Robo Pac

Table of contents
DOCUMENTATION PRESENTATION
This documentation includes all the documents that accompany your machine during its foreseen
working life. Keep it in a known place, easily accessible to all those who must use it.
The illustration depicts the document sequence.
INTERACTIVE CD-ROM: digital document version

(some attachments may only be provided in hard copy)
Title page
Type A or B Declaration of conformity

(2006/42/EC Appendix I, paragraph 1.7)
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Instructions for use

(in the language of the country of use)
Instructions for use
(in the manufacturers original language)
Spare parts catalogue
Attachments
Aetna Group S.p.A.
S.P. Marecchia, 59 - 47826 Villa Verucchio - Rimini - Italy

Tel. (+39) 0541 673411 - Fax. (+39) 0541 679576
www.aetnagroup.com
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damaged or illegible
Carefully read the warnings on safety, maintenance and the descriptions.
Aetna Group S.p.A. is not liable for any improper machine use or for damages caused by unreasonable operations
or those not discussed in this manual.
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hazardous.
Any intervention that alters the machine structure and the operating cycle must be previously and exclusively
authorised by Aetna group S.p.A engineering department otherwise, not only shall Aetna Group S.p.A not be held
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to safety aspects, the CE markings will be automatically invalidated according to Dir. 2006/42/CE.
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of unoriginal spare parts.
All rights reserved. The information in this manual may not be disclosed to third parties without Aetna Group
S.p.As written authorisation.
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who already possess similar models.
The original version of this manual was drafted in Italian and translated into other languages if necessary.
Therefore, the Italian version is the Original Instruction Manual while versions in other languages are to be
considered Translations of the original instructions. If you believe that any part of the translation is incorrect or
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translation, if necessary.
This manual was drafted as per Machine Directive 2006/42/EC (Appendix I, paragraph 1.7).
Introduction and safety
1 - Introduction and safety
01.01.02 EN
1 - 177
HOW TO CONSULT THE USE AND MAINTENANCE MANUAL

The use and maintenance manual is made up of several chapters that contain general information and others that
describe the single units that comprise the machine.All general information chapters are always included while
chapters that describe units are only included if the relevant unit is part of your machine. These units are listed in
paragraph Machine composition.
Chapter contents are found on page 3 of all chapters.
All pages are numbered as follows: chapter n. - page n.
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look for the chapter using the number and title found on the heading of each page;
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Their meanings are explained below.
Danger Warning!
Indicates potentially hazardous situations which, if ignored, could cause serious harm to personal health
and safety.
Important
Indicates particularly important technical information that should not be ignored.
Mandatory ecological waste material disposal sign.
PURPOSE OF THE MANUAL

This manual, which is an integral part of the machine, was created by the manufacturer to provide the necessary
information to people who are trained and authorized to operate on the machine during its expected working life:
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,QDGGLWLRQWRDGRSWLQJJRRGXVHWHFKQLTXHVWKHVHSHRSOHVKRXOGFDUHIXOO\UHDGDQGVWULFWO\DSSO\WKLVLQIRUPDWLRQ
Time dedicated to reading this information will prevent personal health and safety risks and economic damages.
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not interfere with your comprehension of this manual.
Keep this manual for all the life of the machine in a known and accessible place as to always have it available
when necessary.
The manufacturer reserves the right to make changes without any prior notice.
1 - 178
01.01.02 EN
GLOSSARY AND TERMINOLOGY

Some terms that are repeated in this manual are described to provide a more complete interpretation.
Operator:
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to use and supervise the machine.
Maintenance technician:
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maintenance on the machine. Therefore this person must possess precise information and skills with special
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Installation technician:
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to install and inspect the machine.
System manager:
technician chosen and authorised to supervise all the organizational and operating aspects of system and
production activities.
Routine maintenance:
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scheduled by the manufacturer and must be performed by the maintenance technician.
01.01.02 EN
1 - 179
SAFETY WARNINGS
GENERAL WARNINGS
During design and construction, the Manufacturer has carefully considered possible hazards and personal risks
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users to use extreme caution to avoid risks. However, discretion is invaluable. Safety is also in the hands of all
the operators who interact with the machine. Carefully read the instructions in this manual and those applied
directly on the machine; in particular, observe those that pertain to safety. Time dedicated to reading this manual
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reserved for all technological indications and information illustrated by the manufacturer.
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may cause serious personal health and safety hazards.
Personnel who perform any type of intervention on the machine during its expected working life must possess
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safety garments and/or devices indicated in the instructions for use provided by the manufacturer and those
foreseen by the workmans safety laws in force. During normal use or for any intervention, keep surrounding
areas, especially control access areas, in suitable working conditions to prevent personal health and safety risks.
HANDLING AND INSTALLATION WARNINGS
Lift and handle observing the information provided by the manufacturer and found directly on the packaging, on
the machine and in the instructions for use.Personnel who load, unload and handle the machine must possess
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the lifting means.
Suitable capacity machines must be used for lifting and handling, anchoring the machine at the points foreseen
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experience in order to protect their safety and those of others.
During installation, observe the surrounding space indicated by the manufacturer, also keeping in mind all
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safety regulations in force.Installation and connections must be performed according to the manufacturers
instructions.
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connections. After installation and before use phases, the manager must conduct a general inspection to ensure
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WARNINGS ON OPERATIONS AND USE
The operator, in addition to being suitably trained and informed on machine use, must have the skills and knowledge
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some test runs to identify controls, especially those concerning machine start and stop and their main functions.
Only use the machine for the manufacturers designed use. Improper use of the machine may cause personal
safety and health hazards and damages.The machine was designed and constructed to satisfy all the operating
conditions indicated by the manufacturer.
1 - 180
01.01.02 EN
Tampering with any device to obtain performances other than those foreseen can cause personal health
and safety hazards and economic damages.
Do not use the machine without the safety devices perfectly installed and in good working conditions. Failure to
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SIZE CHANGE, ADJUSTMENT AND MAINTENANCE WARNINGS
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instructions for use.Personnel who perform any type of intervention on the machine must possess the capabilities
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by the manufacturer. Good maintenance will lead to better performance, long working life and constant upkeep
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prevent access to all devices that could, if activated, cause unexpected personal safety hazards.To perform
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and others, observing workmans safety regulations in force. Perform worn parts with original spare parts. Use
oils and grease recommended in the manual. All these precautions ensure system operations and the foreseen
safety level.
Danger Warning!
Before performing any size change, adjustment and maintenance operation, the machine must be
stopped and the main switch in the 0 position.
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as replaced parts according to the environmental protection regulations in force.
01.01.02 EN
1 - 181
SAFETY DEVICES
The illustration indicates where the safety devices are located on the machine.
Note
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1 Main switch
The main switch can be locked in the 0 position to prevent unauthorised personnel from powering the
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2 emergency stop button
The machine immediately stops in emergency conditions when one of the emergency buttons is pressed. To
restart the machine, release the emergency buttons and reset the alarm on the switchboard.
3 )L[HGJXDUG
Outer structure that physically prevents access. Could be of various shapes and dimensions according to
machine layout. Furthermore, the safety structure could be part of the supply or installed by the machine user.
4 Interlocking on access door
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machine cycle restarts when the doors are closed and the Reset button is pressed.
5 Intruder-preventing barrier photocells
Electrical protection that prevents intrusion made up of barriers of photocells which, if crossed, immediately
stop the machine in emergency conditions.
To restart the machine, reset the alarm on the switchboard.
1
0
3
1 - 182
5
01.01.02 EN
6 Pneumatic cut-off valve

Used to close pneumatic supply. It can be locked to prevent access by unauthorised personnel during machine
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7 Parachute system
Two parachute systems block rotary ring descent in the event of emergency stop. The pneumatic cylinder
12, if powered, keeps the device in the released position; if there is no air (for example, in the event of
emergency), the device locks and descent is no longer possible. The magnetic endstroke 13 gives consent to
the motion when cylinder is powered.
8 Emergency carriage descent micro switch
Four micro switches (one per chain) put the machine in emergency conditions and thus the parachutes are
activated if the vertical carriage movement chain breaks and in the event of low extra stroke.
6
7
12
13
01.01.02 EN
1 - 183
9 3K\VLFDOORZH[WUDVWURNHVDIHW\EORFNV
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Works as a low carriage limit stop.
10
1 - 184
01.01.02 EN
SAFETY DEVICE CHECK
Frequency
Component
Intervention
Press the button and make sure the machine enters
emergency conditions.
Emergency button
With the machine in emergency conditions, make sure

the channel CH1 and CH2 status indicator leds on the
safety module are off.
Once a month
Key limit switch on perimeter
guards
Once
every
months
Wheel limit switch on

two parachute device
and panel door
ARC guards (if applicable)
Once every 20 years Contactors
01.01.02 EN
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Open the door.
Make sure the channels CH1 and CH2 status

indicator leds on the safety module are off.
A) If limit switch with normally open contacts (NO):

stop the machine and, with the limit switch in the
idle position, make sure the relevant contact is
open on the terminal board using a tester.
B) If limit switch with normally closed contacts (NC):
check for any cam and wheel wear. Replace if
worn.
Replace.
1 - 185
PARACHUTE SYSTEM DESCRIPTION

PARACHUTE SYSTEM OPERATIONS
When triggered, the following alarm is displayed: RING CHAINS NOT TAUT
Hazard - Warning!
The Maintenance technician must visually check chain branch integrity. This operation must be performed
with the machine stopped.
If one or more chains are broken (fault), contact Aetna.
Operating the machine is prohibited.
Inhibit personnel access within perimeter machine guards.
PARACHUTE SYSTEM RELEASE
Hazard - Warning!
Before releasing the parachute system, check lifting chain integrity.
If the system has triggered and the chains are integral, the carriage may not be aligned.
This condition may be caused by the pallet to be wrapped positioned off-centre.
In this case, the ring rests on the product on the pallet during carriage descent, off-balancing chain tension.
To restore normal conditions, proceed as follows:

1 Mute the alarm.
2 Check lifting chain integrity.
3 Make sure no one is inside the machine, exit the internal machine area, close perimeter guards and reset the
machine.
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5 Lift the carriage using the hold-to-run lift button on the operator panel. The carriage lifts at reduced speed until
aligned, afterwards lifting continues at work speed.
6 The machine is ready to resume operations.
1 - 186
01.01.02 EN
PARACHUTE SYSTEM EFFICIENCY CHECK
4
3
1 Nut
2 Plate
3 Switch
4 Parachute system activation cylinder rod
5 Roller stop device
01.01.02 EN
1 - 187
The system must be checked every 1000 work hours and every time the chains are replaced.
The check counter must be reset whenever the chains are replaced.
Proceed as follows:
1 Stop the machine using the emergency stop button.
2 From outside the perimeter guards, check that the parachute system activation cylinder rod (4) is lifted. Check
both devices on the machine.
If the test fails, contact Aetna.
Furthermore, in this case:
Operating the machine is prohibited.
If the test is passed, proceed as follows.

