLEY" selector till the trolley is

completely gone back;

- switch OFF the main switch on the power board;

- move the stops pos.A9 (fig.9) close to the pallet (attached);

- exclude the trolley return positioning "RETURN TROLLEY" in "0" position;



- move out the trolley manually acting on the selector "EXIT TROLLEY" till the trolley is

completely gone out;

- switch OFF the main switch on the power board;

- lock the relative screws;

- in order to adjust the damper action of pneumatic cylinders for the longitudinal stop, adjust

the air pressure by means of the related pressure regulators (shown in fig. 9A).

Also flow regulators are provided to avoid rough movement of the cylinders when these

ones opened or closed, during the damper action;



- let return the trolley manually;




- 30 -


At this point the machine is ready to start to work normally.

fig.9A – typical picture

A9 A9 A9

A9




- 31 -

- Adjustment on the empty pallet loading system

This unit has a capacity of housing 10 empty pallets.

Optional feature: the machine is complete of a movable “wall” (side) capable of reducing and

enlarging the empty pallet housing area manually. The machine operator can

modify the housing area acting on the locking devices A9B (fig.9B), if

installed, and moves the movable side and then fixes again the locking devices.

The lift arms pneumatically drive can be moved vertically according to the

height of the pallets to be loaded. For such purpose loose the fixing bolts B9B

(fig.9B) and move up/down the lifting arms.

fig.9B

A9B

B9B

B9B




- 32 -

- Adjustment of the belt tension on the trolley

In order to adjust the belt tension on the trolley, the following operations are necessary:

- loose the relative nut pos. B10 (fig.10)

- adjust the screw pos. A10 (fig.10) till the belts are loosed

- lock the relative nut pos. B10 (fig.10).

- Replacement of the belts on the trolley

In order to replace the belts on the trolley, the following operations are necessary:

- loose the relative nut pos. B10 (fig.10)

- adjust the screw pos. A10 (fig.10) till the belts are loosed

- replace the old belts with new belts

- adjust the screw pos. A10 (fig.10) till the belts are stretched

- lock the relative nut pos. B10 (fig.10).


B10 A10




- 33 -

Palletizers Controls on Control Board – Functions Description Here below are described the controls installed in the control board of the Automatic palletising unit

with automatic empty pallets feeding unit.

fig.11

01

02 03 04

05 06 07 08 09 10 11

12 13 14 15 16 17

18 19 20 21 22




- 34 -

Here follows the description of the controls installed in the control board.

OVERVIEW

In this page a top view representation of current pallet configuration is available, as well as actual

alarms, rolls and pallet data.

Each circle is a roll. Rolls color code is the following:

BLACK – Rolls already on pallet;

GREEN – Rolls on pallettizer;

WHITE – Rolls not yet on pallettizer/pallet;

By clicking on a circle, the operator is able to change rolls count to match real value if, i.e., a

manual load/unload has been made:

A – PREVIOUS ROW: Change previous row rolls count. This operation has no consequences on

the machine.

B - ACTUAL ROW: Decrease actual rolls count on pallettizer by 1. After this operation, the green

circle will become white.

OPERATOR PANEL HMI-TOUCH PANEL TYPE

POS. 01 FIG.11

B

C

D

A




- 35 -

C – ACTUAL ROW: Increase actual rolls count on pallettizer by 1. After this operation, the white

circle will become green.

D – NEXT ROW: This row can not be modified.

ROLL WEIGHT: Roll weight of last roll. Can be clicked to open the WEIGHT RESET page.

PALLETS COUNT: Partial pallets count. Can be edited.

TOTAL PALLETS: Total pallets count. Can not be edited.

RECIPES: This button opens the RECIPES page.

USER: This is a BOATO staff button only.

ALARMS SUMMARY: See alarms section for details.

ROW-1: This button allows the operator to reduce the actual row number (B).

: This flag allows the operator to change the current language.

RECIPES

In this page the operator is able to TRANSFER/EDIT/DELETE recipes.

TRANSFER: This button allows the operator to download the selected recipe to the PLC.

EDIT: Open the EDIT RECIPES page.

DELETE: The operator can delete the selected recipe using this button.

MENU: Go back to overview page.




- 36 -

EDIT RECIPE

In this page the operator can CREATE/EDIT recipes.

