ILAPack CARRERA 2000PC User Manual
Carrera 2000 PC Touch
SALES AGENTS AND SERVICE ORGANISATIONS.........................................................1
SPARE PARTS ..........................................................................................................1
INTRODUCTION .........................................................................................................2
WARNINGS FOR USE OF THE INSTRUCTIONS............................................................2
PURPOSE AND LIMITS OF THE INSTRUCTION AND MAINTENANCE MANUAL .............2
KEEPING OF THE MANUAL.....................................................................................2
UPDATING OF THE MANUAL ..................................................................................2
COLLABORATION WITH THE USER.........................................................................2
MACHINE IDENTIFICATION DATA .............................................................................3
EC STAMPING AND SAFETY STANDARDS...................................................................... 4
SAFETY RULES.........................................................................................................5
CLOTHING...............................................................................................................7
ACCESS TO THE WORKING ZONE ..............................................................................7
MACHINE USE DESTINATION....................................................................................8
MACHINE APPLICATION ...........................................................................................8
VALUATION OF RISKS..............................................................................................9
RISKS LINKED TO THE INSTALLATION SITE OF THE MACHINE.................................9
RISKS LINKED TO THE FEATURES OF THE MACHINE...............................................9
RESIDUE RISKS ZONES AND OPERATIONS...............................................................10
WARNING SIGNS ...................................................................................................10
RESIDUE DANGERS................................................................................................11
WORKING AND CONTROL ZONES - SAFETY ZONES ..................................................
ENVIRONMENTAL USE CONDITIONS .......................................................................
11
12
NOISE LEVEL ......................................................................................................12
TEMPERATURE AND HUMIDITY............................................................................
OPERATIONAL SITE.............................................................................................
12
12
ILLUMINATION ...................................................................................................12
VIBRATIONS.......................................................................................................12
RESIDUE AND ENVIRONMENTAL CONTAMINATION ...............................................12
SAFETY DEVICES ...................................................................................................13
MACHINE INSTALLATION..........................................................................................14
INSTALLATION SITE REQUIREMENTS......................................................................14
EXTERNAL INSTALLATION REQUIREMENTS .............................................................14
UNPACKING...........................................................................................................
MACHINE UNPACKING AND POSITIONING...............................................................
14
14
LEVELLING ............................................................................................................17
ATTACHMENT OF INFEED CONVEYOR .....................................................................18
Copyright ILAPAK Italia S.p.A. Ed 1 Rev 06 - June 2005 User manual –- 1
Carrera 2000 PC Touch
ELECTRICAL SYSTEM CONNECTION ........................................................................20
EARTHING.............................................................................................................20
PNEUMATIC SYSTEM (OPTIONAL)...........................................................................21
COOLANT INSTALLATION CONNECTION (OPTIONAL)...............................................21
CLEANING .............................................................................................................21
MACHINE DEMOLITION.............................................................................................22
MACHINE CONTROLS................................................................................................23
PUSH BUTTONS AND OTHER ELECTRO-MECHANICAL DEVICES.................................23
SIGNAL LAMPS.......................................................................................................25
USER INTERFACE......................................................................................................26
DISPLAY................................................................................................................26
OPERATIVE KEYS...................................................................................................28
MULTIFUNCTIONAL KEYBOARD...............................................................................29
RECALL KEYS.........................................................................................................30
HELP ON LINE .........................................................................................30
PRELIMINARY OPERATION........................................................................................31
LANGUAGE SELECTION...........................................................................................31
USER PASSWORD...................................................................................................33
ENTERING THE PASSWORD....................................................................................34
DEACTIVATION OF THE PASSWORD........................................................................
MODIFICATION OF PASSWORD “OPERATOR”...........................................................
36
37
OPERATION CYCLE START.........................................................................................39
BASE PAGE............................................................................................................
CREATION OF A NEW PRODUCT .............................................................................
40
41
CREATION OF A NEW DATABASE .........................................................................42
MECHANICAL MACHINE ADJUSTMENTS......................................................................45
DETERMINING THE STEP OF THE PRODUCT FEED LUGS...........................................45
INSERTING THE INFEED LUGS................................................................................46
FIXED FOLDING BOX...........................................................................................47
ADJUSTABLE FOLDING BOX (OPTIONAL)..............................................................48
ADJUSTABLE FOLDING BOX (OPTIONAL)..............................................................48
ADJUSTING PRODUCT GUIDES.............................................................................
DETERMINING THE WIDTH OF THE REEL................................................................
49
50
MOUNTING FILM REELS .........................................................................................50
INSERTING FILM....................................................................................................