3
4
5
6
Enter the machine and approach one of the machine columns.

Loosen the nut (1) until the plate lowers (2), to move the switch (3) to the idle position (not running).
Exit the machine, close the access doors, reset the machine.
If the system is working correctly, the alarm RING CHAINS NOT TAUT should appear on the operator panel.
Otherwise, the test is considered failed.
In this case, stop the machine and replace the position switch.
Operating the machine is prohibited until the switch is replaced.
If the test is passed, proceed as follows.

7 Enter the machine and reset the system by return the switch lever (3) and plate (2) to their original positions.
Secure by tightening the nut (1).
Important
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8 After assembly, reset the machine and make sure there are no error messages on the operator panel,
especially the message RING CHAINS NOT TAUT.
9 Repeat the check on the other three machine chain branches.
1 - 188
01.01.02 EN
ROLLER STOP DEVICE MAINTENANCE (5)

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Stop blocks were designed so that, with use without damages during working life, no maintenance of any kind is
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Routine checks not only increase safety but also trouble-free and long-lasting system operations.
We especially recommend checks and maintenance before performing mandatory regulatory operating tests.
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your supplier.
IMMEDIATE ROLLER STOP DEVICE MAINTENANCE AND CONTROL PLAN

Check the free track/guide runner and stop/guide rollers;

Check for stop roller damages or wear;
Check trigger system mobility;
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01.01.02 EN
1 - 189
Overview
2 - Overview
02.01.02 EN
2 - 191
2 - Overview
CE CONFORMITY
This machine was manufactured in a country that belongs to the European community and therefore meets the
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MANUFACTURER AND MACHINE IDENTIFICATION

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Plate A
Plate B
1
2
3
4
1
2
3
4
5
6
7
Designation
Model
Serial number
Year of costruction
Serial number
Rated voltage
)UHTXHQF\)DVHV
Absorption
Total power
Short circuit current
Electric drawing nb.
AETNA GROUP SPA

S.P.Marecchia, 59
47826 Villa Verucchio (RN)
Tel. +39/0541/673411
Fax +39/0541/679576
www.aetnagroup.com
email [email protected]
Matricola
Serial number
Tensione nominale
Rated voltage
AETNA GROUP SPA

S.P.Marecchia, 59
47826 Villa Verucchio (RN)
Tel. +39/0541/673411
Fax +39/0541/679576
www.aetnagroup.com
email [email protected]
Frequenza/NFasi
Frequency/Fases
Assorbimento
Absorption
Designazione
Designazione
Potenza Totale
Total Power
Modello
Model
Corrente di corto circuito

S.c. current
Matricola
Serial number
N schema elettrico
Electric drawing nb.
Anno di costruzione
Year of costruction
2 - 192
02.01.02 EN
2 - Overview
GENERAL MACHINE DESCRIPTION

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booklets. High production capacity and long operating autonomy make this machine suited for installation in
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components to control the working phases of the cycle and safety devices to guaranty operator safety.
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INTENDED USE
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OP
The machine must be operated and controlled by personnel who have received training on machine characteristics
and who have read the contents of this manual.
IMPROPER USE
Any use other than that intended is to be considered improper and therefore potentially hazardous for the operator
and annuls the contract warranty.
In particular, the machine is suited for:
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outdoor use;
use in explosive environments;
use in environments with relative humidity over 70%;
use in environments with temperatures over 0 C or under +40 C.
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02.01.02 EN
2 - 193
2 - Overview
MACHINE COMPOSITION
The machine is made up of the following units:
4
5
6
7
8
9
10
Base machine unit

Spool carriage unit
Clamp - cut - welder unit
Top inside unit (optional)
Pressure platen unit (optional)
Conveyor unit (optional)
Load lifting unit (optional)
7
4
5
10
6
2 - 194
02.01.02 EN
2 - Overview
WORK CYCLE
The phases that make up the base machine work cycle are illustrated and described below.
For further information please consult the chapters on the installed functional units.
Pallet positioning
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Preparation of the top sheet (optional)
The top sheet is unwound from spool 2, cut to size and centred on the pallet.
Wrapping
Carriage 3 lowers to the upper part of the pallet. The spool carriage 4 begins wrapping, rotating around the pallet
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OPZUDSV7KHFDUULDJHEHJLQVLWVGHVFHQWGHSRVLWLQJWKHWRSVKHHWLIUHTXHVWHGWKDWLVZUDSSHGLQWKHIROORZLQJ
UHYROXWLRQV&RQWHPSRUDQHRXVO\WKHORDGLVVWDELOL]HGE\WKHSUHVVXUHH[HUWHGE\WKHSODWHQLIUHTXHVWHG
Continuing its rotation, the spool carriage reaches the operating speed and goes down to the lowest point of the
pallet to then go up thus obtaining a crossed spiral wrapping (it is however possible to set wrapping cycle different
from the present one).
Film cutting and welding
Near the end of wrapping, the contrast lowers, the spool carriage performs the last wrap and stops.
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Pallet outfeed
Conveyor 1 moves the pallet to the outfeed area and simultaneously moves the next pallet to the wrapping area.
3
2
4
5
02.01.02 EN
2 - 195
2 - Overview
TECHNICAL SPECIFICATIONS
Model
GENESIS FUTURA
Operations
Electromechanical/pneumatic
Operators
1 (occasionally only to check and replace the spool)
Voltage/Power supply
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Installed electrical power
See enclosed lay out
Compressed air
Supply pressure
Consumption
6 bar +/- 1
Ring rotation speed
max 40 rpm
Dimensions
Weight
See machine plate
Noise level (*)
66,5 dB
Permitted environmental conditions

Temperature
Humidity
+5 +40 C
50% max
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the levels to which the operators are exposed in the installation site.
Note
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provided in the enclosed layout.
2 - 196
02.01.02 EN
2 - Overview
02.01.02 EN
2 - 197
Lifting and installation
3 - Lifting and installation
03.01.00 EN
3 - 199
WARNING
Hazard Warning!
Handle and install observing the instructions provided by the manufacturer and found directly on the
packaging, on the machine and in the instructions for use.
All operations must be performed in accordance with the safety warnings provided in paragraph Safety
warnings - chapter Introduction and safety.
HANDLING
PACKING AND UNPACKING
The packaging, limiting size, was created according to the chosen transportation means.
To facilitate transportation, the machine is divided in suitably protected and packaged subgroups for delivery.
All necessary loading and unloading information is found on the packaging.
Some parts, especially electric, are protected to prevent damages from humidity or other elements.
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Packaging material must be appropriately disposed in accordance with laws in force.
Packaging may include:
1
2
3
4
with protective covering (of polyethylene).

on platform with protective covering (of polyethylene).
crate.
barrier bag.
Packaging type
Transportation means
Lifting means
Final destination
3 - 200
03.01.00 EN
LIFTING AND TRANSPORT

The machine is delivered partially dismantled, without columns and chains to reduce dimensions and facilitate
transport; the mobile part (carriage) is lowered to the base, columns and chains removed and cap secured to the
EDVH8VHDIRUNOLIWWROLIWWKHXQLWLQVHUWLQJWKHIRUNVLQWKHVSHFLFVORWV1.
To handle the columns and other boxes, use a forklift with suitable capacity (refer to the weights indicated on the
boxes or in the packing list).
TOTAL WEIGHT = 3500 Kg
03.01.00 EN
3 - 201
INSTALLATION
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VXSSO\DQGH[KDXVWV\VWHPVUHTXLUHGIRUPDFKLQHRSHUDWLRQV
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ORFDWHWKHLQVWDOODWLRQDUHDGHQHGLQWKHOD\RXW,IQHFHVVDU\LGHQWLI\WKHH[DFWSRVLWLRQDQGWUDFHWKHFRRUGLQDWHV
on the ground.
MACHINE ASSEMBLY
Loosen screws that secure the cap 1 to the base;
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assemble the columns on the base.
COLUMN WEIGHT = 80 Kg
3 - 202
CAP WEIGHT = 550 Kg
03.01.00 EN
lift the cap 1XVLQJDIRUNOLIWLQVHUWLQJIRUNVLQWKHVSHFLFVORWV5 and install in on the top end of the columns,
securely tightening the fastening nuts 6;
inset the chains following the paths 7 and 8LQGLFDWHGLQWKHJXUH
Warning!
When installation, including the levelling and connections described below, is complete, after lifting the
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1
03.01.00 EN
3 - 203
MACHINE LEVELLING

Use a level to check machine levelling 1;

correct levelling if necessary using feet shims 2;
VHFXUHWKHIHHWWRWKHRRUXVLQJVFUHZV3 on the expansion dowels (supplied);
level the carriage 4 using the chain regulators (nut and counter nut 5), then regulate the slow arm using the
turnbuckle 6;
3
2
3 - 204
03.01.00 EN

assemble the safety guard panels7 and the four staffs with photocells 8, if included in the supply;
position the electrical cabinet 9;
perform electrical connections between the cabinet and machine;
perform pneumatic connections between the air conditioning unit 10 and the machine.
03.01.00 EN
10
3 - 205
CONNECTIONS
Hazard Warning!
Follow the manufacturers instructions in the enclosed diagrams for connections.
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DQGOHJLVODWLYHUHTXLUHPHQWV
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ELECTRICAL CONNECTIONS
Note
Refer to the enclosed wiring diagram.
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wiring diagram.
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terminals 1 (L1-L2-L3). The yellow/green ground wire must be connected to the terminal 2 marked by the
ground symbol. The blue neutral wire must be connected to the pertinent terminal (N) only when this connection
is foreseen (see wiring diagram).
PNEUMATIC CONNECTIONS

Make sure valve 3 is in the CLOSE position.

