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Data sheet - EKOBAL s.r.o.

1. Line Service Parameters These service parameters are individual for each wrapping line and depend on its configuration and control method they needn t be used at all If used in your wrapping line they are included in a separate appendix at the end of this manual 74 Pragometal s r o WRA TS 7 FAULTS AND THEIR REMOVALS LGA control system program contains system for reporting machine locks and errors This system enables the user to easily find a cause of machine stoppage 7 1 Locks Control systems watches machine state In case that manual manipulation or any machine activity after START led into collision or error state system would block relevant function and shows an error message on display as to why the function cannot be executed This message is shown during forced inactivity of machine after program start or when button or are pressed Lock is announced via running line in upper part of display and a help window with lock description its causes and remedies pops up at the same time Manual functions basic moves Lock f Arm Co aarmen l Arm move is blocked impeding danger of ts Q collision with ending arm __ Tit ending arm into lower position Press confirm button to confirm lock message and close the window of If lock cause persists the lock message is also displayed on error message list see Chap 7 2 19 Pragometal s r o WRA TS 7 1 1 List of Lock Messages The ta
2. Pragometal s r o WRA TS 3 Use button on the switch board see help in top part of the display marked with A to move to initial position for wrapping as necessary Change the film or load it again into the machine the procedure is described below 5 Switch the machine back to auto mode itty Open doors to protection fencing of the machine The doors must stay open during the whole period during which person s are in working space of the machine Spool with film 1 is loosely laid in unwind mechanism under overlap mechanism itself Remove it upwards In the spool core there is an auxiliary axis loosen up one of the wobblers remove cone and take out the auxiliary axis Use reverse procedure to put the auxiliary axis into a new spool with film and place the whole into the unwind mechanism from the top Place the spool with film so that it unwinds during overlap in the direction as shown by an arrow on the figure above In opposite direction could the unwinding be more difficult and the film could slip from mobile tongs 40 Pragometal s r o WRA TS To open the tongs switch OVERLAP STATIS TONGS 2 button to position right Unwind required amount of overlap film from the spool and load it in between jaws of static overlap tongs 3 To ease manipulation unwind approx 10 to 15 cm more of the film and fold it over static part of the tongs To close the tongs switch controller 2 to left initial posi
3. Command Command Command Command Command Command COM D OTB W Press UP Commands will be moved by one line up Command Command Command Command Command Command WO OB WN Button MOV move command to another place in the program Command in the active line will not be changed if MOV is pressed and other lines will be moved upon pressing UP or DOWN Press MOV again and unblock the active line Please note that buttons PAGE UP and PAGE DOWN cannot be used Example of functionality of button MOV Press MOV Commana 5 on the active line will get blocked Command 3 Command Command Command Command Command COMO OB Press 2x Command Command Command Command Command Mwurdoe C 52 Pragometal s r o Command 6 Press 1x DOWN Command 2 Command Command Command Command Command TO B UTD Press MOV thus unblocking the active line which is now placed on a new place in the program Press 1x DOWN Command Command Command Command Command Command COND amp U1 W Button DOWN Browsing in the list one line down Command Command Command Command Command Command LO CO OY OB Press 2x DOWN Commands will be moved by two lines up Command Command Command Command Command Command F 7 O CO NID O1 O Button PAGE DOWN The list displays commands on next page Command Command Command Command Command Command Press PAGE DOWN Commands will be moved by one page down
4. Service parameters 2 designed for manufacturer or service Service parameters 2 Machine configuration Top platen Top platen mechanism mounted on YES NO machine Overlap Overlap mechanism mounted on YES NO machine 03 Pallet lift included for goods wrapping YES NO including pallet fone 04 Conveyor Conveyor included in the line T Disable film error Disables function for checking spent wrapping or overlap film spent film will or YES NO will not cause error message Current pallet If YES is set up then in case that a change wrapped pallet departs from the wrapping machine another pallet will again be driven into the machine for wrapping ESING If NO is set up then the wrapped pallet will first be driven away from the wrapping machine and only then another pallet will be driven into the machine for wrapping 70 Pragometal s r o WRA TS 07 Delay in pallet If parameter 06 Current pallet change is set on YES then the pallet for wrapping will be driven into the machine with this retarding after the moment when the wrapped pallet will have got started in order to leave the machine wrapping s area If parameter 06 Current pallet change is set on NO this parameter will become irrelevant Password set up Dialog box for password display and set up More information in Chap 8 1 1 Program version Displays version of control system program Service parameters 2 Rotary arm rotary arm param
5. Check and maintenance intervals as implied in this manual may be adjusted on the basis of experience from operation and both manufacturer s and user s tests of the machine 103 Pragometal s r o WRA TS 9 SERVICING Reparations within and after warranty period are done by the manufacturer The manufacturer also supplies individual spare parts as per orders of consumer Manufacturer s address PRAGOMETAL spol s r o Videnska 172 252 42 Jesenice u Prahy Telephone 420 234 144 746 790 Fax 420 234 144 710 777 email servis pragometal com Document KLB_LGA_TS 4 GB doc 104 Pragometal s r o Program parameter setup Lecce Oe Oe a Basic set up Use overlapping Spinning speed of arm Upward Stretch mech travel speed At the end Pragometal s r o EOE ue Oe a Ps Le bee ae Spinning speed of arm Overlap No of turns after overlap Sec stretch after overlap Height of pallet for overlap Pragometal s r o WRA TS FACTORY PASSWORD for level 2 user for program access FACTORY PASSWORD for level 5 technician for service parameter setup WARNING Store these password in safe place so that unauthorized person would not get hold of them
6. Hold the push button the belt will be spooled again on the drum this time in correct sense After the down pressure reaches its upper limit position it stops automatically Switch the machine back to the automatic mode 8 2 13 Electrical System Maintenance Provision of Chap 2 2 on qualification of worker doing maintenance must be complied with during maintenance of electrical system MAIN SWITCH must be off and locked with removed key from lock before manipulation with contactor switch board and other electric installation may commence Disconnect power supply by unplugging supply cable from socket during bigger repairs Scheduled and regular maintenance is needed for electric installation By respecting this request you can substantially extend life time of the installation Use shorter intervals for removing dust and dirt from electric installation as well as from other mechanisms Use longer intervals for tightening screws and contactors especially after grave short circuits Also check functioning of thermal protectors insulation resistance or earthing Main switch must be off before any work on engine may begin If the engine is not in operation for longer period its condition must be checked as follows 1 any visible damage to any of its parts 2 winding insulation resistance 3 condition of motor mounting grease filling must be replaced after longer time 8 2 14 End limit switches and sensors Continuously ch
7. current last line will then be shown on the first line of new display line with command 9 in following example O CO N OY OB Command 9 Command 10 Command 11 Command 12 Command 13 Command 14 53 Pragometal s r o WRA TS Button INS insert command Command on the active line before pressing INS and next commands will be moved by one line further Command Command Command Command Command Command Press INS Command 1 Command 2 A AWN Command 3 Command 4 Command 5 and choose command as needed Command 1 Command 2 New command Command 3 Command 4 Command 5 Button DEL deleting command on the active line Commands on next lines will be moved by one line up After pressing this button a confirmation box will be displayed to prevent from unwanted deletion Command 1 Command 2 Command 3 Command 4 Command 5 Command 6 Press DEL and acknowledge Command Command Command Command Command Command JX ANAU ANE Deletion of all program commands After pressing this button a confirmation box will be displayed to prevent from unwanted deletion Program save Program save display is shown see chapter 6 6 1 If a program is created as open it cannot be saved as parametric system will only enable to save the program under numbers 10 to 19 Help Help to the active line is displayed after pressing this button aR n 54 Pragometal s r o WRA TS Program Mo 12 Freely editable
8. following information Press to restore standard display touch the display anywhere on its surface and the standard display as left before screensaver activation appears This switch does not bring any other operation neither it actives a parameter command or function which are displayed 6 2 10 Display Structure Basic displays for manual and auto mode can be switched by mechanical switch MANUAL AND AUTO MODE SWITCH Display structure i e description of mutual dependency and logical sequence of the displays is always displayed in respective chapter auto mode manual mode program free edit mode 3 Pragometal s r o WRA TS 6 3 Loading Wrapping Film Into Machine When the film is used up the machine automatically moves to position for film loading If in exceptional circumstances i e mechanisms are not in position suitable for film change e g following a tearing you need to manually change the film follow these instructions 4 Switch the machine to manual mode KUT W Manual functions Overlapping Tog Platen Basic motion Ending ERR Configuration Other Menu of manual mode for approach to position for film change and to initial position appears on the display This menu always appears as the primary one after switching to manual mode 3 Use button on the switch board see help in top part of the display marked with A to move to initial position for wrapping as necessary Change the fi
9. the arm during travel upwards Secondary stretch secondary film stretch during stretching 60 150 Yo mechanism travel upwards High position wrapping parameters in upper position During the period when the stretching mechanism is in upper position above goods and eventual activity of Overlap mechanism is happening The main task is to fix upper part of goods to pallet 48 Pragometal s r o WRA TS No of Arm Turns Number of turns in upper position after turns start These turns fixate upper part of packed goods to pallet and if overlap film is used they fixate it as well Film end is also fixated during simple wrapping F overlap ab edge of Film overlap above edge of goods cm Jooss Distance which is used for overlapping of upper part of film above edge of goods on pallet Edge of goods is over wrapped Film protects edges of packed goods and eventually fixates overlap film if used Spinning speed of Spinning speed of arm during turns in 0 100 Eag upper position Secondary stretch Secondary film stretch during turns in 60 150 y upper position Downward wrapping parameters downwards Used when machine moves downwards along the goods on pallet Vo Spinning speed of Spinning speed of arm during stretching 0 100 AEM mechanism travel downwards A mech travel Stretching mechanism travel speed 0 200 cia Speed of the stretching mechanism on the arm during travel downwards Secondary stretch S
10. within time limit Static tongs timeout exceeded arm has not reached required position within time limit Mobile tongs timeout exceeded arm has not reached required position within time limit Overlap cutting console timeout exceeded console has not reached required position within time limit Top platen mechanism has not reached required position within time limit 80 Check stretching mechanism travel Check propulsion Check sensors Check setting of the parameters Inputs DI0 006 DI1 006 DI2 006 e Check sensors of cutting bracket position e Check air inlet condition pressure Input DIO 2 003 e Change spool with spent film e Load torn film into stretching mechanism e Check condition of sensor of ending arm position e Check air inlet condition pressure Inputs DIO 0 003 DIO 1 003 e Check condition of sensor of static tongs position Check air inlet condition pressure Check condition of sensor of mobile tongs position Check air inlet condition pressure Check condition of sensor of overlap cutting console position Check air inlet condition pressure Check top platen propulsion e Check top platen sensors Inputs DIO 008 DI1 008 DI2 008 Pragometal s r o WRA TS FAULT 14 Pallet lift has not reached e Check condition of Pallet lift timeout required position within time Sensors limit e Check air inlet hoses gaiters pressure e Goods weight too heavy Input
11. a wrapping program a dialog box for new program selection is displayed after touching program number on standard display of auto mode Auto mode Program No STANDARD WRAPPING Line status Auto mode l Erel Configuration 6 5 3 Automatic Program Switch After Incorporation Into Line Remotely i e using control system of the line without manipulator s intervention programs can be switched over by means of 3 communication signals Parametric programs 0 to 3 and freely editable programs 10 to 13 are used for remote switching To activate this function one of following programs must be manually set up The function is inactive following different program number selection i e program 4 to 9 or 14 to 19 and the wrapping is executed according to program selected on operator panel Tab Assignment of combination of communication signals and programs Communication signal Program 0 Program 1 Program 2 Program 3 Program 10 Program 11 Program 12 Program 13 43 Pragometal s r o WRA TS 6 6 Programming of Operation of Machine Program number or program parameter can be changed at any time even during program execution If wrapping cycle is being executed during program or parameter change parameters valid at the time of start of wrapping are used Changes in program or program parameter as changed during program execution will take effect during following program start after the changed parameters have been
12. air inlet before the machine and the regulating valve position 1 e Open the discharge valve position 5 the condensate is thus discharged and the system vented discharge the compressed air e Wait until the pneumatic system is fully vented as long as you hear the escaping air e After the pneumatic system has been fully vented unscrew the vessel with oil position 4 and fill it with a specified lubricant see Chap 8 2 2 e Screw the vessel back make sure that the sealing O ring is in correct position e Close the discharge valve open the compressed air inlet before the machine and on the air treatment unit position 2 this procedure ensures slow increase of air pressure e Check setting of inlet and operating air pressure 93 Pragometal s r o WRA TS The adjusting screw of oil amount added to the air position 1 has already been set and requires no adjustment for the whole service life of the machine 8 2 6 Inspection of belt of stretching device travel Move the stretching device to its lower limit position The belt must not have frayed edges along all its length nor may it be torn Make inspection of eyes and their seams In case the belt is damaged it should be replaced 8 2 7 Inspection of arm chain tightening Loosened or slacked chain causes vibration of the arm during stopping which is also perceptible on the chain Unscrew the plate with the arm motor 4 screws and tighten the chain with the
13. are fixed in identical manner Remove the securing ring from the pin and take the pin out from the lugs of the down pressure plate or from faces of the spooling drum Using a reverse procedure mount the new belt and secure the pin with a securing cotter Dimensions of the new belt must be identical with the original it is provided as a spare part including stitched on loops on both ends In case the belt is made in your factory ask the manufacturer for documentation a right belt must be used the eyes must have correct dimension and strength of seams must be observed Down pressure moves in reverse sense lf the down pressure moves in a reverse sense i e the down pressure plate moves upward when the downward movement of the down pressure is required and vice versa or the down pressure does not move down onto the wrapped goods although application of the down pressure has been chosen the belt is spooled on the drum in a reverse sense as a result of the previous error This state can be detected visually in correct way the belt must be spooled on the pulley from the top 99 Pragometal s r o WRA TS Remedy If there is a pallet with goods on the machine conveyor remove it Switch the machine over to the manual mode and move the down pressure to its lower limit position using the manual function Down pressure up down for lifting the down pressure using push button i e the push button with logically reverse function than required
