AETNAGROUP Robopac INDEX 50 User manual

INDEX 50/65
serial n°
GB USE AND MAINTENANCE MANUAL
“Translation of the original instructions”
BOX SPACER
Instructions manual code 3709300449
English Edition 0/0215

3710308617_DICHIARAZIONE CE_GB.DOCX
EC DECLARATION OF CONFORMITY
(Annex IIA DIR. 2006/42/EC)
Robopac S.p.A.
Via Fabrizio da Montebello, 81 - 47892
Gualdicciolo Republic of San Marino
DECLARES THAT THE MACHINE
IS IN CONFORMITY WITH DIRECTIVES
European Parliament and Council Directive 2006/42/EC dated May 17, 2006
European Parliament and Council Directive 2004/108/EC dated December 15, 2004
European Parliament and Council Directive 2006/95/EC dated December 12, 2006
Reference to harmonised standards and relevant annexes, in applicable points:
EN ISO 12100:2010, EN 60204-1:2006/A1:2009, EN 415-5:2010, EN 415-6:2013, EN 415-10:2014.
THE INDIVIDUAL AUTHORISED TO DRAFT THE TECHNICAL BOOKLET IS
Mr. Pierangelo Laghi, R&D Manager
Via Fabrizio da Montebello, 81 - 47892 Gualdicciolo (RSM) – Republic of San Marino
Document date and place Ing. Pierangelo Laghi
R&D Manager
San Marino, Firma

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SUMMARY
1 GENERAL INFORMATION
1.1. PURPOSE OF THE MANUAL....................... 3
1.2. MANUFACTURER AND MACHINE
IDENTIFICATION .......................................... 4
1.3. TERMS AND DEFINITIONS.......................... 5
1.4. MODES OF REQUESTING FOR
ASSISTANCE................................................ 6
1.5. ATTACHED DOCUMENTATION ................... 6
2 SAFETY INFORMATION
2.1. GENERAL SAFETY PRECAUTIONS ........... 7
2.2. SAFETY WARNINGS FOR HANDLING AND
INSTALLATION ............................................. 7
2.3. SAFETY WARNINGS FOR USE AND
OPERATION ................................................. 9
2.4. SAFETY WARNINGS RELATED TO
INCORRECT USE....................................... 10
2.5. SAFETY WARNINGS
ON RESIDUAL RISKS ................................ 12
2.6. SAFETY WARNINGS FOR REGULATIONS
AND MAINTENANCE.................................. 13
2.7. INFORMATION AND SAFETY SIGNALS ... 14
2.8. SURROUNDING AREAS ............................ 15
3 TECHNICAL INFORMATION
3.1. MACHINE GENERAL DESCRIPTION ........ 16
3.2. DESCRIPTION
OF THE OPERATION CYCLE .................... 18
3.3. SAFETY DEVICE DESCRIPTIONS ............ 19
3.4. DESCRIPTION OF THE ELECTRICAL
DEVICES..................................................... 19
3.5. DESCRIPTION OF ACCESSORIES ON
REQUEST................................................... 20
3.6. TECHNICAL SPECIFICATIONS ................. 20
3.7. NOISE LEVEL............................................. 22
3.8. INSTALLATION ENVIRONMENT
CHARACTERISTICS .................................. 22
4 INFORMATION ON HANDLING AND
INSTALLATION OPERATIONS
4.1. RECOMMENDATIONS FOR HANDLING AND
LOADING .................................................... 23
4.2. PACKAGING AND UNPACKING................. 23
4.3. TRANSPORT AND HANDLING .................. 24
4.4. MACHINE INSTALLATION.......................... 25
4.5. INSTALLATION
OF CONSENT SWITCH.............................. 26
4.6. RECOMMENDATIONS
FOR CONNECTIONS ................................. 27
4.7. ELECTRICAL CONNECTION ..................... 27
5 INFORMATION ON ADJUSTMENTS
5.1. RECOMMENDATIONS
FOR ADJUSTMENTS ................................. 28
5.2. CONVEYOR BELT ADJUSTMENT ............. 29
5.3. ADJUSTMENT OF SELF-CENTERING
GUIDES DRIVING CHAIN .......................... 30
6 ABOUT THE USE
6.1. RECOMMENDATIONS FOR OPERATION
AND USE .................................................... 31
6.2. CONTROL DESCRIPTION ......................... 31
6.3. SWITCHING THE MACHINE
ON AND OFF .............................................. 32
6.4. STARTING AND STOPPING THE CYCLE . 32
6.5. EMERGENCY STOP AND RESTART......... 33
6.6. FORMAT CHANGE ..................................... 33
6.7. POSITIONING OF SIDE GUIDES............... 34
6.8. HEIGHT SETTING OF WORK TABLE ........ 34
7 MAINTENANCE INFORMATION
7.1. MAINTENANCE INSTRUCTIONS .............. 35
7.2. MAINTENANCE PERIOD TABLE ............... 36
7.3. LUBRICATION POINT DIAGRAM............... 37
7.4. LUBRICANTS TABLE ................................. 38
8 TROUBLESHOOTING
8.1. TROUBLES – CAUSES – REMEDIES ....... 39
9 SPARE PARTS REPLACEMENT
INFORMATION
9.1. RECOMMENDATIONS FOR REPLACING
PARTS......................................................... 40
9.2. REPLACEMENT OF CONVEYOR BELT .... 41
9.3. HOW TO REPLACE THE SELF-CENTERING
GUIDE DRIVING CHAIN............................. 42
9.4. REPLACING THE CHAIN THAT MOVES THE
CONVEYOR BELTS.................................... 43
9.5. LIST OF THE RECOMMENDED SPARE
PARTS......................................................... 44
9.6. MACHINE DISPOSAL AND SCRAPING..... 44
10 ENCLOSED DOCUMENTATION
10.1. WARRANTY CONDITIONS ........................ 45