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Turn on supply line pressure.
Rotate valve 3 to the OPEN position.
Check that the pressure gauge 5 indicates a pressure of at least 6 bar and use the knob 6 to compensate for
any pressure differences. Check again when the machine is running.
3 - 206
03.01.00 EN
MACHINE DECOMMISSIONING
Machine decommissioning means prolonged machine disuse. In these conditions we recommend you take some
measures to keep machine conditions constant.
Disconnect the machine power supply.
Keep the machine in a closed location with room conditions within the values indicated in chapter 2 - paragraph
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Cover the machine with tarps to prevent dust from depositing.
MACHINE DEMOLITION
The machine must be demolished at the end of its working life. Considering the high value of some of its parts,
recovering all parts that are still operational is recommended for future use such as, for example, motors, gear
boxes, drives, electronic components, etc.
For other, non-recyclable parts, divide waste material according to type, for example, iron, aluminium, plastic, oil
or other chemical products, etc., and contact specialised and authorised companies for special product disposal.
Note
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is demolished.
03.01.00 EN
3 - 207
Base machine unit
4 - Base machine unit
04.01.02 EN
4 - 209
DESCRIPTION AND OPERATIONS

The base machine is made up of the following parts:
1
2
3
4
Frame
Carriage
Rotating ring
Safety guards open (optional))
2
1
4 - 210
04.01.02 EN
The frame includes:

the base 5;
the four columns 6, available in various heights according to the size of the pallets to be wrapped;
cap 7, on which motorization of carriage is located.
The carriage moves vertically on wheels 8 which slide on the four columns. Movement is generated by the gear
motor 9 by chains 10. Motor speed is controlled by an inverter and encoder.
10
04.01.02 EN
4 - 211
The rotary ring 3 is assembled on the carriage which rotates the spool carriage.
The rotary ring moves supported by structure 12 on six wheels 13 and the contrast moves laterally on six
wheels 147KHDGMXVWDEOHJXLGHV15 guarantee that the ring cannot move upward.
7KHULQJLVURWDWHGE\DDWEHOW16 wound on its external surface and driven by the gear motor 17 whose speed
is controlled by the inverter.
12
15
3
14
13
16
17
4 - 212
04.01.02 EN
On the rotary ring, diametrically opposite the spool carriage 11, are assembled the carriage power batteries 18.
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wrapping cycle, the rotary ring stops in phase; at each stop in phase, the pins 19, moved by the cylinder 20, touch
the contacts 21 to recharge the batteries.
11
18
20
04.01.02 EN
19
21
4 - 213
The safety guards are made up of metallic mesh panels 22 with an access door 23 controlled by a micro switch
and optical barrier photocell 24 which, if crossed, stop the machine in emergency conditions.
The electric interlocking device, installed on the door, allows access to the operator in safety condition inside
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stopping with electric and pneumatic shutdown; machine restarts when door is closed and the cycle Reset
button is pressed.
Note:
The safety guard could be of various shapes and dimensions from those shown according
to the disposition of the machine and pallet conveyors.
Furthermore, the safety structure can be part of the supply or supplied by the user.
24
22
22
23
22
4 - 214
24
04.01.02 EN
ELECTRICAL CONTROL DEVICES

25
26
27
28
29
30
Carriage position detection encoder.

Low carriage detection sensor.
High carriage detection sensor.
Bottom extra-stroke safety switch and chain breakage.
High extra stroke safety micro switch.
Upper pallet edge detection photocellSURMHFWRUDQGUHFHLYHU
25
29
27
26
28
30
04.01.02 EN
4 - 215
31
32
Ring phase sensor: it is fastened to the carriage structure and counts ring rotations and, after a set
number of rotations, stops the ring in phase; it works on a cam fastened to the rotary ring.
Unwinding power circuit breaker micro switch when rotary ring is idle.
32
31
4 - 216
04.01.02 EN
AIR SUPPLY CONDITIONING UNIT

1 Supply faucet: opens or closes compressed air supply to the machine.
2 3UHVVXUHUHJXODWRUZLWKOWHUDQGSUHVVXUHJDXJHWRDGMXVWJHQHUDOSQHXPDWLFV\VWHPSUHVVXUH7XUQWKH
knob to vary the pressure values indicated on the gauge.
3 Pressure gauge: detects the working pressure value when it lowers to minimum.
4 4XLFN H[KDXVW VROHQRLG YDOYH: to close air supply and lower pneumatic system pressure in the event of
emergency stop.
5 Gradual start solenoid valve: gradually supplies air to the system.
04.01.02 EN
4-5
4 - 217
MAINTENANCE
CONDENSATION DRAINING
Place a container under the drain valve 1.
Release the valve by unscrewing and pushing it up; hold up until all condensation is drained.
Close the valve.
FILTER CLEANING
Remove the cup 2DQGUHPRYHWKHOWHU?
&OHDQWKHOWHUZLWKFRPSUHVVHGDLUDQGZDVKLWZLWKSHWURORUWULFKORURHWK\OHQHLIQHFHVVDU\
Replace the cup.
BEARING LUBRICATION
Grease the carriage lifting shaft bearings using lubricators 3 and the type of grease indicated in the lubricant
table.
CARRIAGE LIFTING CHAIN LUBRICATION
Lubricate the carriage lifting chains 4 using the type of oil indicated in the lubricant table.
4 - 218
4
04.01.02 EN
BELT TENSIONING

Loosen the turnbuckles 1 and 2 and remove the belt from the pulleys.
Make two markings 100 cm apart on the belt.
Replace the belt on the pulleys and turnbuckles.
Use the turnbuckle 1WRDGMXVWEHOWWHQVLRQ7LJKWHQXQWLOWKHGLVWDQFHEHWZHHQWKHWZRPDUNLQJVKDVLQFUHDVHG
by 2% (102 cm).
ROTARY RING CENTRING

Proceed as follows in the event the rotary ring shifts off centre:
Completely loosen the belt 3 using turnbuckles 1 and 2 and remove it from the pulleys but not from the lateral
wheels 4.
Loosen the lateral wheels 4 and move them away from the belt.
Insert six spacers 5ZLWKWKHVDPHWKLFNQHVVWKDWDFFXUDWHO\WEHWZHHQWKHURWDU\ULQJDQGWKHORZHUZKHHO
support block.
Rest the lateral wheels 4 against the belt and tighten them.
Assemble the belt on the pulleys.
Remove the spacers 5.
Rotate the ring at low speed and check centring before starting the machine cycle.
04.01.02 EN
4 - 219
CARRIAGE LEVELLING
After using a level to check carriage levelling, proceed as follows if necessary:
Use nut 1 and counter nut 2WROLIWRUORZHUWKHFDUULDJHXQWLOLWLVOHYHOPDNLQJVXUHWKHIRXUFKDLQVDUHHTXDOO\
loaded.
:KHQQLVKHGWLJKWHQWKHNQRE2.
Note
Correct levelling permits perfect carriage movement.
CHAIN ADJUSTMENT
Loosen the nuts 3.
Rotate the turnbuckle 4 inserting a pin in the hole 5.
Tighten the nuts 3.
1
2
3
4
4
4 - 220
04.01.02 EN
WHEEL REPLACEMENT
Note
The following procedure applies to both the ring and vertical carriage guide wheels.
Remove screw 1 and remove the wheel 2.
Assemble a new wheel, accurately tightening the screw.
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move them slightly apart.
Important!
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BELT REPLACEMENT
Loosen the turnbuckles 3 and 4.
Remove the belt 5 from the pulley and extract it.
Replace the gas spring 6 (see Gas spring replacement). Generally, when the belt is worn the gas spring has
DOVRORVWRULJLQDOHIFLHQF\DQGUHSODFHPHQWLVUHFRPPHQGHG
Assemble the new belt 5 and tighten it using the turnbuckle 4 (see Belt tensioning).
6
04.01.02 EN
4 - 221
LIFTING CHAIN REPLACEMENT

Important!
When replacing one chain, replace all the others.
Start the machine in manual mode.
Lower the carriage 1 until it rests against the limit stop blocks 2.
Danger Warning!
Cut off machine power supply before proceeding.

Completely unscrew the turnbuckles 3.

Remove the chains 4.
Insert the new chains and assemble in reverse order.
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GAS SPRING REPLACEMENT

Loosen turnbuckle 5.
Replace the gas spring 6 with a new one.
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1
4 - 222
04.01.02 EN
CARRIAGE LIFTING MOTOR REPLACEMENT

Danger Warning!
Electrically disconnect motor 3.
If the gear motor is brand SEW:
- Place an oil container under the gear motor and completely drain it.
- Remove the motor by removing the fastening screws.
- $FFXUDWHO\FOHDQDQGJUHDVHWKHJHDUPRWRUDQJHDQGDSSO\DVHDOLQJSDVWH/RFWLWHRYHULWVHQWLUH
surface. The sealing paste should be even.
- Assemble a new motor.
- Fill the gear motor with the oil indicated in the Lubricant table.
If the gear motor is brand BONFIGLIOLI:
- Remove the motor by removing the fastening screws.
- Assemble a new motor.
Electrically connect the motor.
04.01.02 EN
4 - 223
CARRIAGE LIFTING GEAR MOTOR REPLACEMENT

Danger Warning!

Completely unscrew the couplings 3 of the chains on the side of the geared motor.
Remove chains from pinions 4.
Electrically disconnect motor 5.
Remove the screw 6 from the anti-rotation staff.
Remove the screws on the three bearing support 7.
Lift the gear motor unit shaft supports and place it on the ground.
Clean the shaft surface 8 with thinner.
Loosen the pinion fastening screws and remove them from the shaft.
Remove the bearing supports from the shaft.
Remove the shaft from the gear motor.
Replace the gear motor 9.
Reassemble the unit in reverse order.
4 - 224
5
04.01.02 EN
ROUTINE MAINTENANCE
Frequency
Component
Intervention
40 hours
$LUOWHUXQLW
Drain condensation
Clean
200 hours
Rotary ring belt
Belt tensioning
Belt aligning
Carriage lifting chain
Lubrication
Aligning
Wheels
Clean with compressed air
Ring supports and sensors
Control
Motors and gear motors
Check oil level
Battery support frame screws
Check tightness
500 hours
Rotary ring wheel supports
Control
1000 hours
Rotary ring belt and gas spring
Replacement
4000 hours
Wheels
Replacement
Motors and gear motors
Oil change
Lifting chains
Replacement
Carriage lifting shaft supports
Lubrication
Once a year
04.01.02 EN
4 - 225
LUBRICANT TABLE
Application
Gear motors
Mineral oil
Worm gear reducers
Gears and worm gear

motors
Chains
23E at 50C - 320 cSt at 40C

MELLANA OIL 320
IP
SPARTAN EP 320
ESSO
BLASIA 320
AGIP
MOBILGEAR 632
MOBIL
OMALA EP 320
SHELL
ENERGOL GR-XP 320
BP
32E at 50C - 460 cSt at 40C
Grease
Synthetic oil
Bearings with support

Slewing rings
%UDQGW\SHVSHFLFDWLRQV
Lubricant type
Lithium grease
Synthetic oil
MELLANA OIL 460
IP
SPARTAN EP 460
ESSO
BLASIA 460
AGIP
MOBILGEAR 634
MOBIL
OMALA EP 460
SHELL
ENERGOL GR-XP 460
BP
TELESIA COMPOUND B
IP
STRUCTOVIS P LIQUID
KLUBER
TOTALCARTER SYOO
TOTAL
TELESIA OIL 150
IP
SYNTHESO D 220 EP
KLUBER
BLASIA S 220
AGIP
ALVANIA R2
SHELL
HL 2
ARAL
ENERGREASE LS2
BP
BEACON 2
ESSO
MOBILIX
MOBIL
ROCOL MTS 2000
AGIP
CENTOPLEX GLP 500
KLUBER
- 5C at + 5C VG 68 (SAE 20)
Use oil with

viscosity
suited forwork
environment
temperature.
+ 5C at + 25C VG 100 (SAE 30)