14. arm and back plate tilt back and conveyor carries away the wrapped pallet Sealing arms and film fixture are powered by compressed air I WARNING Risk of scorch Overburning wire and sealing device are red hot for a short time during cutting and sealing the film 21 Pragometal s r o WRA TS 5 3 Top platen Mechanism The mechanism serves for fixing unstable light goods during wrapping It is not part of standard package and has to be ordered extra Shearlegs top platen device attached to rotary arm can be used Adherence pressure of approx 300N 30kg is developed by self weight of part of the mechanism 5 4 Overlap Mechanism The mechanism is not part of standard package and has to be ordered extra If the mechanism is not requested with the initial delivery of the wrapping machine it cannot be supplied later machine frame with the mechanism is not identical with the one without it The mechanism serves for protection of upper area of packed goods against atmospherical factors Edges of protection film are fixated to pallet with stretching film Overlap film can be laid automatically command to overlap the pallet is sent in the program of the wrapping machine so that the entire overlap process is done without any intervention of the manipulator Adjustment of the process is possible only by setting optical sensors and changes in program and operation parameters 5 4 1 Description of Overlap Mechanism 1 C
15. divided into 2 pages overlap 1 Overlap tongs delay Delay between closing overlap mobile tongs and opening overlap static tongs 0 5 sec after film pulling delay between opening mobile tongs and their travel Delay for overl tongs Delay for overlap tongs return return Delay before return of mobile tongs to 0 5 sec starting position Overlap cutting Time during which overlap cutting wire is heat up being heat up on temperature needed for 1 10 sec cutting overlap film 53 Overl timeout Overlap timeout forward backward forw backw 0 60 sec i i Timeout of horizontal overlap travel Overlap timeout Timeout of vertical overlap travel 5 60 a up down Pragometal s r o WRA TS CO oey O Parameername Range Unit Max speed of Max speed of movement of mobile tongs extending in horizontal direction Parameter serves 0 100 cm for calculations to change it has no sec impact on change of maximum speed Min speed of Minimum speed of movement of mobile 0 100 o extending tongs in horizontal direction i 57 Max travel speed Max speed of movement of mobile tongs in horizontal direction Parameter serves cm s 0 100 for calculations to change it has no ec impact on change of maximum speed Service Parameters 2 Overlap 2 Min travel speed Min speed of movement of mobile tongs 0 100 in horizontal direction 59 Film unroll speed Mobile tongs speed in vertical direction of 0 100 Yo during unrolling film from
16. gt i 4A V de sk 172 Vestec 252 42 Jesenice u Prahy Cesk republika PRAGOMETAL spol T o Tel 420 234 144 746 790 Fax 420 234 144 710 777 Rotary Arm Product Specification Service Instructions Maintenance Pragometal s r o WRA TS Rotation wrapping machine can only be operated by an employee who has been assign to it and has been acquainted with these instructions and safety rules herein stated in a demonstrable way TABLE OF CONTENT 1 GENERAL enn en 4 2 SAFETY INSTRUCTIONS cccccccsscsscsscssccessesseesseseeesevenseen 10 3 ACTIVATION AND HANDLING ccccseescseceesseceeseeseeesensene 14 4 TECHNICAL PARAMETERS cccccscscsscssssscsessesssesseseneeens 17 5 EQUIPMENT scsccsssesdepceesicecetsescetacetaevetnnsiicamenienieneeeestneiaes 19 6 OPERATING STAFF cccccssccscsscssccesssscessesseseeseneeenseeseensnss 29 7 FAULTS AND THEIR REMOVALG c ccccsscsesseseseeeree 75 8 MACHINE MAINTENANCE AND CLEANING sasasi 86 9 WARRANTY CHYBA Z LO KA NEN DEFINOVANA 10 SERVICING ou cccccccscssccessesecesesseeseessesseesenssneeesseusaessnseaesans 104 Pragometal s r o WRA TS 1 GENERAL These instructions are the original instructions for use according to Directive EU no 2006 42 ES and they are authorized by the manufacturer 1 1 Utilization Rotary Arm WRA is a fully automated machine to be included in transportation lines eventually for a freestanding
17. longer displayed The password is entered and valid and the system enables changes of parameters and programs their saving and immediate testing of changed parameters and programs during the time when LOG OUT Password buttons are displayed 6 2 8 Statistics Counters of wrapped pallets are displayed on main displays of service parameters 1 and 2 Both counters only count fully wrapped pallets pallets whose wrapping has been interrupted either by user or following a failure are not included in the count Both counters can be set up after touching a number of wrapped pallets as shown in Chap 6 2 3 Service parameters 1 set up of a number of wrapped pallets is password protected level 5 technician It is designed for monitoring a number of wrapped pallets according to the needs of the user e g number of pallets per shift week month for a delivery order etc Service parameters 2 set up of a number of wrapped pallets is password protected level 8 administrator It is designed for monitoring a number of wrapped pallets according to the needs of the service e g total number during machine lifetime number of pallets from general revision configuration change etc 6 2 9 Screensaver lf the display is not active for longer time operating staff is not controlling the machine via the touch display for longer time a screensaver with dark and non contrast image is activated Automatically set time is 7 minutes Display shows
18. mechanisms should move smoothly and uniformly in the whole movement range Check conditions of the pneumatic distribution in particular the state of hoses for possible breaking or other damage also check whether they are correctly fixed in screw joints and other pneumatic elements Inlet air pressure should be within the range 0 6 to 1 5 MPa its checking and regulation depends on the pneumatic distribution of the machine user 92 Pragometal s r o WRA TS Air pressure in the machine must be set to a value stated on the plate next to the unit of air treatment standard 0 5 MPa It is set by a regulating valve position 2 air pressure is monitored on the manometer position 3 In case the condensate level is less than 10 mm under the upper edge of the separator filter on the air treatment unit open the discharge valve position 5 The condensate with sedimented dirt is expelled from the separator vessel by air pressure After the condensate is discharged close the discharge valve again Under normal conditions the pneumatic system does not require lubrication slow and intermittent movements of the mechanisms In an environment heavily polluted with air dust or with aggressive vapours in the atmosphere it is recommended to lubricate the pneumatic system as follows e Oil should be refilled no later than in case when the oil level in the vessel position 4 falls below the lower edge of the inspection window e Close the
19. not desirable to be changed without good knowledge of the machine and the system It allows a change of all machine parameters and programs which are available for administrator technician user and manipulator 33 Pragometal s r o WRA TS Technician For company maintenance and machine administration System requires this password level for service parameters 1 which are not dedicated for users 1 It enables change of parameters and programs available for technician user and manipulator User For machine operation This level is used for setup of program parameters machine programming It is possible to change parameters and programs available for user and manipulator Manipulator General access Given parameter is not password protected it can be changed at will and system does not require its insertion This level is set up at machine start up It only concerns a selection of a number of run program System itself manages password insertion it requests it only when you try to select a password protected function i e attempt to save changed program parameters or values of machine parameters User 8 password administrator is only known to the manufacturer and service companies User 5 technician and 2 user passwords are listed on the last page of this Service manual We recommend that you remove this page before handing the manual to manipulators and only reveal the passwords to authorized workers Pas
20. ry 62 Pragometal s r o WRA TS Display Controlling Ps Open close static tongs Open static overlap tongs O Close static overlap tongs Open close mobile Open tongs on overlap bracket f D tongs Close tongs on overlap bracket Manual function group Other mechanisms co operating with wrapping machine These functions may be implemented in control system of your machine or be skipped otherwise Installation of your particular machine and line determines utilization of manual functions for conveyor control t Lifting jack with pallet up z Lifting jack with pallet down r Conveyor Conveyor forward ti Conveyor backward Turn Turn forward Turn backward 6 8 Machine Service Parameters These parameters serve for adjusting machine functions during its mounting or repairing They adjust machine functions to particular plant ambient and packed goods They are important for correct functioning of the machine and their incorrect set up may lead to machine breakdown or health hazard and that s why they are not commonly available for machine manipulators and are password protected from unauthorized access Password system enables some parameters to be only changed by manufacturer or service workers some parameters may be changed by user see more details about password system in Chap 6 2 6 Values of all parameters are pre set from manufacturer to accommodate vast majority of common wrapping methods
21. system Control elements of the fencing electric lock buttons are located outside the main panel of the switch board just beside doors to the fencing Protection fencing is perfected with light barriers see Chap 5 7 5 7 Light barriers Light barriers support the protection fencing by guarding roller conveyor at entrance and egress to the working space of the machine In case of an attempt to enter the working space of the machine using conveyor the machine is immediately switched off Category 3 safety elements as per CSN EN 13849 1 are used Operation of light barriers is fully automatic and does not depend on the personnel Light barriers status is indicated as text on display and with bollard Light barriers protection function is moderated for essential period during passing the pallet into the working space of the machine function muting light barriers stop working during this period and unauthorized access is enabled There the access on the conveyor must be physically disabled by light barriers by protection fencing reaching the light barriers and by mounting the light barriers just beside conveyors to disable the access between pallet and light barriers Activity of light barriers is indicated with bollard Line Status Bollard Status Standard status machine is on and light barriers work as iit normally Mute status muting pallet with goods is just passing the light not lit barrier Emergency status attempt t
22. the machine The button is mechanically blocked in on position and is placed within reach of the manipulator on the control panel 10 Pragometal s r o WRA TS 2 CONTROL VOLTAGE button On power supply outage or upon touch of EMERGENCY STOP button the supply of control system is switched off and the machine stops performing any activity even if the supply is recovered or the EMERGENCY STOP button is prematurely unblocked as a result of accidental or inadequate action of the manipulator or service Only the touch of CONTROL VOLTAGE button enables further activity of the machine 3 Machine control is executed from the control panel which is placed on the side of the machine or independently as per the project The control panel is out of reach of working space of the machine 4 There is a protective fencing around the whole machine eventually equivalent safety measures are used as per project as designed in Chap 3 1 5 Ending mechanism Control element reverser for opening and closing film fixture is placed in a way that during its operating the mechanism of film fixture is out of reach for the manipulator 2 3 2 Duties of Manipulator and Machine User For personal safety the manipulator is obliged to follow these instructions 6 The crew of the machine is made up of one person only No other person than the manipulator is allowed to be in the vicinity of the machine during run 7 Only a worker older than 18 years who ha
23. the panel Displayed buttons serve for data input changing displays and panel operating Their location and purpose are adapted to usefulness and comfort of the personnel to the maximum extent Durable mechanic buttons and on the switch board serve for direct manipulation of manual functions 5 8 3 Special Buttons The rest of the buttons and controllers are only used in some machines to help with particular needs They are not necessarily placed on the control panel or in its vicinity yet there where it is more practical in terms of functionality and safety e g near controlled element If your machine does not feature these buttons or controllers please ignore their description Two phase controller FILM FIXTURE Default position during operation is Closed controller left Film fixture is mounted on coo co the conveyor it grabs loose end of the film from stretching mechanism at the end of wrapping and holds it till the next wrapping N Two phase controller OVERLAP STATIC TONGS Default position N Y during operation is Closed controller left 5 9 Safety Equipment The machine is fitted with several safety elements for manipulators health protection or minimizing damage after accidents 2 Pragometal s r o WRA TS 5 9 1 Emergency Stop Button EMERGENCY STOP button is placed near control panel and serves for immediate machine halt in case of emergency machine failure fallen goods from pallet crash inju
24. tightening screw so that minimum clearance about 15 to 20 mm would be left in the chain middle Check whether the chain is in correct engagement with the gears If not the chain should be replaced If after replacement chain wheels do not have correct engagement with the chain the fault wear is in the chain wheels and they should be replaced After the chain has been replaced check and if necessary adjust its tightening after the chain running in i e after about 1 to 2 weeks of operation 8 2 8 Inspection of looped collector Remove the collector cover cylindrical cover above the main bearing of the rotating arm Gradually lift off all contacts of the looped collector along its vertical axis clean the contact surfaces of the collector and check their condition In case the contact surfaces of the collectors show an excess wear i e height of any contact is smaller than 0 5 mm see the figure replace the contact It is recommended to replace all contacts in the collector at the same time gt 0 5 Inspect functional surfaces of the collector rings loops and clean them as necessary Remove possible baked on residual dirt and signs of corrosion or oxidized surface If the functional surface is worn through its edges are distorted or its parts broken off replace the collector ring the contact is being excessively 94 Pragometal s r o WRA TS worn In case all rings or most of them show approximately the same
25. wear it is recommended to replace all rings as prevention Inspect condition of cables connected to the collectors they must be properly fixed must not be broken or their insulation damaged mechanically or thermally During the re assembly make sure that the cables are correctly laid same as before the inspection the risk of cables being caught in the collector mechanism and damaged is thus prevented 8 2 9 Maintenance of single motor stretching device During the inspection and maintenance no film should be inserted in the device The following should be checked on the stretching device e State and tightening of the belt The belt condition should be checked if its top layer is frayed the belt is broken or pieces of rubber are torn off from it it should be replaced for a new one of identical dimension and specification e Smooth and even run of all pulleys on the stretching device The pulleys must not be deformed If necessary replace the pulleys or in case of incorrect run replace their bearings e During the operation watch function of the balancing pulley it is installed on a spring mounted swinging lever In case the spring is weak i e the balancing lever cannot maintain tightness of the film that becomes slackened for a short time during wrapping the spring should be replaced e The friction insert on the film roll holder if the insert is excessively worn this is manifested by an apparent thinning of t
26. 6 8 1 Editing of Service Parameters Entering mode for editing of service parameters Service parameters can be operated and edited both in manual and auto mode of the machine Press Configuration button to switch from main display of auto mode to menu for programming and configuration of the machine 63 Pragometal s r o WRA TS Auto mode Program No 9 P STANDARD WRAPPING Line status Auto mode Auto mode Program No 9 Edit Service 1 Service 2 Line Similarly you can get to from main display of manual mode to editing of service parameters by pressing Configuration Manual functions Starting position J caan i Top Flaten ERHI Configuration 64 Pragometal s r o WRA TS senice parameters Service 1 A Service 2 Line ERR Back Open the main display of service parameters 1 by pressing Service 1 in any mode It is a guide post for an access to individual groups of service parameters 1 Service parameters 1 Oriented Fail Stop parameters e Overlap IN OUT gt parameters state SAVE OF r aiis j return v Number of wrap cycle 9999 Similarly by pressing Service 2 in any mode you will open the main display of service parameters 2 Senice parameters Z Machine configuration E Streching Endin gt mechanism 4 Top platen Overlapping Save Blowing return v Number of wrap cycle 99999 65 Pragometal s r o WRA TS Service paramete
27. A TS The left chain when viewed from the switchboard to the machine working space has a simple tightener position 1 providing for correct tightening of the chain With the right chain it is possible to set each chain branch separately By setting each branch separately the chain can be correctly tightened tightener 2 and position of the moving tongs adjusting nut 3 can be adjusted so that they are parallel with the fixed tongs deviation max 5 mm Inspection and tightening of arm travel chains horizontal chains The chain tightening is checked on the upper branch in the middle between the supporting pulleys With a slight force exerted in the middle of the chain about 1 kp the chain should be sagged by 50 to 80 mm The data of the previous paragraph concerning the vertical chains apply fully to engagement of the chains with the chain wheels replacement of the chains and running in of the replaced chains The chains are tightened using the tighteners on the return pulley the most distant from the initial position of the overlap arm each chain extra Loosen the nut in the pulley axis and tighten the chain by turning the tightening screw Then retighten the nut Adjustment of arm travel All adjustments of the arm travel are carried out on the arm carts The following is adjusted 98 Pragometal s r o WRA TS e Parallel orientation of the moving and fixed tongs By the adjusting nut position 1 the adj
