Robopac ROTOPLAT 108-308-508-708 User manual

ROTOPLAT 108-308-508-708
ROTOPLAT LP 308FR-508PDS-708PVS
ROTOPLAT TP 108-308-508-708
USE AND MAINTENANCE MANUAL
ENG

ENG
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Index
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Index
1. GENERAL INFORMATION ................................................................................................................................. 6
1.1. PURPOSE OF THE MANUAL ............................................................................................................................. 6
1.2. MANUFACTURER AND MACHINE IDENTIFICATION ....................................................................................... 7
1.3. TERMS AND DEFINITIONS ................................................................................................................................ 8
1.3.1. PICTOGRAMS INDICATING DANGER ....................................................................................................... 9
1.3.2. PICTOGRAMS INDICATING PROHIBITION ............................................................................................. 10
1.3.3. PICTOGRAMS INDICATING OBLIGATION............................................................................................... 11
1.4. HOW TO REQUEST ASSISTANCE .................................................................................................................. 12
1.5. ATTACHED DOCUMENTATION ....................................................................................................................... 12
1.6. HOW TO READ THE INSTRUCTIONS FOR USE ............................................................................................ 12
2. SAFETY INFORMATION...................................................................................................................................13
2.1. GENERAL SAFETY WARNINGS ...................................................................................................................... 13
2.2. SAFETY WARNINGS FOR HANDLING AND INSTALLATION......................................................................... 14
2.3. SAFETY WARNINGS FOR USE AND OPERATION ........................................................................................ 15
2.4. SAFETY WARNINGS RELATED TO MISUSE.................................................................................................. 16
2.4.1. REASONABLY FORESEEABLE MISUSE ................................................................................................. 16
2.4.2. EMPLOYER OBLIGATIONS ...................................................................................................................... 16
2.5. SAFETY WARNINGS ON RESIDUAL RISKS ................................................................................................... 17
2.6. SAFETY WARNINGS FOR ADJUSTMENTS AND MAINTENANCE ................................................................ 20
2.7. SAFETY WARNING FOR THE ELECTRICAL EQUIPMENT ............................................................................ 20
2.8. INFORMATION AND SAFETY SIGNS .............................................................................................................. 21
2.9. PERIMETER AREAS ......................................................................................................................................... 23
3. TECHNICAL INFORMATION ............................................................................................................................24
3.1. MACHINE GENERAL DESCRIPTION............................................................................................................... 24
3.1.1. MACHINE MODELS DESCRIPTION ......................................................................................................... 26
3.2. DESCRIPTION OF THE OPERATION CYCLE ................................................................................................. 27
3.3. SAFETY DEVICE DESCRIPTION ..................................................................................................................... 28
3.4. DESCRIPTION OF ELECTRICAL DEVICES .................................................................................................... 31
3.4.1. REMOTE CONTROL SOFTWARE ............................................................................................................ 33
3.5. DESCRIPTION OF PNEUMATIC DEVICES ..................................................................................................... 34
3.6. DESCRIPTION OF ACCESSORIES ON REQUEST......................................................................................... 35
3.7. "ROTOPLAT 308-508-708" TECHNICAL DATA................................................................................................ 39
3.7.1. MACHINE AND PALLET DIMENSIONS .................................................................................................... 39
3.7.2. MACHINE TECHNICAL FEATURES.......................................................................................................... 40
3.7.3. PRESSER TECHNICAL FEATURES ......................................................................................................... 40
3.7.4. PNEUMATIC CREASING HEAD TECHNICAL FEATURES ...................................................................... 40
3.7.5. SPOOL FEATURES ................................................................................................................................... 41
3.8. "ROTOPLAT LP 308 - 508 - 708" TECHNICAL DATA ...................................................................................... 42
3.8.1. MACHINE AND PALLET DIMENSIONS .................................................................................................... 42
3.8.2. MACHINE TECHNICAL FEATURES.......................................................................................................... 43
3.8.3. PRESSER TECHNICAL FEATURES ......................................................................................................... 43
3.8.4. PNEUMATIC CREASING HEAD TECHNICAL FEATURES ...................................................................... 43
3.8.5. SPOOL FEATURES ................................................................................................................................... 44
3.9. “ROTOPLAT TP3 308-508-708" TECHNICAL DATA ........................................................................................ 45
3.9.1. MACHINE AND PALLET DIMENSIONS .................................................................................................... 45
3.9.2. MACHINE TECHNICAL FEATURES.......................................................................................................... 46
3.9.3. PRESSER TECHNICAL FEATURES ......................................................................................................... 46
3.9.4. PNEUMATIC CREASING HEAD TECHNICAL FEATURES ...................................................................... 46
3.9.5. SPOOL FEATURES ................................................................................................................................... 47
3.10. NOISE LEVEL................................................................................................................................................ 48
3.11. INSTALLATION ENVIRONMENT CHARACTERISTICS .............................................................................. 48
4. INFORMATION ON HANDLING AND INSTALLATION ......................................................................................49
4.1. RECOMMENDATIONS FOR HANDLING AND LOADING................................................................................ 49
4.2. PACKING AND UNPACKING ............................................................................................................................ 49
4.3. TRANSPORT AND HANDLING......................................................................................................................... 51
4.4. HANDLING AND LIFTING ................................................................................................................................. 52
4.5. INSTALLATION OF THE MACHINE.................................................................................................................. 53

