Robopac Rotoplat DW 108-508 User manual

ROTOPLAT DW / DW-C
108-508
serial n°
GB USE AND MAINTENANCE MANUAL
“Translation of the original instructions”
MACHINE WITH ROTATING PLATFORM FOR WINDING PLASTIC
STRETCH FILMS
Instructions manual code 3710308590
English Edition 1/1114

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

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English
SUMMARY
1 GENERAL INFORMATION
1.1. PURPOSE OF THE MANUAL....................... 3
1.2. MANUFACTURER AND MACHINE
IDENTIFICATION .......................................... 4
1.3. TERMS AND DEFINITIONS.......................... 5
1.4. MODES OF REQUESTING FOR
ASSISTANCE................................................ 6
1.5. ATTACHED DOCUMENTATION ................... 6
2 SAFETY INFORMATION
2.1. GENERAL SAFETY PRECAUTIONS ........... 7
2.2. SAFETY WARNINGS FOR HANDLING AND
INSTALLATION ............................................. 7
2.3. SAFETY WARNINGS FOR USE AND
OPERATION ................................................. 9
2.4. SAFETY WARNINGS RELATED TO
INCORRECT USE....................................... 10
2.5. SAFETY WARNINGS
ON RESIDUAL RISKS ................................ 12
2.6. SAFETY WARNINGS FOR REGULATIONS
AND MAINTENANCE.................................. 14
2.7. INFORMATION AND SAFETY SIGNALS ... 15
2.8. SURROUNDING AREAS ............................ 16
3 TECHNICAL INFORMATION
3.1. MACHINE GENERAL DESCRIPTION ........ 17
3.2. DESCRIPTION OF THE OPERATION CYCLE
“ROTOPLAT DW 108-508”.......................... 20
3.3. DESCRIPTION OF THE OPERATION CYCLE
“ROTOPLAT DW-C 108-508” ...................... 20
3.4. SAFETY DEVICE DESCRIPTIONS ............ 21
3.5. DESCRIPTION OF THE ELECTRICAL
DEVICES..................................................... 22
3.6. DESCRIPTION OF ACCESSORIES ON
REQUEST................................................... 23
3.7. TECHNICAL SPECIFICATIONS
“ROTOPLAT DW 108-508”.......................... 25
3.8. TECHNICAL SPECIFICATIONS
“ROTOPLAT DW-C 108-508” ...................... 27
3.9. COIL TECHNICAL SPECIFICATIONS ........ 29
3.10. NOISE LEVEL ............................................. 30
3.11. INSTALLATION ENVIRONMENT
CHARACTERISTICS .................................. 30
4 INFORMATION ON HANDLING AND
INSTALLATION OPERATIONS
4.1. RECOMMENDATIONS FOR HANDLING AND
LOADING .................................................... 31
4.2. PACKAGING AND UNPACKING................. 31
4.3. TRANSPORT AND HANDLING .................. 32
4.4. INSTALLATION OF DISMOUNTED PARTS 32
4.5. FASTENING THE MACHINE ...................... 35
4.6. RECOMMENDATIONS
FOR CONNECTIONS ................................. 35
4.7. PNEUMATIC CONNECTIONS.................... 36
4.8. ELECTRICAL CONNECTION ..................... 36
5 INFORMATION ON ADJUSTMENTS
5.1. RECOMMENDATIONS
FOR ADJUSTMENTS ................................. 37
5.2. ADJUSTING FILM “STRETCH” .................. 37
5.3. REEL CARRIAGE LIFTING CHAIN
ADJUSTMENT ............................................ 40
5.4. TABLE ROTATION
CHAIN ADJUSTMENT ................................ 41
5.5. “PLURIBALL” REEL BRAKE
ADJUSTMENT ............................................ 41
5.6. GRIPPER ADJUSTMENT ........................... 42
5.7. CARRIER HEIGHT
ADJUSTMENT ............................................ 43
5.8. CAM ADJUSTMENT FOR THE HEIGHT OF
THE COATING WRAPPING ....................... 44
6 ABOUT THE USE
6.1. RECOMMENDATIONS FOR OPERATION
AND USE .................................................... 45
6.2. CONTROL DESCRIPTION ........................ 45
6.3. DESCRIPTION
OF THE USER INTERFACE ....................... 46
6.4. “HOME” SCREENSHOT ............................. 51
6.5. “MANUAL HANDLING” SCREENSHOT...... 53
6.6. “RECIPES” SCREENSHOT ........................ 54
6.7. “WRAPPING CYCLE” SCREENSHOT ....... 55
6.8. “GENERAL PARAMETERS”
SCREENSHOT ........................................... 57
6.9. “PRODUCTION COUNTERS (PALLETS”)
SCREENSHOT ........................................... 57
6.10. “H.M.I SETTINGS” SCREEN ...................... 58
6.11. “PASSWORD MODIFICATION”
SCREENSHOT ........................................... 58
6.12. “PASSWORD INSERTION (USER LOGIN)”
SCREENSHOT ........................................... 59
6.13. “SERVICE” SCREENSHOT ........................ 60
6.14. PROGRAMMING A NEW RECIPE.............. 61
6.15. SWITCHING THE MACHINE ON AND OFF62
6.16. CYCLE PARAMETER SETTING................. 62
6.17. WRAPPING CYCLES DESCRIPTION........ 63