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SUMMARY
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1.1. PURPOSE OF THE MANUAL
– The manual is an integral part of the machine and is aimed to
provide the operator the instructions for use in order to prevent and
reduce the risks that arise from man-machine interface.
The information have been written by the manufacturer into
Italian (the original language) in full compliance with the
professional writing principles and the regulations in forc e.
The communication principles were chosen according to the
target readers in order to ease the reading and understanding
of the information.
The information may be translated into other languages to
satisfy the legal and/or market requirements.
The manuals must be translated directly from the ORIGINAL
INSTRUCTIONS, without modication.
Each translation (including that provided by the purchasing
agent or by the company that introduces the machine into the
country in question) must specify the message “Translation
of the original instruction”.
– Keep this manual for the entire duration of its useful life in a well
known and easy to access place, available for reference any time
the need should arise.
– Refer to the table of contents and the analytical index in order to
easily identify the subjects of interest.
– Some information may not correspond completely to the actual
conguration of the machine delivered.
– Any additional information does not affect the readability of the text
and the safety level.
– The manufacturer reserves the right to modify the contents of the
manual without prior notice provided that the safety level is not
altered.
– All information supplied by the recipients represents an important
contributionto the improvement of the after-sales service that the
manufacturerwill offer to his/her customers.
– The symbols described below are used to highlight the most important
information or specications.
Danger
Warning
The symbol indicates extremely hazardous situations which, if
ignored, could seriously jeopardise personal health and safety.
Caution
Warning
The symbol indicates that suitable actions must be adopted to
preventpersonal health and safety risks and avoid economic
damages.
Important
This symbol indicates critical technical and operating
informationthat shall be observed.
Chapter 1
GENERAL INFORMATION

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Chapter 1
GENERAL INFORMATION
1.2. MANUFACTURER AND MACHINE
IDENTIFICATION
The illustrated identication plate is applied directly on the machine.
It contains references and indispensable operating safety indications.
A) Machine model.
B) Machine’s serial number.
C) Year of manufacture.
D) Power supply voltage.
E) Power supply frequency.
F) Power supply phases.
G) Electrical power consumption.
H) Total installed power.
L) Air consumption.
M) Max. air supply pressure.
N) Machine weight.
P) Manufacturer’s name.