A – RECIPE PREVIEW: This is a on the fly preview of actual recipe. By editing number of rolls

and/or shift, the circles will appear/disappear or shift to reflect the final pallet output.

RECIPE CODE : This is a unique number for actual recipe. It cannot be edited.

RECIPE DESCRIPTION: The description of actual recipe can be edited in this field.

N ROW: Number of the row.

N ROLLS : Number of rolls in the row. If there is an error in the configuration of the pallet, this

field becomes red.

SHIFT: Select YES if a shift for this row is required. The corresponding circles in the preview will

be shifted as well.

SHIFT (mm) : Set the turning table width by means of the values of the distances of the membrane

roll edge from the beginning of the turning table, respectively with the turning table (SHIFT) in

open and closed configuration.

FLAP: Select YES if the flap is required for this row. This value does not affect the preview.

SAVE: Save the actual recipe. A description must be entered in order to perform this operation

successfully. If there is an error in the configuration of the pallet, this button is not available.

LOAD: Load a recipe.

BACK: Go to previous page.

A




- 37 -

ALARMS

When an alarm occurs, his description will appear in the overview alarms summary table.

The alarm is still active and has not been acknowledged yet.

The alarm is still active and has already been acknowledged.

The alarm is returned but has not been acknowledged yet.

When an acknowledged alarm returns, it disappears from the overview alarms summary table.

ACK: The operator must use this button to acknowledge an alarm.

HIST ALARMS: This button opens the historical alarms page.




- 38 -

In the full-pallet unloading area a safety device is installed. This type of safety device is provided

with photocells and safety barrier and detects if it is a pallet to pass through the device or an

operator, on the basis of the covered areas and of the sequence and time of interruption of the

photocells and barrier (called “muting” sequence). In case of intervention of the barrier, the light of

the push button (pos.03) turns ON and the moving parts of this working area stop. To restore the

safety barrier is needed to push the reset button (pos.03). During the normal passage of the pallet, a

yellow blinking light is switched ON at one side of the safety barrier, on the top.

In case it is necessary to manually move away from the palletizer the full pallet, in order to pass

through the barrier, it is necessary to push the OVERRIDE button (pos.02) and hold it, then push

the reset button and move the pallet with manual controls (described further on). In case the

photocells are not covered, it is necessary to cover them manually.

This warning light flashes in case a motor of the machinery is in overload condition.

Check and solve the problem that caused the overload and restore the relative magnetic thermal

relay.

Positioning this selector in position “MAN” the operator activates the motor of the belt conveyor

which transfers the finished rolls from the existing automatic winding machine of the production

line to the second connection bench. When the selector is released it goes back automatically to its

centre “0” position. Positioning this selector in position “AUT” the motor is activated automatically

according to the production cycle.

SAFETY BARRIER MUTING BUTTON AND RESET PUSH-BUTTON

POS. 02-03 FIG.11

THERMAL INTERVENTION WARNING LIGHT

POS. 04 FIG.11

FIRST CONNECTION BENCH

SELECTOR MAN-0-AUT

POS. 05 FIG.11




- 39 -

Positioning this selector in position “MAN” the operator activates the motor of the rollers conveyor

which transfers the finished rolls from the first connection bench to the following inclined belt

transport conveyor. When the selector is released it goes back automatically to its centre “0”

position. Positioning this selector in position “AUT” the motor is activated automatically according

to the production cycle.

Positioning this selector in position "MAN", the pivoting movement (pneumatically acted) of the

second connection bench which discharges the roll onto the inclined belt transport conveyor is

activated even if the roll is not present in the bench.

When the selector is released it goes back automatically to its centre "0" position.

Positioning this selector in position "0", the pivoting movement is excluded.

Positioning this selector in position "AUT", the pivoting system discharges the roll automatically

onto the inclined belt conveyor according to the production cycle.

Positioning this selector in “MAN” position the inclined belt conveyor advances of one step. When

the selector is released it goes back automatically to its centre "0" position.

Positioning this selector in position "0", the inclined belt conveyor is excluded.

Positioning this selector in “AUT” position the inclined belt conveyor moves automatically

according to the production cycle.

