Siat ProWrap Series Manual de usuario

Code SBC0035151 ed. 05-2018 - rev. 1

Semi-automatic pallet wrapper

Translation of the “ORIGINAL

INSTRUCTIONS”

Operation and maintenance

manual

ProWrap

No part of this publication may be reproduced without the written consent of the Manufacturer. Pursuing a policy of continuous improvement, the Manufacturer reserves the right to change this

document without notice, provided that such changes do not create risks to safety.

IDM 510-128-1_Sommario

English languageOperation and maintenance manual

Summary

Safety information

Purpose of the manual ............................................................................................................ 3

Glossary of the terms .............................................................................................................. 3

Attached documentation ......................................................................................................... 4

General safety warnings ......................................................................................................... 5

Safety Warnings for Handling and Installation ........................................................................ 5

Safety Warnings for Operation and Use.................................................................................. 6

Safety Manager Obligations ................................................................................................ 7

Safety Warnings on Misuse..................................................................................................... 7

Safety Warnings on Residual Risks ........................................................................................ 8

Safety Warnings for Maintenance and Adjustments................................................................ 8

Safety warnings for the electrical equipment .......................................................................... 9

Safety warnings for the environmental impact ...................................................................... 10

Safety and information symbols .............................................................................................11

Technical Specications

general description of the machine ....................................................................................... 13

Description of the main components..................................................................................... 15

Manufacturer and machine identication .............................................................................. 16

Cycle ..................................................................................................................................... 17

Types of wrapping ................................................................................................................. 18

Residual risks........................................................................................................................ 19

Incorrect uses that are reasonably expected ........................................................................ 20

Optional Accessories............................................................................................................. 20

Description of the safety devices .......................................................................................... 21

Technical data of machine..................................................................................................... 22

Dimensions and weights (Standard version) ..................................................................... 22

Dimensions and weights (version HSD) ............................................................................ 23

Technical specications ..................................................................................................... 23

Technical specications of pressing roller.......................................................................... 23

Specications of the accessories available on request ..................................................... 24

Technical data of reel ............................................................................................................ 24

Dimensions of lm reel ...................................................................................................... 24

Net reel dimensions ........................................................................................................... 24

Description of outer areas ..................................................................................................... 25

Safety and information symbols ............................................................................................ 26

Maintenance

Recommendations for maintenance interventions ................................................................ 27

Scheduled maintenance intervals ......................................................................................... 28

Diagram of the points of lubrication....................................................................................... 29

Problems, causes, remedies................................................................................................. 30

Alarm message table ............................................................................................................ 32

Cleaning and replacement of the air lter ............................................................................. 34

Adjustment of chain controlling the rotation of platform ........................................................ 35

Sensitivity adjustment for the product to be wrapped detection photocell ............................ 37

Replacing the rotating platform wheels (standard version) ................................................... 38

Replacing the rotating platform wheels (version HSD) ......................................................... 39

Replacing the lifting belt of the carriage ................................................................................ 41

Pressing roller

Description of the main components of the Pressing Roller ................................................. 44

Disassembly and re-assembly of the Pressing Roller........................................................... 45

Re-assembly of the Pressing Roller .................................................................................. 46

Reel holding carriage (M)

Reel holding carriage (M)...................................................................................................... 47

Main components .............................................................................................................. 47

Film Coil Feeding............................................................................................................... 48

IDM 510-128-1_Sommario

2English language Operation and maintenance manual

Tension adjustment of lm ................................................................................................. 49

Cleaning and replacement of brake disc ........................................................................... 50

Replacing the outer surface of roller.................................................................................. 51

Reel holding carriage (FM)

Reel holding carriage (FM).................................................................................................... 52

Main components .............................................................................................................. 52

Film Coil Feeding............................................................................................................... 53

Cleaning and replacement of brake disc ........................................................................... 54

Adjustment of brake........................................................................................................... 55

Replacing the outer surface of roller.................................................................................. 56

Reel holding carriage (PW)

Reel holding carriage (PW) ................................................................................................... 57

Main components .............................................................................................................. 57