28. A TS 6 OPERATING STAFF This service manual has been drawn up for maximum machine configuration If your machine does not include some of the described parts please ignore respective chapter 6 1 Machine Start up and Shutdown TO ensure proper machine operation this procedure on how to active the machine must be followed e Press MAIN SWITCH e Visually check situation on the line pallets are correctly loaded with goods not colliding with the machine the line or each other There are no strange objects on the line or in the working space of the machine There is nobody in the working space of the machine Safety equipment is OK and in correct position and switch on the control voltage by pressing CONTROL VOLTAGE button e Displaying of machine initialization display this display is displayed after each make of power circuits after closing doors etc e When the conveyor line is controlled by wrap machine system the START button is displayed visually check situation on the line pallets are correctly loaded with goods not colliding with the machine the line or each other There are no strange objects on the line or in the working space of the machine There is nobody in the working space of the machine Safety equipment is OK and in correct position and if everything is OK by pressing START button you initialize the machine and line If not all problems must be rectified see Chap 7 Activate the machine Next procedu
29. V See Chap 8 2 5 Tab 2 List of lubricants Recommended type Mogul LV 2 3 or usual lithium soaps intended for general use under normal conditions temperature speed environment Oils WS40 or usual oils intended for lubricating chains under normal conditions temperature speed environment life In case of oil escape contact the manufacturer of the wrapping machine or your nearest technical agency of the firm Bonfiglioli Festo OFSW 32 Aral Vitam GF 32 Mobil DTE 24 BP Energol HLP HM 32 From the producer the filling of gearboxes is for the whole service 91 Pragometal s r o WRA TS 8 2 4 Daily inspection Before each starting of the machine or always once a day carry out daily check of the machine This check is accomplished by inspection requires no tools and is short its objective is to discover small defect and thus prevent costly repairs and outages of the machine Such inspection should always be done in case of suspicion of a damage to the machine e g after a bump with manipulation technique fall of goods etc after service interventions maintenance or repair Because in the daily inspection actual state of the machine is compared with the usual state during normal faultless run the daily inspection must be carried out by a technician acquainted with the machine and its function The inspection concerns e Condition of all chains no link may be yawed such state means that the cha
30. anism which is ejected from the main tenon and its correct position is during the whole course of action secured by shear mechanism 5 Ending mechanism The machine is equipped with ending mechanism by default As per order one of following two mechanism can be delivered e smoothing ending mechanism e sealing ending mechanism Pragometal s r o WRA TS 6 Film gripper It is placed on a conveyor and works in co operation with ending arm During the ending it grips the end of the film from the stretching mechanism and at the beginning of the following wrapping it secures the film on the pallet 7 Overlap mechanism Not part of standard package it can be fitted per order onto model PROFI only It lays overlap film on top of the wrapping pallet 8 Conveyor It serves to carry pallets with wares into the workplace of the machine and to carry wrapped wares further on the line 9 Switch board with control panel 10 Protection fencing not displayed It is mounted as per project see Chap 3 1 and ensures safety of manipulation staff as well as other people in the vicinity of the machine Detail description of individual parts of the machine incl its manipulation in Chapter 5 Pragometal s r o WRA TS 1 3 Wrapping Material 1 3 1 Wrapping Foil The machine is designed for wrapping the wares on pallets with linear low density polyethylene stretch film LLDPE with thickness of 20 40 um The film must have dilatability o
31. anual function group Ending Complete ending full ending sequence happens including moving the stretching mechanism to low position 61 Pragometal s r o WRA TS Display Controlling Slide in eject fixture Eject film fixture erection from low position Slide in film fixture move down to low position Open close fixture Open fixture release film Close fixture grab film Seal back plate Eject seal back plate Slide in seal back plate Eject slide in ending Eject ending arm arm Slide in ending arm Cutting arm eject Arm with cutting wire is ejected and the wire heated until the button is released Eject slide in smoothing Eject smoothing arm arm Slide in smoothing arm Sealing impulse voltage in sealing Stripe Directed air flow blows on film end iiil L Lift top platen mechanism Lower top platen mechanism on goods Arm to overlap Arm turns 180 to be in position for overlap Full overlapping Full overlap sequence Overlap up down Overlap static tongs bracket up Overlap static tongs bracket down Overlap Overlap bracket forward towards goods forward backward on pallet After reaching centre sensor it stops To continue press Overlap bracket backward towards spool with overlap film Up down overlap cutting Cutting is initiated cutting bracket drops bracket and comes back Overlap cutting Overlap film cutting Overlap film is being while the button is pressed cue
32. any intervention can only be carried out by person competent in accordance with national regulations for electrical work Machine manipulators must be demonstrably familiarized with this service manual and the manual must be made available to them at all times The main machine switch on the switch board is lockable and it enables to lock the switch in the off position We recommend the machine user to sort out handling of the key on the floor where the machine has been fitted up and thus prevent the machine from running by unauthorized person 2 3 Occupational Safety 2 3 1 Protective Devices for Occupational Safety Dangerous places which could endanger the manipulator during operation are secured by protective fencing which is connected with the control system of the machine eventually the project executed according to Chap 3 1 must apply safety measures which provide equal health protection of machine manipulators as well as other people in the vicinity of the workplace If both the specified operation for wrapping and instructions as stated in this documentation are met the work with the wrapping machine is safe Dangerous places outside the working space of the machine result from principles of individual activities of the machine 1 Roller or chain conveyors enable independent movement of pallets with wrapped wares To ensure safety of personnel the following are used 1 EMERGENCY STOP button for quick switch off of
33. at the machine user has given them for that purpose 2 5 Fire Protection To ensure the fire protection during operating the wrapping machine the user must equip the workplace of the wrapping machine with relevant fire fighting means Their purpose and placement must be consulted with and approved by experts in fire protection and inspection mainly in relation to nature of processed material and to the fact that the wrapping machine is an electrical device The placement of fire extinguishers and their selection is done by fire prevention officer of the user according to local conditions 12 Pragometal s r o WRA TS 2 5 1 Instructions for Machine Staff In case of fire accident the manipulator must in the first instance turn off power supply by switching off the main switch To subsequently put out the emerged fire the manipulator must only use the fire extinguishers designed for it Neither water nor foam fire extinguishers are allowed during fire extinguishing 13 Pragometal s r o WRA TS 3 ACTIVATION AND HANDLING A supplying company normally executes machine assembly and activation There must be a three phase supply and compressed air at disposal on side For parameters of power supply and compressed air see Chap 4 After the assembly and connecting to power supply it is necessary to carry out revision of electrical installation before activation see Chap 3 3 3 1 Project Before the machine assembly a proje
34. aten If YES top platen is used during YES NO wrapping Use overlapping If YES Overlap is used during wrapping Use wrap with Use wrapping with ejected fixture YES NO ejected fixture If YES wrapping starts with erected film fixture if NO the fixture is down Erected spike is important if ground plan of packed goods is smaller than that of pallet If its the case initial tapered part of film is laid on pallet Use pallet lift If YES pallet lift is used during wrapping YES NO i e the wares is wrapped with the pallet under wrapping Low position wrapping parameters in low position as used at start of wrapping when the stretching mechanism is down Main purpose of this phase of wrapping is to firmly and reliably fixate start of the film to the goods and part of the goods to pallet No of Arm Turns Number of turns at start of wrapping in 1 9 turns low position Only after completing these turns the stretching mechanism starts to go up The turns fixate the film to pallet Spinning speed of Spinning speed of arm during turns in 0 100 arm low position Secondary stretch Secondary film stretch during turns in 60 150 low position Upward Used when stretching mechanism moves up along the pallet Ordinary wrapping phase Spinning speed of Spinning speed of arm during stretching 0 100 AEM mechanism travel upwards o mech travel Stretching mechanism travel speed eee Speed of the stretching mechanism on
35. aximum frequency converter frequency 71 0 500 1 aS Pragometal s r o WRA TS Stretch m regulation Maximum frequency of frequency converter controlling stretching mechanism Value should be equal to 10 500 Hz parameter HSP as set up on frequency converter Stretch m travel on Maximum frequency of frequency arm converter controlling travel of stretching mechanism on arm Value should be 10 500 Hz equal to parameter HSP as set up on frequency converter Service parameters 2 Ending ending parameters 30 Ending arm slow Time delay needed for further activity of 0 10 sec down ending 31 Ejection fixture Angle for tilt of film fixture lever at a angle wrapping start 0 720 32 Fixture delay open Number of turns after wrapping start to rome 0 5 5 turn open film fixture Fixture delay close Time needed to close fixture 34 Fixture delay Number of turns after wrapping start to 0 5 set ejection open film fixture Ending arm timeout Timeout needed to eject slide in ending arm Service parameters 2 top platen top platen mechanism parameters Top plat dev travel Top platen device travel timeout 5 60 sec timeout Max freq conv Maximum frequency of frequency frequency converter controlling arm turns Value 10 500 Hz should be equal to parameter HSP as set up on frequency converter Service parameters 2 Overlap due to big number of parameters is the parameter list
36. ay is blocked out wrapping machine starts moving pallet on conveyor towards light barriers Wait until SAFETY BLOCKINGS RESET button starts blinking and then unblock light barriers according to following paragraph Unblocking light barriers Press SAFETY BLOCKINGS RESET button twice within 4sec Light barriers will be unblocked after second press while the button is being pressed no more than 10 minutes though Unblocking will be stopped immediately after releasing the button or after unblocking time has lapsed The machine is operational in both manual and auto mode during unblocking light barriers After the button has been released the system evaluates status of light barriers and will either reset them SAFETY BLOCKINGS RESET button shines and machine is ready for wrapping or re activate them light barriers will block the machine again and SAFETY BLOCKINGS RESET button is off 85 Pragometal s r o WRA TS 8 MACHINE MAINTENANCE AND CLEANING The wrapping winding machine requires regular maintenance If you respect this request your machine will show longer life time For correct check a pallet must not be on swivel and film must not be loaded into stretching mechanism 8 1 Machine Setting 8 1 1 Password Change Password system has been described in Chap 6 2 6 If needed the password can be changed as shown in Chap 6 8 1 set up service parameters 2 Machine Configuration Semice parameters 2 Machine configuratio
37. ble below shows inputs to the control system of the machine that detect necessity of blocking the machine and its electric wiring can be checked according to the wiring diagram For more details see chapter 7 3 Lock 2 ending Rotary arm is not in initial position Lock 3 ending Ending arm lock from smoothing desk Lock 4 ending Ending arm lock from cutting Lock 5 ending Smoothing desk lock from sealing arm Lock 6 ending Cutting lever lock from sealing arm Lock 7 arm Ending is not in starting position Lock 8 arm Overlap travel is not in starting position Lock 9 arm Top platen device is not in defined position Lock 10 top platen Overlap device is not in defined position Lock 11 overlap down Mobile tongs lock from cutting lever Ending arm move is blocked impeding danger of its collision with rotary arm Move arm to starting position Input DI1 007 Ending arm move is blocked impeding danger of its collision with smoothing desk Move smoothing desk to initial position Inputs DIO 3 003 DIO 0 003 DIO0 1 003 Ending arm move is blocked impeding danger of its collision with film cutting lever Move cutting lever to initial position Inputs DIO 2 003 DIO 0 003 DIO 1 003 You can move smoothing desk only if sealing arm is in upper position Input DIO 1 003 You can move cutting lever only if sealing arm is in upper position Input DIO 1 003 Arm move is blocked impeding dan
38. ch Mech Ab Pal 20 Ue 8 Sec Prestretching 09 17 Str M Down speed 10 10 Stretch M4 Down Left part contains list of six lines of the program Line marked in yellow is the active line and serves for direct editing line number 7 on the picture Press command on the active line to display list of commands Program Mo 12 Freely editable program 05 7 Turn delay J A gt U6 9 Stretch Mech Ab Pal 20 io 3 Ui Uo Use Up Down arrow 1 to move in the parameter list Press and drag scroll bar 2 enables quick shift in command list If you press selected command combo list will be closed and the command is displayed in the active line Existing command will be overwritten Touch the parameter and activate parameter value editing see Chap 6 2 3 Some commands have no parameters so touching them will cause no action Tab below shows functions of individual program buttons For simplicity the examples are generic and simply illustrate displayed commands Active line is in bold 51 Pragometal s r o WRA TS BS PAGE UP button List will display commands on previous page Command 8 Command 9 Command 10 Command 11 Command 12 Command 13 Press PAGE UP Commands will move one page up current first line will show on the last line of the new display line with command No 8 in following example Command Command Command Command Command Command COW D OTB W Button UP Browsing in the list one line up
39. connect cables nuts and washers 5 and unscrew bolts 7 Take down sealing body 96 Pragometal s r o WRA TS e If a new Teflon cloth is needed 8 replace it at this stage Teflon cloth is clenched between sealing strip 9 and insert 10 During the dismounting take heed to proper tension of Teflon cloth and check that slots in Teflon cloth match with slots for bolts in sealing strip Assembling is a reverse procedure to dismounting Self adhesive cloth is used in some cases If sealing resistive strip 11 must be replaced loose nuts and washers 12 after removing Teflon cloth Replace the strip slide ends between big washers 13 and nuts 12 re tighten so that the strip is properly fixated Put the Teflon cloth back or replace for new if needed Assembling is a reverse procedure to dismounting 8 2 11 Maintenance of overlap Make a daily visual inspection of the state and integrity of the wire If residues of the overlapping film are baked on it remove them with a rag or an appropriate tool made of plastic or wood never metallic make sure that the Teflon coat of the wire is not damaged In case the wire is ruptured slipped out from its attachments or the Teflon coat is damaged replace the wire both ends of the wire are attached in an identical way Loosen the screws fixing the wire to the holder and remove the old wire Mount the new wire so that after assembly the springs on the stretcher would be pressed to the li
40. conveyor 0 Check propulsion Check pallet sensor FAULT 22 Pallet has not reached Check propulsion Conveyor 0 pallet i posmon WILMA ime Obstacle in trajectory of in out move Check pallet sensor 81 Pragometal s r o WRA TS FAULT xx Conveyor xx pallet in out FAULT 29 Sealing timeout failure 31 Communication CAN cannot be established FAULT 33 CAN address 12 LGC counter conveyors FAULT 34 Light barriers FAULT 36 Emergency stop FAULT 37 CAN address 9 LGC counter overlap FAULT 38 CAN address 4 LGC counter encoders FAULT 39 CAN address 3 LGC counter ending FAULT 40 CAN address 2 LGC counter communication FAULT 41 CAN address 10 overlap frequency converter lift FAULT 42 CAN address 11 overlap frequency converter travel Pallet has not reached required position within time limit Number of conveyor see the plan of your line Time of sliding sealing blade of ending mechanism to starting position has been exceeded Communication of the CAN bus cannot be established Mechanism at CAN address 12 cannot be initiated counter LGC conveyors Machine stop error signal from light barriers or attempted entry on roller conveyor Machine stop button of emergency stop pressed NOT STOP Mechanism at CAN address 9 cannot be initiated counter LGC overlap Mechanism at CAN address 4 cannot be initiated counter LGC encoder