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Chapter 1
GENERAL INFORMATION
1.3. TERMS AND DEFINITIONS
Some recurring terms found within the manual are described in order
to provide a more complete image of their meanings
‒ Routine maintenance:
Group of functions necessary to maintain suitable machine operations
and efciency. Normally the manufacturer, who denes the necessary
skills and intervention procedures, plans these operations
‒ Non-routine maintenance:
The whole of the operations necessary to keep the operating and
efciency capacity of the machinery. These operations are not
scheduled by the manufacturer and must be carried out by the
maintenance technician
‒ Operator:
A person authorised and chosen from those who have the
requirements, skills and information necessary for installation, use
and ordinary maintenance of the machine
‒ Maintenance technician:
A person authorised and chosen among those who have the
requirements, skills and information necessary to perform ordinary
and extraordinary machine maintenance. He is expected, therefore,
to possess precise information and skills with particular expertise
in the eld of intervention
‒ Format Change:
series of operations to carry out on the machine before starting to
work with the machine with different characteristics respect to the
previous ones
‒ Training:
training process aimed to transfer to the operator the knowledge,
skills and behaviour required to operate the machine autonomously,
properly and safely
‒ Installer:
technician chosen, among those that meet the requisites, and
authorised by the manufacturer or by its representative, to install
and test the machine or the system in question
‒ Assistant:
employee assigned to assist the production processes of the machine
or system in question

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Chapter 1
GENERAL INFORMATION
1.4. MODES OF REQUESTING FOR
ASSISTANCE
The distribution network ROBOPAC is at your service for any problem
that requires technical support, to order spare parts, and for whatever
new type of need that can help develop your business.
Report the data displayed on the ID plate, the estimated hours you
have used the machine, and the type of aw you have uncovered when
requesting technical support.
Contact one of our authorized dealers at the listed address for all your
needs.
ROBOPAC SPA
VIA FABRIZIO DA MONTEBELLO, 81
47892ACQUAVIVAGUALDICCIOLO, REPUBBLICAS. MARINO (RSM)
Phone: 0549 (international ++378) 910511
Fax: [phone] - 905946
http://www.aetnagroup.com
1.5. ATTACHED DOCUMENTATION
The machine is provided with the documentation listed below, in the
absence of a different trade agreement.
‒ CE statement of conformity.
‒ Warranty conditions (included in this booklet).
‒ Instructions for unpacking and installation.
‒ Quick start guide.
‒ Wiring diagram and list of components.
‒ Manuals of installed commercial devices (if necessary for machine
use).
‒ USB ash drive that contains the information listed.
-Use and maintenance manual translated into various languages.
-Spare parts catalogue.