Film Coil Feeding............................................................................................................... 58

Adjustment of drive chain tensioning ................................................................................. 59

Pre-stretch percentage variation (lm pre-stretch kit )....................................................... 60

Disassembly and re-assembly of the reel holding carriage ............................................... 62

Control system

Recommendations on Operation and Use ............................................................................ 63

Control description ................................................................................................................ 64

Description of the operator interface ..................................................................................... 65

Operator interface navigation diagram (standard) ................................................................ 66

Operator interface navigation diagram (advanced)............................................................... 68

Description of a typical screen .............................................................................................. 70

Description of the keyboard .................................................................................................. 70

Function description of the displayed icons .......................................................................... 71

Programming icons (shaded gray background)................................................................. 71

Display icons (gray background) ....................................................................................... 73

Non-release hold keys (shaded gray background) ............................................................ 74

Single-action keys (orange or shaded gray) ...................................................................... 74

Language selection mode ..................................................................................................... 76

Password entering mode ...................................................................................................... 76

How to programme or edit the parameters ........................................................................... 77

Recipe management ............................................................................................................. 77

How to programme a new recipe....................................................................................... 77

Modifying a recipe.............................................................................................................. 78

How to load a recipe in the PLC ........................................................................................ 79

How to programme the bands and the wrapping reinforcements ......................................... 80

How to display the wrapping statistics .................................................................................. 84

How to display the Setup parameters ................................................................................... 86

Manual wrapping................................................................................................................... 88

Normal stop ....................................................................................................................... 89

(Single or double) automatic wrapping.................................................................................. 90

Normal stop ....................................................................................................................... 91

(Single or double) automatic wrapping with sheet feeder ..................................................... 92

Normal stop ....................................................................................................................... 93

Stop in alarm conditions and restart...................................................................................... 94

Emergency stop and new start-up ........................................................................................ 95

Use of the weighing unit (optional)........................................................................................ 96

Calculation of lm pre-stretch................................................................................................ 97

Calculation of lm tensioning ................................................................................................ 98

1Disposal and scrapping

Machine Disposal and Scrapping.......................................................................................... 99

Analytical index ................................................................................................................... 101

IDM 510-004-5

Safety information

English languageOperation and maintenance manual

Purpose of the manual

– The purpose of the manual is to inform and train operators so that they can inter-

act with the machine in SAFE CONDITIONS.

– Its aim is also to prevent risks, to reduce the social costs resulting from accidents

and damage to the health of people, property and to the environment.

– In some cases, accidents may be due to the Operator using the machine

carelessly.

– Caution is always necessary. Safety is also the responsibility of all the per-

sons interacting with the machine throughout its operating life.

– Remember that it is too late to think about safety issues when the accident

has already occurred.

– It is important to dedicate enough time to read the “Instruction Manual” in

order to minimise the risks and to avoid any unpleasant accidents.

– The content of this manual was originally edited by the Manufacturer in the moth-

er tongue (ITALIAN), in compliance with the professional writing standards and

the regulations in force.

– Any translation of the manuals shall be carried out directly and without alterations

from the texts of the ORIGINAL INSTRUCTIONS.

– This applies also to the translations carried out by the agent or by the person who

is in charge of delivering the equipment in the specic linguistic area.

– The Manufacturer reserves the right to update the documentation, should this

prove necessary.

– All information supplied by the recipients represents an important contribution to

the improvement of the after-sales service that the manufacturer will offer to his/

her customers.

– All supplied information is organised into an index and a table of contents, so as

to easily track specic topics of interest.

– The SAFETY WARNINGS and the INSTALLATION MANUAL are supplied as

hard-copy publications.

– The USE AND MAINTENANCE MANUAL, operation diagrams and all other

post-sale documents can be downloaded from the INTERNET.

– Keep the manual and the attached documents in a place known and easily trace-

able, so that you may refer to them whenever necessary.

Glossary of the terms

The glossary includes some terms used when processing information, with

their denition, in order to facilitate understanding.

