Robopac Compacta S4 User manual

COMPACTA
S4-S6-S9-S12
USE AND MAINTENANCE MANUAL
Translation of original instructions
ENG

ENG
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Index
ENG
Index
1. GENERAL INFORMATION .................................................................................................................................5
1.1. PURPOSE OF THE MANUAL ............................................................................................................................. 5
1.2. MANUFACTURER AND MACHINE IDENTIFICATION ....................................................................................... 6
1.3. TERMS AND DEFINITIONS ................................................................................................................................ 7
1.3.1. PICTOGRAMS INDICATING DANGER ....................................................................................................... 8
1.3.2. PICTOGRAMS INDICATING PROHIBITION ............................................................................................... 9
1.3.3. PICTOGRAMS INDICATING OBLIGATION............................................................................................... 10
1.4. HOW TO REQUEST ASSISTANCE .................................................................................................................. 11
1.5. ATTACHED DOCUMENTATION ....................................................................................................................... 11
1.6. HOW TO READ THE INSTRUCTIONS FOR USE ............................................................................................ 11
2. SAFETY INFORMATION...................................................................................................................................12
2.1. GENERAL SAFETY WARNINGS ...................................................................................................................... 12
2.2. SAFETY WARNINGS FOR HANDLING AND INSTALLATION......................................................................... 12
2.3. SAFETY WARNINGS FOR USE AND OPERATION ........................................................................................ 13
2.4. SAFETY WARNINGS RELATED TO MISUSE.................................................................................................. 14
2.4.1. REASONABLY FORESEEABLE MISUSE ................................................................................................. 14
2.4.2. EMPLOYER OBLIGATIONS ...................................................................................................................... 14
2.5. SAFETY WARNINGS ON RESIDUAL RISKS ................................................................................................... 15
2.6. SAFETY WARNINGS FOR ADJUSTMENTS AND MAINTENANCE ................................................................ 17
2.7. SAFETY WARNING FOR THE ELECTRICAL EQUIPMENT ............................................................................ 17
2.8. INFORMATION AND SAFETY SIGNS .............................................................................................................. 18
2.9. PERIMETER AREAS ......................................................................................................................................... 20
3. TECHNICAL INFORMATION ............................................................................................................................21
3.1. MACHINE GENERAL DESCRIPTION............................................................................................................... 21
3.1.1. MACHINE MODELS DESCRIPTION ......................................................................................................... 23
3.2. DESCRIPTION OF THE OPERATION CYCLE ................................................................................................. 23
3.3. SAFETY DEVICE DESCRIPTION ..................................................................................................................... 35
3.4. DESCRIPTION OF ELECTRICAL DEVICES .................................................................................................... 37
3.5. DESCRIPTION OF PNEUMATIC DEVICES ..................................................................................................... 38
3.6. DESCRIPTION OF ACCESSORIES ON REQUEST......................................................................................... 39
3.7. TECHNICAL SPECIFICATIONS........................................................................................................................ 39
3.7.1. PRODUCT DIMENSIONS .......................................................................................................................... 40
3.7.2. MACHINE DIMENSIONS............................................................................................................................ 41
3.7.3. MACHINE DIMENSIONS WITH CONVEYORS ......................................................................................... 42
3.7.4. FILM TECHNICAL FEATURES .................................................................................................................. 43
3.7.5. SOLENOID VALVES TECHNICAL FEATURES......................................................................................... 44
3.8. NOISE LEVEL .................................................................................................................................................... 45
3.9. INSTALLATION ENVIRONMENT CHARACTERISTICS................................................................................... 46
4. INFORMATION ON HANDLING AND INSTALLATION ......................................................................................47
4.1. RECOMMENDATIONS FOR HANDLING AND LOADING................................................................................ 47
4.2. PACKING AND UNPACKING ............................................................................................................................ 47
4.3. TRANSPORT AND HANDLING......................................................................................................................... 49
4.4. HANDLING AND LIFTING ................................................................................................................................. 50
4.5. INSTALLATION OF THE MACHINE.................................................................................................................. 51
4.5.1. CONVEYORS ASSEMBLY......................................................................................................................... 52
4.5.2. PRESSER UNIT INSTALLATION............................................................................................................... 57
4.6. RECOMMENDATIONS FOR CONNECTIONS ................................................................................................. 57
4.7. PNEUMATIC CONNECTION............................................................................................................................. 58
4.8. ELECTRICAL CONNECTION............................................................................................................................ 59
5. INFORMATION ON ADJUSTMENTS ................................................................................................................ 60
5.1. RECOMMENDATIONS FOR ADJUSTMENTS ................................................................................................. 60
5.2. INFEED AND OUTFEED CONVEYOR HEIGHT ADJUSTMENTS ................................................................... 60
5.3. ROLLER OR SKID GUIDES ADJUSTMENTS (OPTIONAL)............................................................................. 62