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Index
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4.5.1. ELECTRIC BOX ASSEMBLY ..................................................................................................................... 54
4.5.2. SLIDE SHAFT ASSEMBLY ........................................................................................................................ 55
4.5.3. SLIDE SHAFT ASSEMBLY ........................................................................................................................ 56
4.5.4. LOADING/UNLOADING RAMP ASSEMBLY ............................................................................................. 57
4.5.4.1. LOADING DIRECTION MODIFICATION .......................................................................................... 58
4.5.5. PNEUMATIC PRESSER ASSEMBLY (OPTIONAL) .................................................................................. 62
4.5.6. “BUBBLE WRAP” KIT ASSEMBLY (OPTIONAL)....................................................................................... 63
4.5.7. MECHANICAL PRESSER ASSEMBLY (OPTIONAL) ................................................................................ 64
4.6. MACHINE FIXING.............................................................................................................................................. 65
4.7. MACHINE UNDERGROUND INSTALLATION .................................................................................................. 66
4.8. RECOMMENDATIONS FOR CONNECTIONS ................................................................................................. 66
4.9. PNEUMATIC CONNECTION............................................................................................................................. 66
4.10. ELECTRICAL CONNECTION........................................................................................................................ 67
5. INFORMATION ON ADJUSTMENTS ................................................................................................................ 68
5.1. RECOMMENDATIONS FOR ADJUSTMENTS ................................................................................................. 68
5.2. ADJUSTING THE “CARRIAGES” ...................................................................................................................... 69
5.2.1. SPOOL CARRIAGES OF "PDS" TYPE (PRE-STRETCH GEAR REPLACEMENT) ................................. 69
5.2.2. SPOOL CARRIAGES OF "FR for mesh" TYPE ......................................................................................... 71
5.3. SPOOL CARRIAGE LIFTING CHAIN ADJUSTMENT....................................................................................... 72
5.4. ROTARY TABLE CHAIN ADJUSTMENT .......................................................................................................... 72
5.5. “TP3” TABLE ROTATION CHAIN ADJUSTMENT............................................................................................. 73
5.6. ADJUSTING ROTARY TABLE GEAR WHEELS............................................................................................... 74
5.7. ADJUSTING THE TABLE GUIDE WHEELS ..................................................................................................... 75
5.8. “BUBBLE WRAP” SPOOL BRAKING ADJUSTMENT....................................................................................... 75
6. INFORMATION ABOUT THE USE .................................................................................................................... 76
6.1. RECOMMENDATIONS FOR OPERATION AND USE...................................................................................... 76
6.2. DESCRIPTION OF THE CONTROLS ............................................................................................................... 77
6.3. DESCRIPTION OF USER INTERFACE ............................................................................................................ 78
6.3.1. NUMERICAL AND ALPHANUMERICAL KEYBOARD............................................................................... 81
6.3.2. PROGRAMMING WINDOW ....................................................................................................................... 82
6.4. “HOME” PAGE ................................................................................................................................................... 83
6.5. “MANUAL HANDLING” PAGE ........................................................................................................................... 85
6.5.1. MANUAL REINFORCEMENT FUNCTION................................................................................................. 86
6.6. “RECIPES” PAGE .............................................................................................................................................. 87
6.7. “WRAPPING CYCLE” PAGE ............................................................................................................................. 88
6.8. “GENERAL PARAMETERS” PAGE................................................................................................................... 89
6.9. “PRODUCTION COUNTERS (PALLETS)” PAGE ............................................................................................. 90
6.10. “HMI SETTINGS” PAGE ................................................................................................................................ 91
6.11. “PASSWORD CHANGE” SCREEN ............................................................................................................... 92
6.12. “ENTER PASSWORD” SCREEN (USER LOGIN)” ....................................................................................... 93
6.13. "SERVICE” SCREEN..................................................................................................................................... 94
6.14. NEW RECIPE PROGRAMMING ................................................................................................................... 95
6.15. PHASE ANGLE ADJUSTMENT .................................................................................................................... 96
6.16. MACHINE SWITCHING ON AND OFF ......................................................................................................... 96
6.17. CYCLE PARAMETERS SETTING ................................................................................................................ 97
6.18. DESCRIPTION OF THE WRAPPING CYCLES ............................................................................................ 97
6.18.1. SINGLE WRAPPING CYCLE................................................................................................................ 97
6.18.2. DOUBLE WRAPPING CYCLE .............................................................................................................. 97
6.18.3. WRAPPING CYCLE WITH FEEDER .................................................................................................... 98
6.19. CYCLE START AND STOP........................................................................................................................... 99
6.20. PRESSER HEIGHT CHANGE....................................................................................................................... 99
6.21. PNEUMATIC CYLINDER WITH ROD ......................................................................................................... 100
6.21.1. MECHANICAL PRESSER................................................................................................................... 100
6.22. SPOOL LOADING ....................................................................................................................................... 101
6.23. “BUBBLE WRAP” SPOOL LOADING .......................................................................................................... 102
7. MAINTENANCE INFORMATION..................................................................................................................... 103
7.1. RECOMMENDATIONS FOR MAINTENANCE ................................................................................................ 103
7.2. PERIODICAL MAINTENANCE INTERVALS ................................................................................................... 104

