Rotech RF LITE Series Installation and operation manual

Operating & Maintenance
Manual
Rotech RF-Lite Version 1.3
2016 © Copyright Rotech machines Limited

Contents
1. Introduction 1
2. Product information 2
3. Safety information 3
4. Transportation 6
5. Assembly 7
6. Installation 8
7. Decommissioning and disposal 10
8. Operation 11
9.Maintenance 17
10. Provision of spares, in-service support and guarantees 18
11. RF-Lite recommended spares list 19
12. Wiring diagrams 20

1.1 Background
The machine as supplied consists of an integrated product feeding and transport system, complete
with product collection device. A printer can be added according to customer requirements.
The purpose of this manual is to provide instruction on the system as a whole. A
separate manual is provided for comprehensive information on the printer.
1.2 Important notes
1.2.1 The purpose of this manual is to provide information only. Every effort has been made to
ensure the accuracy of the contents of this manual. However, Rotech Machines Limited
can assume no responsibility for any errors, or their consequences contained within.
1.2.2 The information contained within this manual shall be considered to be commercially
confidential and shall not be released to third parties without the prior written consent of
Rotech Machines Limited.
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1. Introduction

2.1 Name of equipment
Rotech RF-Lite
2.2 Applicable model type
This manual applies to all RF-Lite models.
2.3 Location of machine
Manufactured in the UK by Rotech Machines Limited.
2.4 Machine functions
The function of this machine is to feed products from a feeding device onto a flat conveyor for
presentation to a printer that has the ability to print onto the product surface. After this process, the
product continues to the end of the conveyor where it is deposited into a catcher-tray.
2.5 Description of products the machine can accommodate
Products are presented to the feeder in their flat form.
The maximum and minimum sizes that can be accommodated are:
Maximum: 300 mm wide x 200 mm long (subject to product)
Minimum: 60 mm wide x 50 mm long
Where width is measured across the machine, perpendicular to the direction of travel.
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2. Product information

3.1 Guidelines
3.1.1 Read this manual and also familiarise yourself with any associated documents or addition-
al training videos provided
3.1.2 To avoid risk of electric shock, always disconnect the machine from the main supply
before removing any guards or covers.
3.1.3 To avoid risk associated with pneumatic circuits, always disconnect from mains and purge
any pneumatic systems before removing any guards or covers.
3.1.4 Follow the procedures and specifications outlined in this manual.
3.1.5 Notice is hereby given to the customer to ensure that the machine is in conformance with
applicable national and local health and safety legislation in the country of use.
3.1.6 If in doubt do not take any personal risks.
3.1.7 Only trained personnel should be allowed to work with the machine during operation,
maintenance, installation, or decommissioning.
3.2 Alarm and warning systems
3.2.1 All electrical control boxes are labelled with warning signs.
3.2.2 Residual risks are identified in this manual,
3.3 Component safety features
3.3.1 Do not operate any machine with fixed guards removed or fastened incorrectly.
3.3.2 Do not use the machine with functional and safety sensors and devices maladjusted or
removed
3.4 Features for operator safety
3.4.1 The machine is guarded and provided with safety features in conformance to current
machinery directive requirements.
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3. Safety information

3.5 Interlocking
3.5.1 Safety interlocks are not fitted. All guards are fixed.
3.6 Personal protective equipment (PPE)
3.6.1 PPE is not required to operate this machine.
3.6.2 No loose clothing should be worn. Long hair, ties, etc. should be adequately retained.
3.7 Conditions for safe use
3.7.1 This machine is designed to be used within a normal light industrial production line type
environment. Do not use outside this environment
3.7.2 The machine has not been designed with any ingress protection (IP) rating consideration.
In the event that the machine has become wet, e.g. a factory sprinkler system, do not
attempt to turn on or operate the machine until a suitably competent person has
thoroughly inspected the machine.
3.7.3 Additional safety measures, beyond those detailed in this manual, are not required for safe
operation of the equipment.
3.7.4 The customer should ensure that there is no ingress or solid, liquid, or gaseous
contaminant that may affect machine safety.
3.7.5 The machine is not provided with any integral lighting. It is the responsibility of the
customer to ensure adequate local and area lighting is provided, in accordance with
statutory instrument building standards (SIBS) codes.
3.8 Operation
The machine has been designed to be easy to operate. Initial training in the loading, operation, and
unloading of the machine is required. Training Videos are loaded on a USB Memory Stick provided
with the RF-Lite.
3.9 Maintenance
Suitably qualified and trained engineering technicians shall only effect maintenance of the machine.
3.10 Installation and dismantling
Should only be effected by suitably qualified and trained engineering technicians
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3. Safety information

3.11 Residual risks
3.11.1 The functional design of the machine has not resulted in there being present a residual
risk to users of the machine. The residual risks are considered to be low.
3.11.2 The loading and unloading of the machine during operation can be considered as a
repetitive action. The customer should regularly review any repetitive strain injury (RSI)
impact on operators.
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3. Safety information