41. ct tackling the following must be drawn up e meeting machine ambient requirements See Chap 1 5 e occupational safety of the personnel and other persons in the vicinity of the workplace Access to the working space of the machine must be barred during the wrapping process by e g using protective fencing light barriers electronic locks and other protective measures as needed e location and orientation of the machine within the wrapping line in term of functionality of both the machine and the line and according to needs of the packed goods e if the machine is fitted with the overlapping device it is necessary to minimize airflow in the machine vicinity the cut off overlapping film is carried by the airflow away from its optimum position and the overlap can be of poor quality e location of the switch board and the personnel in case the machine is delivered without the switch board or with detached one e access to places of manipulation and places essential to maintenance and repair works e mechanical electric and software co operation with other machines on the line e supply of electricity and compressed air and cable guide so that neither the supply and the cables could not be damaged nor the manipulator or other persons in the vicinity of the workplace be injured e positioning of more Emergency stop buttons if need be so that they would be easily accessible for both the manipulator and other persons in the vicini
42. description put the machine out of operation and provide for its service For the light barriers and safety modules of the firm LEUZE the manufacturer orders that an inspection of the device should be done once a year by a service technician authorized by the firm LEUZE Contact your nearest trading or technical agency of the firm LEUZE or your supplier of the machine Rotary Arm 102 Pragometal s r o WRA TS Emergency stop The module is installed in the switchboard Stop the machine by pressing the push button EMERGENCY STOP Keep the push button depressed and press the push button CONTROL VOLTAGE the push button must not light up and the machine must not start working or moving in any way Then put the machine into Operation according to Chap 5 9 1 Successively test all push buttons EMERGENCY STOP used on the machine and connected to its switchboard Following this procedure test function of the push buttons EMERGENCY STOP and of the safety module controlling operation of the machine Electro magnetic lock of protective fencing The module is installed in the switchboard Test its functionality with no exception it must perform all functions as referred to in Chap 5 6 Test mechanical reliability of the lock it must not permit the door to open by applying usual force In this way test the lock and the safety module in the switchboard that co operates with the control system and with the machine power supply 8 3 Notes
43. e equipment cover keyboard sheet is dismounted or damaged 3 To touch moving palette 4 To operate the machine if working space of the machine and workplace are not well illuminated 5 To carry out maintenance cleaning and repairs if the machine is not switched off with the main switch and secured against accidental start up 6 To carry out checks or repairs of electrical installation by a person without necessary qualification 7 To put out of operation safety protective and security equipment or otherwise interfere with the installation and electrical elements of the machine 2 4 Health and Occupational Hygiene Weight of the wrapping film is approx 17 kg To handle loads over 15 kg is prohibited to all women and juveniles Working ambient in which the machine is operated is influenced by the nature of manufactured and packed goods The user is obliged to guarantee occupational safety and hygiene of workers in conformity with national regulations for occupational hygiene To reduce the physical effort the manipulator must during manipulation with packed pallets use hoist means of mechanisation which have been assigned to him by the employer If the nature of the packed product could lead in hand or any other injury of the manipulator during operation or if packed goods does not meet hygiene limits chemical and biological materials dustiness din etc the operating staff must use personal means of protection th
44. ecified in Chapter 8 2 1 e Damage to machine or goods caused by using wrong consumable material other than approved by the manufacturer see chapter 1 3 1 7 Manipulation The machine is designed for manipulation by one person Working station at the control panel in combination with specified protecting device ensure that the manipulator will work beyond reach of the working space of the machine 1 8 Electrical Installation of Machine Electrical installation of the machine has been executed pursuant to EN 60204 1 Electrical installation of the machine comprises of a switch board and an electric distribution on the machine There are bipolar supply terminal and machine on off switch in the switch board Machine supply must be protected by fuses or circuit breaker The mains to which the machine will be connected must comply with both international and national regulations and standards Pragometal s r o WRA TS 2 SAFETY INSTRUCTIONS 2 1 Revisions and Tests of Electric Installation The machine is subject to regular revisions and tests of electrical installation It is necessary to meet requirements as set out in EN 60204 1 during those operations The revision of electrical installation must be executed prior to initiation of the machine see Chap 3 3 2 2 Safety Recommendation Since every unprofessional interference with electrical installation could cause major damage to the machine or an injury to the personnel
45. eck correct function of switches and sensors the machine stops or performs required operation in correct places and at right time During mechanical inspection of the switched off machine check mechanical state of the switches non damaged cables the switch fix fitted to the machine non damaged levers and pulleys of mechanical switches correct closing clunking of contacts during movement For the optical and induction sensors their state with the machine running is indicated by an LED Clean the windows and mirrors of optical sensors in regular intervals Sensitivity of optical sensors if not given by choice of the sensor type is factory set so that they can reliably scan the goods on the pallet and that the sensor would not react to remote objects or movement outside the machine Adjustment of an insufficiently or excessively sensitive sensor if possible is carried out using the adjusting screw on the optical sensor 100 Pragometal s r o WRA TS Sensitivity of induction sensors is given by the type chosen by the designer for given purpose Wrong function of the induction sensor is either caused by incorrect position of the sensor with respect to the indicated part the gap should range between 2 and 5 mm and after adjustment it should be tested or the sensor is defective Adjustment except gap adjustment or repair of a defective sensor is impossible and it should be replaced for a sensor of identical type and specificatio
46. econdary film stretch during stretching 60 150 mechanism travel downwards Only used for double cross wrapping At the end wrapping parameters at the end of wrapping Used for end of wrapping These parameters need to be set up so that wrapping is optimally finished and stretching mechanism film is properly fixed in film fixture No of Arm Turns Number of turns in low position before 1 9 turns wrapping end in case of double cross wrapping These turns fixate film end These turns do not include turns needed to finalize the film Spinning speed of arm during final turns 0 100 arm Secondary film stretch during final turns 60 150 Overlap overlap wrapping parameters Set up these parameters so that overlap film has optimum length is evenly laid on top of goods on pallet and is properly fixed by stretching film Overlap film length Overlap film length Overlap film is cut 80 200 cm to this length from spool Overlap film shift Distance from rotary arm centre by 0 80 cm which cut overlap film shifts in horizontal move over the goods on pallet The parameter is used to centre the film on goods and to align it 49 Pragometal s r o WRA TS No of turns after Number of turns after overlap overlap secondary film stretch after overlap 60 150 overlap Height of pallet for Height to which the moving tongs of 0 300 cm overlap overlap drive before measurement of the pallet height For the va
47. erwise in the order the primary film stretching is set to 160 which suits commonly used films and wrapping procedures If you need to change the primary stretching you have a set of belt gear for different stretching size from 80 to 290 at your disposal Pinion and primary gear remain identical for all values of primary stretching only belt gear wheel and secondary gear belt need to be changed Remove top cover of the stretching mechanism unscrew shaft axis bolts in belt wheels and pull down both wheels as well as the belt Conversely mount new belt and new belt wheel together with the original pinion the pinion must always be on output shaft of the roller closet to electromotor No of cogs Order No Manufacturer No Order No 80 36 RTA 3 0 01 22 HTD 405 5M 15 1K RE 0301 120 44 RTA 3 0 01 23 HTD 425 5M 15 1K RE 0302 160 o RTA 3 0 01 24 HTD 450 5M 15 1K RE 0303 RTA 3 0 01 25 HTD 475 5M 15 1K RE 0304 250 E RTA 3 0 01 34 HTD 500 5M 15 1K RE 0351 290 RTA 3 0 01 27 HTD 525 5M 15 1K RE 0305 Correct belt tension and procedure for setting are described in Chap 8 2 9 Maintenance of this device includes occasional check of belt tension and its condition see Chap 8 2 9 5 1 2 Measuring Height of Goods on Pallet The wrapping machine is equipped with optical system for measuring the height of goods on the pallet This device is designed for automatic halt of the stretching machine after wrapping top of the pallet Optical sen
48. etergents During cleaning the machine must be disconnected from electric power supply Clean regularly also windows and mirrors of optical sensors In doing this do not use sharp tools aids or chemicals that could scratch optical elements or windows and or cause their non transparency 8 2 3 Lubrication The numbers in the diagram of inspection points correspond to the numbers of lubricating points in the table The lubricating diagrams apply to the machine with the highest configuration In case some component is not fitted to your machine ignore particular point 89 Pragometal s r o WRA TS 90 Pragometal s r o WRA TS Table 1 List of lubricating points t inspection maintenance 1 Chain of arm rotation small small maintenance maintenance Radial bearings of arm rotation small maintenance Axial bearing of arm rotation small small maintenance maintenance Overlap chains small medium maintenance maintenance Other bearings small maintenance 5 Drives of arm rotation large stretching device travel and 3 A maintenance overlap Bearings of electric motor of medium stretching device maintenance 7 Pneumatic system small small maintenance maintenance Notes A Justin case of escape lubricant filling is for whole service life B Check for possible grease escape if so replace the bearing for new one of identical type and version grease escape causes damage to sealing rings
49. eters 10 Max number of arm Maximum possible rotation speed of arm turns Parameter is used for calculations only its change has no impact on change of maximum speed Minimum arm speed Minimum arm speed which is set for its 5 100 5 finish 70 Arm acceleration Time during which swivel accelerates l 0 1 5 sec from zero to maximum speed and back 13 Arm deceleration Time during which swivel accelerates l 0 1 5 sec from zero to maximum speed and back Max frequency of Maximum frequency of a frequency freq conv converter that controls arm turns Value should be equal to parameter HSP as set up on converter 1 40 turn 10 500 Hz Service parameters 2 Stretching mechanism stretching mechanism parameters Max speed of Maximum possible speed of stretching stretch m mechanism Parameter serves for calculations to change it has no impact on change of maximum speed 100 cm 5000 min Convert of pulse Conversion of gauge drum encoder encoder constant for calculation of precise gauging Only for manufacturer 100 1000 Film conversion Value for calculation film amount mm constant released from pre stretching mechanism at HSP within 50ms 23 Stretch m timeout Timeout of stretching mechanism travel on pillar aoe ovr Distance between Distance between goods sensor and goods sensor and upper edge of film Used for calculation 0 50 oe film edge of film crossing over upped edge of goods on pallet M
50. f 150 be in spools of 500 10 mm in width and diameter of maximum of 250 mm The tube onto which the film is wound must have inside diameter of 7643 mm and length of 510 5 mm Both one sidedly adhesive and non adhesive film can be used Adhesion of one side means that individual layers wrapped around the wares will very well stick together yet they do not tend to damage the wares on the pallet in any way The main purpose of utilizing this film is to better set the wares on pallet better firmness of the wrapping and its bigger resistance against climatic effects and mechanic straining during transportation After wrapping a pallet with the wares it is recommended that the wound film be oriented with its adhesive side onto the wares so that the pallets will not stick together with each other during manipulation and transportation The film is normally resistant against UV radiation for 6 months i e the wrapped wares can be stored during this time outdoors and be exposed to the solar radiation while keeping all original characteristics of the wrapping If required to be stored outdoors for longer time some films can be supplied with better resistance against UV radiation Stretch films meet above mentioned requirements POWERFLEX 250 Automatic machines with Various thickness HPQ mechanical single or twin engine Non adhesive and one stretching mechanism sidedly adhesive High UV radiation resistance POWERFLEX 300 Use simi
51. for overlap Input DI3 007 Overlap move is blocked impeding danger of its collision with ending arm Tilt ending arm to low position Inputs DI0 003 DIO 3 009 Overlap move is blocked impeding danger of its collision with top platen mechanism Move top platen mechanism to upper position Input DI2 008 Overlap move is blocked impeding danger of its collision with goods Input DI6 009 Cutting levers move is blocked impeding danger of their collision with mobile tongs Move mobile tongs higher Input 0 2 009 Conveyor move bringing goods in away is possible only if machine is in starting position Inputs DI2 008 DIO 011 DI1 007 External signal Wrapping Granted is not active superior line system has not granted wrapping machine operation Input 0 0 002 If a fault happens from any reasons the machine stops and an indicator ERROR is displayed on the display as well as a running text with list of error messages and ACK button The machine is stopped in auto mode whereas in manual mode the error is only announced Tf Pragometal s r o WRA TS Auto mode STANDARD WRAPPING Line status Auto mode 4 Srel Configuration If the cause of error message is known remove it and then press ACK to confirm error message After pressing ACK the indicator will be switched off in case that fault has been resolved If not it keeps blinking To remove the fault source use manual functions of the machine If the faul
52. fter If YES arm rotates during trolley overlap movement upwards if NOT arm starts YES NO rotation at the moment when film trolley is in goods high according to overlap film Lowering of overlap Difference between the set height of the arrival goods and the height to which the moving tongs drive before measurement of the pallet height Combined overlap Before laying of the overlapping film is started the overlap moves to higher position and during laying it moves down The risk of the film being caught by sharp edges of the goods on the pallet is thus reduced see chap 5 4 2 Moving for Before the combined overlap the combined overlap overlapping mechanism moves up above the goods to the height given by the sum of the parameters 20 and 30 69 Pragometal s r o WRA TS Delay in overlap After the overlap runs this distance in the moving down horizontal travel the overlapping mechanism starts moving down The figure shows the track of the moving tongs at combined overlap thick line and numbers of parameters influencing this track beginning of the horizontal movement from the intermediate position of the overlap when the upper edge of 0 300 the goods is detected 31 Serviceparameters1 Language parameters 1 Serviceparameters1 Language Button group for switching languages Access to buttons is password protected on level User 5 Technician See procedure of setting language in Chap 6 2
53. ger of its collision with ending arm Tilt ending arm into lower position Input DIO 0 003 Ending arm move is blocked impeding danger of its collision with overlap construction Move overlap travel to starting position Input DIO 011 Arm move is blocked top platen mechanism is not in upper position or not on the goods Inputs DIO 008 DI1 008 DI2 008 Top platen mechanism move is blocked impeding danger of its collision with overlap mechanism Move overlap mechanism to starting position Inputs DIO 011 DI2 011 DI0 4 009 You can move overlap frame down only if cutting lever is lifted off Input DI1 010 76 Pragometal s r o WRA TS Lock 12 overlap Mobile tongs lock from travel position Lock 13 overlap Rotary arm is not in proper position Lock 14 overlap Ending arm is not in starting position Lock 15 overlap Top platen mechanism is not in upper position Lock 16 overlap Frame not exceeding goods height Lock 17 overlap Cutting levers Lock 18 conveyor Machine is not in starting position Lock 20 wrapping Line blocks wrapping 7 2 Faults You can move mobile overlap tongs only if vertical overlap travel is at one of the end controllers on initial or middle position Use manual function Overlap Up Down to move it to one of the extreme positions Inputs DIO 011 DI2 011 Overlap move is blocked impeding danger of its collision with rotary arm Move arm to the position