+ 25C at + 45C VG 150 (SAE 40)
+ 45C at + 70C VG 220 (SAE 50)
Important!
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4 - 226
04.01.02 EN
04.01.02 EN
4 - 227
Spool carriage unit (B.S.C.S.P.)
5 - Spool carriage unit (B.S.C.S.P.)
05.01.01 EN
5 - 229

The B.S.C.S.P. type spool carriage (Battery Self-Controlled Stretch Powered) is a device that unwinds and
SUHVWUHWFKHVSRO\WKHQHVWUHWFKOP,WSHUPLWVVLJQLFDQWZRUNLQJHFRQRPLHVWKDQNVWRUHGXFHGOPFRQVXPSWLRQ
DQGDEVROXWHVWDELOLW\LQWKHZHLJKWRIWKHOPXVHGIRUHDFKORDGHGSDOOHW)LOP1, running from spool 2 to pallet
3, passes across two rollers driven by the pre-stretch motor 11, which have different peripheral speeds (roller
4 slow, roller 5IDVW7KLVLVGXHWROPVWUHWFKLQJSUHVWUHWFKZKRVHH[WHQWFDQEHYDULHGDQGVHWE\VLPSO\
UHSODFLQJ D SXOOH\ DFFRUGLQJ WR OP VSHFLFDWLRQV DQG XVH QHHGV 7KH VWUHWFK HIIHFW RQ WKH OP EHWZHHQ WKH
rollers before load wrapping, in addition to reducing the section, provides physical characteristics that make it
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device 6 FRQWUROV DQG DGMXVWV OP RXWIHHG VSHHG :LWKRXW D OP WHQVLRQLQJ GHYLFH WHQVLRQLQJ GXULQJ SDOOHW
ZUDSSLQJ ZRXOG EH XQHYHQ VLQFH WKH SDOOHW H[HUWV D JUHDWHU GHPDQG IRU OP DW WKH FRUQHUV7KH %6&63
VSRROFDUULDJHLVHTXLSSHGZLWKDQHOHFWURQLFV\VWHPWKDWJXDUDQWHHVFRQVWDQWWHQVLRQ)GXULQJZUDSSLQJ7KH
idle roller 6PRYHGE\WKHOPZRUNVRQDQDQDORJVHQVRUWKDWDFWLYDWHVWKHUROOHUSUHVWUHWFKPRWRULQ'&VRWKDW
WKHXQZLQGLQJVSHHGLVDOZD\VSURSRUWLRQDWHWRWKHSDOOHWOPGHPDQG
5
F
FILM WITH INTERNAL ADHESIVE
11
5 - 230
FILM WITH EXTERNAL ADHESIVE
05.01.01 EN
ELECTRICAL CONTROL DEVICES

7 Unwinding motor speed control sensor
8 Pre-stretch control motor circuit breaker: when the ring is stopped in phase, the battery recharge contacts
move forward and, pressing plate 9, open the micro switch 8; in this condition, the operator can replace the
VSRRODQGXQZLQGWKHOPEHWZHHQWKHUROOHUZLWKRXWFDXVLQJWKHUROOHUVWRVWDUWGXHWRWKHOPSXVKLQJRQWKH
motor speed control roller 6. Light 17 off means power off.
10 Pre-stretch motor circuit breaker: cuts off power to the pre-stretch motor 11. The operator can safely work
on the spool unwinding unit, even moving it from the in phase position.
17
10
11
05.01.01 EN
5 - 231
12
Near empty spool control sensor (optional): a message appears on the display and the orange light
EOLQNVZKHQUHPDLQLQJUHHOOPLVWRZDUQWKHRSHUDWRU
13-14 Photocell (projector and receiver)WRWUDQVPLWHQGRUEURNHQOPLQIRUPDWLRQGHWHFWHGE\WKHXQZLQGLQJ
motor speed control sensor.
15-16 Photocell (projector and receiver): to transmit reel near empty information detected by the reel near
empty control sensor (optional).
12
16
5 - 232
13
15
14
05.01.01 EN
TECHNOLOGICAL WRAPPING INFORMATION

,I ORZ OLQHDU GHQVLW\ SRO\]HQH OP LV VXEMHFWHG WR SURJUHVVLYHO\ LQFUHDVLQJ WHQVLRQ WKH VWUHQJWK UDWH DQG
FRUUHVSRQGLQJGHIRUPDWLRQVDUHUHSUHVHQWHGLQDJUDSKVXFKDVWKHRQHLOOXVWUDWHGLQWKHJXUH
6F
Fr
R
<LHOG ORDG ZKHUH VWUHWFKLQJ VWDUWV WR LQFUHDVH ZLWKRXW VLJQLFDQW LQFUHDVHV LQ ORDG WKLV ORDG FUHDWHV
FRQVLGHUDEOHOPVWUHWFKZLWKRXWLQFUHDVLQJWKHGHIRUPDWLRQIRUFH
%UHDNORDGZKHUHOPEUHDNVDIWHUVWUHWFKLQJ
Film break point.
FORCE
(KG)
Fs
6L
STRETCH %
6L
05.01.01 EN
5 - 233
TECHNICAL SPECIFICATIONS
Descrizione
Valore
Motor drive
in DC
Pre-stretch value (see Available Pulley table)
from 0 to 300%
D
TECHNICAL SPOOL SPECIFICATIONS
Description
Value
Material
Polyethylene
Thickness
P
Spool core diameter (d)
76 mm
Maximum spool diameter (D)
250 mm
Maximum spool height (H)
500 mm
Spool core length
515 mm
Maximum spool weight
17 kg
AVAILABLE PULLEYS
Code
A (No. of teeth)
% pre-stretch
5400310007
60
300
5400310016
56
273
5400310017
52
246
5400310018
50
233
5400310019
48
220 (*)
5400310020
45
200
5400310021
42
180 (*)
5400310022
40
166
5400310023
36
140 (*)
5400310024
34
126
5400310005
32
113
5400310026
30
100
5400310027
28
86
5400310028
26
73
5400310029
24
60
5400310030
22
46
5400310085
15
(*) Standard machines are delivered with pulleys for pre-stretch values: 140% - 180% - 220%.
5 - 234
05.01.01 EN
SPOOL LOADING
Danger - Attention!
Before intervening on the spool unwinding carriage, cut off the power supply from the batteries to the
pre-stretch motor by separating connectors 1. Due to falling hazards, wear safety shoes when changing
the spool (spool weight = 17 kg)
Stop the machine in the spool change position.
Note:
,QWKHHYHQWRIVSRROGHSOHWLRQRUOPEUHDNWKHPDFKLQHLVDXWRPDWLFDOO\SRVLWLRQHGLQSKDVH
Enter the machine through the access door; the door must remain open.
If the previous spool is empty, remove the cardboard core using the stop teeth 2.
Insert the new spool on the spool carriage roller
Danger - Attention!
DAfter inserting the spool, make sure the spool carriage roller teeth are correctly fastened. Otherwise,
the spool could slip off during pallet wrapping and cause serious machine damage.
:KHQXVLQJVPDOOVL]HGVSRROVXVHWKHVSHFLFVSDFHUV3.
Select manual cycle on the control panel.
0DQXDOO\XQZLQGOPIURPWKHVSRRODQGWKUHDGDVVKRZQRQWKHFDUULDJHSODWH4. The dotted line represents
WKHVSRRODGKHVLYHLQWKLVJXUH
1
FILM WITH INTERNAL ADHESIVE
05.01.01 EN
FILM WITH EXTERNAL ADHESIVE
5 - 235
,QVHUWWKHOPEHWZHHQIUDPH6 and clamp 5.
CHANGE SIZE
PRE-STRETCH VALUE CHANGE
To change pre-stretch, pulley 1 PXVW EH UHSODFHG ZLWK WKH RQH WKDW KDV WKH QXPEHU RI WHHWK HTXDO WR WKH
UHTXLUHGYDOXHVHH$YDLODEOHSXOOH\WDEOH
Loosen turnbuckle roller 2VHH3UHVWUHWFKEHOWUHSODFHPHQWDGMXVWPHQW
Remove screw 3 and remove the pulley.
Tension the belt.
Important!
'RQRWH[FHVVLYHO\WHQVLRQWKHEHOWVRDVQRWWRFDXVHRSHUDWLQJDQRPDOLHV
5 - 236
05.01.01 EN
MAINTENANCE
Danger - Attention!
Before intervening on the spool unwinding carriage, cut off the power supply from the batteries to the
pre-stretch motor by separating connectors 1.
MOTOR BELT REPLACEMENT/ADJUSTMENT

Remove the guard (if applicable).

Loosen screws 2 on support 3DQGPRYHLWWRDGMXVWEHOWWHQVLRQ4 or replace if necessary.
Tighten the screws 2.
Reassemble the guard (if applicable).
PRE-STRETCH BELT REPLACEMENT/ADJUSTMENT

Remove the guard (if applicable).
Loosen the lower screws 5 on turnbuckle roller 6DQGPRYHLWWRDGMXVWEHOWWHQVLRQ7 or replace if necessary.
Reassemble the guard (if applicable).
3
7
05.01.01 EN
2
5
5 - 237
OSCILLATING ROLLER SPRING HOUSING LUBRICATION

Loosen the fastening screw 1.

Lift the roller 2.
Lubricate the spring housing 3 using the grease type indicated in the lubricant table.
Lower the roller and tighten the screw 1.
INTERVENTI DI MANUTENZIONE ORDINARIA

Frequency
Component
Intervention
200 hours
Belts
Tensioning
Pre-stretch carriage supports
Check screw tightness
D.C. motor brushes
Check
wear
and
cleaning
(see enclosed documents)
Batteries
Check charge
Lower oscillating roller spring housing
Lubrication
Belts
Replacement
Batteries
Replacement
500 hours
1000 hours
6 months
Important!
Periodically clean battery charge contacts to avoid the accumulation of combustible dust which could
VWDUWUHV
5 - 238
05.01.01 EN
05.01.01 EN
5 - 239
Clamp - cut - welder unit
6 - Clamp - cut - welder unit
06.01.00 EN
6 - 241

7KHFODPSFXWWLQJZHOGHUXQLWLVDGHYLFHWKDWFODPSVFXWVDQGZHOGVOPDWWKHHQGRIWKHZUDSSLQJF\FOH,WLV
HTXLSSHGZLWKDOPFODPS1, hot wire 2WRFXWWKHOPDQGZHOGLQJSODWH3 to weld it. It is assembled on a carriage
4 that moves orthogonally to the pallet on guides 5 by cylinder 6 to near the pallet in the operating phase and
move away in the wrapping phase.
Motion controls are built-in the machine control panel.
6 - 242
06.01.00 EN
ELECTRICAL DEVICES
1
2
3
4
5
6
7
8
Sensor: detects the carriage in the REAR position.