4.1 Equipment handling and transportation
4.1.1 No gantry, crane or lifting points are provided.
4.1.2 The machine is to be placed securely on a level bench or floor of sufficient strength to
support the weight of the machine with no risk of toppling. If supplied with the optional
wheeled stand the machine should be sited on a level floor of sufficient strength to support
it.
4.1.3 It is important to ensure that the machine is level about both axes.
4.1.4 The contact points between any lifting device and the machine should be covered to avoid
damage to the surface of the machine.
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4.2 The weights of equipment and modules
The weight of the machine complete with printer but without the packaging is estimated to be 20kg.
The weight of the machine inclusive of packaging is 25kg
4. Transportation

5.1 Product catcher tray
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The catcher-tray will have been removed from the machine for transportation. It can be re-fitted by
simply locating it on the two mounting studs in the uprights at the end of the machine.
5. Assembly

6.1 Installation requirements
6.1.1 The installation site should be clean, dry and level, at a suitable position determined by the
customer.
6.1.2 The installation site should have a single 220v/240v AC supply via a 3-pin socket (unless
rated for 110v operation).
6.1.3 Before installing and using the machine it is recommended that staff or operators read this
manual and view the training videos installed on the USB Memory Stick provided.
6.1.4 Installation should be effected within the following hierarchy:
• National legalisation requirements.
• Corporate regulations: installation and safety standards and procedures.
• The installation description given this manual.
6.1.5 No specific materials are required for installation.
6.1.6 Tools may be required to change service connections to ensure that they are compatible
and correctly fitted.
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6.2 Installation procedures
6.2.1 Site the machine in a suitable position in relation to the production line.
6.2.2 Ensure that the machine is sited on a horizontal surface and cannot slide or roll.
6.2.3 Connect the machine to the mains AC supply. With the power cord supplied
6. Installation
6.3 Inspection and testing procedures upon installation
6.3.1 Check machine supplies have been connected and their function and safety are validated.
6.3.2 Ensure that moving parts are free from obstruction, and any packaging has been
removed, especially around the printer..
6.3.3 Switch on the mains power switch to both the feeder and the printer.
6.3.5 Pressing the green start button on the control panel at this point will start the machine
running. Pressing the red ‘mushroom’ stop button will stop the machine.

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6.4 Commissioning plans and procedures
6.4.1 Once installation has been successfully completed the machine is ready to run.
6. Installation

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7.1 Decommissioning
7.1.1 Turn off the machine normally. Engage e-stops. If fitted, isolate pneumatic supply at the
mains air supply. Isolate the electrical supply at the mains supply switch located at the
rear left of the machine.
7.1.2 Maintenance staff should then disconnect the machine from the main services following
the customer’s code of practice, ensuring that the supply ends of services are rendered
safe.
7.1.3 Place a secure label on the machine to identify that the machine has been
decommissioned.
7.2 Disposal
When the machine is no longer required it may be returned to Rotech Machines Limited for
disposal. The following conditions apply:
• Laws & codes of practice applicable govern conditions for return and disposal at the time of
the first delivery of the machine to the customer.
• Rotech Machines Limited will not be liable for decommissioning, transportation or storage.
• Rotech Machines Limited will only accept for disposal those part of the machine that were
supplied.
• Any additions to the machine will not be accepted, including, dust, dirt, residue, spilled or
misplaced product, compound, chemical element or production waste.
• Rotech Machines Limited do not accept for disposal any product that has been subjected to
radiation or been in contact with known toxic substances or biological material unless
decontamination can be verified.
7. Decommissioning and disposal