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51
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ADJUSTING THE MECHANICAL ARM ........................................................................52
ADJUSTING THE FILM REEL BRAKE.........................................................................53
JAW HEIGHT ADJUSTMENT.....................................................................................54
VERSION “CARRERA 2000 PC 400” .......................................................................54
JAW HEIGHT SELECTION.....................................................................................54
VERSION “CARRERA 2000 PC 250” .......................................................................55
MOUNTING THE INTERCHANGEABLE PRODUCT SUPPORT ........................................56
ENTERING PRODUCT DIMENSIONS AND ADJUSTMENTS..............................................57
ENTERING THE OPERATING PARAMETERS OF THE MACHINE ....................................61
“TEMPERATURE” PAGES .........................................................................................62
“TEMPERATURES ACCORDING TO THE MACHINE SPEED ............................64
PAGE “PRODUCTION RELATED DATA”.....................................................................66
OFF SET PARAMETER ...........................................................................68
“ACCESSORIES” PAGE ............................................................................................69
DESCRIPTION OF PARAMETERS ....................70
ACCESSOIRES PAGE: PRINTER/GUSSET/CARDBOARD CUTTER...............................71
PRINTER ...........................................................................................71
GUSSET ............................................................................................71
CARDBOARD CUTTER
INDEPENDENT CUT
.....................................................................72
.........................................................................72
ACCESSOIRES PAGE: LABEL APPLICATOR/SPRAY...................................................73
LABEL APPLICATOR ............................................................................73
SPRAY ...............................................................................................73
VARIOUS ACCESSORY PAGES...............................................................................74
"USER CAMS" PAGE ....................................................................................75
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PAGE “FUNCTIONS” ....................................................................................78
PRE-PRODUCTION....................................................................................................81
VERIFICATION OF SETTINGS AND ADJUSTMENTS....................................................81
ADDITIONAL TESTING PROCEDURES WITH REGISTERED PRINT ......................... 82
TEST RUN..............................................................................................................85
ADVANCED FUNCTIONS: MISPLACE - NO PRODUCT NO BAG .....................................87
PRODUCT SAFETY SYSTEM (MISPLACE) .....................................................87
INTRODUCTION OF THE FUNCTION “PRODUCT SAFETY”......................................88
ENTERING PARAMETERS .....................................................................................89
ACTIVATION OF THE FUNCTION “PRODUCT SAFETY” (MISPLACE)..........................91
“NO PRODUCT / NO BAG” .................................................................92
NOTES FOR THE CORRECT CALIBRATION OF THE PHOTOCELL..............................92
CONDITIONS FOR THE CORRECT FUNCTIONING................................................92
OPERATING RULES...........................................................................................92
ACTIVATING THE “NO PRODUCT / NO BAG” FUNCTION......................................93
AVAILABLE INSTRUMENTS................................................................................93
OPERATING .....................................................................................................94
DATA NEEDED FOR THE AUTOMATIC CALCULATION...........................................94
HOW TO CHANGE THE PRODUCT STOP POSITION..............................................96
USE OF THE FILM ADVANCE..............................................................................
FORCING OF THE FILM STOP CYCLE AT THE CUT-OFF........................................
SAVING PARAMETER VALUES
......................................................................98
96
97
PRODUCTION.........................................................................................................100
SIZE CHANGE
...........................................................................................102
STATISTICS ..............................................................................................104
PRODUCTS LIST MANAGEMENT...............................................................................105
DELETION OF A PRODUCT ........................................................................105
COPYING A PRODUCT ...............................................................................107
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CORRECTING/CHANGING A PRODUCT NAME .........................................................109
DIAGNOSTIC..........................................................................................................111
“DIAGNOSTIC” PAGE............................................................................................111
“INFEED AXIS” PAGE............................................................................................112
“FILM AXIS” PAGE................................................................................................113
“ROLLER AXIS” PAGE............................................................................................114
“JAW AXIS” PAGE.................................................................................................115
“DISCHARGE BELT” PAGE (OPTIONAL)..................................................................116
“AUTOMATIC FEEDER” (OPTIONAL) ......................................................................117
“TEMPERATURE” PAGE.........................................................................................118
“I/O STANDARD” PAGE.........................................................................................119
“DIGITAL INPUT” PAGE ........................................................................................120
“DIGITAL OUTPUT” PAGE .....................................................................................121
“ANALOG INPUT/OUTPUT” PAGE...........................................................................122
“ALARM LIST” PAGE .............................................................................................123
TROUBLESHOOTING...............................................................................................124
MACHINE MALFUNCTION DURING OPERATION......................................................124
ERROR MESSAGES ...............................................................................................139
MESSAGGE ..........................................................................................................139
PROBLABLE CAUSE / REMEDY............................................................................139
MAINTENANCE .......................................................................................................142
GENERAL.............................................................................................................142
SAFETY CONDITION.............................................................................................
PUTTING IN MAINTENANCE CONDITION...............................................................
142
143
PERIODICAL MAINTENANCE .................................................................................143
MACHINE.............................................................................................................
MACHINE MAINTENANCE......................................................................................
144
146
FRAME CLEANING AND MAIN COMPONENTS.......................................................146
INFEED CONVEYOR...........................................................................................146
MACHINE BODY ................................................................................................146
LONGITUDINAL SEALING AND PROPELLING ROLLERS .........................................147
JAWS................................................................................................................147
DISCHARGE CONVEYOR BELT ............................................................................147
JAW AND ROLLER HEATER ROTARY COLLECTORS...............................................147
LEVELLING CHECK.............................................................................................
MECHANICAL PARTS MAINTENANCE......................................................................
