Omni Group Superplus User manual

Omni Superplus

EC- DECLARATION OF CONFORMITY
under Annex II.A ofthe 2006/42/EC Directive on Machines
DECLARES
Under hissole responsibility that the machine TURNTABLE MACHINE WITH AUTOMATIC
WORKING CYCLE designed for winding pallet loads with extensible film
Model: Omni SUPERPLUS
IS IN CONFORMITY with the following provisions:
-European Community Directive 2006/42/EC – on the safety of machines;
NOTE: the Directive 2006/42/EC replaced the Directive 98/37/EC and its amendments
-European Community Directive 2014/30/EU and amendments – on Electromagnetic Compatibility;
NOTE: the Directive 2014/30/EU replaced the Directive 2004/108/CE and its amendments
-National decrees that implement the Community Directives mentioned above.
List of the Harmonized Technical Rules applied:
EN 12100-1
Safety of machinery -- Basic concepts, general principles for design -- Part 1: Basic
terminology, methodology
EN 12100-2
Safety of machinery -- Basic concepts, general principles for design -- Part 2: Technical
principles
EN 60204-1
Electrical equipment of the machines Part 1: General requirements
EN 61000-6-2
Electromagnetic compatibility (EMC) – Part 6-2: Generic standards – Immunity for
industrial environments
EN 61000-6-4
Electromagnetic compatibility (EMC). Generic standards. Emission standard for industrial
environments
With a view to continuous improvement of this machine’s functions, some of its components and/or
characteristics could be modified without notice and without prejudice to the validity of this
document. If differences are found between the contents of this manual and the actual machine
operation, please communicate them to the Builder.
Omni SUPERPLUS EN IGM_REV63

INDEX
GENERAL INFORMATION.............................................................................................................7
1.1 AIM OF THE MANUAL..........................................................................................................7
1.2 CONSERVING THE MANUAL...............................................................................................7
1.3 BUILDER...............................................................................................................................7
1.4 CERTIFICATION...................................................................................................................8
1.5 WARRANTY..........................................................................................................................8
1.6 TECHNICAL ASSISTANCE...................................................................................................8
1.7 TASKS TO BE CARRIED OUT BY THE CUSTOMER...........................................................8
1.8 SYMBOLS AND TERMS.......................................................................................................8
1.9 MACHINE IDENTIFICATION.................................................................................................9
1.10 GENERAL SAFETY INFORMATION.................................................................................10
DESCRIPTION OF THE MACHINE..............................................................................................15
2.1 OPERATING PRINCIPLE....................................................................................................15
2.2 COMPONENTS OF THE MACHINE....................................................................................15
2.2.1 MAIN OPTIONAL GROUPS..........................................................................................16
2.2.2 ACCESSORIES............................................................................................................16
2.3 TECHNICAL DATA..............................................................................................................16
2.4 PLATES AND PICTOGRAMS .............................................................................................17
2.5 OVERALL DIMENSIONS OF THE MACHINE.....................................................................21
2.6 NECESSARY SPACE .........................................................................................................21
2.7 ELECTRICAL TOLERANCES OF THE MACHINE..............................................................21
2.8 POWER EQUIPMENT.........................................................................................................21
2.9 ELECTROMAGNETIC ENVIRONMENT..............................................................................22
2.10 ENVIRONMENTAL CONDITIONS ....................................................................................22
2.11 SOUND EMISSIONS.........................................................................................................22
2.12 VIBRATIONS.....................................................................................................................22
2.13 GAS, DUST AND FUME EMISSIONS...............................................................................23
SAFETY DEVICES.......................................................................................................................25
3.1 EMERGENCY STOP...........................................................................................................25
3.2 SAFETY DEVICES..............................................................................................................26
3.3 PROTECTIONS AND FIXED REPAIRS..............................................................................26
3.4 SAFE USE OF THE MACHINE ...........................................................................................29
3.5 CORRECT USE ..................................................................................................................30
3.6 INAPPROPRIATE AND INCORRECT USE.........................................................................30
3.7 OTHER RISKS....................................................................................................................31
TRANSPORT AND INSTALLATION.............................................................................................33
4.1 HANDLING AND TRANSPORT...........................................................................................33
4.2 PACKAGING.......................................................................................................................34
4.3 STOCKING..........................................................................................................................34
4.4 INSTALLATION...................................................................................................................35
4.5 PRELIMINARY INSPECTIONS...........................................................................................36
Omni SUPERPLUS EN IGM_REV65