Sensor: detects the carriage in the FORWARD position.
Sensor: detects the welder in the FORWARD position.
Sensor: detects the welder unit in the HIGH position.
Sensor: detects the welder unit in the LOW position.
Sensor: detects the contrast in the LOW position.
Sensor: detects the clamp in the CLOSED position.
Photocell: sets the carriage stop point according to pallet dimensions.
06.01.00 EN
6 - 243
WORK CYCLE
Phase A: at the end of the wrapping cycle, the contrast 1ORZHUVDQGLVZUDSSHGWZLFHE\WKHOPDIWHUZKLFK
the rotary ring stops.
Phase B: clamp 2 lowers, the welding unit 3ORZHUVDQGWKHOPLVFODPSHG
Phase C: WKHZHOGHUPRYHVZLWKWKHFDUULDJHWKDWVXSSRUWVWKHHQWLUHXQLWOPLVFXWDQGZHOGHG
Phase D: the welder unit and clamp lift.
Phase E: the entire carriage completely lifts, vertically extracting the contrast.
Phase F: the contrast rotates upwards returning horizontal.
Phase G: the carriage moves away from the pallet; the unit is thus ready for the next cycle.
6 - 244
06.01.00 EN
MAINTENANCE
CARRIAGE LUBRICATION
Grease carriage runners using lubricators 1 and the grease type indicated in the lubricant table (see Base
Machine unit).
CUTTING WIRE CLEANING
Lower the unit.
Clean the cutting wire 2 with a dry cloth or use thinner if necessary.
CUTTING WIRE REPLACEMENT

Lower the unit.

Remove the screws 3 and 4 and disconnect the wires.
Remove the spring 5 from the eyelet 6.
Wrap the new wire 2 on the screw 4, insert the spring and lower wire end on the screw and tighten the nut.
Reassemble the spring on the eyelet 6.
Pass the wire on the two rollers 7 and up to roller 8 and screw 3.
Tension the wire and wrap it around the screw, insert the upper end of the wire and tighten the nut.
Important!
0DNHVXUHWKHVSULQJLVVXIFLHQWO\OHQJWKHQHGVRWKDWZKHQWKHZLUHOHQJWKHQVGXHWRKHDWLQJLWUHPDLQV
taut. Any loosening could cause unit malfunctions and a short circuit due to contact with the frame.
1
5
4
06.01.00 EN
6 - 245
RESISTANCE/TEFLON/SILICON RUBBER REPLACEMENT

Lower the welding unit.
Remove the screw 1 and disconnect the wires.
Unscrew nut 2.
6 - 246
06.01.00 EN

Remove the unit 3 and place it on the work bench.

Remove the thread unit 4 removing the screws 5.
Remove the side fastening pad 6LIWKH7HRQQHHGVUHSODFLQJUHPRYHWKHVHFRQGSDG
5HPRYHWKH7HRQOLQLQJ7.
Remove the terminals 8 and the resistance 9.
Remove the silicon rubber 10.
After replacing worn parts, assemble all parts in reverse order.
10
7
06.01.00 EN
6 - 247
ROUTINE MAINTENANCE
Frequency
Component
Intervention
50 hours
Cutting wire
Cleaning
500 hours
Runners
/XEULFDWLRQ
Cutting wire
Check integrity or replace
7HRQIDEULF
Resistance
Periodically
Danger Warning!
Burn hazard due to contact with cutting wire or welding element.
6 - 248
06.01.00 EN
06.01.00 EN
6 - 249
16
Load lifting unit
16 - Load lifting unit
16.01.01 EN
16 - 251
DESCRIPTION AND OPERATION

The load lifting unit can lift loads to be wrapped to cover the bottom part of the load itself.
It is combined with an automatic wrapping machine that fully integrates with its operating cycle.
It can be both installed on chain or roller conveyors; the upward stroke is variable according to the operating
UHTXLUHPHQWV
,W LV HTXLSSHG ZLWK LQGHSHQGHQW HOHFWULF DQG SQHXPDWLF SODQW WKH RSHUDWLQJ FRPPDQGV DUH LQWHJUDWHG LQ WKH
machines control panel.
7KHOLIWLQJXQLWLVHTXLSSHGZLWKFURVVEDUV1 for connection to roller conveyors or frame type 2 for connection to
the chain conveyors.
ELECTRIC CONTROL DEVICES

3 Sensor: detects lifting unit in the HIGH position.
4 Sensor: detects lifting unit in the LOW position.
16 - 252
16.01.01 EN
OPERATING CYCLE
Operation is as follows:
A) The load stops at the centre of the conveyor, in correspondence to the centre of the lifting unit.
B) The lifting unit lifts the load to allow wrapping of the bottom part of it.
C) At cycle end, the lifting unit lowers returning to the rest position.
C
B
TECHNICAL DATA
Supply tension
See attached layout
Working pressure
61 bar
Air consumption
50 Nl/min
Work stroke
150300 mm
Air spring
141/2 with two or three stages
Spring capacity
for minimum height
for maximum height
50005200 daN
15002000 daN
Total weight
500 kg
Dimensions
See attached layout
Not2
2WKHUFRQJXUDWLRQXSRQUHTXHVW.
16.01.01 EN
16 - 253
INSTALLATION

Lift and position the machine according to the attached layout.

Fix the machine to the ground by using the wedges 1 supplied.
If necessary, insert metal plates 2 for levelling.
Perform all electric connections and settings according to the attached layout.
ADJUSTMENTS
WORKING PRESSURE ADJUSTMENT
Working pressure is to be set according to the weight of the load to be lifted.
$GMXVWUHJXODWRU1 and read the pressure value on manometer 2.
At testing, working pressure is set at 4 Bar.
Not2
Do not set high pressure if not necessary.
16 - 254
16.01.01 EN
LIFTING SPEED ADJUSTMENT

/LIWLQJVSHHGLVDGMXVWDEOHDOVRDFFRUGLQJWRWKHW\SHRIORDG
$GMXVWUHJXODWRU3 and check the results obtained by performing a lift test of the load.
WORK STROKE ADJUSTMENT

7KHOLIWZRUNVWURNHLVDGMXVWHGE\IRXUVWRSSLQJWKUHDGHGSLQV4LIQHFHVVDU\DGMXVWUHJXODWLQJQXWV
7KHGRZQZDUGZRUNVWURNHLVDGMXVWHGE\IRXUVWRSSLQJSDGV5 that act on the wheels located externally from the
OHYHUVLIQHFHVVDU\DGMXVWUHJXODWLQJQXWV
16.01.01 EN
16 - 255
SENSORS ADJUSTMENT
6HQVRUVDGMXVWPHQWLVSHUIRUPHGE\FKDQJLQJWKHLUSRVLWLRQRQWKH[LQJEDU
MAINTENANCE
ORDINARY MAINTENANCE INTERVENTIONS
Frequency
Component
Intervention
50 hours
Sliding guides
Cleaning and greasing
200 hours
Air spring
&KHFN[LQJVFUHZV
(tightening couple not greater than 20 Nm)
16 - 256
16.01.01 EN
16.01.01 EN
16 - 257
19
Impianto pneumatico
19 - Impianto pneumatico
19.01.02 EN
19 - 259
SCHEMA PNEUMATICO
PNEUMATIC DIAGRAM / DRUCKLUFTANLAGE / CIRCUIT PNEUMATIQUE / INSTALACIN NEUMATICA
LEGENDA
Legend / Legende / Leyenda / Lgende
SIMBOLO
SIGNIFICATO
VALVOLA DI INTERCETTAZIONE LUCCHETTABILE
Cut-off lockable valve - Sperrventil (verschliebarer Hahn) - Vlvula de interceptacin
(grifo con candado) - Valve dinterception (Robinet verrouillable).
FILTRO
Filter - Filter - Filtro - Filtre
REGOLATORE DI PRESSIONE E MANOMETRO
Pressure regulator and pressure gauge - Druckregler und manometer - Regulador
de presin y manmetro - Rgulateur de pression et manomtre.
PRESSOSTATO
Pressure gauge - Druckwchter - Presostato - Pressostat
VALVOLA DI SCARICO RAPIDO E AWIAMENTO PROGRESSIVO
Quick exaust valve and progressive starter - Schnellablassventil und stufenstarter 9iOYXODGHGHVFDUJDUiSLGD\DUDQTXHSURJUHVLYR6RXSDSHGpFKDSSHPHQWUDSLGH
et dmarreur progressif
REGOLATORE DI FLUSSO UNIDIREZIONALE
2QHZD\RZUHJXODWRU8QLGLUHNWLRQDOXVV5HJOHU5HJXODGRUGHXMRXQLGLUHFFLRQDO
- Rgulateur dcoulement unidirectionnel.
VALVOLA DI BLOCCO
/RFNYDOYH%ORFNYHQWLO9iOYXODGHEORTXHR9DQQHGHEORFDJH
CILINDRO PNEUMATICO
Pneumatic cylinder
SQHXPDWLTXH
Pneumatikzylinder - Cilindro neumtico
Cylindre
VALVOLA SELETTRICE
Selector valve - Selector ventil - Valvula selectora - Vanne de selection
REGOLATORE DI FLUSSO
)ORZUHJXODWRU)OXVVUHJOHU5HJXODGRUGHXMR5pJXODWHXUGpFRXOHPHQW
SILENZIATORE
Silencer - Schalldmpfer - Silenciador - Silencieux
VALVOLA DI SCARICO RAPIDO
Quick exaust valve - Schnellablassventil - Vlvula de descarga rpida - Soupape
dchappement rapide
19 - 260
19.01.02 EN
GRUPPO TRATTAMENTO ARIA

Air conditioning unit / Luftaufbereitungsgruppe / Grupo tratamiento aire / Traitement daire
19.01.02 EN
19 - 261
GRUPPO PINZA TAGLIO SALDATORE