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2.1. GENERAL SAFETY PRECAUTIONS
– Carefully read the “Instructions for use” specied in the manual and
those applied directly to the machine.
It is important to dedicate a little time to read the “Instructions for
use” in order to minimise the risks and avoid unpleasant accidents.
– Before performing any operation, the operator must make sure that
he/she understood the “Instructions for use”.
– Pay attention to the SAFETY WARNINGS, do not use the machine
for UNSPECIFIED PURPOSES and assess the possible RESIDUAL
RISKS.
– Caution is essential.
Safety is also in the hands of those who interface with the machine
throughout its life span.
Sometimes, accidents can be caused by a “careless” use of
the machine by the operator.
Usually it is too late to remember what should have been
done when the accident has already happened.
– Preserve the readability of the information signs and observe the
indications given.
The information signs may have different shapes and colours,
indicating hazards, obligations, prohibitions and information.
– The manufacturer has designed the machine observing all the “good
manufacturing regulations” and the standards in force.
The machine has been designed to be constructed and equipped
with devices that ensure intrinsic safety.
Tampering with the safety devices and the removal of the same
may create risks (even severe) for the operators.
– The personnel authorised to carry out any operation with the machine
must have acknowledged experience in the specic eld.
– The manufacturer is not responsible for any damage to the
product delivered in the package during the wrapping and
stabilisation and the following operation phases.
Non compliance with the instructions given may cause risks
for safety and health of the persons and economic damages.
2.2. SAFETY WARNINGS FOR HANDLING AND
INSTALLATION
– The personnel authorised to handle the machine (loading and
unloading) must possess particular expertise in the eld of
intervention.
– Handle (load and unload) the machine according to the instructions
afxed directly to the machine, to the package and those in the
user manual.
– During handling use one or two assistants, if required. This operation
may generate unpredictable risks.
In order to minimise the risks related to assistants’ involvement, you
must inform them priorily on the type of work and the behaviour
to be used.
Chapter 2
SAFETY INFORMATION

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Chapter 2
SAFETY INFORMATION
– The machine must be handled with the aid of specic means (crane,
forklift etc.) by qualied personnel capable of observing the safety
requirements.
– When using the lifting means, insert and/or fasten the devices
(hooks, forks etc.) ONLY into the points provided on the package
and/or the machine.
– Transport the machine suitable means of adequate capacity.
– Make sure the machine and its components are properly fastened
to the transport mean.
Check the machine dimensions and afx proper signs if the machine
overall dimensions exceed the values allowed by road regulations.
– The minimum and maximum temperature (during transport and/
or storage) must fall within the range allowed in order to prevent
damaging the electrical components.
– Install the machine ONLY in spaces free of explosion and /or re
risks.
– Avoid the spaces exposed to atmospheric and corrosive agents.
– Assess, prior to installation, if it is necessary to draw up a “safety
plan” in order to protect the safety of the personnel involved.
– Provide proper safety conditions when operating at high altitudes
areas that are dangerous and hard to access.
– Install the machine according to the minimum perimeter indicated
by the manufacturer and the surrounding activities.
– Should the machine interface directly/indirectly with other machines
or production lines, draw up the installation design of the machine.
The design must include all the operating conditions in order to
comply with the standards in force on safety at work place.
– Check that the installation space is properly ventilated in order to
avoid air concentration unhealthy for the operators.
– Apply the most suitable solutions for reducing the noise levels and
the acoustic pollution to minimum.
– Carry out the electrical connections professionally and in full
compliance with the instructions provided by the manufacturer and
the specic regulations in force.
The electrical connections must be carried out EXCLUSIVELY
by operators with particular expertise in the eld of intervention.
‒ The operator must test the machine and check, through a general
test, that the machine can be commissioned without any risk for
the operator.
‒ Dismantle all the packaging components in compliance with the
standards in force in the country of installation.
Non compliance with the instructions given may cause risks
for safety and health of the persons and economic damages.

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Chapter 2
SAFETY INFORMATION
2.3. SAFETY WARNINGS FOR USE AND OPERATION
– The operator must be trained and possess the proper knowledge
required to carry out the specic tasks and must meet the conditions
required for the safe use of the machine.
– When using the machine for the rst time, the operator must read
the manual and identify the controls and simulate some operations,
especially the start-up and shutdown.
– The machinery has been designed and manufactured to satisfy all
the operating conditions indicated by the manufacturer.
Use the machine only with the original safety devices installed
by the manufacturer.
Do not tamper with, remove or bypass the safety devices
installed on the machine.
– Do not modify the constructive and functional characteristics of
the machine.
– Do not use the machinery with the safety devices not properly
installed and efcient.
– Always wear the individual safety devices indicated in the “instructions
for use” and provided by the standards in force regarding the safety
at workplace.
– Always keep the surrounding areas in suitable conditions and free
of obstacles in order to minimise the risks, especially near the
control station.
– The machine must be used by one operator only, that must be
assigned and authorised by the employer.
– The involvement of one or more assistants when performing some
operations or maintenance (ordinary) interventions may present
unpredictable risks.
In order to minimise the risks related to assistants’ involvement, you
must inform them priorily on the type of work and the behaviour
to be used.
– Make sure that no foreign persons are present within the machine
operating area during its production activity and maintenance.
Non compliance with the instructions given may cause risks
for safety and health of the persons and economic damages.