– Training: A process aiming at transferring the knowledge, skills and behaviours

required to work in an autonomous, correct and hazard-free manner.

– Assistant: person chosen, trained and coordinated in an appropriate manner to

minimize the risks in carrying out their tasks.

– Emergency stop: voluntary activation of the special control that stops the dan-

gerous elements of the work unit in the case of imminent risk.

– Stop in alarm conditions: this state causes the components to stop and is acti-

vated when the control system detects a problem in the machine operation.

– General shut down: In addition to the normal stop this state also causes the in-

terruption of all the power sources (electrical, pneumatic, etc.).

Safety information

IDM 510-004-5

4English language Operation and maintenance manual

– Operating Stop: state that does not cut off power supply to the actuators, but

ensures control system monitoring in safe conditions.

– Size change: a set of interventions to be carried out before beginning to work

with specications different with respect to the ones previously in use.

– Test-run: a series of operations required to ensure compliance to the design

specications, and to commission the machine under safety conditions.

– Installer: a technician chosen and authorized by the manufacturer or his author-

ized representative, among those who full the requirements for installation and

testing of the machine or plant in question.

– Maintenance Operator: a technician chosen and authorized, among those who

full the requirements, to carry out routine and extraordinary maintenance opera-

tions on the machine. Therefore, the maintenance operator shall possess precise

knowledge and skills, with particular skills in the relevant eld.

– Routine Maintenance: all the operations necessary to maintain the functionality

and efciency of the machine. Normally, these operations are scheduled by the

manufacturer, who denes the necessary skills and methods of action.

– Operator: a person chosen and authorized, among those who full the require-

ments, having the knowledge and skills necessary to operate the machine and

carry out routine maintenance interventions.

– Production Manager: technician with expertise and knowledge on the use of

packaging machines and similar equipment, who is authorised to supervise the

production activity.

– Person in charge of the installation: a technical expert who must carry out the

installation in compliance with the laws applicable to the workplace and, at the

end, assess its compliance.

– Residual risks: all the risks remain even if all the safety solutions have been

adopted and integrated when the machine has been designed.

– Expert Technician: A person authorised by the Manufacturer and/or his represent-

ative to carry out services that require specic technical skills and abilities.

– Forwarder and Handler: Authorized persons with recognized expertise in the

use of means of transport and lifting devices, in safety conditions.

– Foreseeable improper use: reasonably foreseeable use other than that recom-

mended in the instruction manual, which may result from human behaviour.

Attached documentation

The SAFETY WARNINGS and the INSTALLATION MANUAL are supplied as

hard-copy publications.

– The USE AND MAINTENANCE MANUAL, operation diagrams and all other post-

sale documents can be downloaded from the INTERNET.

– The list shows the documentation supplied with the machine.

– CE Declaration of conformity

– Operation and maintenance manual

– Installation manual

– Wiring diagrams

– Pneumatic system diagrams

– Specic Manuals for installed components or sub-assemblies available commer-

cially

IDM 510-004-5

Safety information

English languageOperation and maintenance manual

General safety warnings

– The machine has been designed and built with all the precautionary measures

aimed at minimising the possible risks over its expected life cycle.

– Tampering with and bypassing the safety devices may lead to severe risks for the

Operators.

– Before interacting with the machine, and in particular, before its rst use, read the

SAFETY WARNINGS contained in the manual.

– Spend some of your time reading this information to avoid any risk for people’s

health and safety as well as economic damage.

– Respect the SAFETY WARNINGS. Avoid any IMPROPER USE of the machine

and assess the RESIDUAL RISKS.

– When operating the machine, DO NOT wear clothes and/or accessories that

could become caught in the moving or protruding parts.

– Before machine use and/or maintenance, read the information contained in the

reference documents and accurately implement the described procedures.

– Carry out the interventions ONLY according to the modes recommended by the

Manufacturer in the “Instructions for use”.

– The personnel in charge of carrying out interventions on the machine must have

suitable and proven experience in this specic eld.

– Please keep safety signs and information legible and follow the instructions.