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Index
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7.3. LUBRICATION POINT DIAGRAM ................................................................................................................... 106
7.4. LUBRICANT TABLE......................................................................................................................................... 108
7.5. CONDENSATE DRAINAGE ............................................................................................................................ 109
7.6. AIR FILTER CLEANING .................................................................................................................................. 109
7.7. MACHINE CLEANING ..................................................................................................................................... 110
8. FAULT INFORMATION ................................................................................................................................... 111
8.1. ALARM MESSAGES........................................................................................................................................ 111
9. REPLACEMENT INFORMATION .................................................................................................................... 112
9.1. RECOMMENDATIONS FOR REPLACING MACHINE PARTS ...................................................................... 112
9.2. REPLACING THE ROTARY TABLE WHEELS ............................................................................................... 113
9.3. REPLACING THE ROTARY TABLE ROLLERS .............................................................................................. 114
9.4. REPLACING THE GUIDING ROLLERS .......................................................................................................... 115
9.5. REPLACING THE ROTARY TABLE GEAR WHEELS .................................................................................... 116
9.6. RECOMMENDED SPARE PARTS LIST ......................................................................................................... 117
9.7. MACHINE DECOMMISSIONING AND SCRAPPING...................................................................................... 117
9.7.1. MACHINE DECOMMISSIONING ............................................................................................................. 117
9.7.2. MACHINE SCRAPPING ........................................................................................................................... 117
10. ANNEXES....................................................................................................................................................... 118
10.1. WARRANTY CONDITIONS......................................................................................................................... 118
10.2. PRESSER PNEUMATIC DIAGRAM............................................................................................................ 119
10.3. CREASING HEAD PNEUMATIC DIAGRAM ............................................................................................... 120

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GENERAL INFORMATION
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1. GENERAL INFORMATION
1.1. PURPOSE OF THE MANUAL
-The manual is an integral part of the machine and is aimed at providing the operator with the “Instructions for
use” in order to prevent and minimise the risks that arise from human-machine interaction.
The information has been written by the Manufacturer in Italian (the original language) in full compliance with
the professional writing principles and the regulations in force.
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 modifications.
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 instructions”.
- Refer to the table of contents in order to easily identify the subjects of interest.
- Some information may not correspond completely to the actual configuration 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.
- Every notification by the recipients can be an important contribution to the improvement of after-sales services
that the manufacturer intends to offer to its customers.
- The symbols described below are used to highlight important information or specifications.
Danger - warning
The symbol indicates critically dangerous situations that if neglected can result in serious personal safety
and health hazards.
Caution - warning
The symbol indicates that suitable actions must be taken in order to avoid personal safety and health
hazards and economic damages.
Important
The symbol indicates particularly important technical and operating information that should not be
neglected.