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Chapter 2
SAFETY INFORMATION
2.4. SAFETY WARNINGS RELATED TO INCORRECT
USE
Incorrect use that can be reasonably expected
– The predictable incorrect use consists of: “the use of the machine
different from the indications given in the manual, that may
stem from the easily predictable human behaviour”.
The machine should only be used for moving and spacing
products packed in cardboard boxes of various formats.
‒ The machine must be used ONLY for the uses intended by the
manufacturer.
‒ Do not allow the machine to be used by operators that are not
properly trained, informed and unauthorised.
‒ Packages that contain liquid or inconsistent products must ensure
that they do not leak.
– Do not move loose, irregularly shaped and unsuitable collected
products, in order to prevent the machine from malfunctioning.
– Do not use the machine for moving living beings (for example
animals and people).
‒ Do not use the machine as a workbench.
‒ Do not use or let the machine be used for purposes or in ways not
provided by the manufacturer.
‒ Do not use or make use of machines with defective, deactivated
and/or not perfectly installed safety devices.
‒ Do not continue to use the machine if malfunctions have been
detected.
Stop the machine immediately and restart it only after the normal
conditions of use have been restored.
‒ Never carry out an intervention with the machine enabled but only
after having stopped it properly, under safety conditions.
‒ Never use the machine without wearing the personal protective
devices indicated by the manufacturer and required by current
workplace laws.
‒ Never use the machine if the scheduled maintenance interventions
have not been carried out accordingly.
‒ Do not clean or wash the machine with aggressive products to
avoid damaging the components.
‒ Do not replace the components with non-original spare parts or
with different design and constructive features.
‒ Do not leave the machine unattended at the end of the work without
shutting it down rst in safety conditions.

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Chapter 2
SAFETY INFORMATION
Employer obligations
– The operator must be trained to acquire the skills required for the
packaging machine or an equivalent machine.
Upon completion of training, make sure the operator has understood
the contents in the use manual, especially the information regarding
safety.
– The operator must possess the required training and meet the
suitable conditions for carrying out the activities in safety conditions.
– The employer must inform the operator on the INCORRECT USES
predictable and on the persistent Residual risks.
– The operator must be capable of reading and understanding the
user manual and must easily identify the safety signs.
– Make sure the machine is ONLY used by adequately trained,
documented and authorized operators.
The employer must draw up the documentation of the specic
training carried out by the operators in order to exhibit it in
case of litigation.

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15C011002
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Chapter 2
SAFETY INFORMATION
2.5. SAFETY WARNINGS ON RESIDUAL RISKS
When 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.
The residual risks are: “all the risks that persists although all safety
solutions have been applied and integrated during machine design”.
The list species the residual risks specic for this type of machine.
‒Danger of arms crushing:
do not put your hands inside the
moving organs.
‒Danger of entanglement:
Do not get close to the conveying
belts to avoid getting entangled
with parts of the body or clothes.