4.6 ELECTRICAL CONNECTION..............................................................................................37
4.7 PNEUMATIC CONNECTION...............................................................................................38
MAINTENANCE............................................................................................................................39
5.1 GENERAL INFORMATION ON MAINTANANCE.................................................................39
5.2 MECHANICAL PARTS MAINTENANCE .............................................................................40
5.2.1 GREASING...................................................................................................................40
5.2.2 CHAIN TENSIONING....................................................................................................41
5.3 ELECTRICAL PARTS MAINTENANCE...............................................................................41
5.4 PNEUMATIC PARTS MAINTENANCE................................................................................43
5.5 EXTRAORDINARY MAINTENANCE...................................................................................44
5.6 CLEANING..........................................................................................................................44
DEMOLITION AND DISPOSAL ....................................................................................................45
6.1 DISPOSAL OF PRODUCTION WASTE ..............................................................................45
6.2 MACHINE DEMOLITION.....................................................................................................45
Omni SUPERPLUS EN IGM_REV66

CHAPTER 1
GENERAL INFORMATION
1.1 AIM OF THE MANUAL
This manual is an integral part of the machine and was drawn up by the building company in its
own language (Italian) to provide all the necessary information for a correct and safe use
throughout its lifecycle (from transport, delivery, installation, use and maintenance to disposal). The
manual is divided into sections, chapters and paragraphs, so that the information structure
complies with the EU Machinery Directive and with the specific harmonized standards.
Before carrying out any operation on the machine, the operators and skilled technicians must read
carefully the instructions included in this manual and must follow them carefully. In case of doubts
on the interpretation of the instructions, please turn to the Builder for the necessary explanations.
The only way to ensure a correct functioning in the long run and to prevent dangerous situations
for people and objects from taking place is to follow these instructions carefully.
Please carefully read this manual before installing and starting the machine.
1.2 CONSERVING THE MANUAL
The instruction manual should be kept near the machine throughout its lifecycle, should be kept far
from any agent that might deteriorate it and should be available for all the operators and skilled
technicians that might need it. The manual should be sent with the machine if the machine is sent
to a new user or owner.
1.3 BUILDER
Wide experience and radical innovation have made the building of this cutting-edge, cost-effective
wrapping machine possible.
If you need information on use and maintenance, or if you wish to request spare parts, please
give the identification data of the machine placed on the Builder plate.
Omni SUPERPLUS EN IGM_REV67

1.4 CERTIFICATION
The machine was manufactured in conformity with the EC Directives in force when the machine
was placed on the market, as stated clearly in the declaration of conformity, therefore it complies
with the safety requirement of the Machinery Directive.
1.5 WARRANTY
The machine is covered by a warranty on materials for the period indicated in the contractual
documents. The buyer loses the right to the warranty if and when modifications or repairs are
made to the provision without the manufacturer's consent. Labour and service call charges are not
covered by the warranty. In no case can compensation for damages be demanded. For further
clarifications on guarantee assistance conditions refer to the sales contract.
1.6 TECHNICAL ASSISTANCE
Ordinary and extraordinary maintenance must be carried out in compliance with the instructions
contained in this manual. Should any case occur which is not included here, and for any kind of
assistance, please contact directly the Builder, referring to the data written on the plate located on
the machine:
-machine model;
-serial number;
-building year.
Prompt and precise answers can be only guaranteed if the data are referred correctly.
The Builder disclaims any liability for any damage to persons, property or environmental goods,
arising from improper use of the machinery, from mistakes in the installation or usage, and due to
incompetence, carelessness or neglect with regards to the advice and instructions contained in the
manual.
The Builder disclaims any liability for any damage to persons or property, or for any malfunction of
the machine, in case of use of non-original spare parts or non-suggested cleaning and
maintenance products.
1.7 TASKS TO BE CARRIED OUT BY THE CUSTOMER
The Customer shall carry out the activities indicated in the documents enclosed in the sale contract
and within the time agreed with the Builder. If there are not any different agreements the following
tasks have to be carried out by the Customer:
-providing the premises and taking care of any brickwork or duct system that might be
requested;
-taking care of the sources of energy and of the connection to them, in conformity with the Laws
in force in the country in which the machine is used.
1.8 SYMBOLS AND TERMS
The most important parts of the text are in bold and are signalled by the following symbols that are
placed before them.
Omni SUPERPLUS EN IGM_REV68