54. he command 25 Overlap 27 Pallet Lift Up It lifts the pallet up if the machine is equipped with pallet lift mechanism 28 Pallet Lift Down It lowers down the pallet on conveyor if the machine is equipped with pallet lift mechanism 29 Combined When this parameter is added the overlap overlap will be laid by the procedure for the combined overlap by horizontal and vertical movement see chap 5 4 2 6 8 2 The command is only functional before the command 25 Overlap 6 7 Manual Functions of Machine individual mechanism This controlling is not designed for normal wrapping it is used for machine manipulation during service work or emergency situations Machine control system enables manual controlling of its AUT ley Enter the manual mode through switch on the control panel 6 7 1 Display If the machine is switch on or to manual mode display of manual mode which is currently selected for the machine is shown 59 Pragometal s r o WRA TS Manual functions Starting position fh ERR EEE 1 Mechanism switches 2 Help for travel to initial position This move can be directed directly from this main display by pressing mechanic button on the control panel of the machine Parameter edit and machine configuration button 4 If errors are detected rolling text with error messages is displayed in upper part of the display By pressing ERR you enter display with error messages list where yo
55. he insert its deformation non uniform wear local waviness or visible approach to a worn through insert replace the insert In a dusty environment check the insert within the monthly maintenance and later according to practical experience adjust the actual interval of the inspection 8 2 10 Check and Maintenance of Ending Mechanism Check condition of the device during day to day maintenance of the machine 95 Pragometal s r o WRA TS e overburning wire 1 it must be reasonably tense 2 wire suspension must not be sitting in any of the extreme positions wire tension must be delimitated by spring If film residues are on the wire remove them e sealing body 3 configuration Teflon fabric coating must not be frayed or torn Sealing resistance strip 11 placed under Teflon fabric must be unfailingly fixated on both sides to sealing body e film fixture beside conveyor make sure that no film residues have remained in the fixture If yes open the fixture with FILM FIXTURE controller take out loaded film and remove film residues Then reload the film into the mechanism and close the fixture with FILM FIXTURE controller If you are dismantling sealing body while replacing damaged Teflon coating or sealing resistance strip follow this procedure 8 11 3 9 13 12 10 1 2 6 ac i A oe VIEU A A N 9 A 9 7 Ga A MTT e take out bolts 4 and remove cover 5 e dis
56. he machine maintenance is described for the machine with maximum outfit In case your machine does not include some outfit item ignore its description Maintenance operation Daily Monthly Large zal di cada 8 2 4 ius inspection or oar or sreing doveevaer s26 a a a e Visual inspection of belt of down pressure travel 8 212 w m u e R EENT Cleaning and il kal of ae collector 8 2 8 cesketiniontasy aries fons e e e Check of tightening and lubrication of arm drive chain 8 2 7 Inspection of electric installation sensors 8 2 13 PP te 8 2 14 Inspection of pneumaticsystem 8 25 f isso egos foas H H dead of st device 8 2 10 Inepecion and aqusment of overapsng mecanism 828 Le Monthly maintenance every 500 operating hours at least once per month Small maintenance every 1000 operating hours at least once per 3 months Medium maintenance every 5000 operating hours at least 1x annually Large maintenance every 10 000 operating hours at least once per 3 years Recommended cycles of operations according to what comes sooner 8 2 1 Warranty Warranty as defined in the Warranty Sheet an in chap 1 6 does not apply to tear and wear parts which are as follows 88 Pragometal s r o WRA TS 8 2 2 Cleaning In short intervals adapted to character of a workplace it is necessary to remove dust and dirt The machine surface can be washed with water and common d
57. iated given mechanism frequency converter for stretch mechansm lift control FAULT 46 Mechanism at CAN address e Check power supply of CAN address 5 rotary 5 cannot be initiated given mechanism frequency converter for rotary arm control mechanism lift frequency converter arm frequency converter 7 3 Monitoring state of sensors The tables of blockings and errors show sensors and inputs to the control system their state is evaluated and in case of an incorrect state particular blocking or error is activated The system of the wrapping machine enables the state of these sensors to be monitored Set the display to Service parameters 1 chapter 6 8 1 push button Display of inputs outputs For a number of inputs and outputs two displays are at disposal changing over between them is made using push buttons Transition upwards and Transition downwards Inputs DIO x yyy are inputs to the system group CPU on the display yyy is CAN address of the system Inputs DIx yyy are inputs to frequency converters group GF on the display yyy is the CAN address of the freqyency converter On the Display of inputs outputs x is number of input column and yyy is row of the display senice parameters 1 Inputs Outputs IM CIE OSE ey la lee Aaya cPU BHGGRERE m1020 2 BERRRREE ERE mnnn Cunmiu mA Higdaea i Clee aa 7 m mA Service parameters 1 state of inputs and outputs 83 Pragometal s r o WRA TS Examp
58. ice parameter 1 Saving Cancel Save service parameters by pressing Save button Saving of changed service parameters is password protected see Chap 6 2 6 For description of password protection see Chap 6 2 7 for how to enter password Press Cancel to cancel all changes Mode for editing service parameters is finished without saving changed values and the main display of manual or auto mode is displayed depends on a position of Manual Auto Mode switch This button is also used in cases when you don t know the right password Press Back Edit button to return to the main display of service parameters 1 or 2 depends on where you enter the display from If you forgot to change a parameter you can add it this way 6 8 2 List of Service Parameters Service parameters 1 designed for users Service parameters 1 Oriented stop Finish distance Distance when arm starts to slow down _ ae 5 350 to the minimum speed before finishing Film pre stretching Moment when setup pre stretching is 0 5 turn delay activated Slow motion at start Slow arm motion at start of wrapping During this time the arm rotates with arm 0 360 speed at start so that the film does not get ripped out from the fixture 04 Arm speed at start Arm speed at start of wrapping 20 100 Service parameters 1 Film parameters Film stretch at Value of secondary stretch during ending 60 150 ending Resistive wire in cutting mechanism of wrapping f
59. ilm is being heated during this 0 10 sec time Film sealing time Resistive band in sealing mechanism is i ie 0 10 Sec being heated during this time 68 Pragometal s r o WRA TS 13 Film cooling down Time between film sealing and departure i of ending bracket The film becomes cold 0 10 ee during this time so that the sealed joint is rigid enough The minimum value of secondary stretch which can be set up for the stretching a 60 150 Yo mechanism during wrapping in manual mode and at wrapping start Film stretch at start Secondary pre stretch during turns GP 60 150 Yo before activating set up pre stretch Service parameters 1 Overlap parameters 1 20 Overlap height Height of mobile tongs above the goods 0 200 Drop for overlapping Distance by which pre stretching mechanism slides down before laying cm overlap film 22 Overlap cutting time Time for tilt of overlap cutting lever 23 Length for release Movement of mobile tongs in horizontal 0 50 direction after releasing overlap film Slow turns after Number of turns in low speed after 0 3 n overlap overlap 25 Speed after overlap Arm rotation speed after overlap 0 100 26 Overlap dragging Speed of overlap travel during laying film s 0 100 Yo speed on pallet Service parameters 1 Overlap parameters 2 27 Stretch m speed Stretch mechanism speed after overlap S Speed of film trolley movement upwards 0 200 o after overlap Rotation a
60. in pin is seized up and the chain Ge CD damages the chain wheels Replace the chain damaged in this way e Anchorage of the machine and the conveyors to the floor e Position and orientation of optical sensors Condition of the over firing wire of the ending device and overlap if necessary clean the wire see Chap 8 2 10 and 8 2 11 e Overall appearance of the machine no signs of collision with manipulation technique or of possible fall of goods from the pallet deformation damaged varnish loosened or damaged joints parts of the machine off their usual position may be visible on the machine protection fencing safety barriers or conveyors If so it is necessary to check mechanical condition of the workplace i e to check integrity of mechanical units and electric installation integrity and tightening of screw joints anchors etc The line can only be started in case that the inspection discovers no damage to the machine e Condition of safety and information plates In case of a damage or loss they should be restored in the original state 8 2 5 Pneumatic system Make a visual inspection of the state of pneumatic cylinders piston rods must not be bent or otherwise deformed mechanically damaged or corroded The pins in clevises and hinges of pneumatic cylinders must be properly secured with cotters Check function of pneumatic mechanisms in the manual mode and watch them carefully during the wrapping process The
61. ing run watch whether the pallets pass smoothly through the barriers By watching the beacon check whether the barriers are dampened for a necessary period only e Check whether skew beams of the damping sensors on the horizontal arm of the safety barriers are oriented to corresponding reflection plates on the opposite stand e Make sure that there is no person in the protected space e Start the wrapping process by pressing the push button Start or wait for automatic start of the wrapping Simulate non permitted passage on the entry track by interrupting one of the beams of the safety barriers The beams of the light barriers are oriented 101 Pragometal s r o WRA TS perpendicularly to the conveyor axis see the figure with example The wrapping machine should stop immediately the run out time of the machine should correspond to the maximum value valid for your machine given in table in Chap 3 1 e ave the beam of the light barriers shielded using the procedure referred to in Chap 7 4 unblock the machine and test the machine control in the manual mode On releasing the unblocking push button the machine should stop immediately e emove the shield of the light barrier and following the procedure referred to in Chap 7 4 point 1 unblock the machine After unblocking the machine should be prepared to normal operation In case of any deviation in behaviour of the machine or in function of the safety barriers from this
62. lar as POWERFLEX Various thickness SPQ HPQ Non adhesive and one sidedly adhesive High UV radiation resistance At wrapping machine setting in operation we recommend you to contact the supplier or the manufacturer which will recommend you optimum stretch film for wrapping the wares from their experience We do not recommend using of packaging material other than stated here e g perforated films reticular films laminated films printed films etc without prior consultation with and without permission of the manufacturer as a proper functioning of the wrapping machine cannot be guaranteed If during guarantee period the machine wraps imperfectly or if the machine or the wrapped wares get crippled then usage of uncertified films or packaging material by the manufacturer may be a reason for the claim rejection Pragometal s r o WRA TS 1 3 2 Overlapping film The overlapping device provided that it is fitted to the machine should be operated with a smooth non stretching film of polyethylene PE thickness 50 to 80 um supplied in rolls Without a consent of the manufacturer an atypical film may not be used e g network like perforated layered with bubbles made of other material than PE etc Concerning the machine design no requirements are defined for other properties of the overlapping film than those specified in this chapter Specific width of the film is given by dimensions of the wrapped goods on the pallet and the wrap
63. le DI0 5 002 is input to the system CPU with Can address 2 row no 2 input 5 column of inputs IN no 5 In the figure this input has value 1 The display provides also for monitoring outputs DOO x yyy DOx yyy 7 4 Light barriers Light barriers may be placed on access of conveyor to machine i e to working space of machine and egress from it Connected light barriers enable fluent supply of pallets with goods into working space of machine and stop the machine in case of collision fallen goods from pallet or attempted entry of people on conveyor Their usage depends on project Following procedures show how to unblock machine which has been stopped by protection circuit of light barriers in emergency This unblocking enables to remove the object which has cause the emergency stop The machine can also be unblocked this way in case that some of the light barriers is blocked out at machine start At least two people must work with the machine if light barriers need to be unblocked one unblocking the barriers and another working with machine If control voltage is switched off as a result of an error CONTROL VOLTAGE button must be pressed to switch it on button shines Unblocking function switches safety equipment temporarily off Only persons authorised to rectify the fault may be for necessary time in vicinity of the machine during this time They are asked to pay maximum attention during their work at all times Only
64. lm or load it again into the machine the procedure is 4 described below 5 Switch the machine back to auto mode as necessary aut A Films which are not designed for stretching mechanisms are specified in Chap 1 3 Loading of the film itself differs in details for various stretching mechanism types which are mounted on the machine 38 Pragometal s r o WRA TS 1 Put the machine in initial position if needed using button in manual mode on the main display of manual mode 2 Place film spool on spike and load it into the stretching mechanism using procedure suitable for your stretching device type as per Chap 5 1 3 Open film fixture using controller on back side of the switch board 4 Load film end into the open film fixture Close the film fixture using auxiliary controller J i The film is loaded and the machine is ready for further operation Reload torn film using similar way of loading 6 4 Loading Overlap Film Into Machine We advise that spool with overlap film weights approx 60 to 80 kg Wait until all machine mechanisms have come to halt Overlap mechanism is in initial position by default i e mobile tongs are in upper position If it is not so from any reasons follow these instructions 4 Switch the machine to manual mode RUT W Manual functions Overlapping Top Platen Basic motion Ending ERR Configuration Other Main display of manual mode appears on the display 39
65. lue O the moving tongs drive to height after cutting off the film Combined overlap When Yes is chosen for this parameter YES NO the overlap will be laid by the procedure for the combined overlap laying of the film by horizontal and vertical movement at the same time see chap 5 4 2 6 8 2 6 6 3 Freely editable programs Open programs are more difficult to set up yet they enable to set up the program more precisely Open program bear program numbers from 10 to 19 and are indicated on the display by a letter F placed beside program number The treely editable programs cannot be saved as parametric program i e program number 0 to 9 Auto mode Program No 15 F STANDARD WRAPPING Line status Auto mode L ERR Configuration Open program editing enables the most precise parameter set up and unlike parametric programs to alter most of the values during wrapping or to program special wrapping procedures To facilitate the programming we recommend you to copy similar suitable program either editable or parametric The easiest way is to prepare the most similar parametric program save it with program number 10 and higher and to edit it in free edit mode Having followed procedure as in Chap 6 6 button order Configuration Edit you have switched to the main display of parametric programs 50 Pragometal s r o WRA TS Program Mo 12 Freely editable program 05 7 Turn delay 3 A gt 06 9 Stret
66. m number O to 9 and are indicated with a letter P beside program number on the display Auto mode Program No 9 P STANDARD WRAPPING Line status Auto mode l ERR Configuration Using process as per Chap 6 6 button order Configuration Edit you have switch to the main display for parametric programs Program Mo 9 Wrap parameters You can access the display with parameters for respective wrapping part from the main display of parametric programs Switching between pages using buttons Next Page Previous Page and One Level Up is transparently shown in tab 46 Pragometal s r o WRA TS Main display of parametric programs ee TA TTT LY towrosiion T TT y Parameters Program Upward High position Downward Yate Sonn vee TE Number of edited program and displayed part of program are shown in the display heading Program Mo 9 Basic set up Wrap Use top platen Use overlapping Use wrap with ejected fiture Use pallet litt gt Use button Save to call dialog box to save program see Chap 6 6 47 Pragometal s r o WRA TS 6 6 2 Automated Wrapping Cycle Parameters Text Displayed Parameter Name Values Unit Basic set up Activities to be performed by the machine are defined here what mechanisms are to be used during wrapping Wrap Wrap Yes Full wrapping sequence will YES NO be executed after start up Wrap No Pallet will only pass through the machine Use top pl