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English
6.18. SET UP FOR WRAPPING PALLETISED
LOADS ........................................................ 65
6.19. STARTING AND STOPPING THE CYCLE . 66
6.20. CHANGE THE PRESSER HEIGHT............ 67
6.21. REEL LOADING.......................................... 70
6.22. “PLURIBALL” REEL LOADING ................... 71
7 MAINTENANCE INFORMATION
7.1. MAINTENANCE INSTRUCTIONS .............. 72
7.2. MAINTENANCE PERIOD TABLE ............... 73
7.3. LUBRICATION POINT DIAGRAM............... 74
7.4. LUBRICANTS TABLE ................................. 75
7.5. CONDENSATE DISCHARGE ..................... 76
7.6. CLEANING THE AIR FILTER...................... 76
8 TROUBLESHOOTING
8.1. ALARM MESSAGES................................... 77
9 SPARE PARTS REPLACEMENT
INFORMATION
9.1. RECOMMENDATIONS FOR REPLACING
PARTS......................................................... 79
9.2. REPLACING ROTATING TABLE WHEELS 80
9.3. LIST OF THE RECOMMENDED SPARE
PARTS......................................................... 81
9.4. MACHINE DISPOSAL AND SCRAPING..... 81
10 ENCLOSED DOCUMENTATION
10.1. WARRANTY CONDITIONS ........................ 82
10.2. PRESSURE PLATEN PNEUMATIC
DIAGRAM.................................................... 83
SUMMARY

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

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

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

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

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

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

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

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Chapter 2
SAFETY INFORMATION
2.4. SAFETY WARNINGS RELATED TO INCORRECT
USE
Incorrect use that can be reasonably expected
–The predictable incorrect use consists of: “the use of the machine
different from the indications given in the manual, that may stem
from the easily predictable human behaviour”.
The machine must be EXCLUSIVELY used in order to wrap and
stabilise products contained in packs (boxes, containers for
liquids, etc.), having a regular shape or a shape that allows
for stable palletising.
The packs that contain liquids or insubstantial materials must
be suitable for the product and must be perfectly closed and
tight in order to prevent any leaks of the content.
DO NOT wrap or palletize products in packaging (boxes, containers
for liquids, etc…) with an irregular form or one that does NOT
guarantee their stability.
–The machine must be used ONLY for the uses intended by the
manufacturer.
– DO NOT allow the machine to be used by operators that are not
properly trained, informed and unauthorised.
–Packages that contain liquid or inconsistent products must ensure
that they do not leak.
– DO NOT wrap products that are loose, that have an irregular shape
or that are not suitably collected, to prevent inadequate palletisation.
–Do not use the machine to wrap and stabilise living beings (animals
and humans).
– DO NOT use the machine with wrapping material different from
that provided by the manufacturer.
–Do not use the machine as a lifting device or as a rest surface for
work activities (for example, a workbench).
–Do not over stretch or pre-stretch the lm and do not wrap with an
excessive number of bindings in order to prevent damaging the
packages and products contained inside.
– DO NOT use or let the machine be used for purposes or in ways
not provided by the manufacturer.
– DO NOT use or make use of machines with defective, deactivated
and/or not perfectly installed safety devices.
– DO NOT continue to use the machine if malfunctions have been
detected.
Stop the machine immediately and restart it only after the normal
conditions of use have been restored.
– NEVER carry out an intervention with the machine enabled but
ONLY after having stopped it properly, under safety conditions.
– NEVER use the machine without wearing the Personal Protective
Devices indicated by the manufacturer and required by current
workplace laws.
–NEVER use the machine if the scheduled maintenance interventions
have not been carried out accordingly.