[email protected]
www.omnigroup.com.au
Ph : 1300 764 963
DANGER: means that it is necessary to pay attention in order to prevent
dangerous situations from taking place and from putting seriously at risk
the safety and the health of people or from causing damages to objects.
BEWARE: highlights critical functions or
key information. Pay careful
attention to the text highlighted by this symbol.
INFORMATION: highlights very important information.
MAINTENANCE: refers to information on periodical maintenance that has to
be carried out by skilled technicians.
OPERATOR: person who fulfils the necessary requirements and skills and has all the necessary
information for the ordinary use of this machine.
SKILLED TECHNICIAN: person who fulfils the necessary requirements to carry out interventions
of ordinary maintenance and who has precise information and skills relevant to the specific
intervention sector.
1.9 MACHINE IDENTIFICATION
The machine is identified by means of the Builder plate located on the machine column. The
following data are written on the plate.
MACHINE MODEL
SERIAL NUMBER
BUILDING YEAR
MACHINE MASS (kg)
ABSORBED POWER (kW)
SUPPLY VOLTAGE (V)
CAPACITY (kg) (MAXIMUM WEIGHT
OF LOADING)
The machine identification plate, listing the technical data, the serial number and the marking, is
visibly located on the electrical panel, as shown in the picture below.
Omni SUPERPLUS EN IGM_REV69

THE IDENTIFICATION PLATE MUST NEVER BE REMOVED.
1.10 GENERAL SAFETY INFORMATION
During project and manufacturing phases, the Builder paid careful attention to all those situations
that might cause risks to the safety and the health of people. The relevant laws were fully
respected and all the “rules of good building technique” were applied. The aim of this type of
information is to raise the awareness of users on the importance of preventing any risk, always
using caution.
Carefully read the information reported in the manual and placed directly on the machine,
especially safety information.
Please read this manual carefully before using or servicing the machine.
Do not tamper with, sidestep, eliminate or bypass the safety and warning devices
installed on the machine. Non-compliance with this requirement can cause serious risks
and can compromise the safety of people.
Omni SUPERPLUS EN IGM_REV610
[email protected]
www.omnigroup.com.au
Ph : 1300 764 963

Never start the machine with the fixed or mobile guards disassembled.
Never inhibit the emergency features installed on the machine.
The regulating operations, with reduced safety, must be done by a qualified technician
and during their progress it is necessary to prevent access to the machine by
unauthorized persons.
After adjusting the machine under reduced safety conditions, restore proper safety
conditions as soon as possible.
Make sure that the machine is connected to an efficient grounding circuit.
Do not modify, for any reason, any part of the machine in order to adapt other devices.
In case this condition is not respected, the Builder CANNOT be held responsible for
malfunction or other related problems. Request any modifications to the Builder’s
Commercial or Technical Office.
When in use, some parts of the machine are subject to dangerous voltage. Disconnect
power supply and block reinsertion devices before servicing the machine or any
equipment connected to it.
Every intervention on the system or the equipment must be exclusively carried out by
qualified electrical maintenance workers.
Prevent water from dripping onto the electrical panel.
Staff persons operating in any way on the machine must have precise technical skills
and competences and must have acquired experience in the field. The lack of any of
these requirements may compromise the safety and efficiency of the machine.
The operation space that surrounds the machine should be clear of obstacles, cleaned
up and very illuminated.
Omni SUPERPLUS EN IGM_REV611