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8.1 The machine
1. Infeed Product Hopper
2. Control Panel (Page 16)
3. Gating Finger Adjustment Knob
4. Infeed Product Hopper Locking Lever
5. Stand (Optional Extra)
6. Gating Finger Adjustment Locking Lever
7. Outfeed Conveyor Adjustment
8. Product Gating Finger
9. Catcher Guide
10. Samples
11. Catcher Tray
12. Outfeed Product Guide
13. Outfeed Conveyor
14. Printer
15. Printer Encoder (Optional)
16. Printer Adjustment Locking Lever
8. Operation
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8.2 The Feeder
8.2.1 Setting the Gating Finger
1. Rotate the Hopper Locking Lever anti-clockwise to its end stop to release the Hoppers
2. Slide the Hoppers to each side.
3. Place the product centrally around about the Gating Roller/ Gating Finger
4. Rotate the Gating Finger Clamp Lever anti-clockwise to unclamp the Gating Finger
5. Adjust the Gating Finger to slightly clamp the product by rotating the Adjustment Knob clock-
wise to increase the grip and anti-clockwise to decrease the grip. (I revolution of the Adjust-
ment Knob will adjust the Gating Finger height up or down by 0.25mm)
6. When the Gating Finger is set, tighten the Clamp Lever to lock the Gating Finger in position
1. Move the Hopper side plates in on both sides to allow 1mm of clearance about the product
Rotate the Hopper Lock Lever clockwise to clamp them in position
2. Load a few more products into the hopper but overlap them slightly so that they fall naturally
into place within the hopper.
3. Place the rest of the product in the hopper.
8. Operation
8. Operation
8.2.2 Setting the Hopper
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8.2.3 Setting the Printer
1. NB: When initially setting the printer position be aware that the printer internal product sensor
must see through the slot in the conveyor plate to be able to detect the product and provide a
print signal. The product sensor cannot be obscured by a conveyor belt.
2. With the feeder set on slow speed, feed 1 product and stop the feeder when the product is in
position with the printer.
3. Unclamp the printer slide bracket and move the printer to the so that it is in line with the print
area.
4. Clamp the printer in position.
1. With the feeder running on slow speed the position of the outfeed conveyor belts can be ad-
justed. Rotate the adjustment screw knob clockwise to move the belts out to the side of the
feeder and anti-clockwise to move them in.
2. Position the belts so that the product is evenly supported. NB: Ensure that the belt does not
run under the print area of the printer or this will obscure the built in product sensor of the
printer and it will not detect product as it is fed.
3. Position the Outfeed Runners so that they sit on top of the belts
8. Operation
8. Operation
8.2.4 Setting the Outfeed Conveyor Belts
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8.2.5 Using the Infeed Guide
Some products may need to be tipped forward to feed properly. In order to do this you can use the
Infeed Guide.
1. Release the adjustment knob and slide the Infeed Guide forward to assist the product feed.
Re-tighten the knob when in position and the product feeds correctly
1. Loosen the locking screw to move the catcher guides into position.
2. Tighten the locking screw to secure the catcher guides in position.
8. Operation
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8.2.6 Setting the Outfeed Catcher
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8.3 The conveyor
The conveyor performs a key role in transporting the product from the feeder to a position where it
is printed and then depositing it neatly into the catcher-tray. It is made from a material that holds the
product firmly and prevents it from slipping while being transported and printed.
Two outfeed guide plates are fitted on top of the conveyor to control the product before printing and
before dropping into the catcher.
The speed of the machine can be adjusted from ‘Low’ or High’ speed using the rocker switch on the
control panel.
8. Operation
8.4 The printer or labeller
The printer has a comprehensive manual covering all aspects of its operation.

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8.5 The Control Panel
In order to run the machine follow the instructions below:
1. Press the green start button on the machine to start the conveyor.
2. Once the conveyor is clear of all product, press the red stop button to stop the conveyor.
Please note:
• Do not stop the conveyor until all of the product has been collected in the catcher.
Setting the speed:
 Adjust the speed of the machine by selecting either low or high speed using the speed
selector switch
Please note:
• When ‘Low’ speed is selected the conveyor runs at approx. 20M/min
• When ‘High’ speed is selected the conveyor runs at approx. 60M/min
8. Operation
1 - Speed Selector Switch
2 - Stop Button
3 - Start Button
4 - IEC Connector
5 - Power On/ Off Switch
6 - Reset Button
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9.1 Description of mechanical and electrical protection systems
9.1.1 There are no particular protection systems provided for maintenance staff. Observe all the
safety information detailed in section 3
9.1.2 Only trained maintenance staff should attend to the maintenance of the machine.
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9.2 Points and frequencies of inspection
9.2.1 Operator daily checks
Before commencing work each day the work area should be clean and tidy.
9.2.2 Operator weekly checks
In addition to the Operator Daily tasks above, it is recommended that the following be carried out at
the end of each working week.
Before commencing these operations, ensure the isolator is turned to the OFF position.
a) Feeder roller cleaning.
1. Spray a small amount of Platen Cleaner onto a non-paper, lint-free piece of cloth
2. Remove all product from the Infeed Hopper.
3. Set the feeder to slow speed, switch the feeder on and gently wipe each of the 3 friction
rollers.
b) General cleaning
With either a piece of cloth or a vacuum cleaner remove as much dust as possible from the
machine.
c) Ensure that all cables, plugs etc. are undamaged.
9.2.3 Engineering preventative maintenance
It is recommended that at six monthly intervals the following be carried out.
1. Check that the conveyor belts and friction rollers are in good condition
9. Maintenance

10.1 Spares
Spares are available by contacting Rotech Machines Limited or their authorised distributor/agent.
10.2 In-service support
In-service support can be provided by contacting Rotech Machines Limited or their authorised
distributor/agent.
10.3 Guarantees
This machine is guaranteed to be free from defects for a twelve-month period. The guarantee
excludes consumable items such as ribbons and those items subject to fair wear and tear, in
particular, the rollers within the feeder and the conveyor.
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10. Provision of spares, in-service support and guarantees