147
148
BOLTS AND NUTS TIGHTENING CHECK ..............................................................148
WEAR AND TEAR CHECK AND REEL BRAKE OPERATION: .....................................148
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LUBRICATION OF DRIVE CHAINS .......................................................................148
CHECK OF TRANSMISSION BELT TENSION..........................................................148
CHECK OF MOTOR BELT....................................................................................148
MAINTENANCE MOTOR – ADAPTORS – VARIATOR .................................................149
CHECK AND OIL REPLACEMENT..........................................................................149
MAINTENANCE OF SAFETY DEVICES .....................................................................150
EFFICIENCY CHECK OF THE EMERGENCY STOP BUTTON .....................................150
EFFICIENCY CHECK OF THE SAFETY SWITCHES..................................................150
ELECTRICAL INSTALLATION MAINTENANCE...........................................................151
CABLES FIXING CHECK......................................................................................151
MAINTENANCE PUSHBUTTONS, CONTROL SELECTORS AND INDICATORS.............151
PNEUMATIC INSTALLATION MAINTENANCE (OPTIONAL)........................................152
CONDENSATION DRAINAGE AND PRESSURE REGULATOR FILTER CLEANING ........152
LUBRICATING OIL LEVEL CHECK........................................................................152
EFFICIENCY CHECK OF THE PNEUMATIC INSTALLATION COMPONENTS................154
COOLANT INSTALLATION MAINTENANCE (OPTIONAL) ...........................................155
WATER CIRCULATION CHECK ............................................................................155
COOLANT CIRCUITS PIPING CHECK....................................................................155
AIR CLEANING FILTER REPLACEMENT...................................................................156
REPLACEMENT OF COMPONENTS..........................................................................157
REPLACEMENT OF UPPER JAW KNIFE.................................................................157
ADJUSTMENT OF UPPER JAW KNIFE...................................................................157
REPLACEMENT OF LOWER JAW ANVIL................................................................157
REPLACEMENT OF HEATING RESISTANCES CARBON BRUSHES.............................159
JAW HEATER..................................................................................................159
SEALING ROLLER HEATERS.............................................................................
REPLACEMENT OF HEATER RESISTANCES...........................................................
159
161
UPPER JAW HEATER.......................................................................................161
LOWER JAW HEATER......................................................................................
SEALING ROLLER HEATERS................................................................................
161
162
REPLACEMENT OF TEMPERATURE PROBES .........................................................162
UPPER AND LOWER JAW TEMPERATURE PROBE...............................................162
SEALING ROLLER TEMPERATURE PROBE ............................................................163
Copyright ILAPAK Italia S.p.A. Ed 1 Rev 06 - June 2005 User manual –- 6
Carrera 2000 PC Touch
SALES AGENTS AND SERVICE ORGANISATIONS
The Sales Agent and Service Organisation in your area is:
TO BE FILLED IN BY THE AGENT OR AREA REPRESENTATI VE
The machine subject of this publication was designed by ILAPAK S.p.A. (Nova Milanese;
Milano; Italy), which is a company of the ILAPAK group.
ILAPAK ITALIA S.p.A. puts its proper Assistance Service at disposition of the customers in
order to solve whatever problem regarding the use and the maintenance of their
machines.
The customers can signal their requests to the related commercial ILAPAK
companies.
SPARE PARTS
It is recommended to use exclusively original spare parts.
The requests for spare parts should be made at the related commercial ILAPAK
Company, observing the standards contained in the catalogue of the spare parts and
nominating always the type and serial number of the machine.
Copyright ILAPAK Italia S.p.a
Ed 1 Rev 06 - June 2005 PAGE -1
Carrera 2000 PC Touch
INTRODUCTION
WARNINGS FOR USE OF THE INSTRUCTIONS
PURPOSE AND LIMITS OF THE INSTRUCTION AND MAINTENANCE
MANUAL
This manual is destined to all the operators in charge of the use, maintenance and
surveillance of the machine during its working life.
The purpose of the manual is to supply the information regarding:
- The technical features of the machine
- The preparation of the working site regarding the environmental characteristics and
the feeding sources
- The accident prevention standards, use and calibration of the safety devices
- The use of the machine as provided in the project
- The ordinary and extraordinary maintenance
- The availability of the spare parts
The manual cannot replace the specific preparation, which the operators should have
carried out previously on equal appliances or who will be accompanied on this machine by
already skilled staff.
KEEPING OF THE MANUAL
The use and maintenance manual is considered integral part of the machine and should
be kept for future reference till the final dismantling of the machine.
The manual should always be available for consultation and should be kept with care; in
case of damaging which compromises also partially the consultation, the user has to ask a
new exemplar to the constructor.
UPDATING OF THE MANUAL
This manual has been prepared at the same time with the realization of the referred
machine and cannot be considered inadequate only because successively updated (also
for similar machines) according to new experiences.
ILAPAK ITALIA S.p.A. has the right to modify together with its production also the related
manuals, without the obligation to update the previous supplied ones. Possible
integrations sent to the users, under the form of “UPDATING”, have to be kept together
with the manual.
COLLABORATION WITH THE USER
ILAPAK ITALIA S.p.A. is at disposition of its customer to supply further information
regarding the use and the maintenance of their machines as well as considering
improving proposals for the manual in order to make them always more suitable to the
requirements of the customers.
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Ed 1 Rev 06 - June 2005 PAGE -2
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MACHINE IDENTIFICATION DATA
The main identification data of the machine are printed on the proper plate with the EC
marking installed outside the machine.
