Matco A400 User manual

Basics Manual Semi-automatic
English

Basics Manual
1
Inhoudsopgave
1FOREWORD ................................................................................................................................................2
2SAFETY .......................................................................................................................................................3
2.1 SAFE USE .....................................................................................................................................................3
2.2 QUALIFIED PERSONNEL................................................................................................................................... 4
2.3 ACCIDENT PREVENTION ..................................................................................................................................4
3USE.............................................................................................................................................................5
3.4 OTHER RISKS ................................................................................................................................................ 6
3.5 THE SCOPE OF THIS MANUAL............................................................................................................................6
4INSTALLATION ............................................................................................................................................7
4.1 UNPACKING ................................................................................................................................................. 7
4.2 TRANSPORT .................................................................................................................................................7
4.3 STORAGE.....................................................................................................................................................7
4.4 WASTE DISPOSAL .......................................................................................................................................... 7
4.5 INSTALLING..................................................................................................................................................7
4.6 ELECTRICAL CONNECTION................................................................................................................................8
4.7 MOUNTING ................................................................................................................................................. 8
5MAINTENANCE...........................................................................................................................................9
5.1 GENERAL..................................................................................................................................................... 9
5.2 SPARE PARTS................................................................................................................................................ 9
5.2.1 Maintenance schedule................................................................................................................... 10
5.2.2 Lubricants ...................................................................................................................................... 10
5.3 INSPECTIONS ..............................................................................................................................................11

Basics Manual
2
These operating instructions for the pallet wrapping machine are made so:
-It is safe to use;
-One is able to make settings;
-One can perform maintenance.
Additionally included in this basic manual are:
•Machine specific manual
•CE declaration
SERVICE
In the event of a malfunction, contact:
Matco International.
Tel: [phone]
E-mail: [e-mail]
SPARES
Order spare parts at:
Matco International
Hamburgweg 16,
7418 ES Deventer, Nederland
Tel: [phone]
E-mail: [e-mail]
1Foreword

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3
2Safety
2.1 Safe use
We use the following symbols to warn about dangers and possible sources of risk. Get to know them
well! Ignoring a warning can lead to personal injury and/or damage to this equipment or other
machinery.
Attention:
Failure to observe warnings may result in a fatal accident, personal injury or
damage to equipment.
Attention:
Live electrical components. Failure to observe warnings may result in a
fatal accident, personal injury or damage to equipment.
Attention:
Danger from rotating parts
Prohibited:
Risk of entering a dangerous area. Prohibited for unauthorised personnel!
Attention:
Heat hazard, burn hazard

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2.2 Qualified personnel
Our definition of "qualified personnel" in this context is "personnel with a thorough knowledge of the
equipment itself and how to operate and maintain it safely". Qualified personnel must be physically fit
enough to perform the necessary tasks, have a good knowledge of all the relevant safety precautions
and be trained to install, operate and/or maintain the equipment safely. The company using the
equipment is responsible for ensuring that the personnel comply with these conditions.
2.3 Accident prevention
1. Before starting to work with the installation, the manual must first be studied.
2. Use of the installation by unauthorised personnel is prohibited.
•
3. Never allow persons to use the equipment if they are under the influence of medication that
may impair reaction times or are not in physically fit condition for operating the installation.
4. Ensure at all times that work / maintenance / service on the installation is done safely and
without voltage. Make sure that the installation cannot be switched on accidentally by locking
the main switch.
5. Safety guards must be checked before starting the machine – they may not be loose or
removed. This also applies to the foot protection under the film carriage.
•
6. If it is necessary to remove any safety device to allow installation, repairs or maintenance, the
safety device must be replaced immediately after completing the task.
•
7. Keep limbs and clothes away from rotating parts. Do not wear neckties or loosely hanging
clothes when using or maintaining machines with rotating parts. Remove wristwatches, chains
and similar jewellery. Cover or tie up long hair before carrying out any task on or with the
machine.
•
8. Only machines with a suitable protection rating may be used in humid conditions.
•
9. Do not use the equipment in an area with risk of explosion.
•
10. Always use the equipment in a well-ventilated space.
•
11. If a pneumatic hold-down plate is used, the supply air line will remain under pressure when
entering the danger zone. Other parts will become voltage / energy-free.
Dangerous situations may result from failure to comply with the
conditions listed above.