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Chapter 2
SAFETY INFORMATION
– DO NOT clean or wash the machine with aggressive products to
avoid damaging the components.
– DO NOT replace the components with non-original spare parts or
with different design and constructive features.
– DO NOT leave the machine unattended at the end of the work
without shutting it down rst in safety conditions.
Employer obligations
–The operator must be trained to acquire the skills required for the
packaging machine or an equivalent machine.
Upon completion of training, make sure the operator has understood
the contents in the use manual, especially the information regarding
safety.
–The operator must possess the required training and meet the
suitable conditions for carrying out the activities in safety conditions.
–The employer must inform the operator on the INCORRECT USES
predictable and on the persistent Residual risks.
–The operator must be capable of reading and understanding the
user manual and must easily identify the safety signs.
–Make sure the machine is ONLY used by adequately trained,
documented and authorized operators.
The employer must draw up the documentation of the specic
training carried out by the operators in order to exhibit it in
case of litigation.

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Chapter 2
SAFETY INFORMATION
2.5. SAFETY WARNINGS ON RESIDUAL RISKS
When designing and building the machine, the manufacturer has paid
particular attention to the RESIDUAL RISKS that may affect the safety
and health of the operators.
The residual risks are: “all the risks that persists although all safety
solutions have been applied and integrated during machine design”.
The list species the residual risks specic for this type of machine.
–Danger of collision and slipping.
Do not get onto machine
partsduring its operation.
–Danger of collision and slipping
do not come near machineparts
during its operation.
–Upper limb cutting hazard
Do not place hands inside
components in motion.

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Chapter 2
SAFETY INFORMATION
–Body crushing hazard
Do not linger in the machine
operating area.
–Body crushing hazard.
Do not linger in the machine
operating area.
–Danger of collision and slipping
Do not draw close to or climb onto
machine parts (i.e. the turntable)
with the lifting device while the
machine is running
–Danger of projecting or falling
objects
Do not use the machine at a
speed that is not appropriate for
the product you need to wrap.
If the packages you need
to wrap contain unstable or
hazardous elements, you
must adopt suitable safety
precautions (i.e. perimeter
guards) to prevent the risk
of harming the physical
wellbeing of personnel.

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

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14C214066
Rotoplat DW 108 - 508
Rotoplat DW-C 108 - 508
English - 15 -
Chapter 2
SAFETY INFORMATION
2.7. INFORMATION AND SAFETY SIGNALS
The gure indicates the position of the safety and information signs
afxed to the machine.
For each sign is specied the relative description:
Important
Check that the plates are clearly readable, and, if necessary,
replace them with new ones that shall be positioned in the same
places as previously.
A) Electrical hazard sign
Do not access this area: risk of
electrical shock or electrocution.
B) Information sign
Indicates the points for lifting with
a hook device.
C) Information sign
indicatesthe lifting points with a
fork device.
D) Information sign
Indicates the direction in which
the turntable rotates.
E) Prohibition sign
Do not operate the component
with your hands

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14C214067
Rotoplat DW 108 - 508
Rotoplat DW-C 108 - 508
English
Chapter 2
SAFETY INFORMATION
2.8. SURROUNDING AREAS
The illustration depicts the perimeter work areas of the machine.
A) Operator’s working area
B) Pallet loading/unloading area
C) Sorrounding area
Min
800
Min
800
Min
800
Min
800
Min
1500
Min
1500
Min
1500
Min
1500