The plate notes the following data:
- Name of manufacturer and his address
- Type of machine
- Serial number
- Construction date
- Feeding voltage
- Absorbed power
- EC marking
Another plate, fixed inside the electrical panel, notes furthermore the values in relation to
the electrical supply
- Serial number of the electrical panel
- Nominal voltage
- Frequency
- Number of phases
- Frequency
- Full load current
- Number of the wiring diagram
- Short-circuit interruption power
NOTE In case of a technical assistance request or an order of the spare parts, nominate
always the type and serial number of the machine a/o the data in relation to the
electrical supply.
Machine identification
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Ed 1 Rev 06 - June 2005 PAGE -3
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EC STAMPING AND SAFETY STANDARDS
The machine bears the EC stamp indicating conformity with Directive 89/392/EEC,
and subsequent modifications, of the European Community Council.
NOTE: The stamp is affixed to the machine nameplate.
The original copy of “EEC Statement of conformance” is handed over to the customer
at the time of machine delivery.
This document shall be carefully kept by the Customer, and produced upon request
by the concerned Authorities.
The “EEC Statement of Conformance” is to be considered an integral part of the
machine, and shall be transferred to the new owner whenever the machine is re-sold.
Copyright ILAPAK Italia S.p.a
Ed 1 Rev 06 - June 2005 PAGE -4
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SAFETY RULES
The following safety rules should be observed during installation, operation
and maintenance of the machine. Lack of compliance with the following rules
may result in impaired effectiveness of the machine safety features.
The staff in charge of the use, the maintenance and the surveillance of the machine
should be instructed by the employer regarding the accident risks, the safety devices
installed on the machine and the general accident prevention rules, provided by the
international norms and the laws of the country where the machine is installed.
ILAPAK denies any liability for machine damage or injuries to the operator
third parties arising from the lack of compliance with the safety rules listed
hereafter.
MACHINE DISPLACEMENT DURING INSTALLATION MUST BE CARRIED OUT
ONLY BY SPECIALISED PERSONNEL, AND BY USE OF SUITABLE LIFTING
AND TRANSPORTATION EQUIPMENT.
MAKE SURE THAT ALL NECESSARY PRECAUTIONS ARE TAKEN DURING
LIFTING OR TRANSPORTATION OF THE MACHINE, AND THAT ALL THE
INSTRUCTIONS CONTAINED IN THIS MANUAL ARE CAREFULLY ADHERED
TO.
MACHINE CONNECTION TO THE ELECTRICAL POWER MEANS
SHALL BE CARRIED OUT ONLY BY SKILLED PERSONNEL.
BEFORE CONNECTING MACHINE TO THE ELECTRICAL POWER
MAINS, MAKE SURE THAT THE MAINS ELECTRICAL CHARACTERISTICS
CORRESPOND TO THOSE SPECIFIED ON THE MACHINE NAMEPLATE. ALSO,
MAKE SURE THAT THE MAINS IS PROVIDE WITH A SUITABLE GROUND
WIRE, AND THAT THE VOLTAGE MEASURED ON THE NEUTRAL WIRE IS
ZERO.
THE WIRES OF THE ELECTRICAL CONNECTION CABLE SHALL HAVE
A MINIMUM CROSS-SECTION OF 4 SQUARE MM.
THE MACHINE SHALL BE OPERATED ONLY BY SKILLED AND AUTHORISED
PERSONNEL.
THE MACHINE OPERATOR SHALL MAKE SURE THAT ALL THE
INSTRUCTIONS GIVEN IN THIS MANUAL ARE CORRECTLY FOLLOWED.
JAW MOTION REPRESENTS THE GREATEST DANGER FOR THE
OPERATOR WHEN THE MACHINE IS RUNNING. IN ORDER TO PROTECT THE
OPERATOR, THE MACHINE IS PROVIDED WITH A SAFETY DEVICE THAT
PERMITS MACHINE OPERATION ONLY WHEN THE PROTECTION GUARDING
ARE CLOSED.
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Ed 1 Rev 06 - June 2005 PAGE -5
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IN CASE OF MAINTENANCE OR REPAI R ACTIONS REQUIRING THAT
THE MACHINE OPERATES WITH PROTECTION GUARDING OPEN (SAFETY
DEVICE CUT OUT), PROCEED WITH EXTREME CAUTION TO PREVENT
HAZARDS OR INJURIES TO THE OPERATOR.
IN CASE OF DANGER FOR THE OPERATOR, OR WHENEVER IT IS
NECESSARY TO IMMEDIATELY STOP THE MACHINE, PRESS THE RED
EMERGENCY STOP PUSH-BUTTON. THIS BUTTON STOPS THE MACHINE AT
ONCE IRRESPECTIVE OF THE KIND OF WORKING OPERATIONS IN
PROGRESS.
THE USER IS RESPONSIBLE FOR THE OPERATIONAL SAFETY OF ANY
AUXILIARY EQUIPMENT NOT SUPPLIED BY ILAPAK.
ANY ACTION ON THE MACHINE WHICH MAY INTERFERE WITH THE SAFETY
DEVICES IS CARRIED OUT AT THE OPERATOR’S RISK.
IN CASE OF MAINTENANCE OR REPAIR ACTIONS REQUIRING
OPENING OR DISABLING OF PROTECTIONS, PROCEED WITH THE UTMOST
CARE AND IMPLEMENT ALL THE APPLICABLE SAFETY MEASURES. THESE
ACTIONS SHALL BE CARRIED OUT ONLY BY AUTHORISED PERSONNEL.