– The information signals may be of different shapes and colours, to indicate dan-

gers, obligations, prohibitions and indications.

– Signals which are no longer legible must be replaced and repositioned in the

same place of origin.

– The non-compliance with the information provided herein may lead to risks

for the safety and health of the persons involved and may also lead to eco-

nomic damages.

Safety Warnings for Handling and Installation

– The manufacturer has attached special attention to the packaging of the ma-

chine, to minimise the risks associated with the shipping, handling and transport

phases.

– The personnel authorised to handle the machine (loading and unloading) must

have acknowledged technical skills and professional ability.

– Before handling, please read the instructions, in particular those on safety, con-

tained in the installation manual, on the packages and/or on the removed parts.

– In order to make transport easier, the equipment can be shipped with a few dis-

assembled and properly protected and packaged components.

– Loading and transport must be carried out with equipment of adequate capacity

by anchoring it to specic points indicated on the packages.

– DO NOT attempt to by-pass the instructions concerning the lifting requirements

and special points provided for lifting and handling each item and/or disassem-

bled part.

– Slowly lift the pack to the minimum necessary height and move it very carefully in

order to avoid dangerous vibrations.

Safety information

IDM 510-004-5

6English language Operation and maintenance manual

– The packs being shipped must be properly fastened to the means of transport in

order to ensure safe conditions during transfer and the integrity of their contents.

– During some handling phases, the support of one or more operators may be re-

quired; these operators must be trained and informed about the tasks assigned

to them.

– Download packages in the immediate vicinity of the machine setting, which must

be sheltered from bad weather.

– Do not stack the packs onto each other in order to avoid any damage and to avoid

the risk of sudden and dangerous movements.

– In case of prolonged storage, regularly check that the component stocking condi-

tions do not change.

– The installation area is to be prepared so as to be able to carry out the operations

as specied in the manuals and in conditions of safety.

– Ensure that the installation environment is protected against atmospheric agents,

free of corrosive substances and free of any risk of explosion and/or re.

– Signal and delimit the installation area in a proper way in order to prevent non

authorised personnel from accessing the installation area.

– The connections to the power sources (electric, pneumatic, etc.) must be per-

formed correctly, as shown in the diagrams and in compliance with the regulatory

and legal requirements in force.

– ONLY qualied and experienced personnel are allowed to carry out the electrical

connections.

– After completing the connections, perform a general check to ensure that all the

interventions have been carried out properly and that the requirements have

been met.

– The installation manager, before commissioning, must check that all the safety

devices are properly installed and functioning.

– At the end of operations check that there are no other tools or other material near

the moving parts or in dangerous areas.

– Dispose of all packing in accordance with the laws in force in the country of instal-

lation.

– The non-compliance with the information provided herein may lead to risks

for the safety and health of the persons involved and may also lead to eco-

nomic damages.

Safety Warnings for Operation and Use

– The machine must be used by one single operator ONLY, who must be trained

and capable of performing the work and be in suitable conditions.

– Consult the user manual, in particular during the rst use, and make sure that you

fully understand its content.

– Find out the position and function of the controls and simulate some operations

(in particular start and stop) in order to acquire familiarity.

– The machine shall be used ONLY for the purposes and complying with the proce-

dures specied by the Manufacturer.

– Make sure that all the safety devices are properly installed and efcient.

– The machine should be used ONLY with the original safety devices installed by

the Manufacturer.

IDM 510-004-5

Safety information

English languageOperation and maintenance manual

– Ensure the area around the machine, especially the control post, is ALWAYS

unobstructed and in good condition to minimize the risks for the Operator.

– According to the type of operation to carry out, wear the Personal Protective

Equipment listed in the “Instructions for use” and that indicated by the Labour

laws.

– The non-compliance with the information provided herein may lead to risks

for the safety and health of the persons involved and may also lead to eco-

nomic damages.

▀Safety Manager Obligations

– The safety manager must train the operator and help him or her familiarise and

interact with the machine in an independent, adequate and risk-free manner.

– The operator must be informed about the PROPER USE of the machine and

about the remaining RESIDUAL RISKS.