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3Use
3.1 Intended use
The fully automatic wrapping machine, hereinafter also referred to simply as “the installation”, may
only be used for wrapping pallets of the suitable products that meet the data as stated in the
description. In case of doubt, the manufacturer must be consulted for permission.
Using the installation in any way other than specified in the description can lead to danger, e.g. it can
damage the wrapping machine and/or threaten the safety of operator or other persons near the
installation.
To ensure safety, all personnel must read these operating instructions thoroughly before commissioning
the installation, troubleshooting or performing maintenance.
We would like to call your attention to chapter 2 Safety, which specifies the intended use and the unsafe
situations that cannot be prevented through the design and manufacture of the machine.
3.2 Improper use
The installation may not be used in the following situations:
•When it is in poor condition
•In an environment with risk of explosion (unless the machine is specially adapted)
•With unsuitable materials and consumables
•Without full compliance with the values specified under "Technical data".
•In a humid environment
The following materials may not be processed in the installation:
•Materials presenting a risk of explosion or fire
•Caustic and corrosive materials
•Foodstuffs (unless the machine is specially adapted)
3.3 Intended use
The installation is intended for industrial applications.

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3.4 Other risks
In terms of design and construction, everything has been done to protect users from possible dangers.
However, some risks cannot be entirely eliminated. Users must be aware of the following:
•The risk of entering a dangerous area
•Control line cylinder pressure plate remains under pressure in all cases
•Control line of the film clamp remains under pressure (for turntable winder with 90 ° infeed
or outfeed).
The risk of entering a dangerous area
It is possible to enter dangerous areas when loading and unloading products.
Attention: Prohibited for unauthorised personnel!
Risk of entering a dangerous area.
3.5 The scope of this manual
This manual is only valid in combination with all the other documentation included in the user manual.
For special versions, this manual may be supplemented with extra specifications and/or additional
documentation.
The images only show the installation's essential parts.

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4Installation
Attention:
Only allow qualified personnel to perform the following tasks. Observe all
the safety instructions in this manual and all other relevant documentation.
4.1 Unpacking
Unpack the installation carefully and check for any transport damage. Retain the pallet, fixings and
wrapping material for possible future transport or dispose of it in accordance with the appropriate
waste handling regulations.
4.2 Transport
•For weight specifications check the “Machine specific manual”. Only use suitable lifting gear.
•Protect the installation from damage, damp and dust, using suitable packing materials.
•Avoid bumps and shocks.
4.3 Storage
Do not store the installation outdoors! Protect it against dust and fluctuating temperatures
(condensation formation).
4.4 Waste disposal
When the installation reaches the end of its working life or there is no further use for it, the
equipment should be handled according to the currently valid waste disposal regulations.
4.5 Installing
Only install the installation in a location that conforms to the stated safety classification. Install the
installation in a well-ventilated space. Do not put it in an area with any risk of explosion!
Protect the installation against vibration. Remove transport protection materials (when present).
Make sure there is enough free room, especially above the installation. Check the "Machine specific
manual" for dimensions.

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4.6 Electrical connection
Attention:
Hazardous electrical voltage. Failure to observe warnings and safety measures
may result in a fatal accident, personal injury or damage to equipment.
-Connecting to a power source:
•The preferred way to connect the installation is via a power cable with a plug, connected to an
earthed mains socked that is protected by a circuit breaker or fuse.
•The power supply must, in principle, comply with applicable requirements regarding
acceptable voltage variations, ripple, attenuation of higher harmonics, etc.
4.7 Mounting
Attention:
All of these activities may only be performed under the supervision of
qualified personnel from the manufacturer or an authorised representative!
-The concrete floor must be completely flat and horizontal within the tolerances set by the
installation
-Anchor machine parts to concrete floor.

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5Maintenance
Attention:
-Switch off the main switch and secure it with a padlock before performing
any maintenance on the installation.
-Ensure that no one else can switch on the installation.
-Ensure that safety guards and suchlike are installed when the installation is
activated.
5.1 General
Preventive maintenance will ensure that the installation has a longer working life. This means that the
condition of various parts of the installation must be inspected on a weekly, monthly or annual basis.
The environmental conditions will affect the service life. The specified maintenance frequency applies to
normal operational conditions (8 hours per day, 5 days per week, at 20C, in a clean environment).
When subjected to more demanding conditions we recommend performing maintenance more
frequently. Ensure that moving parts are free of dirt.
Please refer to the maintenance schedule in section 5.2.1 Maintenance schedule for information about the
maintenance frequency required for the different systems and parts.
5.2 Spare parts
The parts lists for the machine parts describe the parts used, which can be ordered as spare parts.
Bij bestelling van onderdelen dient op het volgende gelet te worden:
1Provide the machine's serial number.
2For electrical parts, provide the (schematic) position number, description, article number and
manufacturer's name.
3For mechanical parts, provide the drawing number, position number, article number and
description.
To facilitate the rapid repair of a possible malfunction, we recommend keeping a number of spare
parts in stock.