The lighting level should always be such as to guarantee the safest possible working
conditions. Should any maintenance operation be necessary in areas or parts of the
machine with poor lighting, the maintenance staff must be equipped with a portable
lighting system.
Use accident-prevention equipment. Make sure that sleeves are tightened up around the
wrists or tucked up. Wear undamaged working clothing and use common sense when
operating the machine.
Wear suitable clothing and individual protection devices according to the used
products.
Do not use any neckties, bracelets, rings or other things that swinging could be
dangerously entangled in parts that are fixed or in motion.
Use the machine in normal psycho-physical conditions.
Should it be necessary to have an assistant or some assistants, train them and inform
them on the type of activity to be carried out.
The location of fire extinguishers and their operating instructions must be indicated in
the departments.
Make sure that the staff members know how to stop the machine in an emergency.
Do not leave the machine unattended when operating.
Only carry out the actions expressly included in the functional cycle of the machine.
Before starting production, make sure that no people are in the work area.
Omni SUPERPLUS EN IGM_REV612

Tighten all screws, bolts and lock nuts of every adjustable mechanical element following
normal tightening values, without using any levers or hitting any spanners.
Never climb onto the machine while operating.
All plates and pictograms must be kept entirely readable. If the identification plate
deteriorates with use and turns unreadable, even just partly, a new one should be
requested from the Builder, referring to the data contained in this manual or written on
the original plate.
Do not clean or lubricate any parts of the machine when operating.
Do not clean the machine with water nor aggressive products, even if diluted.
Omni SUPERPLUS EN IGM_REV613

CHAPTER 2
DESCRIPTION OF THE MACHINE
2.1 OPERATING PRINCIPLE
This machine is a rotating table wrapping machine to wrap palletized loads with stretch film. By
means of an automatic wrapping cycle, it maintains the load’s form, dimensions and height while
wrapping it.
2.2 COMPONENTS OF THE MACHINE
A. Frame: it is made up of a framework with plates and steel sections in order to provide a strong
support to the column and the rotating platform.
B. Column:it is the part of the machine that supports the film roll carriage, the control panel and
the electronic control devices.
C. Rotating platform:it consists of a circular steel sheet, on which the loads to be wrapped are
placed. The rotation takes place by means of a gear motor with chain drive.
D. Power pre-stretch carriage:it allows the film to be pre-stretched before wrapping.
E. Control panel: it contains all the buttons for the control and running of the machine. It is located
on the column. It is built according to the Directives and to the rules in force.
F. Plier: device for the automatic cut and the welding of the film.
A
B
D
E
F
C
Omni SUPERPLUS EN IGM_REV615

2.2.1 MAIN OPTIONAL GROUPS
Motorized top press: it allows to stabilize the load during the wrapping phase. It is controlled by the
logic of the machine. See separate attachment for further details.
2.2.2 ACCESSORIES
The Builder has foreseen and designed a wide range of accessories integrating the machine.
The available accessories are:
-adjustable motorized pre-stretch;
-ramp to access the table with transpallets;
-clamps to fix the ramp to the ground ;
-pit frame;
-machine feet allowing the use of pallet stacker;
-disconnector;
-stopped by 90°;
-black loads photocell;
-external pushbutton to return to the program memorized;
-Start or Reset or Esc or Stop by external pushbutton;
-light signal on the main column.
Accessories, especially if combined, are sufficient to satisfy main needs, improving the machine’s
performance and simplifying its use.
The description and the operating instructions of additional accessories are enclosed to the main
operating and maintenance “base” machine manual.
2.3 TECHNICAL DATA
The following are the data and the technical characteristics for a correct installation.
Omni SUPERPLUS EN IGM_REV616

SUPPLY VOLTAGE (V) 230
ABSORBED POWER (kW) REFER TO DATA ON PLATE
MASS (kg) REFER TO DATA ON PLATE
DIMENSIONS (mm) REFER TO PARAGRAPH 2.5
MAXIMUM LOAD WEIGHT (kg) REFER TO DATA ON PLATE
ROTATION SPEED (RPM) 12
ROTATION WISE CLOCKWISE
2.4 PLATES AND PICTOGRAMS
Please find below a list of the warning pictograms and plates located on the machine.
INDICATES DANGEROUS VOLTAGE.
MEANS DANGER OF COMPRESSION OF THE UPPER LIMBS.
Omni SUPERPLUS EN IGM_REV617