SECOND CONNECTION BENCH

SELECTOR MAN-0-AUT

POS. 06 FIG.11

SECOND CONNECTION BENCH – PIVOTING

MOVEMENT

SELECTOR MAN-0-AUT

POS. 07 FIG.11

INCLINED BELT CONVEYOR

SELECTOR MAN-0-AUT

POS. 08 FIG.11




- 40 -

Positioning this selector in position "MAN", the two-arms system move even if the roll is not

present on the holding frame that holds the membrane roll discharged from the inclined transport

conveyor.

The row counter roll is increased by 1 unit every time the arms make the lifting operation. When the

selector is released it goes back automatically to its centre "0" position.

Positioning this selector in position "0", the rolls lifting arms are excluded.

Positioning this selector in position "AUT", as soon as the photocell reads the presence of the

membrane roll on the holding frame at the end of the inclined conveyor, the two-arms system

withdraws the roll and put it on the turning table of the palletizer.

The row counter roll is increased by 1 unit every time the arms make the lifting operation.

The arms do not lift the roll neither in manual neither in automatic mode when the turning table of

the palletizer is not in horizontal position and when the quantity of the rolls on the turning table is

not lower than the number of rolls selected for that row.

Positioning this selector in position "MAN", the turning table of the palletizer will perform the

turning operation only if the lifting arms are in lower position and the trolley is gone back. When

the selector is released it goes back automatically to its centre "0" position.

The turning table stops when the it finds the pallet (an electronic barrier stops gradually the rotation

movement) or when the turning table goes down till to reach the limit switch.

When the turning table turns completely and the selector "TURNING TABLE RISE" is in "AUT"

position , the turning table goes back in its horizontal position automatically.

Positioning this selector in position "0", the turning table descent is excluded.

Positioning this selector in position "AUT", the turning table turns every time the pre-set value is

shown on the display (turning table full).

If the trolley does not go back, the turning table does not work.

If the turning table does not find any pallet on the trolley, it goes back automatically in its

horizontal position if the selector "TURNING TABLE RISE" is in "AUT" position.

In order to release the turning table it is necessary to perform a manual turning operation taking care

to place a pallet before.

MEMBRANE ROLL LIFTING ARMS SELECTOR MAN-0-AUT

POS. 09 FIG.11

TURNING TABLE-DESCENT SELECTOR MAN-0-AUT

POS. 10 FIG.11




- 41 -

Positioning this selector in position "MAN", the turning table will rise only if the lifting arms are in

lower position. When the selector is released it goes back automatically to its centre "0" position.

Positioning this selector in position "0", the turning table rise is excluded.

Positioning this selector in position "AUT", the turning table rise will be performed when the roll

pusher has carried out its function or when the turning table does not find any pallet on the trolley.

Positioning this selector in position "MAN", the roll pusher will push the rolls on the pallet, only if

the turning table is in vertical position. When the selector is released it goes back automatically to

its centre "0" position.

Reached the limit switch the roll pusher goes back.

If the selector is in position "0" the roll pusher is excluded, the turning table does not rise if the

selector "TURNING TABLE RISE" is in position "AUT".

Positioning the selector "ROLL PUSHER" in position "AUT", the pusher will push the rolls on the

pallets when the turning table will be in vertical position. After this it goes back automatically.

Every time the roll pusher start to go back, the counter rows is increased by 1 unit.

The turning table start to rise if the selector "TURNING TABLE RISE" pos. 8 fig. 11 is in "AUT"

position.

Positioning this selector in position "MAN" with the turning table in horizontal position, the trolley

start going out till to reach the limit switch. When the selector is released it goes back automatically

to its centre "0" position.

Positioning this selector in position "0" exit trolley is excluded.

Positioning this selector in position "AUT" with the turning table in horizontal position, the trolley

start going out according to the pre-set value of the rows, shown on the display pos.1 fig. 11 (pallet

full).

TURNING TABLE - RISE SELECTOR MAN-0-AUT

POS. 11 FIG.11

ROLL PUSHER SELECTOR MAN-0-AUT

POS. 12 FIG.11

EXIT TROLLEY SELECTOR MAN-0-AUT

POS. 13 FIG.11




- 42 -

Positioning this selector in position "MAN" with the turning table in horizontal position, the trolley

start going back till to reach the loading position and stops after that you must put the selector to

“0” and again in “MAN” to reach the internal proximity switch. When the selector is released it

goes back automatically to its centre "0" position.

Positioning this selector in position "0" the return trolley is excluded.