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5.2.1 Maintenance schedule
Maintenance frequency
8
hours
40
hours
100
hours
200
hours
500
hours
1000
hours
2000
hours
Clean daily
X
Check cutting wire
X
Check cutting blade
X
Clean photocell lens
X
Chain under turntable
3
Sprockets turntable
X
Timing belt pulley for pre-
stretch
X
String for pre-stretch
X
Bearings
X
Running wheels film
carriage
X
Running wheel turntable
X
Limit-/proximity switch
X
Gearmotors
X
1
Electrical system
X
The numbers in the maintenance schedule refer to the applicable products as shown in the lubricants table.
Attention:
Check safety/instruction stickers. If they are damaged or missing, they must be
replaced.
5.2.2 Lubricants
SYMBOL
LUBRICANT
SHELL
BP
ESSO
MOBIL OIL
TEXACO
GLEITMO
1
OMALA 220
ENERGOL
GR-XP 220
SPARTAN
EP 220
MOBILGEAR
630
MEROPA 220
2
OMALA 680
ENERGOL
GR-XP 680
SPARTAN
EP 680
MOBILGEAR
636
MEROPA 680
3
TONNA T68
MACCURAT 68
FEBIS K 68
EP220
VACTA.4
WAX LUBRI-
CANT X68
4
ALVANIA R
ENERGREASE L2
BEACON 2
MOBILUX 2
MULTIFAK EP2
5
TELLUS 46
HPL 46
NUTCO H46
DTE 26
RANDO HD46
6
TORCULA 32
ENERGOL
RD-E 80
AROX EP 56
ALMOBIL 1
ARIES 32
7
TELLUS 15
RANDO HDZ 15
8
RETINAX WB
STARPLEX
PREMIUM 1
(depends on the
application)
9
FIN
GREASE
OG
10
UNIREX EP

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5.3 Inspections
Attention:
Only allow qualified personnel to perform the following tasks. Observe all the
safety instructions in this manual and all other relevant documentation.
Attention:
Tracing faults can possibly require checking while the installation is under
power. Take care to observe the safety regulations concerning working on live
equipment (active parts). Ignoring them can lead to danger of electric shock.
Inspections
Tasks
Electrical system
-Check the switches, emergency stops and other operating buttons to ensure
they are working correctly.
-Check the indicator lights.
-Check and test the thermal protection devices.
-Check the contactors and relays for burned contacts and humming.
-Check the cabling and connections.
-Check the photocells and reflectors to ensure correct operation and adjustment
(lenses must be clean).
-Check the limit and proximity switches for correct operation and adjustment.
Motors/gear units
-Check the fan.
-Check that the fan cover is undamaged.
-Check the oil level in the gearbox (top up if required).
-Check that the fastening bolts are tightened and tighten them when required.
-Check and lubricate moving parts if required.
Turntable
-Check the tooth flank wear of the chain wheels / sprocket / slewing bearing
-Check and lubricate the chain wheels / sprocket / slewing bearing
-Check whether the drive gear on the motor shaft has expired. If necessary, align
and secure with the locking bolts.
Column
-Checking the lifting strap for wear.
If wear is visible, the tire should be replaced
Film carriage
-Check that there are no film residues in the brake system.
-Check the conductivity of the film carriage in the mast via running wheels.
-The running wheels must have a max. clearance of 2mm in relation to the
guide. Replace if necessary due to wear.
-The guiding construction for the film carriage in the mast must NEVER be
lubricated!
-Check the parallel running of the film carriage.
-The film carriage may max. 2 - 3mm at an angle
-Check the timing belt pulley and the timing belts of the front rack for wear.
Replace if necessary.
AW ( implementation )
Pneumatic system
-Regularly check that the filter is clean. If required, clean or change.
-Regularly drain any accumulated condensation
-Check hoses, cylinders, hose connections and valves for leaks
Film inlay-unit
-Check the condition of the rubber of the film inlay jaws. These must not have
become too hard and / or damaged. Replace if necessary.
-Check that the film inlay jaws close properly. These must close properly over
the entire length. Readjust or replace if necessary.
-Check that the sides on which the film slides are smooth and without damage.
Update or replace as necessary.
-No film residues in the film inlay. These can prevent proper operation.