MAKE SURE THAT THE ELECTRICAL POWER SUPPLY IS
DISCONNECTED AND THE PNEUMATIC SYSTEM IS DISCHARGED BEFORE
CARRYING OUT ANY ADJUSTMENT/CALIBRATION OF THE MACHINE.
MAKE SURE THAT THE MACHINE IS DISCONNECTED FROM THE
ELECTRICAL POWER MAINS BEFORE CARRYING OUT ANY CLEANING OR
LUBRICATION OPERATION. POSITIVELY AVOID DIRECTING WATER JETS
ON THE MACHINE, INSIDE IT, ON THE CONTROL PANEL, AND ABOVE ALL
INSIDE THE ELECTRICAL CABINET.
DO NOT EMBODY MODIFICATIONS IN THE MACHINE WITHOUT PRIOR
AUTHORISATION BY ILAPAK.
ANY MODIFICATION SHALL BE EMBODIED BY ILAPAK AUTHORISED
PERSONNEL ONLY, AND RECORDED IN THE APPLICABLE TECHNICAL
DOCUMENTATION. ANY TAMPERING OF THE MACHINE, OR MODIFICATION
PERFORMED BY THIRD PARTIES VOIDS ANY RESPONSIBILITY OF ILAPAK
IN CASE OF MALFUNCTION OR INJURY TO THE OPERATOR.
Copyright ILAPAK Italia S.p.a
Ed 1 Rev 06 - June 2005 PAGE -6
Carrera 2000 PC Touch
CLOTHING
The clothing of the operator or the person, who carries out maintenance on the machine
should be according to the legal safety rules in the country of application. In general, the
operator should wear accident prevention shoes, and it is forbidden to wear moccasins,
clogs, slippers or any kind of footwear that could compromise the mobility of the person.
Use proper thermo-protective fireproof gloves when working in areas, which are
characterised by heat emission.
NOTE : When working on the machine, don’t wear bracelets, watches, rings or chains
which can dangle or hinder movements. Pay maximum attention, when working
near moving parts of the machine, that the proper clothing is suitable and avoid
hitching up with these devices (sleeves, shirt tails, hair, etc.)
ACCESS TO THE WORKING ZONE
The working area should never be occupied so that nothing interferes with the freely
movement of the operator. The immediate access to the machine from the staff in charge
should be guaranteed in emergency cases.
It is forbidden to have access to the working area to people who are not directly in
charge with the operation of the machine. This should be signalled with proper signs.
ATTENTON During the maintenance operations , in particular way when you work with
protections or disconnected safety devices, it is necessary to pay the
maximum attention that the working area is not accessible to people, who
are not directly in charge with these operations. At the end of the
maintenance interventions verify that no used tool remains inside the
accident prevention guards or inside the working area.
Copyright ILAPAK Italia S.p.a
Ed 1 Rev 06 - June 2005 PAGE -7
Carrera 2000 PC Touch
MACHINE USE DESTINATION
MACHINE APPLICATION
THE WRAPPING MACHINE MODEL CARRERA 2000 PC IS DESIGNED TO WRAP
FOOD PRODUCTS AND INERT MATERIALS.
IT MAY NOT BE USED TO WRAP PRODUCTS WHICH MIGHT REPRESENT A
SAFETY HAZARD FOR THE OPERATOR OR SEVERELY DAMAGE THE MACHINE
POSITIVELY DO NOT WRAP GAS-CONTAINING BOTTLES,
CONTAINERS OR JELLIES OF THE FOLLOWING MATERIALS: GUN POWDER
OR SIMILAR MATERIALS, FLAMMABLE FLUIDS, GLUES, SOLVENTS, ETHER,
ALCOHOL, GASOLINE, CATALYST AND CORROSIVE ACIDS, ETC.
POSITIVELY DO NOT WRAP ANY CHEMICALS OR OTHER
MATERIALS WHICH MAY REACT AT THE SEALING TEMPERATURES AND
RELEASE POISONOUS, FLAMMABLE OR EXPLOSIVES GASES, ETC.
WHEN THE OPERATION OF THE MOTORISED PRODUCT SUPPORT
DEVICE HAS BEEN ACTIVATED (FUNCTIONAL KEY ) AVOID THAT THE
MAXIMUM PRODUCTION SPEED EXCEEDS 90 PIECES PER MINUTE.
THE MACHINE SHOULD BE USED FOR THE WRAPPING WITH EXACTLY
DEFINED CHARACTERISTICS AND WITHIN THE LIMITS ESTABLISHED BY THE
SUPPLYING CONTRACT, DRAWN BETWEEN THE PURCHASER AND THE
CONSTRUCTOR. THE USE OF THE MACHINE TO OBTAIN HIGHER PRODUCTION
VALUES OR DIFFERENT FROM THE ESTABLISHED ONE IS CONSIDERED AS AN
IMPROPER USE AND THE CONSTRUCTOR DENIES EVERY LIABILITY FOR
DAMAGES CAUSED TO THINGS OR PEOPLE AND DOESN’T ACCEPT ANY KIND
OF GUARANTEE ON THE MACHINE.