MEANS SCALDING DANGER.
MEANS CUT DANGER.
MEANS DANGER OF INJURY BY MOVING PARTS.
The plates and pictograms must be located on the machine as shown in the pictures.
Omni SUPERPLUS EN IGM_REV618

Omni SUPERPLUS EN IGM_REV619

Do not remove plates or pictograms.
Omni SUPERPLUS EN IGM_REV620

2.5 OVERALL DIMENSIONS OF THE MACHINE
The table diameter can be 1650 mm, 1800 mm or 2000 mm.
The standard height of the machine is 2463 mm, according to the Client’s needs, the machine can
be 1963 mm, 3188 mm or 3463 mm high.
H=2463 (STANDARD) – H=1963 (OPTIONAL) – H=3188 (OPTIONAL) – H=3463 (OPTIONAL)
2.6 NECESSARY SPACE
The necessary space for using and maintaining the machine can be deduced from the dimensions
of the machine itself and from the need to load pallets onto the rotating platform. Under normal
usage and maintenance conditions it should therefore be possible to operate comfortably, without
any obstacles to accessing the machine, in any of its parts.
2.7 ELECTRICAL TOLERANCES OF THE MACHINE
Working voltage: the electrical equipment is designed to operate a nominal voltage of 230 V. Any
variations will compromise the life of the electrical equipment. If variations larger than the standard
values are foreseen, please contact the machine Builder.
2.8 POWER EQUIPMENT
The label with the power equipment data is located in a readable position. On it there are written
the builder’s name, the symbol CE, the serial number, the supply voltage and the absorbed power
data, in accordance with regulations currently in force.
Omni SUPERPLUS EN IGM_REV621

2.9 ELECTROMAGNETIC ENVIRONMENT
The machine can run in a correct way both in an industrial and in a residential electromagnetic
environment. The conformity is guaranteed by the implementation of the Harmonized Technical
Norms.
2.10 ENVIRONMENTAL CONDITIONS
The machine is designed to operate in indoor environments, with limited exposure to dust and
humidity and in an environment with a temperature ranging between 5°C and 40°C.
The machine can work in environments in temperatures less than 5°C or higher than 40°C only if
equipped with specific heating or cooling kits.
Environmental conditions different from those prescribed may cause breaking and malfunction.
Should environmental conditions be very variable, special measures will have to be agreed with
the Builder.
The machine is not designed to operate in explosive atmospheres. It is therefore forbidden to
use the machine in explosive atmospheres.
The machine has to be installed within a building with a strong and well-levelled flooring. The
building lighting has to comply with the laws in force in the country in which the machine is installed
and, in any case, it has to ensure adequate visibility on the whole working area that is also used for
the handling of products.
2.11 SOUND EMISSIONS
After examining the values of Leq during a test with the machine complete with all its components
and placed in an environment without any other sources of noise, the Continuous and Equivalent
Level of sound pressure considered in scale “A” [Leq in dB(A)] at the distance of 1 m when the
machine is operating will never be higher than 76 dB(A), as shown in the proof conditions.
The noise values indicated are emission levels and are not necessarily safe operation levels.
Although there is a relation between emission and exposure levels, it is not possible to use this
relation in a reliable way in order to determine whether other precautions are necessary. The
factors which determine the exposure level of the manpower include the duration of the exposure,
the features of the working place and other sources of noise (number of machines, contiguous
processes, etc.).
Furthermore, the allowed exposure levels can change from country to country.
In any case the information included will help the operator to evaluate any dangers and risks in a
more precise way.
2.12 VIBRATIONS
If the machine is used according to the instructions for a correct use, the vibrations cannot cause
any dangerous situations.
Omni SUPERPLUS EN IGM_REV622

2.13 GAS, DUST AND FUME EMISSIONS
If the machine is used according to the instructions for a correct use, there are no gas, dust or
fume emissions, nor emissions of dangerous substances.
Omni SUPERPLUS EN IGM_REV623