Cutting-sealing unit / Trenn-Schweisstation / Grupo corte soldador / Groupe coupe soudeur
19 - 262
19.01.02 EN
19.01.02 EN
19 - 263
GRUPPO METTIFOGLIO
Top sheet dispenser unit / Gruppe oberer bogenanleger / Grupo cubre-pallet superior / Groupe poise de
coiffe superieure
19 - 264
19.01.02 EN
19.01.02 EN
19 - 265
19 - 266
19.01.02 EN
GRUPPO PRESSORE
Pressing unit / Niederhalter / Prensor / Presseur
PRESSORE VERTICALE
Vertical pressing unit / Vertical niederhalter / Prensor verticale / Presseur vertical
PRESSORE A PARALLELOGRAMMA
Parallelogram pressing unit / Parallelogramm niederhalter / Prensor paralelograma / Presseur parallelogramme
19.01.02 EN
19 - 267
CAMBIO BOBINA AUTOMATICO

Automatic reel changing / Automatische spulewechsel / Automatico remplazo de la bobina / Changement
de bobine automatique
19 - 268
19.01.02 EN
19.01.02 EN
19 - 269
19 - 270
19.01.02 EN
19.01.02 EN
19 - 271
19 - 272
19.01.02 EN
20
Guard
20 - Guard
GENERAL INFORMATION
7KHVDIHW\JXDUGSDQHOVDUHVKLSSHGRQDVSHFLFPHWDOOLFSDOOHWWRIDFLOLWDWHKDQGOLQJ$OODVVHPEO\DFFHVVRULHV
are packaged complete with assembly instructions. The layout illustrates the fully assembled external safety
guards. If necessary, trace the coordinates to identify the exact installation position and observe the reference
TXRWDVLQGLFDWHGLQWKHOD\RXW
To facilitate component preassembly and assembly, the supplied instructions are divided by assembly type.
The following symbols indicate the relevant assembly sheet.
01 STRAIGHT PANELS
02 SLANTED PANELS
01
06
03 WIND-BRACING
04 ANGLED PANELS WITH REINFORCEMENT
07
02
05 ANGLED PANELS
06 SUPPORT FOOT
03
08
07 STRAIGHT DOOR
08 SLANTED DOOR
04
09
09 DOUBLE DOOR
10 SLIDING DOOR
05
10
20.01.00 EN
20 - 275
20 - Guard
ASSEMBLY INSTRUCTIONS
A single operator can also perform assembly by following a series of instructions listed below.
-
Preassemble one or more panels near the machine.

Join the various preassemble parts and complete external safety guard assembly.
NOTE: the assembly sequence is at the installation operators discretion.

-
8VHWKHVSHFLFVFUHZV$WROHYHOWKHH[WHUQDOVDIHW\JXDUGV
)DVWHQWKHH[WHUQDOVDIHW\JXDUGVWRWKHRRULQWKHH[DFWLQVWDOODWLRQSRVLWLRQLQGLFDWHGLQWKHOD\RXW
Important
Periodically check correct door and relevant electrical device operations for constant maintenance of
safety requisites.
20 - 276
20.01.00 EN
20 - Guard
ASSEMBLY SEQUENCE
20.01.00 EN
20 - 277
20 - Guard
20 - 278
20.01.00 EN
20 - Guard
20.01.00 EN
20 - 279
20 - Guard
20 - 280
20.01.00 EN
20 - Guard
20.01.00 EN
20 - 281
20 - Guard
A
A
20 - 282
20.01.00 EN
20 - Guard
C
A
B
B
20.01.00 EN
20 - 283
20 - Guard
20 - 284
20.01.00 EN
20 - Guard
20.01.00 EN
20 - 285
20 - Guard
20 - 286
20.01.00 EN
20 - Guard
GUARD LAYOUT
20.02.00 EN
287
20 - Guard
288
20.02.00 EN
21
Machine use
21 - Machine use
21 - 290
21.01.03 EN
21 - Machine use
ELECTRICAL CABINET CONTROLS

A
Multi-function keyboard
Displays and sets parameters of machine cycle; also allows automatic cycle start of machine.
For what concerns the information relating to the programming and use of the keyboard, consult the proper
booklet.
Main switch (lockable)

Starts up and shuts off main power supply of the machine.
O (OFF)
power off.
I (ON)
power on.
Battery charger selector

7XUQVRQDQGVKXWVRIISRZHUVXSSO\WRWKHEDWWHU\UHFKDUJHV\VWHPRIWKHOPVSRROFDUULDJH
0 battery charger not powered.
1 with main switch B on POS. 0 (OFF) the battery charger circuit is not powered;
with main switch B on POS.1 (ON) the battery charger circuit is powered in controlled mode by the
PLC when the pre-stretch carriage is in phase and the ring is in the resting condition (OFF).
2 with main switch B on POS.0 (OFF), the battery charge circuit is not powered;
with main switch B on POS.1 (ON) the battery charge circuit is powered to charge the battery.
Note:
With main switch B on POS. 1, turn switch C to POS. 2 to charge the batteries when the machine is
not powered.
21.01.03 EN
21 - 291
21 - Machine use
Three-colour indicator light

Indicates battery charge conditions:
- green: 100% battery charge
- yellow: 80% battery charge
- red: batteries charging.
Emergency stop
Mushroom head button that immediately stops all machine working functions.
- Press to stop machine.
- Rotate counter clockwise to reset.
Blinker (if present)

Indicates machine operating conditions.
Green light
automatic drive.
Red light
machine on emergency.
2UDQJH[HGOLJKW

OPEUHDNRUHQG
2UDQJHDVKLQJOLJKWLQGLFDWHV OPUHPDLQLQJRSWLRQDO
Acoustic signal
Signals the start of the automatic cycle.
F-G
21 - 292
21.01.03 EN
21 - Machine use
Following are the descriptions of all commands that can be found on the electric panel.
Power on white indicator light
On: signals that the main switch is on and that the machine is powered. For further information consult the wiring
diagram.
Emergency red indicator light
On: signals that the machine was stopped in emergency conditions or normally.
Aut/man Selector
Rotate to select the automatic or manual cycle.
Machine motors on button
Press to reset power to the machine motors after an emergency stop.
Reset button
Press the button when the machine is being turned on and after an emergency stop.
Automatic drive button
Press to start the automatic cycle; the button light turns on.
If work cycle does not start, look up the cycle start procedures.
Stop cycle button
Press to immediately stop the automatic cycle.
All machine parts stop at the end of their phases.
To restart cycle, press the Automatic operation button.
2SHUDWLRQH[HFXWLRQEXWWRQLIDYDLODEOH
Press to perform the procedure selected from the multi-function keyboard.
By-pass & reset safety guards button (if present)
Resets the safety guards in case of intervention on the guards themselves.
0 Barriers on.
1 Barriers reset.
Open door request selector
Releases the access doors.
0 Doors blocked.
1 Doors released.
If the machine is in operation, putting selector in position 1 the spool unwinding carriage completes the cycle
stopping in phase, the safety condition is activated (electric and pneumatic power supply shutdown), after which
the doors are released allowing the operator to enter.
If pre-stretch carriage is steady in phase, putting selector in position 1 activates the safety condition (electric and
pneumatic power supply shutdown), after which the doors are released allowing the operator to enter.
21.01.03 EN
21 - 293
21 - Machine use
COMMANDS ON MACHINE
B
C
D
Pre-stretch motor power shutdown switch

Turns on and shuts off power supply to the pre-stretch motor.
O (OFF)
pre-stretch electric power off.
I (ON)
pre-stretch electric power on.
Film unwinding unit power supply sectioning connectors.
Power on (green) indicator light.
On: signals that the Reel carriage unit is powered.
L
H
21 - 294
21.01.03 EN
21 - Machine use
BATTERIES
Important!
If the machine works on three daily shifts (24 hours), provide for a complete battery recharge once a
week. Charge is complete when warning light D is green.
21.01.03 EN
21 - 295
21 - Machine use
AUTOMATIC CYCLE START

Danger Warning!
Before starting the machine make sure that all moving units (carriage, clamp, etc.) stop at limit stop.
If machine operates in very cold environments, perform the Preheating procedure described in the keyboard
booklet.
Rotate main switch on I (ON): the Tension present warning light turns on.
Turn the Aut/Man selector on the Manual position.
Press the Machine operation motors button.
Press the Reset button and the machine moves all working units to cycle start.
,QVHUWWKHOPVSRRORQWKHOPVSRROFDUULDJHFRQVXOWWKHVSRROFDUULDJHERRNOHW
%ORFNOPLQWKHFODPS
Turn selector Aut/Man in the Automatic position.
Press the Machine automatic operation button until the cycle start acoustic signal stops.
The automatic cycle is started (see Operation Cycle in chapter 2).
If the automatic cycle does not start, repeat the cycle start steps.
MANUAL START
Important!
Machines that operate in very cold environments, perform the Preheating procedure described in the
keyboard booklet.
Select Manual cycle.
Select desired function on keyboard.
Press the Operation execution button. Manual cycle begins and all groups stop in the proper endstrokes.
21 - 296
21.01.03 EN
21 - Machine use
NORMAL STOP
Danger - Warning!
For normal machine stopping, do not use the emergency button.
Press the Cycle stop button and wait for phase stopping of the pre-stretch carriage.
The Emergency light turns on at completion.
To restart the automatic cycle:
Press the Machine motors operation button.
Press the Reset button.
Press the Automatic machine operation button.
MACHINE RESTART AFTER EMERGENCY STOP CAUSED BY PRESSING

THE EMERGENCY BUTTON
Press the mushroom button.
After resolving any problem or fault, restart the automatic cycle.
Reset the emergency button.
Press the Machine motors operation button.
Press the Automatic machine operation button.
MACHINE RESTART AFTER INTANGIBLE BARRIERS TRIGGER

After checking the causes and ensuring that no one is inside the machine:
Reset barriers using the operator panel (selector).
Press the Motor drive button
Press the Automatic motor drive button.
SUDDEN STOP AND RESTART

After a sudden machine stop, press the emergency button and inform the responsible person of the plant who will
have to perform the following checking.
If a fault signal is sent to the inverter, proceed as follows:
Check inverter display that is in fault.
Consult the inverters manual and eliminate fault.
Bring back the machine to operating conditions resetting to restart with automatic cycle.
If a thermal alarm emergency is indicated, proceed as follows:
&KHFNWKHRSHUDWLQJVWDWXVRIWKHHTXLSPHQWDQGRUDX[LOLDU\GHYLFHV
Check network tension on all phases.
Check functionality of all circuits inside the electric cabinet.
21.01.03 EN
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21 - Machine use
OPERATOR MANUAL
Important!
Accident frequency derived from machine use depends upon many factors that cannot always be
foreseen and controlled. Some accidents can depend upon unforeseeable environmental factors; others
depend especially upon the users behaviour.
,QDGGLWLRQWREHLQJDXWKRULVHGDQGDSSURSULDWHO\LQIRUPHGRQUVWXVHSHUVRQQHOPXVWVLPXODWHVRPH
manoeuvres to identify the main commands and functions.
Only perform the manufacturers foreseen uses and do not tamper with any device to achieve performances
other than those foreseen.
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Users, in addition to striving to satisfy these requirements, must apply all the safety regulations and
carefully read the descriptions of the controls and start up.
21 - 298
21.01.03 EN
21 - Machine use
CONTROL DESCRIPTIONS
7KHIROORZLQJJXUHLOOXVWUDWHVWKHSRVLWLRQVRIWKHFRQWUROVRQWKHPDFKLQH
2
11
3
5
6
8
9
10
12
1
13
1
2
3
4
5
6
7
Main switch
Power on light
Emergency light
Motor drive button
Reset button
Automatic cycle button
Automatic/manual selector
21.01.03 EN
8
9
10
11
12
13
Stop cycle button