Positioning the selector "RETURN TROLLEY" in position "AUT", the trolley goes back till to

reach the loading position after loading new pallet goes to the internal proximity switch.

The turning table can turn when the trolley goes back completely till to reach the loading limit

switch.

Positioning this selector in position "MAN", the trolley metallic belts turns FORWARD when the

trolley is stopped on unloading position and BACKWARD when the trolley is stopped on loading

position.

Positioning this selector in position "0" the trolley belts is stopped.

Positioning this selector in position "AUT" the metallic trolley belt turns when the trolley is on

unloading and loading position.

The belt turns for a max. time of 15 seconds or till the discharged pallet does not reaches the

photocell placed at the end of the final belts.

Positioning this selector in position "MAN", the metallic belt of the conveyor installed at the outlet

of the palletizing unit turns even if the full pallet is not present on it.

Positioning this selector in position "0" the metallic belt is stopped.

Positioning this selector in position "AUT" , when requested from the automatic production cycle,

the metallic belts turns transferring the full pallets to the following sections of machinery.

Positioning the selector EMPTY PALLET FEEDER in pos. MAN, with this pushbutton the

operator can manually move the feeding rollers.

RETURN TROLLEY SELECTOR MAN-0-AUT

POS. 14 FIG.11

TROLLEY BELT (OF THE PALLETIZER) SELECTOR MAN-0-AUT

POS. 15 FIG.11

METALLIC BELT TRANSPORT CONVEYOR

FOR FULL PALLETS (OF THE PALLETIZER) SELECTOR MAN-0-AUT

POS. 16 FIG.11

EMPTY PALLET FEEDER ROLLERS

SELECTOR MAN-0-AUT

POS. 17 FIG.11




- 43 -

Positioning this selector in position "ALWAYS OPEN" , the motorised flap of the turning table is

always completely opened without consider the programmed data.

Positioning this selector in position "AUTOMATIC" , the motorised flap of the turning table is

opened or closed, it depends by the programmed data.

Positioning this selector in position "ALWAYS CLOSE" , the motorised flap of the turning table is

always closed without considering the programmed data.

Positioning this selector in position "ON" with the turning table opened, the pneumatic flap of the

turning table closes when start the turning operation in order to compact the row of rolls during the

unloading.

Positioning this selector in position "OFF" the pneumatic flap is excluded. Note that the pneumatic

flap must be enabled in the recipe in order to work in automatic mode.

In case that a membrane roll falls down during the phase of creation of the finished pallet, the

palletising automatic cycle stops. The operator puts the membrane roll straight (vertically) by hands

and then pushes this push-button to restore the palletising automatic cycle (before pushing this reset

it is obviously necessary to operate the reset push-button pos.03, since the barrier is interrupted

when the operator enters the area).

After you have pushed the button "EMERGENCY STOP":

- release the push-button "emergency stop"

- push the button "start" to start again the machine.

MOTORIZED FLAP FOR THE TURNING

TABLE WIDTH

SELECTOR ALWAYS OPEN - AUT – ALWAYS

CLOSED

POS. 18 FIG.11

PNEUMATIC FLAP OF THE TURNING TABLE

SELECTOR ON-OFF

POS. 19 FIG.11

FALLEN ROLL RESET

PUSH BUTTON

POS. 20 FIG.11

START PUSH-BUTTON

POS. 21 FIG.11




- 44 -

Pushing this button the machine or any of its part is not in operation and turn-off all the electrical

devices on the machine.

In order to start-up the machine again it is necessary to rotate the "EMERGENCY STOP" button for

releasing it, and then push the "START" button placed on the palletizing unit control board.

Before to start to perform any operation make sure that the main switch on the power board is

switched OFF.

EMERGENCY STOP PUSH-BUTTON

POS. 22 FIG.11




- 45 -

Automatic Trolley Controls The controls of the Automatic trolley for the full pallets transport are installed in the Electric Power

Board of the Automatic palletising unit on duty to Production Line 2 (in line with the Automatic

stove).

fig.12

In AUTOMATIC mode the automatic trolley is stationed on duty to Production Line P2. When a

finished full pallet is ready in the final position of the transporting belt at the end of the palletizing

section of Production Line P1, automatically the trolley is receiving the request, moves to the

Production Line P1, loads the full pallet, moves again to Production Line P2 and as soon as possible

discharges the full pallet to the Automatic Stove.