ILAPAK DENIES ANY LIABILITY DERIVING FROM IMPROPER USE OF THE
MACHINE.
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Ed 1 Rev 06 - June 2005 PAGE -8
Carrera 2000 PC Touch
VALUATION OF RISKS
Risks linked to the installation site of the machine
On the installation site of the machine there can be some risky situations, which could
compromise the correct operation.
FLOOR
The surfaces where the machine is placed on should guarantee during time the correct
placing and levelling; for example some asphalt floor under high temperatures condition
and in presence of soluble liquids can present an accelerated wear and tear with possible
formation of holes corresponding to the supporting points and therefore making the
machine position unstable.
TEMPERATURE
The established environmental temperature should be guaranteed (from 2 to 35 °C); high
temperature peaks could cause machine operation problems (for example cooling
difficulty of the motors).
POLLUTING MATERIAL
The potential damage coming from the use in the working area with polluted material
should be preventively valuated; for example:
DUST which could accelerate the wear and tear of the seals;
PVC which thermal degradation, generating HCl, can cause aggressive emissions of
the metal surfaces without proper protections.
MAGNETIC FIELDS,
Determined by the passage of electrical power lines near the electronic appliances
installed on the machine. They can cause disturbances and malfunctioning.
WARNING The user should assure the suitability of the installation place of the machine,
in order to save its integrity during time.
RISKS LINKED TO THE FEATURES OF THE MACHINE
According to the EEC 89/392 standards, all the areas of the machine characterised by
intrinsic with the working process or with the structure of the machine have been
analysed. The most suitable measurements have been taken to reduce, as well as to
eliminate possible risks to people in charge, equipping the machine with a series of
standard protections, fixed and movable, which stop the access to the dangerous areas
during the working. However, the best safeguarding for the operator’s safety is that the
operator himself pays attention and has a good sense and that the greatest experience
during time using the machine, can improve the safety margins during the operation.
Copyright ILAPAK Italia S.p.a
Ed 1 Rev 06 - June 2005 PAGE -9
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RESIDUE RISKS ZONES AND OPERATIONS
The areas of the machine or the procedures, which, even with suitable safety
measurements present a high danger degree are defined residue risks, for example the
presence of high voltage, high temperature or moving parts. All the areas with residue
risks have been marked with proper name plates according to the ISO standards;
WARNING SIGNS
In compliance with the EC regulations, and in order to highlight the machine areas
requiring special operator’s attention, or involving particular hazards for operator safety,
the following warning signs are used.
LIVE LINE
HOT SPOT
CUT/SEVER HAND AND
FINGERS
MOVING GEARS
PUT TENSION OFF
BEFORE WORKING
INSIDE
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Ed 1 Rev 06 - June 2005 PAGE -10
Carrera 2000 PC Touch
RESIDUE DANGERS
INFEED CONVEYOR END
There is the danger that your hands may caught and crushed where
product lugs return upward at the end of the infeed conveyor. Therefore,
avoid working in this area, and pay much attention if working there cannot
be avoided.
ADJUSTMENT OF PRODUCT GUIDES
Adjustment of the product guides shall be such as there is a gap of less
than 5 millimeters or of more than 25 millimeters between the guide and
the pusher.
If the product to be wrapped requires that the distance between the guide
and the pusher is set a value between 5 and 25 mm, pay much attention as
you run the risk that your hands are caught between the guide and the
pusher.
CONVEYOR AREA
Lug overturning creates a serious danger for your hands. They may be
crushed. Pay much attention when working in this area.
LOADING OF FILM REELS
The loading of reels weighing between 18 and 36 kg shall be made by two
people.
Load the heavier reels by use of a suitable equipment (not supplied with
the machine).
WORKING AND CONTROL ZONES - SAFETY ZONES
The description of the working and control areas, is indicated in the layout included with
the statement of conformance.
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Ed 1 Rev 06 - June 2005 PAGE -11
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ENVIRONMENTAL USE CONDITIONS
NOISE LEVEL
The noise emitted by the wrapping machine during operation is 73 dB as resulting from
the measurements carried out by using a sample machine.
TEMPERATURE AND HUMIDITY
The machine can be used in rooms with room temperature included between 2 and 35 °C
and with a related humidity lower than 80 %.
OPERATIONAL SITE
The machine should be used protected against atmospheric conditions (rain, hail, snow,
fog, etc.). Should the machine be used in corrosive sites, it is necessary to intervene on
the modality and the maintenance periods, adapting it in order to avoid an excessive
wear and tear of the components.
The use of the machine under explosive or partially explosive conditions isn’t
provided, therefore it is forbidden to use it under these conditions.
ILLUMINATION
The room where the machine is placed should be illuminated in such a way to individuate
easily the buttons and the devices for the control and the emergency stop.
The illumination should allow carrying out under safety condition the ordinary
maintenance operations; the user should carry out these interventions according to the
legal rules regarding the modality of the illumination.
VIBRATIONS
Under normal use conditions, following the indications from this manual, the vibrations
may not cause danger situations. In case of anomalous vibrations, stop immediately the
machine and get in touch with the assistance service.
RESIDUE AND ENVIRONMENTAL CONTAMINATION
If the used material for the production is elaborated according to the recommendations of
the constructor, there won’t be noxious substances, as regards the EN 626-1 standards.