ENG
Index
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5.4. POSITION OF PHOTOCELLS........................................................................................................................... 65
5.5. PRESSERS ADJUSTMENT .............................................................................................................................. 66
5.6. PRESSER PRESSURE ADJUSTMENT............................................................................................................ 68
5.7. ADJUSTMENT OF SPOOL CARRIAGE ROLLER CLUTCH............................................................................. 69
5.8. WRAPPING TENSION ADJUSTMENT ............................................................................................................. 70
6. INFORMATION ABOUT THE USE ....................................................................................................................72
6.1. RECOMMENDATIONS FOR OPERATION AND USE...................................................................................... 72
6.2. DESCRIPTION OF THE CONTROLS ............................................................................................................... 73
6.3. DESCRIPTION OF CONTROL PANEL ............................................................................................................. 74
6.3.1. USING THE PANEL.................................................................................................................................... 75
6.3.2. MAIN PAGE ................................................................................................................................................ 76
6.3.3. OPERATOR AND PASSWORD CHANGE................................................................................................. 77
6.3.4. DEFAULT PASSWORD RESET ................................................................................................................ 78
6.3.5. GENERAL PARAMETER SETTINGS ........................................................................................................ 79
6.3.6. SOFTWARE SETTINGS AND DISPLAYS ................................................................................................. 81
6.3.7. DATE AND TIME SETTING........................................................................................................................ 84
6.3.8. DESCRIPTION OF CONTROL PANEL MANUAL CONTROLS................................................................. 85
6.4. SETTING MODIFICATION MODE..................................................................................................................... 87
6.4.1. TEXTS AND VALUES EDITING ................................................................................................................. 87
6.4.2. PROGRESSIVE ADJUSTMENT OF VALUES ........................................................................................... 87
6.4.3. “COPY RECIPES” FUNCTION................................................................................................................... 88
6.5. CYCLE PARAMETER SETTING (RECIPE COMPOSITION) ........................................................................... 89
6.6. CYCLE RESET .................................................................................................................................................. 93
6.7. MACHINE STATUSES....................................................................................................................................... 94
6.8. PREPARATION OF THE MACHINE FOR OPERATION................................................................................... 94
6.9. MACHINE START-UP........................................................................................................................................ 94
6.10. CYCLE START .............................................................................................................................................. 99
6.11. STOP AND RESTART TYPES ...................................................................................................................... 99
7. MAINTENANCE INFORMATION..................................................................................................................... 102
7.1. RECOMMENDATIONS FOR MAINTENANCE................................................................................................ 102
7.2. PERIODICAL MAINTENANCE INTERVALS ................................................................................................... 103
7.3. CONDENSATE DRAINAGE ............................................................................................................................ 104
7.4. AIR FILTER CLEANING .................................................................................................................................. 104
7.5. ROTARY RING HANDLING............................................................................................................................. 105
7.6. ROTARY RING BELT ADJUSTMENT ............................................................................................................. 106
7.7. INFEED AND OUTFEED CONVEYOR BELT ADJUSTMENT ........................................................................ 107
7.8. MACHINE CLEANING ..................................................................................................................................... 108
8. FAULT INFORMATION ................................................................................................................................... 109
8.1. SOME SUGGESTIONS ON OPERATION ...................................................................................................... 109
8.2. ALARM MESSAGES........................................................................................................................................ 109
9. REPLACEMENT INFORMATION .................................................................................................................... 111
9.1. RECOMMENDATIONS FOR REPLACING MACHINE PARTS ...................................................................... 111
9.2. FILM CUTTING BLADE REPLACEMENT ....................................................................................................... 111
9.3. RECOMMENDED SPARE PARTS LIST ......................................................................................................... 112
9.4. MACHINE DECOMMISSIONING AND SCRAPPING...................................................................................... 112
10. ANNEXES....................................................................................................................................................... 113
10.1. WARRANTY CONDITIONS......................................................................................................................... 113
10.2. STANDARD MACHINE PNEUMATIC DIAGRAM ....................................................................................... 114

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GENERAL INFORMATION
ENG
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.

ENG
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.

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GENERAL INFORMATION
ENG
1.3. TERMS AND DEFINITIONS
Some recurring terms found within the manual are described in order to complete their meaning.
Ordinary maintenance:
The set of operations required to maintain the machine efficient and in good working order. Normally
these operations are scheduled by the Manufacturer, who defines the necessary skills and methods of
intervention.
Extraordinary maintenance:
The set of operations required to maintain the machine efficient and in good working order. These
operations are not scheduled by the Manufacturer and must be carried out by the maintenance
technician.
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.

ENG
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
ENG
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

ENG
GENERAL INFORMATION
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1.3.3. PICTOGRAMS INDICATING OBLIGATION
The following table summarises the safety-related pictograms indicating OBLIGATION.
GENERIC OBLIGATION
The presence of the symbol next to the description indicates the obligation to carry out the
operation/manoeuvre as described and in compliance with current safety regulations, in order to avoid risks
and/or injuries.
OBLIGATION TO REFER TO THE OPERATOR’S MANUAL
Obligation, before carrying out any operation on the machine, to read the Instruction Manual supplied with
the machine.
OBLIGATION TO USE LUBRICANTS RECOMMENDED BY IMA
Obligation, before changing the oil or the lubricants, to read the Instruction Manual supplied with the
machine.
OBLIGATION TO WEAR PROTECTIVE GLOVES
The presence of the symbol next to the description requires the use of protective gloves by the operator,
since the risk of injury is implicit.
OBLIGATION TO WEAR PROTECTIVE GOGGLES
The presence of the symbol next to the description requires the use of safety goggles by the operator,
since the risk of injury is implicit.
OBLIGATION TO WEAR A PROTECTIVE HELMET
The presence of the symbol next to the description requires the use of a protective helmet by the operator
since the risk of injury is implicit.
OBLIGATION TO WEAR A PROTECTIVE MASK
The presence of the symbol next to the description requires the use of a respiratory protective mask by the
operator, since the risk of injury is implicit.
OBLIGATION TO WEAR SAFETY SHOES
The presence of the symbol next to the description requires the use of protective shoes by the operator,
since the risk of injury is implicit.
OBLIGATION TO WEAR PROTECTIVE CLOTHING
The presence of the symbol next to the description requires the use of a protective overall by the operator,
since the risk of injury is implicit.
OBLIGATION TO WEAR EARMUFFS FOR PROTECTION AGAINST NOISE
The presence of the symbol next to the description requires the use of earmuffs by the operator as the risk
of injury is implicit.