In MANUAL mode, by using the joystick, it is possible to move the trolley as follows:

- LEFT/RIGHT: translational movement of the trolley

- UP/DOWN: trolley belt movement forward/reverse

MANUAL/AUTOMATIC MODE

SELECTOR MAN-AUT

POS. 01 FIG.12

MANUAL MOVEMENT

JOISTICK

POS. 02 FIG.12

01 02

03




- 46 -

Pushing this button the machine or any of its part is not in operation and turn-off all the electrical

devices on the machine.

In order to start-up the machine again it is necessary to rotate the “EMERGENCY STOP” button for

releasing it, and then push the “START” button placed on the palletizing unit control board.

Before to start to perform any operation make sure that the main switch on the power board is

switched OFF.

EMERGENCY STOP PUSH-BUTTON

POS. 03 FIG.12




- 47 -

Electric control and power boards

DANGER

It’s strictly forbidden to work internally to the control and power board if

supplied by current

DANGER

Before making any maintenance operations on the machine, switch

OFF the main switch on the power board

DANGER

In case of extraordinary/ordinary maintenance or in case of anomaly

situations take care that the electric voltage supply must be taken off.

DANGER

The electric control and power boards can be opened only by an

authorised electrician. Remember to remove tension to the board in case

the door must be opened by turning the main switch to OFF (0) position.

The board door will not open if this main switch is not at its OFF (0)

position. Never switch to ON (1) the main switch with the door opened.

!

CAUTION

At the end of the week the have to be checked the proper functioning of

the Emergency stops on the control board

!

CAUTION

In order to allow to reach easily the Emergency stop, do not leave any

objects close to control boards




- 48 -

Description of the fences/protections installed in the working area

ID Type Function

1 Fixed protection net type It doesn’t allow the operator to enter in the area without the removal of the protection (to be carried out with the machine in safety conditions)

2 Safety barrier with muting system

With its intervention the operations of the whole Automatic palletising unit are stopped. To restore the barrier, refer to the description of the controls installed in the control board in the previous pages.

3 Emergency safety ropes If one of the safety rope is activating the safety switch, all the operations which involve dangerous movements of the components in the related areas are stopped, as in emergency condition

4 Safety doors If one of the doors which is part of the fence made by fixed protection net is opened, all the operations of the area are stopped. To restore the operation it is necessary to act on the apposite reset push-button

5 Safety laser scanner The Automatic trolley for full pallets transport is equipped with safety laser scanner to stop the translation movement in case of detection of obstacles in the way of the trolley




- 49 -

GENERAL

After the first starting of the machine, to check at least once a week for the first two working

months the tightening of all the bolts.

After the mentioned period of time, the mentioned check can be performed less frequently, but it is

always necessary.

Make sure that there is no any unexpected behavior of the machine due to the loosening of fixing

elements.

Pay attention to check that the guide bearings of the fulcrum of the turning table of the palletiser are

properly tightened.

MAINTENANCE CARD: SUPPORTS WITH SELF-ALIGNING BEARINGS

All the bearing units are prelubricated, that means they are completed with the normal grease

charge. Such grease charge is sufficient to guarantee a perfect lubrication for about 300 hours

running.

- Relubrication

All the bearing units have a lubricator which gives the possibility of periodical relubrications.

For such operation use the following greases:

ALVANIA R3 SHELL

ALVANIA RA SHELL

ENERGREASE LS3 B.P.

BEACON 3 ESSO

MULTIS SPECIAL 3 TOTAL

CUPUS A3 CENTURY OILS

MOBILUX 3 MOBIL OIL CO.

General rules: introduce gently the grease, possibly during running. Too much lubrication is

deleterious, therefore it is better to lubricate often with small quantities of grease.

Never lubricate with oil but only with grease.




- 50 -

MAINTENANCE CARD: LUBRICATION POINTS

In various points of the machine lubricators are provided to allow a periodic relubrication.

Such operation should be repeated every 300 working hours using only the following greases:

ALVANIA R3 SHELL

ALVANIA RA SHELL

ENERGREASE LS3 B.P.