– The operator must demonstrate that he has acquired the relevant skills and has

understood the “User Instructions” in such a way as to carry out his activities

safely.

– The operator must be able to recognise the safety signals and demonstrate that

he is in suitable condition to carry out his assigned duties.

– The safety manager must release educational material to trainees and document

the delivered training, so as to be able to produce such documentation in case of

litigation.

Safety Warnings on Misuse

– ONLY trained, documented and authorized Operators are allowed to use the ma-

chine.

– DO NOT use or allow other persons to use the machine if the safety devices are

faulty, disabled and/or incorrectly installed.

– DO NOT use or allow other persons to use the machine for purposes and in ways

different from what specied by the Manufacturer.

– DO NOT use the machine in home environments.

– DO NOT wear clothes and/or accessories that could become caught in the mov-

ing or protruding parts.

– When operating the machine, ALWAYS wear the Personal Protective Equipment

specied by the Manufacturer and by the current regulations on safety at work.

– If troubles arise, do NOT continue to use the machine. Stop it immediately and

restart only after restoring the normal operating condition.

– DO NOT use the machine if the scheduled routine maintenance interventions

have not been carried out.

– DO NOT tamper with, override, bypass or eliminate the safety devices installed

on the machine.

– DO NOT modify the manufacturing and functional characteristics of the machine

in any manner whatsoever.

– DO NOT perform any interventions other than those specied in the Operation

Manual without the explicit authorization of the Manufacturer.

– DO NOT carry out any intervention when the machine is being operated. Stop the

machine and put it in safety condition before carrying out any intervention.

– DO NOT clean or wash the machine with water, steam or aggressive products

that might irreversibly damage the components.

Safety information

IDM 510-004-5

8English language Operation and maintenance manual

– DO NOT replace the components with non-genuine spare parts or other compo-

nents with different design and manufacturing specications.

– DO NOT dump in the environment any materials, polluting liquids and mainte-

nance waste generated during the operations. Dispose of them according to the

regulations in force.

– DO NOT leave the machine unattended during operation and DO NOT leave it at

the end of the work without stopping it to safety conditions.

– The non-compliance with the information provided herein may lead to risks

for the safety and health of the persons involved and may also lead to eco-

nomic damages.

Safety Warnings on Residual Risks

Residual risks: all the risks remain even if all the safety solutions have been

adopted and integrated when the machine has been designed.

– Upon designing and building the machine, the Manufacturer has paid particular

attention to the RESIDUAL RISKS that may affect the safety and health of the

Operators.

– For specic information about residual risks, please refer to the machine user

manual.

Safety Warnings for Maintenance and Adjustments

– Always keep the machine in optimum operating condition and carry out the rou-

tine maintenance according to the intervals and procedures specied by the Man-

ufacturer.

– A good maintenance will ensure a stable performance over time, longer

working life and constant compliance with the safety requirements.

– The personnel authorized to carry out the ordinary maintenance must have qual-

ied expertise and specic skills in the eld of intervention.

– Any work on the electrical system must ONLY be performed by technicians with

acknowledged, eld-specic skills.

– Mark the intervention area and prevent access to the devices that, if activated,

may cause unexpected hazards and jeopardize the safety level.

– According to the type of operation to carry out, wear the Personal Protective

Equipment listed in the “Instructions for use” and that indicated by the Labour

laws.

– Respect the SAFETY WARNINGS. Avoid any IMPROPER USE of the machine

and assess the RESIDUAL RISKS.

– Before carrying out any intervention, activate all the safety measures, and assess

any residual energy which may still be present.

– Carry out the operations in areas which are difcult to access or hazardous ONLY

after disconnecting all power sources.

This operating mode is necessary in order to work under safe conditions.

– Carry out the operations according to the procedures and modes shown by the

Manufacturer in the “Instruction Manual”.

– All operations must be carried out ONLY with suitable tools which shall be in good

condition, in order to avoid damaging any components and parts of the machine.

– Replace the components and/or safety devices ONLY with original spare parts in

order not to alter the required safety level.

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