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GENERAL INFORMATION
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1.2. MANUFACTURER AND MACHINE IDENTIFICATION
The illustrated identification plate is applied directly to the machine. It contains references and indispensable operating
safety indications.
1) Machine model.
2) Machine serial number.
3) Year of manufacture.
4) Power supply voltage.
5) Power supply frequency.
6) Power supply phases.
7) Absorbed electric current.
8) Installed power.
9) Air consumption.
10) Air supply max. pressure.
11) Machine weight.
12) Manufacturer’s identification.
13) Name.

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GENERAL INFORMATION
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1.3. TERMS AND DEFINITIONS
Some recurring terms found within the manual are described in order to complete their meaning.
Maintenance:
The set of operations required to maintain the machine efficient and in good working order.
Normally some operations are scheduled by the manufacturer, who defines the necessary skills and
methods of intervention.
Some unscheduled operations must be performed after consulting the manufacturer.
Operator:
A person chosen and authorised among those who have the requirements, skills and information
necessary for installation, use and ordinary maintenance of the machine.
Maintenance technician:
Technician chosen and authorised among those who have the requirements to perform routine and
extraordinary maintenance on the machine. Therefore, the technician must have accurate information
and competences with particular skills in the field of intervention.
Format changeover:
Set of operations to carry out on the machine before starting to work with characteristics other than
the previous ones.
Training:
Training process aimed at transferring to the new operator the knowledge, skills and behaviours
required to operate the machine autonomously, properly and safely.
Installer:
Technician chosen and authorised by the manufacturer or by its representative, among those with the
requirements to install and test the machine or the relevant system.
Assistant:
Employee assigned to assist the production processes of the machine or system in question.
Production manager:
Qualified technician, with experience and competence in the field of machinery for the reference
sector.
Depending on the production requirements, the production manager can operate the machine directly,
or
select the operator to be assigned to the task.

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GENERAL INFORMATION
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1.3.1. PICTOGRAMS INDICATING DANGER
The following table summarises the safety-related pictograms which indicate DANGER.
ATTENTION - GENERIC DANGER
This draws the attention of the personnel concerned to the risk of physical injuries caused by the operation
described if it is not carried out in compliance with safety regulations.
ATTENTION - DANGER DUE TO CONTACT WITH LIVE PARTS
This indicates to the personnel concerned that the described operation poses, if not carried out in
compliance with safety regulations, a risk of electric shock.
ATTENTION - DANGER DUE TO FLAMMABLE MATERIAL
ATTENTION - DANGER DUE TO MOVING PARTS
ATTENTION- DANGER DUE TO HIGH TEMPERATURES
ATTENTION - DANGER DUE TO SUSPENDED LOADS
ATTENTION - DANGER DUE TO CONTACT WITH OVERHEAD OBSTACLES
ATTENTION - TRIPPING OR FALLING DANGER
ATTENTION - TANGLING DANGER
It signals to the concerned personnel that the device bearing this pictogram features parts where there is
the risk getting tangled when accessed.
ATTENTION - HAND CRUSHING DANGER
ATTENTION - SHEARING DANGER
ATTENTION - CUTTING DANGER
It signals to the concerned personnel that the device on which the pictogram is located has sharp parts that
may injure their hands.
ATTENTION - DANGER DUE TO CARRIAGE MOVEMENT
ATTENTION - EXPLOSION DANGER

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GENERAL INFORMATION
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1.3.2. PICTOGRAMS INDICATING PROHIBITION
The following table summarises the safety-related pictograms indicating PROHIBITION.
GENERIC PROHIBITION
NO SMOKING
Smoking is not allowed in the area where this sign is located.
NO NAKED FLAMES
This symbol prohibits the use of naked flames near the machine or parts of it to prevent a fire hazard.
NO PEDESTRIANS
Pedestrians are not allowed to pass through the area where this signal is located.
DO NOT EXTINGUISH WITH WATER
Any fire that may occur near the machine or parts of it must NOT be extinguished with jets of water.
DO NOT INSERT YOUR HANDS
DO NOT PUSH
DO NOT SEAT DOWN
DO NOT CLIMB ONTO THE SURFACE
DO NOT REMOVE THE OPERATOR GUARDS