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Cutting wire construction
(for A700 AW machine)
-Check the condition of the glow / cutting wire
-Check, and if necessary adjust the cutting wire to the correct tension.
-Check whether the cutting wire is clean of dust or impurities
-Check that the cutting wire does not come into unwanted contact with other
parts (such as cables and air hoses)
Cutting blade construction
(for A900 AW machine)
-Check the band tension of the band cylinder.
-If the band is not tight on the cylinder, the band must be readjusted or replaced.
Adjust or replace in accordance with the regulations of the supplier.
-Check the condition of the band. The ribbon must not be damaged. Replace if
necessary.
-Check the condition of the cutting blade. The cutting knife should cut and cut
through the foil. Replace if necessary.
-Check free height space between the bottom of the cutting blade fixation arm
and the conveyor track construction. The bottom of the cutting blade fixation
arm must remain at least 5mm above the top of the conveyor track. Adjust if
necessary.

Matco A400 Manual
English

Manual Matco A400
Table of Contents
1OPERATION ................................................................................................................................................1
1.1 ESSENTIAL COMPONENTS................................................................................................................................ 1
1.2 DIMENSIONS ................................................................................................................................................2
2TECHNICAL DATA........................................................................................................................................3
2.1 MACHINE ....................................................................................................................................................3
2.2 ELECTRIC .....................................................................................................................................................3
2.3 DIMENSIONS AND WEIGHT .............................................................................................................................. 3
3OPERATION ................................................................................................................................................4
3.1 INSERTING FILM ROLL ..................................................................................................................................... 4
3.2 CONTROL PANEL ........................................................................................................................................... 5
3.3 EXPLANATION OF CONTROL PANEL....................................................................................................................6
3.4 CONTROL SCREENS ........................................................................................................................................ 7
3.4.1 Main menu ...................................................................................................................................... 7
3.4.2 Manual operation............................................................................................................................ 8
3.4.3 Programme parameters .................................................................................................................. 9
3.4.4 Messages....................................................................................................................................... 12
3.4.5 Supplier information...................................................................................................................... 14
3.4.6 Statistics ........................................................................................................................................ 14
3.4.7 Service / System data .................................................................................................................... 15
4TREE DIAGRAM OF MENUS.......................................................................................................................16
5COMPONENTS..........................................................................................................................................17
5.1 TURNTABLE................................................................................................................................................17
5.2 COLUMN ...................................................................................................................................................19
5.3 FILM CARRIAGE...........................................................................................................................................22
5.4 DRIVE SYSTEM ............................................................................................................................................ 31
5.5 CONTROL PANEL ......................................................................................................................................... 33
5.6 FILM CUTTING UNIT ..................................................................................................................................... 35

Manual Matco A400
1
1Operation
1.1 Essential components
Caution:
The machine may not be used if protective covers are not present
Photocell load height
Drive protection
Film carriage
Column
Drive system
Control panel
Base protection
Lower frame
Turntable
Foil cutting unit

Manual Matco A400
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1.2 Dimensions

Manual Matco A400
3
2Technical Data
2.1 Machine
Speed
3-12 revolutions per minute
Clearance height
Min. 3000mm
Environment
Clean, dry, non-aggressive
Operating temperature
0 to +45 oC
2.2 Electric
Connection
1x230 VAC - 50 Hz, with protective earth
Installed power
1.1 kW
Insulation class
IP 54
2.3 Dimensions and weight
Weight
Approx. 500 kg
Dimensions (L x W x H)
2550x726x2772mm, turntable roller Ø1650mm
(Depending on model and version)
Product dimensions
1200x1000mm
Loaded height
Min. 500mm / max. 2500mm
Weight loaded pallet turntable
Min. 200kg / max. 2000kg
Film width to be processed
500mm
Film thickness
17 –35 μ

Manual Matco A400
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3Operation
3.1 Inserting film roll
1 - Place a film roll (direction of unwinding depends on the side of the cling).
2 - Apply film according to the illustration below.
CI = CLING INSIDE (adhesive side inside)
This is how the film has to be placed in the braking system if the adhesive side is on the inside of
the film, when unwinding it from the film roll.
CO = CLING OUTSIDE (adhesive side outside)
This is how the film has to be placed in the braking system if the adhesive side is on the outside of
the film, when unwinding it from the film roll.
Film
Film diameter
Max. 230 mm
Sleeve diameter
76.4 mm (3 inch)
Film width
Max. 500 mm
Thickness
17 - 35 μm

Manual Matco A400
5
3.2 Control panel