67. manipulators are shown in the tab In case of them being damaged or lost restoration must happen The list shows all labels and tags that may appear on fully equipped machine Potential use restriction is shown in Use column labi Position Manufacturer label 7 bottom part of pillar copy inside switch board lightning warning of electric switch board door shock in case of removed cover Scheme of loading film into arm near film spool machine 18 Pragometal s r o WRA TS 5 EQUIPMENT 5 1 Stretching Mechanism The film for which the stretching mechanism is designed is specified in Chap 1 3 Primary stretching happens between stretching mechanism rollers as a result of their different rotation speed The main outcome is film saving Secondary stretching happens between the stretching mechanism and pallet directly by pulling the pallet against retarded rollers of the mechanism and it determines the tightness of the wrapping tightening of the film around the goods The entire stretching mechanism is mounted on a trolley which moves along the full length of rotation arm pillar The operation is controlled from a control panel of the wrapping machine 1 WARNING Any part of wrapping machine must not be in motion during any work near stretching mechanism rollers 5 1 1 Single engine Stretching Device Working principle of the single engine stretching device is primary film stretching between
68. mend doing this 56 Pragometal s r o WRA TS 6 6 4 List of Commands of Freely Editable Program mm a 1 Program End End program command e 4 2 Turn Arm speed turn as set up in parameter Arm Speed Function Arm Speed must be set up before this parameter 4 Oriented Stop Position of oriented arm stop is 0 1 determined by parameter value 0 figure standard oriented stop 1 oriented stop for overlap Fixture ejection at wrapping start Fixture mechanism movements are controlled by values as set up in service parameters 6 Arm Speed Arm turn speed set up as a of 20 30 100 maximum speed 0 0 1 25 5 7 Turn Delay Turn delay in turn decimal Program turn waits for reaching this position and then it start next function 8 Sec Pre Secondary pre stretching set up 60 62 400 stretching 0 1 100 cm 9 Stretch Mech Stretching Mechanism Above Pallet Ab Pal Passing the stretching mechanism over pallet by distance and with speed as set by parameter Arm Speed Function Arm Speed must be set up before this parameter 10 Stretch Mech Command for descending stretching Down mechanism to low position with speed as set in parameter Stretch M Down Speed Stretching Mechanism Down Speed Speed parameter must be set up prior to this one 11 Stretch Mech To Position of the stretching mechanism counted from bottom with speed as set up in parameter Stretch M Down Speed Stretchi
69. mit or almost to the limit it should be possible to further press the spring by max 3 mm The Teflon coat of the wire eyes laid under rests on the holder must be removed by scraping off During the assembly provide for good contact of electric supply leads good condition of conductors and assembling eyes tightening of bolts and nuts and integrity of cable insulation Inspection and tightening of tongs travel chains vertical chains Check tightening of the chain in the basic position of the machine moving tongs in lower position With the force 1 kp in the middle of the chain longer branch the chain should get sagged by 60 to 85 mm The moving tongs of overlap must be parallel with the fixed tongs with deviation max 5 mm along the whole length of the tongs The chains must be correctly engaged with the chain wheels if the chain is slacked the run on wheels is irregular and noisy and the chain wheels are damaged The chain damaged in this way should be replaced both chains in the given direction should always be replaced Both chains should also be replaced in case it is impossible to tighten them correctly by the following procedure After certain time when the chains were replaced about one week of operation check tightening of the chains and correct if necessary the chain will run in and get slightly extended to its final length The chain tighteners are fitted on the cart of the overlap moving tongs 97 Pragometal s r o WR
70. n 01 Top platen UW Top sheet 03 Fallet lift U4 Conveyor U5 Disable film error Password setup Program version You can change the passworda of level In which yoy are lagged in plus lower levels Password table After usual log in as shown in Chap 6 2 7 Log In you can display valid passwords and also change them by pressing Password Tab button having 86 Pragometal s r o WRA TS touched password value Passwords of level in which you are logged in plus lower levels are always displayed you can change these passwords You can log out after finishing password edit Log out button Also you can do so on the main display of manual or auto mode 8 1 2 Language Setup Dialog boxes in more languages can be implemented in the machine If this option is supported you can set up language as follows Go to service parameters 1 setup as shown in Chap 6 8 Semice parameters 1 Oriented Fail Stop parameters Top sheet Inputs outputs parameters state Press button with globe symbol and display list of available languages only an example shown on figure Touch a symbol of a flag for a country whose language you want to set up enter password After re pressing of flag button is the language setted Save service parameters as shown in Chap 6 8 1 Level 5 password technician is required i e the same one as for service parameters 87 Pragometal s r o WRA TS 8 2 Machine maintenance T
71. n Potential replacements must be approved by the manufacturer In some cases the sensor can be mechanically secured in correct position with a drop of glue or varnish If necessary changed orientation of the sensor the glue or varnish can be removed using a nitro thinner 8 2 15 Inspection of function of safety devices This chapter relates to safety elements used as standard by the manufacturer of the wrapping machine If the designer of your wrapping line used different safety devices he she should revise this chapter and amend it as necessary These changes and amendments must become an integral part of this accompanying documentation The safety devices undergo regular inspection and check of their functionality The manufacturer and exact type specification of the safety devices referred to in this chapter can be found in the electric wiring diagram and or you can obtain this information from your dealer or designer of the electric installation This chapter relates to safety elements used as standard by the manufacturer of the wrapping machine If the designer of your wrapping line used different safety devices he she should revise this chapter and amend it as necessary These changes and amendments must become an integral part of this accompanying documentation Light barriers module of light barriers Once in three month check functionality of the safety barriers by the following procedure e During the standard wrapp
72. ng Mechanism Down Speed or Stretch M Up Speed Stretching Mechanism Up Speed Speed parameters must be set up prior to this one 12 Stretch M Down Command for descending the mechanism by given distance with speed as set up in parameter Stretch M Down Speed Stretching Mechanism Down Speed The speed parameter must be set up prior to this one 57 Pragometal s r o WRA TS Command Description Range unit 13 Stretch M Reaching position of stretching 0 1 255 cm Position mechanism above upper outside position Next commands will be executed only after reaching this position or after a halt of stretching mechanism travel 14 Pos of Reaching position of stretching Str M Ab Pal mechanism above pallet Next commands will be executed only after reaching this position or after a halt of stretching mechanism travel 15 Pos of Str M Dwn Monitoring a moment when stretching mechanism slides down by set up distance next command is executed only after reaching this position or after a halt of stretching mechanism travel 16 Stretch M Up Setting of travel speed of stretching 11 200 1 Speed mechanism upwards Speed of 100 corresponds with rising of approx 300 mm per 1 arm turn with arm speed 100 17 Str M Down Setting of travel speed of stretching 11 200 Speed mechanism downwards Speed of 100 corresponds with rising of approx 300 mm per 1 arm turn with arm speed 100 18 Time Dela
73. o enter the space accident or fallen blinkin goods in the light barrier J Barrier protection function can be muted manually from serious reasons More information see Chap 7 4 24 Pragometal s r o WRA TS 5 8 Control Panel 5 8 1 Switch board Panel Contains all controllers needed for machine manipulation with exception of protection fencing door operating 1 Operator panel 2 TOTAL STOP button machine emergency switch off 3 CONTROL VOLTAGE button 4 MAIN SWITCH 25 Pragometal s r o WRA TS 5 8 2 Operator Panel Program No 9 P STANDARD WRAPPING Line status Auto mode ERR Configuration 1 2 6 3 T 4 8 5 1 Operator panel MT 057 TST 2 Cycle START button 3 Indicator voltage in machine ON green 4 DEFECT indicator red 5 Cycle STOP button 6 AUTO MANUAL MODE switch 7 button manual function operation of machine one direction 8 button manual function operation of machine different direction The machine is fitted with control system LGA Touch operator panel MT 057 TST serves for connecting the operator with programmed robot It enabled the operator to edit program and operation parameters to choose manual function type and to display possible errors 26 Pragometal s r o WRA TS Auto mode Program No 9 P STANDARD WRAPPING Line status Auto mode L ERR Configuration Graphic LED display is used on
74. o the preset height for the combined overlap and start laying the film by horizontal movement after they have run the preset horizontal distance they start moving down This procedure reduces the risk of damaging the overlapping film by the sharp upper edge of the goods on the pallet we A o dd Pa A E 5 Return All mechanisms move back to their starting positions The mechanism is prepared for laying the overlap on the next pallet 4 A 5 5 Lifting Mechanism Lifting mechanism is optional delivered per order and is located under the conveyor in wrapping machine axis Before start of the wrapping it lifts packed pallet by 10 to 15 cm and thus enables to wrap the wares including the pallet so called under wrapping which fixates the goods to the pallet It is mostly used with light or unstable goods The lifting mechanism is controlled automatically by control system of the machine without any intervention by manipulator Inclusion 23 Pragometal s r o WRA TS of the operation of the lifting mechanism in the program is set in relevant parameter of the machine system see Chap 6 6 2 5 6 Protection Fencing Protection fencing guarantees manipulator s safety It makes it impossible to activate the machine if there is a man in front of the fencing i e it does not allow anybody to stand in front of the fencing during operation Electric lock and its manual manipulation are controlled by machine control
75. oltage must be discharged Dismantle engines with gear boxes drain the oil which is to be stored in solid break resistant and impermeable vessel 15 Pragometal s r o WRA TS Dismantle all parts of the machine Sort all parts according to waste classes steel non ferrous metal plastics cables electrical elements etc Hand over the separated waste including oils to specialized companies for its competent disposal 16 Pragometal s r o WRA TS 4 TECHNICAL PARAMETERS n a Max pallet diagonal 1700 Weigh Proportions as ordered Revolution 30 rom 20 Overlapping film spool weight with OO as ordered Propulsion roller conveyor el motor 550W 50Hz 400V Electric installation IP 54 protection rate 17 Pragometal s r o WRA TS 4 1 Label 4 1 1 Type Label Type label is placed on a bottom part of pillar and its identical copy is in the switch board to be protected from any damage It includes following Name and address of manufacturer Supplier Product type designation Machine serial number Production year Electrical scheme number Machine weight kg Supply voltage V Supply voltage frequence Hz Voltage protection A Machine input kVA Control circuit voltage V Data on type label take precedence over any data about technical parameters or other data in this documentation 4 1 2 Other Labels and Tags Labels and tags serving as source of information and warning of danger for
76. on after removing fault source 7 2 1 List of Reported Faults The table below shows inputs to the control system of the machine that detect errors the machine and its electric wiring can be checked according to the wiring diagram For more details see chapter 7 3 FAULT 01 Error or intern conflict Repeat the saving between saving of the Saving of the data is not program or parameters possible If saving of the data repeatly not happen please call the Service system error FAULT 02 Error in reading data Switch the machine off parameters from the back and on up memory during the system start Data of the system cannot be read If the error appears again call the service the system failure FAULT 04 Fault of frequency converter Check arm propulsion Fequency converter or _ OF arm motor Check sensors of oriented arm motor stop Inputs DIO O06 DI1 006 DI2 006 19 Pragometal s r o WRA TS FAULT 05 Motor of stretching mechanism travel FAULT 06 Cutting timeout FAULT 08 Film error FAULT 09 Ending arm timeout FAULT 10 Static tongs timeout FAULT 11 Mobile tongs timeout FAULT 12 Overlap cutting timeout FAULT 13 Top platen timeout Within given time the required position was not attained or the position was incorrectly indicated Timeout time for cutting bracket exceeded Spent or torn film Ending arm timeout exceeded arm has not reached required position
77. ontainer with overlap film 2 Static tongs hold end of overlap film from spool 3 Chain blade Resistance cutting wire is mounted on it Overlap film is cut by red hot wire 22 Pragometal s r o WRA TS 4 Mobile tongs pull loose end of the film so that it could be cut properly and then lay cut film on top of the goods on pallet mobile tongs are not drawn in the figure For illustration the figure shows a moment when the tongs are off their starting position 5 4 2 Operation Description Operation of the overlap mechanism can be divided into following phases 1 Starting position The overlapping film is inserted into the machine and fastened in the fixed tongs The moving tongs are in their starting position 2 Film cutting The moving tongs catch the film end the fixed tongs open and release the film The moving tongs stretch the film to required length in the vertical direction and then stop The fixed tongs close again and catch the film The cutting bar cuts the film 3 Moving of overlap to the goods The moving tongs with the cut off film move in horizontal direction to the goods and find the upper edge of the goods in the vertical direction 4a Standard overlap laying of the film by horizontal movement The moving tongs lay the film by horizontal movement to the top of the goods on the pallet 4b Combined overlap laying of the film by horizontal and vertical movement at the same time The moving tongs move vertically t
78. ping method The overlapping film on the roll of width max 1700 mm can be inserted into the machine ROTARY ARM 1700 Diameter of the overlapping film roll is max 250 mm The film must be would up on a tube the inner diameter of which should fall within 55 to 85 mm the tube must go beyond the roll face at both ends or must match with it Concerning the machine design no requirements are defined for stretching ability or other properties of the overlapping film than those specified in this chapter 1 3 3 Environmentalism The film can be included into assorted waste polyethylene PE to be precise The material is well recyclable It can be easily burned and while keeping correct combustion conditions no harmful fouling originates It is not biologically decomposable and the decomposition in the dumping ground is very slow No harmful by products to elude to the air or to pollute water or soil are known 1 4 Machine Design On condition of installation and running the machine according to the project done under Chap 3 1 the machine design conforms to relevant technical regulations and standards and meets requirements of relevant safety and fire regulations Standard and regulation requirements are included in the production documentation Precautions on the part of the user are described in this accompanying technical documentation service manual The expected machine lifetime is 10 year or 50 000 service hours what happens first
79. program O0 01 25 5 Turn delay in turn decimal Program waits for reaching this position and then it start next function a First line displays range and min unit of parameters in example above range is 0 to 25 5 min unit is 0 1 turn Min value is set as the difference between the 2 lowest values of After pressing Confirm is the help window closed and the display again shows the standard window of freely editable program After pressing List a display with drop down menu of all commands is shown Program Wo Freely editable program p U5 Using a procedure similar to command selection of standard display you choose a command whose help you want to read 99 Pragometal s r o WRA TS Program Wo Freely editable program p ii J6 Program Wo Freely editable program Help 05 p Help to selected command is displayed after pressing Help button Program Mo 12 Freely editable program Oriented Stop 0 1 Position of oriented arm stop is determined by parameter value O figure standard oriented stop 1 oriented stop for top sheet of Help displayed in this way i e through command list has to be closed by confirm button in order to display window with command list Window with command list is only opened once and you can get to it by moving window with help drag and drop style of working with windows Display then becomes messy and we do not recom
80. providing the machine is used in conformity with this accompanying technical documentation and the specified maintenance and periodical checks of the machine are kept 1 5 Machine Operating Conditions The wrapping machine is designed for operation in the ambience which has to meet following conditions Common ambience in terms of a Czech standard CSN 33 2000 3 IEC 364 3 under the terms as set out further in this chapter and on condition of installation and running in conformity with this accompanying technical documentation Pragometal s r o WRA TS The machine must be fitted up and operated in sheltered operation premises protected from atmospheric factors The floor must be level and braced the maximum variation from the flatness of the floor is 3 mm 2m Before fitting the machine in place it is necessary to remove dirt chips etc from the surface The temperature range for operating the machine should be between 5 C and 40 C the rate of change of the temperature be max of 10 C 30 min The relative humidity should be 30 95 without moisture condensation The machine can only be operated in the premises which meet requirements of governmental working condition regulations regulation No 178 2001 of the Statute Book Government Regulation which establishes conditions for health protection at work and Ministerial Regulation No 48 1982 of the Statute Book Regulation of the Czech Occupational Safety Authori