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Chapter 2
SAFETY INFORMATION
2.6. SAFETY WARNINGS FOR REGULATIONS AND
MAINTENANCE
– Keep the machinery in maximum efciency condition and perform
all the scheduled maintenance operations provided for by the
manufacturer.
Proper maintenance will provide the best performance, a longer life
span and constant compliance with safety requirements.
– Enable all machine safety devices before performing any maintenance
and regulation operations.
– Delimitate the work area complying with the safety conditions as
provided by the standards on workplace safety in order to minimise
the risks.
– The maintenance interventions in the areas that are not easily
accessible or dangerous must be carried out after having ensured
the necessary conditions.
– The personnel authorised to carry out the ordinary maintenance
(regulations, replacements etc.) Must possess the necessary
technical and professional knowledge.
– Do not carry out interventions different from those indicated in the
user manual without the written consent of the manufacturer.
– Do not use products that contain corrosive, toxic and inammable
substances.
– Wear the individual protection devices provided by the laws on
workplace safety and indicated in the “instructions for use” and/or
afxed to the machine.
– Replace the components only with original pare parts or with similar
design and functional features.
– The use of similar but non-original spare parts may lead to improper
repairs, altered performance and economic damage.
The components and/or safety devices shall be replaces
only with original spare parts to avoid altering the provided
safety level.
– Use lubricants (oils or grease) recommended by the manufacturer
or with similar chemical-physical features.
– Do not dump into the environment polluting liquids, worn parts and
maintenance waste.
– Select the components according to the chemical and physical
features of the material and carry out the differentiated waste
disposal as per the standards in force.
– All the extraordinary maintenance interventions shall be carried out
exclusively by authorised personnel with particular expertise in the
eld of intervention.
Non compliance with the instructions given may cause risks
for safety and health of the persons and economic damages.

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Chapter 2
SAFETY INFORMATION
2.7. INFORMATION AND SAFETY SIGNALS
The gure indicates the position of the safety and information signs
afxed to the machine.
For each sign is specied the relative description:
H) Information sign:
it indicates the connection point for earthing the machine.
I) Information sign:
indicates the distance between one box and the next feeding the
machine.
Important
Check that the plates are clearly readable, and, if necessary,
replace them with new ones that shall be positioned in the same
places as previously.
A) Electrical hazard sign
Do not access this area: risk of
electrical shock or electrocution.
B) Information sign
Indicates the points for lifting with
a hook device.
C) Information signal:
indicates the operating direction
of the conveying belt
D) Information sign:
machine Stop symbol.
E) Information sign:
it indentied the power cut-off
switch.
F) Information sign:
machine Start symbol.
G) Mandatory sign:
it indicates the obligation to read
the entire documentation before
using the machine.

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1000
min.
1000
min.
1000
min.
1000
15C011004
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Chapter 2
SAFETY INFORMATION
2.8. SURROUNDING AREAS
The illustration depicts the perimeter work areas of the machine.
A) Operator’s working area
(occasional)
B) Box entry zone
C) Box exit zone
D) Sorrounding area
E) Electric power point

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3.1. MACHINE GENERAL DESCRIPTION
– INDEX 50/65 is a feeder-spacer for carton boxes.
The machine is composed of a frame on which the boxes transit
by means of two motorised conveyor belts.
The machine must be installed upstream a taping machine and
downstream a roller conveyor.
‒ Use machine only for the purposes set forth by the manufacturer.
improper use of machine can cause risks to safety and health of
persons, further to economical damage.
‒ The machine is manufactured in various models to satisfy the
different market requirements.
‒ The packs that contain liquids or insubstantial materials must be
suitable for the product and must be perfectly closed and tight in
order to prevent any leaks of the content.
‒ It is equipped with a series of safety devices designed to avoid
anyharm befalling the operator or other persons who come into
contactwith the machine in any way. The machine is produced in
a range ofdifferent models in order to suit market requirements.
‒ This machine is normally installed in workshops or industrial
environments protected from the atmospheric agents.
Use of this machine in explosive environments or when
exposed to the elements is strictly forbidden.
– Just one operator is required to run it, who takes care of the machine
start up operations and the format change phases.
Chapter 3
TECHNICAL INFORMATION