2SHQGRRUUHTXHVWVHOHFWRU
Barrier reset and bypass selector
Touch-screen panel
Battery charge status indicator
Emergency stop button
21 - 299
21 - Machine use
IG - MAIN SWITCH
turns the main power supply on and off.
Lockable circuit breaker type switch that closes the electrical cabinet.
(O)= Off power off
( I )= On power on
POWER ON LIGHT
White indicator light.
Signals that the main switch is on and that the machine is powered.
EMERGENCY LIGHT
Red indicator light.
The light indicates that the machine is in emergency or similar to emergency conditions.
MOTOR DRIVE BUTTON

Button that electrically enables the machine.
It must be pressed after every emergency stop that cuts off the emergency circuit.
RESET BUTTON
Yellow button.
Resets cycle start conditions after every emergency intervention.
AUTOMATIC CYCLE BUTTON

Green light button.
:KHQ WKLV EXWWRQ LV SUHVVHG WKH DXWRPDWLF F\FOH VWDUWV LI LQLWLDO F\FOH FRQGLWLRQV DUH YHULHG DQG LI WKH
machine is not in emergency conditions. Hold the button down for several seconds until the cycle start
siren stops.
The green light will turn on to indicate correct automatic operations.
AUTOMATIC/MANUAL SELECTOR
Two-way selector for machine operating mode.
Key turned to the right - the machine is in MANUAL mode.
Key turned to the LEFT - the machine is in AUTOMATIC mode.
STOP CYCLE BUTTON

To stop the automatic cycle, the ring decelerates until it is in phase. Press the AUTOMATIC START CYCLE
BUTTON to restart from this condition.
OPEN DOOR REQUEST SELECTOR

To stop the machine and permit operator access to the work area.
10 BARRIER RESET AND BYPASS SELECTOR

Selector that excludes the safety barriers. The automatic cycle is not enabled with the guards off. Some
machine movements can be run in manual mode.
11 TOUCH-SCREEN PANEL
To display and set production parameters.
12 BATTERY CHARGE STATUS INDICATOR
13 EMERGENCY STOP BUTTON
Mechanically retained emergency button.
When pressed during machine operations all operating functions are stopped. To return the machine to
initial conditions, press the reset button. Avoid using the emergency buttons for normal machine stops.
21 - 300
21.01.03 EN
21 - Machine use
OPERATOR PANEL DESCRIPTION

The operating terminal is a screen that lets the user set work parameters and check all machine operating
FRQGLWLRQV,WLVHTXLSSHGZLWKDGLVSOD\DOORZLQJWRDFWLYDWHDOOWKHYDULRXVIXQFWLRQVVLPSO\E\WRXFKLQJZKDWLV
written on it. Each page contains scroll keys to move from one page to the next. If necessary, it contains also the
keys which allow to set the parameters, by executing some commands etc.
HOW TO USE THE DISPLAY

$IWHUWXUQLQJRQWKHWHUPLQDOVHOHFWWKHUHTXLUHGSDJHWRUXQRQHRIWKHIROORZLQJ

Edit text and values

6HTXHQWLDOYDOXHDGMXVWPHQW
Operating alternatives
Enable function
Important!
0RGLFDWLRQV DUH LPPHGLDWHO\ HIIHFWLYH DQG DXWRPDWLFDOO\ VDYHG :RUN SDUDPHWHUV DUH VDYHG LQ WKH
selected program.
(GLWLQJWH[WDQGYDOXHV
For this operation proceed as follows.
1
2
3
4
Display the page with the demanded functionTouch the key corresponding to the demanded function. The editing mode is enabled displaying a number
pad.
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Touch the key Esc to disable the editing mode.
Sequential value adjustments

1
2
Display the page with the demanded functionPress the key (+) to increase the value and the key () to decrease it.
21.01.03 EN
21 - 301
21 - Machine use
DISPLAY CONTRAST RECORDING

1
2
3
4
5
6
7
6LPXOWDQHRXVO\WRXFKWZRRSSRVLWHFRUQHUVRIDQ\RSHUDWRUSDQHOSDJH7KHUVWLQIRUPDWLRQSDJHLVGLVSOD\HG
on the system.
Touch the PROG key. The MENU page is displayed.
Touch one of the ARROW keys until you select the function SET CONTRAST.
Touch the A key. The CONTRAST page is displayed.
Press the key ARROW UP to increase the contrast and the key ARROW DOWN to decrease it.
Touch the key ENTER to memorise the operation.
Press the ESC key to exit the SETUP function.
21 - 302
21.01.03 EN
21 - Machine use
EDITING PASSWORD PROTECTED SETTINGS

Some functions are only accessible by entering the password as to avoid any accidental change or any change
E\QRWTXDOLHGSHUVRQQHO
WARNING
7KHIDFWRU\UHVSRQVLEOHPXVWDVVLJQSDVVZRUGWRTXDOLHGSHUVRQQHORQO\DQGHDFKSDVVZRUGLVWREH
FRQVLGHUHGVHFUHWDQGFRQGHQWLDO
For this operation, proceed as follows:
1
2
Use the number pad to enter the password.

7RXFKWKHNH\(17(5WRFRQUPWKHRSHUDWLRQ
Important!
If the entered password is correct, all protected functions are enabled. These functions are automatically
locked after three minutes of disuse.
WARNING
There are three password levels:
Level 3
(C) Enabled to modify only the times settings. Factory set for this password is 0000.
Level 2
%,QDGGLWLRQWRWKHSDUDPHWHUVLQWKHSUHYLRXVOHYHOSURJUDPGDWDVHWWLQJVFDQEHPRGLHG
in this level. Factory set is to 0001.
Level 1
(A) enables all operations and is the only level that can edit other level passwords. Factory
set to 0002.
Proceed as follows to change a password:

1
2
3
Visualise the Main page and press the key (A) on the display. The Pallet counter page is displayed.
7RXFKWKHNH\%3DVVZRUG/HYHOLVUHTXHVWHG$IWHUWKDWWKHSDVVZRUGPRGLFDWLRQSDJHLVGLVSOD\HG
&KRRVHWKHSDVVZRUGOHYHO\RXZLVKWRPRGLI\LQVHUWWKHQHZSDVVZRUGDQGFRQUP
21.01.03 EN
21 - 303
21 - Machine use
USING THE TERMINAL

:KHQWKHPDFKLQHLVWXUQHGRQDSUHVHQWDWLRQSDJHZLWKWKH52%23$&PDQXIDFWXUHULGHQWLFDWLRQ
Press any part of the screen to open the Main page.
Various information and keys that open different panel pages are found on the Main page.
A
By pressing this key it is possible to change the program the machine will use with the following pallet. The
selected programme number will be displayed inside the key.
By pressing this key you will exclude the wrapping regardless of the setting in the programme in use.
This icon indicates the operations status of the machine and is found on all the pages of the operator panel.
A description of the single icons is provided in the appendix.
The bar in the page centre represents the machine status and it is called Active Programme Bar; inside
the following information is summarized:
5 CURRENT Program number
6 Wrapping type and inclusion in the various optional devices (if present) cycle, such as TOP, PRESSURE
PLATEN, LIFTER
7 Data of the current programme:
Line number
5LQJTXRWD
Reference
Overlapping dimensions
Wrap number
By touching one of these keys the page we are going to describe below will appear.
Enables/Disables the signal at pallet infeed.
B
C
D
21 - 304
21.01.03 EN
21 - Machine use
PROGRAM PARAMETER SETTINGS

Program Parameters are wrapping settings effective during the entire wrapping cycle and can vary from program
to program (in the event of Multiprogramming).
WARNING
Program Parameters can only be edited by Level 2 or 1 password users.
Program parameters can be used to set different wrapping types, also including optional devices if present such
as Top, Pressure Platen and Lifter.
Furthermore, parameters set in one program can be copied to another as described below.
Editing program parameters
1
2
3
4
5
6
From the Main page press the Current Program Bar (A) and enter the password. After this operation, press
the Bar again to open the Program Parameters window.
From this window select the program to be edited by pressing key (B).
Press key (C) to open the parameter window for the program selected in point (2).
Select the parameter to be edited (wrapping, pressure platen, top etc.)
Press key (F) to open program lines page
Save settings by pressing key (D); at this point the operator can either edit another program or exit the
Program settings page by pressing key (E).
Copying parameters from a Program

1
2
3
4
5
From the Main page press the Current Program Bar (A) and enter the password. After this operation, press
the Bar again to open the Program Parameters window.
From this window select the program from which parameters are to be copied by pressing key (B).
Press key (C) to open the parameter window for the program selected in point (2).
Proceed as in point (2) to select the program to which parameters are to be copied.
Save the parameters to be copied by pressing key (D).
21.01.03 EN
21 - 305
21 - Machine use
WRITING A PROGRAM
By entering (Modify the program parameters) the page concerning the program lines, it is possible to specify the
type of wrapping that you wish to select on the pallet.
1
Select the line you wish to modify with pushbuttons (E). The line selected is indicated by (A)
VHOHFWLIWKHUHIHUHQFHRIWKHULQJTXRWDPXVW
be from a high position or form a low position.
set the use of air blows from the bottom.
set the use of air blows from the top.
set the use of the lifter.
set the use of the pressure platen.
set the use of the roping unit device.
VHWWKHQDOTXRWDIRUWKHULQJ%
VHWWKHZUDSQXPEHURQWKHQDOTXRWD&
10 select what operations to carry out at the end of the set wrapping (D)
11 6HWWKHUHTXLUHGRYHUODSYDOXH)
21 - 306
21.01.03 EN
21 - Machine use
USING THE PRODUCT COUNTER