BEACON 3 ESSO




GENERAL RULES: introduce gently the grease, possibly during running. Too much lubrication is






- 51 -

MAINTENANCE CARD: TRANSMISSION BY PINION-RACK SYSTEM

For the transformation of the rotary motion into linear motion, in the machine are used pinion-rack

groups module 3. Such groups due to their low rotation speed, need only a lubrication every now

and then with a type of grease as follows:

ALVANIA R3 SHELL

ALVANIA RA SHELL

ENERGREASE LS3 B.P.

BEACON 3 ESSO




GENERAL RULES: introduce gently the grease, possibly during running. Too much lubrication is



The groups are provided with regulation screws for the adjustment of the right pinion-rack distance,

after an eventual disassembling operation. In case there are no regulation screws, loosen the bearing

screws of the pinion shafts axis and fix the right distance.

Example: Coupling pinion Z19 m3 with racket m3 section 30X30.

Calculation of the assembly distance (d):

p= pinion primitive diameter Z19 m3 = 19X3 = 57 mm.

For a rack m3 section 30X30 ... m=3

The assembly distance (d) is: d = (57/2) + 9 X 3 = 55,5

See sketch:




- 52 -

MAINTENANCE CARD: CHAIN TRANSMISSION

All transmission and driving chains should be periodically checked and lubricated according to the

work load, and in any case, at least once a week.

Oil has to be applied by brush in the inside sections of the chain, near a pinion, in this way the

centrifugal movement will spread the lubricant on the pin-bush and roll-bush surfaces.

TEMPERATURE (C) OIL TYPE

-5 ÷ 5 SAE 20

5 ÷ 40 SAE 30

40 ÷ 50 SAE 40

50 ÷ 60 SAE 50

REGULATION OF THE CHAIN TENSION

To regulate the chain tension, adjustable tighteners are provided. The right tension insures a longer

life of the chain and less noise.

Remove the chain once a year and wash it with fuel-oil in order to remove any eventual material

(bitumen, talc, etc.). Wash the sprockets and the chain tighteners in the same way. After

reassembling of the parts, lubricate them in the usual way.




- 53 -

MAINTENANCE CARD: PNEUMATIC SYSTEM

The compressed air is connected to a group "F.R.L." filter, reducer, lubricator. The group filters the

air, reduces the pressure and forces the nebulized oil into circuit.

The oil lubricates the boxes of the electro-valves and the jackets of the pneumatic cylinders, thus

allowing a constant functioning.

The quantity of oil that passes is controlled by the knob located on top of the oil container. Adjust

the consumption so that the oil lasts for 810 working hours. To refill, unscrew the container and

fill it up to the level mark, exclusively with hydraulic oil.

Before the "F.R.L." group there is a container for the condensed water and for the impurities

contained in the compressed air. remove the container and clean it every 2030 working hours

according to the impurities contained in it.

The central knob is used to reduce the pressure of the air. The working pressure is 6 atm. The

maximum input pressure cannot exceed 10 atm, to avoid the explosion of the containers.

All the pneumatic connections are made of Rilsan pipes and brass junctions. Check periodically if

there are any drippings or pipe occlusions.

The valves are electrically operated by means of a coil and do not need any special care. An

eventual jamming is due either to the electric coils or to an excess of condensed water or by the

filter. In the second case it will be sufficient to disassemble the valve and wash it with petrol.

The pneumatic cylinders, having an alternate movement, wear out in a standard period of time.

Such wear is greater in the pistons seals of the long stroke cylinders.

!CAUTION

Never work with a pressure that is above 6 atm.

(see the attached document from the Camozzi’s supplier brochure)




- 54 -

MAINTENANCE CARD: WORMGEARS SERIES W – WR - VF

(see the attached document from the Bonfiglioli’s supplier brochure)




- 55 -

MAINTENANCE CARD (TECHNICAL DATA): LAFERT MOTOR (see the attached document from the LAFERT’s supplier brochure)




- 56 -

MAINTENANCE CARD (TECHNICAL DATA):ELECTRO MAGNETIC CLUTCH (see the attached document from the LENZE’s supplier brochure)




- 57 -

OPERATING INSTRUCTIONS: SAFETY LASER SCANNER (see the attached manual from the REER supplier brochure)




- 58 -

Pictures and drawings showing the main spare parts of the palletizer

Find here enclosed pictures and drawings showing the main parts subjected of wearing.

In case of spare parts order, mark the component that you need on the picture/ drawing and send to

us by fax the same.

manual palletizer 825pa001

Documents