In case of using toxic or noxious plastic materials, the user has to install proper fume
aspiration hoods and the training of the operators for a correct treatment of these
materials. The user should observe the legal standards and community rules also for the
treatment and the lubrications used on the machine.
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SAFETY DEVICES
The safety devices fitted to the machine are shown in the following picture.
When the safety guards are opened while the machine is in operation, switches stops the
main motor and cuts off the power supply.
When pressed, emergency stop buttons interrupt machine operation and cut off the
power supply.
Isolator switch is a safety device that cuts off electrical power supply to all machine
components when the door of the electrical cabinet is opened.
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MACHINE INSTALLATION
INSTALLATION SITE REQUIREMENTS
The machine should be installed on a supporting floor that can bear the weight of the
machine on the several supporting points, without a decline during time; furthermore the
floors should be on spirit level, non-slipping and shouldn’t present roughness
The installation site should allow the operator to go around the machine without any
hindrances and to carry out easily the normal working operations and service operations
(maintenance and interventions on the machine). Furthermore it is extremely important,
that the protection guards and the doors of the electrical power boards can be opened
without hindrance and in a complete way. For this purpose the minimum distance
according to the building walls or to a possible hindrance should be about 2 meters.
EXTERNAL INSTALLATION REQUIREMENTS
The installation site should be prepared for the connection of the electrical installation,
the earthing, the pneumatic installation and possible coolant installation of the machine to
the outside net. The electrical and earthing installation of the installation site should be
realized according to the standards.
UNPACKING
The machine is shipped using packaging or proper protection means according to the
used kind of transport; pay particular attention when unpacking in order to avoid
damages to people or to the machine and to dismantle the packaging materials according
to the legal rules in force in the country where the machine will be used.
At receipt, control visually regarding possible damaging deriving from the shipment or
missing parts.
In case of damaging or missing part, get immediately in touch with the forwarding agent.
MACHINE UNPACKING AND POSITIONING
ATTENTION
he lifting operations of the parts composing the machine should be
carried out by staff in char
drivers, etc.) and with the assistance on the ground by a person in char
with the signalling if the overall dimension of the load doesn’t allow a
sufficient visibility; the staff should be equipped with the necessary
individual accident prevention protections.
The access to the area where the lifting operations are carried out is
forbidden to the staff, who is not in charge with this operation, using the
most proper means (barriers, signs, etc.). The capacity of the used lifting
means should be suited to the mass to be moved; the movement should
be carried out slowly under good illumination conditions and with sufficient
free space to work under safety conditions.
For no reason, the staff in charge with the operations is authorized to pass
under the load or at its proximity. This is valid also for the staff in charge
with the signalling on the ground.
e of these functions (crane operators, truck
e
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Carefully follow this procedure when unpacking and positioning the machine:
Remove covers and protections, if any from the shipping crate
Remove the infeed conveyor.
By use of suitable equipment , lift the pallet to which the machine is
secured, taking care to operate from the back side in order to avoid any risk
of machine overturning.
Carry the pallet to the location where the machine is to be installed, and
lower it to the ground.
Remove the screws (1) attaching the support channels (2) to the pallet.
Operating from the back of the machine, position the forklift under the base
plate, and lift the machine at a height sufficient to permit pallet removal.
Remove the four bolts (3) that attach the support channels to the machine,
and replace them with the four adjustable feet (4).
Lower the machine to the ground, remove the forklift, and carry out
machine levelling as described in the following paragraph
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TTENTION: ☺ SCRAP PACKING IN THE FIT DUMP
DON'T LEAVE PACKING IN THE ENVIRONMENT !!
OPERATE FROM BACK SIDE
1. Attachment Screw,
2. Support channel to Pallet
3. Support Channel Attachment Bolt, Support Channel to Machine
4. Adjustable foot
Machine unpacking and positioning
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WARNING The instructions supplied in this chapter are a synthesis of the procedures
established during the assembling of the machine and are destined to
technical staff, already in possession of the necessary knowledge for this
operation. However the staff should always be accompanied by specialised
ILAPAK staff. The purpose of these instructions is to supply a general
description of the methods, used for the connection of the main groups,
composing the machine.
LEVELLING
The machine has to run in perfect horizontal direction and should transmit only a minor
quantity of possible vibrations on the floor where it is installed; for this purpose, after
having placed it on the operation site, proceed with the levelling acting on the proper
supporting feet on the base and acting on the four adjustable feet, using as reference the
counter plane. At the end of the procedure, block the four feet by means of the related
lock nuts.
WARNING
he levelling of the machine should be carried out with exact precision in
order to avoid torsion phenomenon, an incorrect parallelism of the planes
and unexpected loads on the elements. The constructor declines each
responsibility for damages or malfunctioning of the machine, deriving from
an incorrect levelling or from a missing execution of the established
periodical checks.
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ATTACHMENT OF INFEED CONVEYOR
Attach the infeed conveyor by following this procedure:
Place the infeed conveyor on its support casting on the machine body making
sure that it rests on the casting correctly.
If necessary, level the infeed conveyor by adjusting the two suppor t feet.
Insert the two paper pins for infeed alignment (these pins are supplied with the
machine) then install the four attachment bolts with their washers
Connect the infeed conveyor chain by following the follows procedure:
If necessary, slacken the chain using the two side tensors.