3UHVVNH\$RQWKH0DLQSDJHWRGLVSOD\DVSHFLFSDJHWKDWFRQWDLQVYDULRXVLQIRUPDWLRQRQPDFKLQHSURGXFWLRQ
such as Total work time, Rotation speed, Total number of wraps, Number of wrapped pallets (partial and can be
reset at any time by pressing key (B) ), the TOTAL number of processed pallets (which includes both wrapped
and only transited pallets) and the Number of Transited Pallets.
WARNING
The information on this page is read-only and can only be used for information purposes. Only the
Wrapped Pallet Counter can be reset.
CHANGE LANGUAGE
The display language can be changed from the Product Counter page by pressing key (C).
21.01.03 EN
21 - 307
21 - Machine use
GENERAL PARAMETER SETTINGS

From the Main page press key (A) to open the General Parameters page.
General parameters include all functional machine timers such as Sealing time, Max. Ring Up/Down speed,
Sealer cooling time etc.
The Sealing device can be INCLUDED or EXCLUDED from this page.
21 - 308
21.01.03 EN
21 - Machine use
USING THE MANUAL CONTROLS

Manual controls are to be used to individually operate the machine moving parts, in case of service or control
before the automatic cycle start-up.
Important!
Manual controls can only be accessed if the AUTOMATIC/MANUAL machine key selector is in the Manual
(Right) position and not Emergency condition is active.
Proceed as follows for this operation:
1
From the Main page press key (A) to open the Movements in manual mode page.
2 - Press key (B) or (C) to scroll the various manual pages (icon (D) indicates the current manual control
page).
6HOHFWWKHUHTXLUHGPDQXDOLFRQDQGSUHVVWKHFRUUHVSRQGLQJNH\
21.01.03 EN
21 - 309
21 - Machine use
AUTOMATIC CYCLE START

Proceed as follows to start the Automatic cycle:
1
Rotate the main switch to I (ON) to power.
3UHVVWKH0RWRUGULYHEXWWRQLQWKHHYHQWRIUVWVWDUWXSNHHSWKH%DUULHU%\3DVVNH\VHOHFWRUWXUQHGWR
enable the emergency circuit).
Press the RESET button to restore the machine to the initial cycle position (and reset any emergencies in
WKHHYHQWRIUVWVWDUWXS
6HOHFWWKHUHTXLUHGSURJUDP
Rotate the key selector to the AUTOMATIC position.
Press the AUTOMATIC CYCLE push-button.
Important!
'XULQJWKHUVWZUDSSLQJF\FOHVPDNHVXUHSURGXFWVDUHFRUUHFWO\SDFNDJHGDQGLIQHFHVVDU\DGMXVWWKH
sealing, skirting, etc. parameters.
WARNING
$Q\SURJUDPFDQEHPRGLHGDQGWKHSURJUDPIRUWKHQH[WSDOOHWFDQEHVHWDWDQ\WLPH7RXVHDGLIIHUHQW
program on the pallet being processed, select it as indicated in the relevant paragraph and RESET in
Manual Mode (turn the key selector to MANUAL and press RESET until the Automatic Cycle button blinks).
21 - 310
21.01.03 EN
21 - Machine use
OPERATOR MACHINE STOP

For temporary stopping of the operation, proceed as follows.
Important!
Do not use the emergency button to stop the machine unless strictly necessary to prevent damages to
things and/or people.
The machine can be stopped when wrapping a pallet by pressing the STOP CYCLE button which decelerates the
machine after two wraps and then stops in phase. The cycle can be continued from the stop position by pressing
the AUTOMATIC CYCLE button or a new wrapping cycle can be started by pressing the RESET button in Manual
mode as indicated in the previous point.
To stop the machine when a pallet has not yet been loaded on the machine or is moving towards the centre of
the machine or towards outfeed (customers conveyor, etc.), turn the key selector to MANUAL or run an Open
'RRU5HTXHVW
7ZRGLIIHUHQWVLWXDWLRQVFDQEHGHULYHGIURPDQ2SHQ'RRU5HTXHVW
1
'XULQJ SDOOHW ZUDSSLQJ DQ 2SHQ 'RRU 5HTXHVW FDXVHV D FRQWUROOHG PDFKLQH VWRS SHUPLWWLQJ WKH SDOOHW LQ
infeed or outfeed to complete transit.
:KHQDSDOOHWLVPRYLQJLQ,1)(('RULQ287)(('PRYHPHQWFRPSOHWHVDIWHUDQ2SHQ'RRU5HTXHVW
(INFEED pallet reaching the machine centre or OUTFEED pallet reaching the customer position) and the
emergency circuit is simultaneously cut off and the electromagnetic lock released.
WARNING
If an Open Door Request is selected during pallet movement and the key selector is then rotated to the
Manual position, movement is not completed as described in the previous point but it is immediately
stopped.
21.01.03 EN
21 - 311
21 - Machine use
EMERGENCY STOP AND RESTART

Press the machine emergency button in conditions of imminent risk. Machine operation stops immediately.
After having normalized the operating conditions, unblock button to allow machine operation again.
To restart the cycle, repeat all the Automatic Cycle Start operations.
Important!
When the mushroom head Emergency button is
pressed the Emergency circuit chain is cut-off; the
same situation occurs after an Open Door Request or
after the emergency barriers are triggered.
In all these circumstances, operating conditions must
be restored as indicated in the Automatic Cycle Start
section.
ALARM DISPLAY
In the event of faults during operations, the machine automatically stops and the alarm icon (A) appears on the
screen. Press this icon to display Alarm messages. Press the ESC key to exit the Alarm display page.
Attenzione
,IDQHZDODUPLVWULJJHUHGDIWHUH[LWLQJWKH$/$50GLVSOD\SDJHZLWKRXWKDYLQJUHVHWWKHPDFKLQHWKH
display emits an intermittent siren to attract attention to the new alarm. To turn off the siren, press key
which indicates the presence of the new Alarm.
(A) again and press
21 - 312
21.01.03 EN
21 - Machine use
APPENDIX
Machine status icons
Signals the presence of an alarm that caused an anomalous machine stop
Machine in Automatic cycle
Machine in manual mode
The machine is ready to move into Automatic mode
General Reset
21.01.03 EN
21 - 313
21 - Machine use
Icone gruppi manuali
Futura:
Manual machine key
Manual controls page
TOP manual controls page
Manual REEL CHANGE page
Genesis:
Manual GENESIS controls page
TOP manual controls page
21 - 314
21.01.03 EN
21 - Machine use
Manual machine controls icons
Ring rotation
Clamp forward/rear
Pressure platen up/down
Lifter: up/down
Futura:
Carriage up/down
Contrast up/down
Clamp open/close
Sealer forward/rear
Sealer up/down
Genesis:
Carriage up/down
Contrast up/down
Clamp up/down
Sealer up/down
21.01.03 EN
21 - 315
21 - Machine use
Top manual controls icons (optional)
Top cut
Top carriage forward/rear
Film pull clamp open/close
Futura:
Carriages hooked up/released
Contrast carriage clamp open/close
Clamp lock open/close
Genesis:
Clamp lock open/close
21 - 316
21.01.03 EN
21 - Machine use
ARC Controls Icons (optional )
Ring rotation forward / backward
Unit for extraction heart of spool up / down
Clamp additional open / close
Clamp additional up / down
ARC selected A/B
ARC carriage forward / backward
ARC clamp forward / backward
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21.01.03 EN
21 - 317
21 - Machine use
Program parameters Icons
Wrapping included
Wrapping excluded
Top excluded
Top inserted before wrapping starts
Top inserted after wrapping starts
Top inserted for waterproof cycle (After ring height 2)
Top sheet length insertion
Quota insertion for top sheet centering
Quota insertion for middle speed selection with top inserted
Time insertion for pressure platen downstroke
Time insertion for lifter upstroke
Enter number of wraps on contrast
Enter number of wraps on closed clamp
Enter roping unit device opening delay time
21 - 318
21.01.03 EN
21 - Machine use
Program line parameters icons
5HIHUHQFHVHWWLQJIURPKLJKIRUULQJTXRWDV
5HIHUHQFHVHWWLQJIURPORZIRUULQJTXRWDV
Air blows included
Air blows from top excluded
Air blows from below included
Air blows from below excluded
Pressure platen included
Pressure platen excluded
Roping unit device on
Lifter included
Lifter excluded
Move to the following program line
Move to the following program line after carrying out the cutting
After the cutting the wrapping cycle stops
21.01.03 EN
21 - 319
21 - Machine use
Counter icons
N. wrapped pallets
N. Transited pallets, wrapped and unwrapped (Cannot be reset)
N. Transited pallets, wrapped and unwrapped (Can be reset)
Total N. of wraps
Rotation speed (RPM) )
Total machine work time
Reset button for partial counter
Miscellaneous Icons
General parameters key
Pallet Counters key
Device disabled
Device enabled
Change password
A fault occurred, press to display alarm message
New alarm displayed
ESC
21 - 320
Exit alarm display page
21.01.03 EN

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Table of contents

INTERACTIVE CD-ROM: digital document version

Type A or B Declaration of conformity

Instructions for use

Spare parts catalogue

Aetna Group S.p.A.

S.P. Marecchia, 59 - 47826 Villa Verucchio - Rimini - Italy

Introduction and safety

1 - Introduction and safety

1 - Introduction and safety

HOW TO CONSULT THE USE AND MAINTENANCE MANUAL

Mandatory ecological waste material disposal sign.

PURPOSE OF THE MANUAL

1 - Introduction and safety

GLOSSARY AND TERMINOLOGY

1 - Introduction and safety

1 - Introduction and safety

1 - Introduction and safety

1 - Introduction and safety

6 Pneumatic cut-off valve

1 - Introduction and safety

1 - Introduction and safety

SAFETY DEVICE CHECK

With the machine in emergency conditions, make sure

Wheel limit switch on

Once every 20 years Contactors

Open the door.

Make sure the channels CH1 and CH2 status

A) If limit switch with normally open contacts (NO):

1 - Introduction and safety

PARACHUTE SYSTEM DESCRIPTION

PARACHUTE SYSTEM RELEASE

To restore normal conditions, proceed as follows:

1 - Introduction and safety

PARACHUTE SYSTEM EFFICIENCY CHECK

1 - Introduction and safety

If the test is passed, proceed as follows.

Enter the machine and approach one of the machine columns.

If the test is passed, proceed as follows.

1 - Introduction and safety

ROLLER STOP DEVICE MAINTENANCE (5)

IMMEDIATE ROLLER STOP DEVICE MAINTENANCE AND CONTROL PLAN

Check the free track/guide runner and stop/guide rollers;

MANUFACTURER AND MACHINE IDENTIFICATION

AETNA GROUP SPA

AETNA GROUP SPA

Corrente di corto circuito

GENERAL MACHINE DESCRIPTION

Base machine unit

1 (occasionally only to check and replace the spool)

Installed electrical power

See enclosed lay out

Ring rotation speed

See enclosed lay out

See machine plate