81. rapping programs with numbers 0 to 19 6 5 1 Display If the machine is switched on in auto mode or switched in it initial auto mode display screen is displayed for the mode in which the machine runs Auto mode 1 Program No 9 F 2 STANDARD VVRAPPIN Line status Auto mode 3 4 Configuration 5 6 1 Program number 2 Program type shown as P parametric program or F freely editable program More information about these programs the difference between them and their features is shown in Chapters 6 6 1 and 6 6 3 Short info text describing wrapping program 4 Ifthe machine is delivered inclusive of wrapping line control line status is displayed here and also other information needed for entire wrapping line control If the machine is delivered solo and does not command the wrapping line row is not displayed 5 Button for edit parameters option and machine set up 6 In case of errors a rolling text with error messages is displayed in the upper part of the display By pressing ERR you enter a display with the list of error messages where you can find more information about particular error and its possible solution See Chap 7 Also if the machine is in error state after start up a yellow button ACK as well as error message are displayed see Chap 7 2 42 Pragometal s r o WRA TS 6 5 2 Program Selection In Auto Mode To select a program follow similar rules as shown in Chap 6 2 3 If you want to change
82. re depends on mode of machine automatic see chap 6 5 or manual chap 6 7 Only the main switch needs to be turned off on machine shutdown 29 Pragometal s r o WRA TS 6 2 Touch Display Control 6 2 1 Basic Terms For comprehensibility following terms are defined for purpose of this manual Panel display panel technical device mounted on switch board and designed for communication between manipulator and machine system Display what is displayed on the display panel Button control button visualized on the display It is visualized protrudently as if being real button Keyboard mean of touch panel system for inputting number or character values 6 2 2 Common Rules Buttons of basic functions are placed on the right edge of the panel Only those buttons which are of some concern for given display are displayed See the text below for detail description of functions of individual buttons One level up Saving parameters or programs into memory A dialog box is displayed that enables saving and also protects the system from undesirable interventions Help a 5 ACK button error message confirmation it is only displayed in case of error or failure See Chap 7 Move up go to previous page Move down go to next page 6 2 3 Number Values Input Examples of editing program parameters are shown in following chapters The Same procedure applies for editing operating parameter
83. rs 1 and 2 are divided into logical groups according to their function Open editing of line parameters by pressing Line button These parameters serve for co operation of the wrapping machine with other machine in wrapping line and their mutual communication They are individual for each machine or line therefore not described further Switch between particular groups of service parameters by pressing button Next Page Previous Page and One Level Up Buttons for switching between groups of service parameters 1 Service parameters 1 w PE Main display of service parameters 1 Parameters for oriented stop FERE Film parameters T a HH Overlap parameters part 2 Language Setup see chapter 8 1 2 Input Output state see chapter 7 3 66 Pragometal s r o WRA TS Buttons for switching between groups of service parameters 2 Me ee End of editing of service parameters You can end mode for editing of service parameters be it with or without saving the changes by one of the following ways a Choose function One Level Up on the main display of service parameters 1or 2 Press Save and Back button on the main display of service parameters 1 or 2 to finish editing of service parameters From any display of service parameters 1 or 2 by pressing Save button All three ways are equivalent and with the same function Finish display will be shown 67 Pragometal s r o WRA TS Sem
84. rst check service voltage and machine frequence as shown on electrical installation label with voltage and frequence of the mains to which the machine should be connected Even voltage variation by maximum of 5 of face value ensures proper functionality of the machine The mains to which the machine will be connected must comply with all international and national standards and regulations Outer protective terminals on the machine and contactor switch board must be connected to protection system of the user and be properly cured Before the machine is put into service a proper functionality of the protection against dangerous contact voltage as per IEC 60364 4 41 must be checked and a revision of the machine supply cable as per IEC 60364 6 be carried out The revision must be executed by revision worker who meets national regulation requirements The machine may be connected to the mains with the main switch after a thorough examination of the supply and specified revision 3 4 Machine Disassembly On machine disposal after finishing its lifetime put all mechanism in such position that no danger could arise from falling detached parts and that all dismounted parts could be safely taken away Remove supply connection by pulling the plug out of the socket and compressed air by disconnecting from the supply A person competent under Chap 2 2 checks remnant voltage in the electric circuit if any before start of dismount potential remnant v
85. ry By pressing it the button is automatically locked in on position to re start the machine the button must be unblocked Pressed EMERGENCY STOP button is indicated by an indicator on panel To re start the machine follow these steps Remove cause of emergency stop Check condition of the machine Film must be correctly loaded in the stretching mechanism Unblock EMERGENCY STOP button by turning it right indicated by arrow on button until the button return into initial position Finally control voltage of the system must be switch on before starting the machine CONTROL VOLTAGE button see Chap 5 9 2 5 9 2 Control Voltage Button This button and its function as a stopper in case of unexpected or unwilling behaviour of the machine after its start breakdown power outage or presence of EMERGENCY STOP button signal meet requirements of Czech and European safety standards On power outage or after pressing EMERGENCY STOP button power supply of the system will be disconnected and the machine will not carry out any activity even if the supply would be restored or the EMERGENCY STOP button would be unblocked by mistake or any other unauthorized intervention Only pressing the CONTROL VOLTAGE button enables further activity of the machine This button must also be pressed on machine start up Power supply is indicated with button illumination which is turned off after disconnection of the supply 28 Pragometal s r o WR
86. s Mechanism at CAN address 3 cannot be initiated counter LGC ending Mechanism at CAN address 2 cannot be initiated counter LGC communication Mechanism at CAN address 10 cannot be initiated overlap frequency converter lift Mechanism at CAN address 2 cannot be initiated overlap travel frequency converter 82 Check propulsion Obstacle in trajectory of move Check pallet sensor Check sensor Check air inlet condition pressure Input DIO 3 003 Check connection of the device to the CAN bus If the error appears again call the service Check power supply of given mechanism Input DIO 2 001 Input DI0 0 001 Check power supply of given mechanism Check power supply of given mechanism Check power supply of given mechanism Check power supply of given mechanism Check power supply of given mechanism Check power supply of given mechanism Pragometal s r o WRA TS FAULT 43 Mechanism at CAN address e Check power supply of CAN address 8 top 8 cannot be initiated given mechanism frequency converter for top laten f e platen control converter FAULT 44 Mechanism at CAN address e Check power supply of CAN address 7 stretch 7 Cannot be initiated given mechanism frequency converter for hani frequenc MeS amS m Wrequeney Stretch mechanism control converter FAULT 45 Mechanism at CAN address e Check power supply of CAN address 6 stretch Cannot be init
87. s Parameter values in examples are illustrative and may vary from your machine We are going to set speed of 100 for arm rotation in following example 30 Pragometal s r o WRA TS Program Mo 9 parameters downwards Spinning speed of arm stretch mech travel speed Secondary stretch After pressing button with number value of Arm Rotation Speed parameter number keyboard is displayed Progra Spinnir Stretch Seconi Help row marked as A shows range of possible values Type in requested value of 100 on the keyboard Press Ent to confirm The keyboard disappears and a new parameter value is displayed on the main display Program Mo 9 parameters downwards Spinning speed of arm 45 YO stretch mech travel speed 100 YO Secondary stretch 150 YO Del button deletes last digit 31 Pragometal s r o WRA TS Cir button deletes contents of the whole line By pressing Esc button you cancel the option and return on the main display of the automatic mode without any change of program set up In this case the Arm Rotation Speed parameter stays with original values of 70 When granted by a parameter the keyboard displays a button with decimal point Similarly when negative values are enabled the keyboard displays a button with minus sign 6 2 4 Value Change YES NO Some parameters can only bear YES or NO value In following example we want to use pallet lift Program Mo 9 Basic se
88. s DI0 005 DI1 005 FAULT 15 Fault of sensor of goods e Lower height of goods Sensor of height of height or goods loaded too e Check sensor connection goods high on pallet sensor indicates goods even in e Check sensor directing upper extreme position Input DIO 007 FAULT 16 Sensor supply fault Check fuses and breakers in switch board Input DIO4 001 FAULT 17 Goods in front of or e Wrongly placed goods on behind reaches in working pallet space of rotating arm with stretching mechanism possible collision of rotating Inputs DI0 4 003 DI0 5 003 arm with goods on pallet Sensor power supply Pallet in trajectory of rotary arm e Check sensor FAULT 18 Spent or torn overlapping e Replace spent film Overlapping film film or sensor fault e Load torn film again e Check sensor indicating unrolling film Input DI2 010 FAULT 19 Mobile overlap tongs have Check propulsion Overlap not reached required e Obstacle in trajectory of forward backward position within time limit move of mobile overlap timeout tongs Inputs DIO 011 DI2 011 DI3 01 1 FAULT 20 Overlap mechanism chase Check propulsion Overlap up down timeout has not reached in direction e Obstacle in trajectory of up down required position move of overlap device within time limit Inputs DIO 0 009 DIO 2 009 FAULT 21 Pallet under wrapping Check loaded goods on machine is outside expected pallet Wrong position of pallet JP P position on
89. s been authorised for it and has been familiarized with this manual and safety rules demonstrably is allowed to manipulate with the wrapping machine 8 The manipulator must not be under influence of alcohol addictive drugs or drugs which may influence safety at work 9 During the operation the manipulator must be beyond reach of the working space i e by the control panel 10 The manipulator must operate and maintain the machine in accordance with this manual Material damage and injuries can be avoided if the machine is properly used 11 The manipulator must check the whole machine a correct functioning of its individual parts mainly integrity of electric cables before work initiation 12 During operation of the machine or the conveyor is prohibited to manipulate with wrapped wares on roller or chain conveyor or with the conveyor itself differently than specified in this manual 13 To remove dismount or lift off covers is only allowed after the machine has been brought to a complete stop and the off position has been secured 14 Safety marking symbols and signs on the machine must be kept in legible condition On their damaging or at their illegibility the user must restore the state in accordance with the original design 11 Pragometal s r o WRA TS It is prohibited 1 To use the machine for other purposes or otherwise than specified in this service manual 2 To start up and to use the machine if protectiv
90. saved Entering program mode Enter the program mode in auto mode by touching Configuration button It is not important whether the program you want to edit is set up or not you will do it in the next step Auto mode Program No 9 P STANDARD WRAPPING Line status Auto mode If you wish to edit program which is offered on following display No 3 in this case press Edit to enter edit mode of the parameters of the selected programs If you wish to edit different program select its number as shown in Chap 6 2 3 and confirm by pressing Edit button Auto mode Program No 2 Edit a Service 1 Service 2 Line ERR Back Should you have entered this display in error you can return on the main display by pressing Back or One Level Up button both buttons are 44 Pragometal s r o WRA TS equivalent Note other displayed button do not relate to programming buttons Service 1 Service 2 and Line relate to service parameters of the machine in Chap 6 8 ERR button serves for displaying and processing error messages see Chap 7 Program Mode Termination button or Save back to get to dialog box display for saving changed You can leave service parameters editing display upon pressing Save parameters save the program Save as program 9 F 1 Description STANDARD WRAPPING 2 Edit 3 Cancel Peal SAVE 5 4 1 Input field displays number of a program being currently edited If you wi
91. sh to save the program under different number a keyboard will pop up after pressing program number see Chap 6 2 3 and you can enter a number under which you want to save the program 2 Short description line It serves for better orientation of the personnel maximum of 20 characters can be inserted here to describe the program Upon touching this line a dialog box for entering text string pops up see Chap 6 2 5 3 SAVE button If a crossed ring is displayed on this button as shown on the picture parameters saving is password protected upon pressing this button a dialog box for password entry is displayed see Chap 6 2 7 and after re pressing of SAVE button is the program saved If no crossed ring is displayed valid password has been entered and program can be saved directly and main display of auto mode will pop up 4 Edit Back button If you forget to change any parameter you can use this button to return to parameter editing 5 Cancel button Changed program is not saved and main display of auto mode is displayed This button can also be used if saving is password protected and you don t know it 45 Pragometal s r o WRA TS 6 6 1 Parametric programs Parametric programs can be relatively easily set up and enable reliable and cost effective wrapping under normal conditions Use freely editable programs if you have bigger call for wrapping and the way of wrapping Chap 6 6 3 Parametric programs have progra
92. sor placed on the stretching mechanism scans current height of the pallet as it travels with the mechanism From a moment when the sensor does not note any reflection i e is above the level of goods on pallet the mechanism carries on with travelling upwards until a moment as set up in the machine parameters and then stops 5 2 Ending Mechanism The mechanism is controlled with operating system of the machine It is designed to stick the film to packed goods at the beginning and the end of wrapping both activities are fully automatic with no crew intervention It is placed on the conveyor or in its close distance in wrapping space of the machine 20 Pragometal s r o WRA TS 5 2 1 Ending by Sealing Ending mechanism consists of three bars while inactive they are tilted under the level of conveyor For better illustration the figure depicts all bars in upright position 1 ending arm device for film sealing and its cutting is mounted here 2 back plate fixing wrapping film during the complete ending of the film 3 film fixture Its function is to hold the film between two consecutive wrappings The entire ending process can be described as follows e Back plate is ejected before the end of ending e Back plate is wrapped with the wares to the pallet e Film fixture fixates the film between the stretching mechanism and the pallet at the end of wrapping Ejected back plate ensures quality sealing e Ending
93. spool Overlap sensor Distance between goods sensor and the 0 50 i distance lowest point of mobile tongs Middle travel Distance between mobile tongs and distance rotation axis during stop at middle travel 0 200 cm sensor of overlap forward wise Maximum frequency converter frequency 62 Travel horizontal Maximum frequency of frequency converter controlling unrolling overlap film above goods Value should be equal 10 500 Hz to parameter HSP as set up on frequency converter 63 Lift vertical Maximum frequency of frequency converter controlling unrolling overlap film upwards from spool Value should be 10 500 Hz equal to parameter HSP as set up on frequency converter Service Parameters 2 Overlap 3 Cut start before Angle of overlap foil cutting before 0 720 overlapping position for overlap Lift acceleration Time during which overlap foil accelerates from zero to maximum speed and back Height of conveyor Vertical distance of the lowest point of overlap the moving tongs in lower position and upper edge of the conveyor Top sheet Timeout of top sheet pneumatic pneumatic timeout mechanisms mobile and fixed tongs cutting arm Service parameters 2 Blowing blowing parameters 70 Blowing start Moment from wrapping start when a See a ae 0 5 3 turn blowing is initiated 13 Pragometal s r o WRA TS 71 Blowing time Period during which is blowing active 0 20 sec