Join the chain ends on the sprocket by use of the special link and the relevant
retaining clips.
Adjust the chain tension by use of the special side tensors, making sure that the
chain is not too tensioned, and that distance “X” measured between the end of
the tensor and the sprocket shaft is the same for both tensors.
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CAUTION. A too tensioned chain may result in bending of the sprocket shaft and
damage to the infeed conveyor.
Plug the electrical connector of the auxiliary control panel of the infeed conveyor
into socket on the left (or right) side of the machine
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ELECTRICAL SYSTEM CONNECTION
CAUTION:
1. Make sure that the mains power characteristics correspond to those of the
machine.
2. Open the electrical cabinet and connect the power supply wires to the terminal
board by referring to the applicable interconnection diagrams shown in Section
wiring diagrams of this manual.
3. Connect the end of the power supply cable to a mains circuit breaker (thermal
or magnetic) according to the machine connection sequence.
Connection of the machine to the electrical mains power is
carried out by the user under his/her full and sole responsibility,
and in compliance with the following instructions:
EARTHING
The machine should be earthed by means of a centralised line, available on the
installation site. The main earthing joint with the outer line is realized inside the electrical
board.
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PNEUMATIC SYSTEM (OPTIONAL)
The machine pneumatic system is designed to the closing of sealing – propelling rollers
In addition to other optional devices such as:
Air gusseting
Air Ejector
Automatic reel splicer
Quality Control
The system is fed directly from the air supply line available at the machine installation
location, through the filter-pressure regulator that is normally set at a pressure of 6-7
bars.
The system is fully controlled by selector valves whose closing and opening is
electronically commanded according to the operating parameters set by the operator.
Each selector valve is also fitted with a pressure regulator that regulates the compressed
air discharge pressure.
COOLANT INSTALLATION CONNECTION (OPTIONAL)
The machine can be equipped with a coolant installation, provided with a specific water
input and output; Check that the water inlet and outlet pipe on the machine are correctly
connected from the distribution block to the users.
CLEANING
Carry out an accurate cleaning of the machine at the end of the installation; remove the
dust and the present residues with particular care to the sliding surfaces. Furthermore
check that there aren’t any oil remnants near the tank of the lubrication installation.
Use a compressed air blowing device and a dry cloth for the cleaning in order to remove
the dust and also a non-aggressive solvent.
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MACHINE DEMOLITION
The machine demolition should be performed by staff specialised in the electric and
mechanic field. The standards in force concerning these operations are often different in
the various Countries, so it is recommended to analyse and apply all the provisions stated
by laws at the moment the machine is to be dismissed. The machine has been realised
using non-dangerous materials, (steel, plastics, rubber), which won’t give any problems
for recycling or disposal at the end of the service; anyway, it is necessary to have a deep
knowledge of the machine construction features and great technical skills to disassemble
the machine, besides the specific tools. It is strongly recommended to contact ILAPAK
assistance service, in order to obtain the maximum safety conditions in carrying out this
job.
WARNING It is necessary to provide for the oil recovery and its differentiated disposal
according to the antipollution standards.
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MACHINE CONTROLS
PUSH BUTTONS AND OTHER ELECTRO-MECHANICAL DEVICES
Push buttons and switches are located on the console except for the mains isolator switch
on the door of the electrical cabinet on the rear of the machine.
Green push button POWER UP /
With the mains isolator on, powers the machine up or resets power after one of the
following events:
use of the EMERGENCY STOP push button
opening of an interlocked guarding during operation of the machine
mains cut-off
Sets the machine in motion after powering up; in specific conditions executes also the
following functions:
reset an alarm or error message on the display screen
initialises co-ordination (synchronisation) of the “axes” (separate drive motors of
carriage, jaws, product infeed, sealing-propelling rollers and film unwinding roller),
when in a non-synchronised condition.
START
(3)
NOTE: Synchronising of the axes will take place automatically upon pushing
the START button, each time the axes are not any more in their
"normal" positions, in particular after:
turning on the mains;
a mains cut-off;
a size change;
operating one single axis separately;
a film rupture;
operation of the “electronic safety clutch”, i.e. when a product has got caught in the
sealing jaws.
co-ordinated start of all motors (under normal operating conditions); the machine
will accelerate continuously up to the speed set on the speed control potentiometer.
Red push button
makes the machine come to a halt in a pre-defined position with open sealing jaws (so
that the film will not be burnt). Normally, after pushing this button the machine will
reduce speed and approach the correct position at lower speed.
POSITIONAL STOP
(1)
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Emergency stop button
Stops the machine with IMMEDIATE effect independent of its momentary position;
In agreement with EC- and other international regulations the operation of the
emergency stop push button has the following effects:
Power off the complete machine;
cut all outputs from the electronic control system;
release compressed air from all pneumatic systems under pressure.
In order to return to working conditions after operating the EMERGENCY STOP button,
it is necessary to unlock it by rotating it in the direction of the arrow.
EMERGENCY STOP
(2)
NOTE: The emergency stop button must not be used other than in case of
real danger or any other emergency situation necessitating an
immediate machine stop.
Using the emergency stop button for “normal” machine stoppages
violates the safety regulations and may lead to damage on the
machine and/or the products to be wrapped.
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Ed 1 Rev 06 - June 2005 PAGE -24
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