94. swords can be changed Person which is logged into the system under a certain password can change passwords of his her own level and lower levels Procedure for password setup is shown in Chap 8 1 1 6 2 7 Password Entry Following text describes password entry on saving program parameters The procedure for password entry is identical with saving service parameters in manual and auto mode for display language change and others You have altered a program want to save the changes and a valid password has not been entered Crossed ring is displayed on a display for parameter saving on SAVE button 34 Pragometal s r o WRA TS save the program Save as program 9 F Description STANDARD WRAPPING Edit Cancel pact SAVE After pressing Save button a dialog box for password entry is displayed Entry the password it comprises of maximum of 8 digits Keyboard display shows instead of digits and so it is not possible for unauthorized person to read the password during entry Save the prosas Password Entry Save as t Descriptor gt ANDAF Cance Four digit password is entered on figure above as an example Confirm entered password by pressing Ent key If the password has been entered correctly the crossed ring icon is not displayed on any of Save buttons for which the password authorizes saving With incorrect password entry will the password keyboard be displayed again After pressing Esc the pass
95. t has been removed the indicator stops blinking and by pressing ACK you will remove all error messages ACK button is available on the main display of both auto and manual mode and also on all displays of machine manual function control Should you need more information on occurred faults press ERR button and open list of error messages Message of locks and falults FAULT 08 Foil error FAULT 36 Emergency Stop Further details Fault Lock a Fields for entering fault or lock number on which you need more information are at the bottom You can have listed information on any fault no matter if it is displayed in valid error messages list or not If non existing fault or lock number is entered system shows warning message Example you need more info on fault 08 Film error Enter fault No 08 as shown in Chap 6 2 3 and confirm 18 Pragometal s r o WRA TS of locks and talults Fault 06 a Spent or torn film Change spool with spent film Load torn film into Furt stretching mechanism a Faure E se p Close window with fault or lock description by pressing confirm button Close list of error messages and return to display for displaying manual or auto mode depends on AUTO MODE MANUAL MODE switch by A pressing One Level Up button In case that control voltage has been switched off because of the fault indicator is off it needs to be switched
96. t up Wrap a Use top platen Use top sheet NO Use wrap with ejected tecture Use pallet litt xo E Values are switched when you press relevant button After pressing Use Pallet Lift button the parameter value changes in this example to YES Program Mo 9 Basic set up Wrap Use top platen se top sheet gt Use wrap with ejected tecture Use pallet litt 32 Pragometal s r o WRA TS 6 2 5 Text Value Input Display with alphanumeric keyboard is displayed on insertion of text values Alt button switches between data input of characters A W and X Y Z numbers and space and symbols By touching Ent button you save the inserted text into memory and return on initial display Del button deletes last inserted characters one by one Cir button deletes entire string Esc button cancels data insertion and closes the panel Edited text remains unchanged as before editing 6 2 6 Password Protection All programs and parameters can be viewed without restriction password protection works when an attempt is made to change and save parameters or program Exception is made for password editing Chap 8 1 1 and language change Chap 8 1 2 The machine and parameters are protected on various levels according to their purpose and importance Administrator Only for manufacturers and service companies It is required for service parameters 2 which are
97. the person who knows machine functions and who must monitor carefully risk area and immediately block machine activity by releasing button s in case of emergency may use unblock function according to following description This chapter is relevant only if your machine is equipped with light barriers LEUZE and safety module LEUZE Button SAFETY BLOCKINGS RESET on display is shining during normal activity of the machine If the machine has been blocked indicator is off and light barriers block the machine If light barriers is activated following unauthorized entry of a person on conveyor or if obstacle was immediately removed light barriers rays were not blocked out on operator intervention any more no objects are in the machine and SAFETY BLOCKINGS RESET button is off e press SAFETY BLOCKINGS RESET button to reset light barriers The button starts shining Wrapping machine is again operational 84 Pragometal s r o WRA TS If light barriers is activated by erected or shattered pallet there are objects in the wrapping machine manipulation with machine or line is necessary to remove the fault and SAFETY BLOCKINGS RESET button is off e Press and release SAFETY BLOCKINGS RESET button If any of light barriers rays is blocked out SAFETY BLOCKINGS RESET button is blinking and it is possible to unblock light barriers according to following paragraph If there is a pallet with goods inside machine and no light barrier r
98. tion The film is loaded Leave working space of the machine and close doors to protection fencing The machine is ready for further operation 6 5 Auto Mode ly To enter auto mode of the machine select AUT on the main panel As the machine is designed for work mainly in automatic lines START command for the machine is given by the control system of the line depending on movement of packed goods on the line Automatic cycle of the machine can also be switched on from control panel by pressing START The machine will execute one wrapping cycle as according to the entered program after START command Auto mode of the machine can be suspended by pressing STOP at anytime After pressing START button the machine moves to initial position if not on it already and a new wrapping cycle begins The film can L be finalized before re start by using manual function Full Ending see manual functions Chap 6 7 Next step be valid only when conveyor line is controlled by wrapping machine system If there is a pallet on the conveyor under rotary arm after machine start up or switch to auto mode system message will appear on the display Auto mode Wrap the pallet vo Press YES to execute wrapping If NO is selected the pallet is considered wrapped and is carried away from the machine 41 Pragometal s r o WRA TS WARNING Only manipulating person can be in the vicinity of the machine The machines support up to 20 w
99. two main rollers which are interlocked via gear transmission Gear ratio is typically 160 and can be adjusted by changing gear wheels on rollers Secondary film stretching happens between the pallet and the main roller whose stopping power is determined by a difference between motor speed and arm rotation Secondary stretching can be controlled from a control panel its range is between 70 and 400 with 100 meaning that the film leaves the stretching mechanism in such a speed that neither stretching nor shortening happens after wrapping on goods Single engine stretching device is designed for plants with middle or higher capacity or packaging demanding good quality of wrapping and film saving and with no or less frequent request for primary stretching value change The stretching mechanism is constructed from bearing structure onto which main rollers their propulsion and gearing are mounted Here are also mounted secondary rollers ensuring proper and even application of the film on the goods 19 Instructions for film initialization Change empty spool for a new one Unwind approx 1 meter of the film from the spool intertwine its end as much as needed for loading into the stretching mechanism and lead it between rollers according to the scheme as stuck on the device The film will later straighten up again between the rollers during operation Act similarly on re initialization after breaking the film If not specified oth
100. ty which establishes basic requirements for ensuring occupational and machine safety It is not allowed to fit up the machine so that the access paths to the electric installation would be reduced under the minimum values as set out in governmental regulations i e CSN 33 3210 Distribution Equipment Common Provisions No obstacles which could cause injuries of manipulators may be placed in the vicinity of the machine e g stairs platforms drop ceilings others machines etc The product must not be used in the explosive atmosphere or where the explosive atmosphere could arise even for a span The machine and especially its electric installation must be fitted up and operated according to instructions of the manufacturer as mentioned in this accompanying technical documentation 1 6 Warranty General warranty conditions are defined in the Warranty Sheet which is an integral part of documentation accompanying the machine The warranty sheet must be duly and fully filled in and confirmed by the manufacturer Prerequisite for warranty is regular check and maintenance of the machine and exclusive usage of original spare parts e Warranty does not apply to defects caused by e mishandling e non respecting the operating instructions of the product e intervention into the product by unauthorized person or organization and e overloading Warranty also does not apply to Pragometal s r o WRA TS e Tear and wear parts sp
101. ty of the workplace e These times of emergency stop of the machine apply to calculating safe distances according to CSN EN 999 1700 o 2o SS a T The project may be drawn up by a company or a person knowing the rules of occupational and machine safety as established by applicable international and national law and standards Safety of the whole workplace must be analyzed by the supplier who is responsible for the solution and if need be prepares 14 Pragometal s r o WRA TS guidelines for occupational safety By default the manufacturer or the supplier of the machine drawn up the project 3 2 Storage If the machine is not put into service immediately after delivery it needs to be stored in original protective wrapping in sheltered place protecting from atmospherical factors rain snow The range of storage temperature is between 0 C and 55 C with humidity between 5 and 95 without moisture condensation Corroding agents or materials releasing vapours that may damage cable insulation or materials that may create combustible or explosive atmosphere must not be stored on the same place as the machine 3 3 Connection To Supply System Electrical package of the machine comprises of a switch board and distribution through the machine The main switch and five pole supply terminal with U V W N and Pe connectors are placed in the switch board The machine supply must be secured with fuses and circuit breaker Fi
102. u will find more information about an error and ways how to fix it See Chap 7 Individual moves are logically grouped according to mechanisms To switch them use mechanism switches 1 Manual functions basic moves Om mechanism y A D jal v Icons and next to those symbols serve as a help for direct controlling of mechanisms This happens through mechanism buttons on machine switch board near display 60 Pragometal s r o WRA TS To return from any manual function group to the main display of manual fy mode use button ONE LEVEL UP Use buttons NEXT PAGE and PREVIOUS PAGE to switch individual manual function groups in following order py Basic basic moves ra y Ea o aA ESCI A y pre A Other other moves 6 7 2 List of Manual Functions Following tab shows a list of manual functions their description and controlling If a particular mechanism as described on the list is not mounted on your machine please ignore it Display Controlling Main display of manual mode Starting position Wrapping machine shifts to starting position Manual function group Basic moves 1 Starting position Wrapping machine shifts to starting position Arm forward Swivel arm forward Stretching mechanism Stretching mechanism moves up the up down pillar Stretching mechanism moves down the pillar Top platen mechanism Lift top platen mechanism up down Lower top platen mechanism on goods M
103. use The machine is designed for plants with higher capacity of wrapping and high wrapping demands it ensures a perfect fixation of wares on the pallet while using a minimum amount of film It is also designed for wrapping of lighter wares where a dynamic momentum working upon the pallet as in the case of conventional method of rotating pallet would otherwise result in moving or spilling the wares High productivity of the machine is provided for by a wrapping technology whereby a pallet is not being rotated as in case of standard machines but is being wrapped by a spool film rotating on an arm around the wares Stretching mechanism moves vertically on a rotary arm track which is fixated by a solid tenon to a stator part of the machine Propulsion of the rotary arm is ensured by a spiral gear drive and chain gear Due to simple construction is this machine noted for its high proportion between utility value and price 1 2 Description Accessories 1 Mainframe Rotary arm with stretching mechanism is hung on it 2 Arm rotates around the wares and stretching mechanism moves vertically on it 3 Stretching mechanism It carries a film spool and ensures both correct wrapping of wares including tightening to ensure better firmness of wrapped pallet and film stretching in order to reduce its usage 4 Top platen mechanism for unstable wares is not part of the standard package It is suitable for light or unstable wares It is a pneumatic mech
104. ustment is made so that the moving tongs in the lower position are parallel with the fixed tongs deviation max 5 mm e Longitudinal allowance in the arm travel direction If the allowance is large the arm is considerably swinging during stopping and starting and a bump of the travel rollers position 2 on guiding profiles is heard Hold the roller pin on the bearing side with a flat spanner and using a box spanner loosen the nut on the other side of the cart weld Move the roller to stop at the guiding profile and retighten the nut After having adjusted all bearings test the travel in case the overlap arm runs heavily set the clearance between the bearing and the guiding profile to max 0 5 mm following the same procedure e Transversal clearance is adjusted with the bearing 3 Adjust both bearings on both carts the carts in the overlap frame must be symmetrical set clearance 0 5 to 1 5 mm between the guiding profile and the bearing 8 2 12 Tongs down pressure In the manual mode move the down pressure to the lower limit position The lifting belt is well visible along all its working length The lifting belt must not be defective ruptured or frayed at its edges Otherwise it should be replaced Make a visual inspection of the down pressure plate as well permitted degree of its wear depends on the goods to be wrapped and on the danger of its damage by the down pressure plate Belt replacement Both ends of the belt
105. word entry will be cancelled and the keyboard will disappear Preceding display will be shown and there is always a possibility to leave this mode without password entry i e without saving changes to do so press button Cancel on the display Only buttons without crossed ring icon are functionally Required operation here the command SAVE will be executed after button re pressing 35 Pragometal s r o WRA TS save the program Save as program 9 F Description STANDARDO WRAPPING Tanec Edit SAVE back Entered password remains valid LOG OUT Password button is displayed on main panel of auto mode during this time Auto mode Program No 9 P STANDARD WRAPPING Line status Auto mode LOG GUT password ERR Configuration The same button is displayed on the display during manual mode if you switch on it or if you edit service parameters Manual functions Starting position i EP me Ea rh Overlapping i gt Top Platen LOG OUT password H Basic motion Ee Ending ERR Configuration Other 36 Pragometal s r o WRA TS After entering the password the set password is valid for 5 min from the last pressing of any key for this time all parameters permitted by the password can be set in the system Entered password is cancelled and the system is again protected from saving changed parameters and programs after pressing LOG OUT Password button LOG OUT Password bution is no
106. y Time delay after which will next 60 0 commands be executed 19 Top Platen Up Top platen mechanism moves to upper outside position 20 Top Platen Down Top platen mechanism moves down to touch the wares eventually to lower outside position Waiting for a moment when moves reach end position next commands will be executed only when moves have finished It concerns top platen mechanism moves stretching mechanism travel oriented arm stop or arm stop on position for overlap If stretching mechanism is above pallet and travel downwards is then executed this command returns the mechanism above pallet at the same place Important for overlap 23 Ending Entire ending sequence including arm ae a turns 24 Overlap Overlap film is pulled out as defined by 80 81 Extension parameter If the parameter is not set up implicit value of 120 cm is used 58 Pragometal s r o WRA TS Command Description Range Unit 25 Overlap Entire overlap is executed including 0 1 80 cm prospect necessary moves of other mechanisms Parameter determines overlap of overlap behind centre of arm rotation If Overlap Extension parameter is not set up its implicit value of 120 cm is used 26 Height of pallet Height to which the moving tongs of cm overlap drive before measurement of the pallet height For the value O the moving tongs drive to height after cutting off the film The command is only functional before t

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