Robot Infoliere Fromm FR330

FR3.1413-Manual-32.21X.XXX.03.04-EN-Version01.
doc FROMM
FROMM
SEMI – AUTOMATIC
SELF PROPELLING ROBOT Wrapping Machine
Series FR3xx/FR4xx
FR3.1413
FR3.1413-Manual OP1-32.21X.XXX.03.04.EN 01/ servisia/ ORIGINAL MANUAL © 10/14
1
It is forbidden to duplicate this manual or parts of it in any way or any form without written permission of the author © 2014
www.fromm-stretch.com
FROMM FR3.1413-Manual-32.21X.XXX.03.04-EN-Version01.doc
INDEX
Page
1 Machine make - up
2 General
3 Safety instructions
4 Safety devices
5 Warnings
6 Identification Sticker
7 Technical Data
8 Dimensions / Layout
9 Explanation of pictograms
10 Main Components
11 Handeling & Transport
12 Installation Instruction
13 Assembly Sequence
14 Control panel
15 Indications
16 Basic operating Instructions
17 Start wrapping Cycle
18 Wrapping Programs
19 Errors during operation
20 Possible errors during first installation
21 Alarms
22 Insering the film
23 Battery charger / Battery
24 Kit external electronic battery charger (optional)
25 Maintenance Instructions
26 Maintenance sheme & Lubrificants
27 Mandatory & Manufacturer / Documentation
28 Warrantee conditions
29 Service logbook
2
FR3.1413-Manual-32.21X.XXX.03.04-EN-Version01.doc FROMM
BE Opgelet!
Leest U in elk geval de gebruiksaanwijzing, vooraleer de machine wordt opgesteld, geïnstalleerd en in
gebruik genomen wordt. Daardoor zorgt U voor Uw eigen veiligheid en vermijdt U schade aan Uw
machine.
DE Achtung!
Lesen Sie unbedingt die Gebrauchsanweisung vor Aufstellung-Installation-Inbetriebnahme.
Dadurch schützen Sie sich und vermeiden Schäden an Ihrem Apparat.
DK OBS!
De bør absolut læse bruganvisningen, inden maskinen opstilles, installeres og tages i brug.
Derved beskytter De Dem selv og undgår skader på maskinen.
ES Atención!
Resulta imprescindible leer las Instrucciones de manejo antes de proceder al Emplazamiento/
Instalacion/Puesta en servicio del aparato, con objeto de protegerse a si mismo y evitar el deterioro de la
máquina debido a un manejo incorrecto.
FR Attention!
Lisez impérativement le mode d'emploi avant l'installation/la mise en service.
Vous vous protègerez ainsi et éviterez des détériorations sur votre appareil.
GB Important!
Read the operating instructions carefully before installation and before using this machine for the first
time.
You will avoid the risk of causing harm to yourself or to your machine in this way.
G R Πρ оσо χή !
Πρ ί ν τ η ν εγ κ ατ ά στα σ η, σ ύ ν δε ο η κ α ί αρχ ικ ή λ ει το υ ργ ια τ ης σ υ σκ ε υ ής δ ι αβ άσ τε
π ρο σ εκ τ ικ ά τ ίς ο δ ηγ ιε ς χ ρ ή ση ς.
‘ Ετ σ ι π ρο στ ατ ε ύετ ε το ν εα υ τό σα ς κ αι α π οφ ε ύγ ε τε π ι θ α νέ ς βλ άβ ες σ υσκ ε υ ή.
IT Attenzione!
Leggere assolutamente le istruzioni d'uso prima di procedere alla posizionatura – installazione - messa
in funzione. In questo modo ci si protegge e si evitano danni all’apparecchio.
NO NB!
De må lese bruksanvisningen før oppstillning, installasjon og start av maskinen!
Gjør det for å unngå skade på Dem selv og maskinen.
NL Let op!
Lees beslist de gebruiksaanwijzing voor het plaatsen, installeren en in gebruik nemen van uw machine.
Dat is veiliger voor Uzelf en U voorkomt onnodige schade aan Uw machine.
PL Ważne!
Przed instalacją maszyny, bądź przed przystąpieniem do pracy z maszyną po raz pierwszy, należy
dokładnie przeczytać i zapoznać się z niniejszą instrukcją obsługi.
W ten sposób uniknie się ryzyka mogącego spowodować uraz ciała bądź uszkodzenie maszyny.
PT Atençāo!
Leia as instruçōes de utilizaçāo antes da montagem - instalaçāo e - primeira utilizaçāoā
Assim evita avarias no aparelho.
SE OBS!
Läs bruksanvisningen noga före uppställning, installation och använding. Ni förebygger därmed olycks-
risker och undviker skador på maskinen.
FI Huomio!
Tutustukaa huolellisesti käyttöohjeeseen ennen laitteen asennusta jä käyttöönottoa.
Näin vältytte mahdollisilta vahingoilta käyttäes-sänne konetta.
3
MACHINE MAKE – UP
THE FR3xx FROMM series is a wheeled robot, which independently rotates around stabilized
products to wrap and stabilize them by means of stretch film.
It is controlled by a dedicated electronic control unit including a FROMM-PLC for execution of the
various processes.
Particular attention must be paid to charging the robot battery in order to ensure a lifetime as long as
possible. (refer to the chapter BASIC OPERATIONS and ASSEMBLY ESQUENCE)
Serial number
Delivery Date
Art.-Nr. Model
32.211.120 FR330 OP1/B1/H2200mm/C2
32.211.140 FR350 OP1/B1/H2200mm/C4
32.211.160 FR390 OP1/B1/H2200mm/C6
32.211.170 FR400 OP1/B1/H2200mm/C7
32.212.120 FR330 OP1/B2-24V-110Ah/H2200mm/C2
32.212.140 FR350 OP1/B2-24V-110Ah/H2200mm/C4
32.212.160 FR390 OP1/B2-24V-110Ah/H2200mm/C6
32.212.170 FR400 OP1/B2-24V-110Ah/H2200mm/C7
32.213.120 FR330 OP1/B3-24V-120Ah/H2200mm/C2
32.213.140 FR350 OP1/B3-24V-120Ah/H2200mm/C4
32.213.160 FR390 OP1/B3-24V-120Ah/H2200mm/C6
32.213.170 FR400 OP1/B3-24V-120Ah/H2200mm/C7
32.211.220 FR331 OP1/B1/H2500mm/C2

32.211.240 FR351 OP1/B1/H2500mm/C4
32.211.260 FR391 OP1/B1/H2500mm/C6
32.211.270 FR401 OP1/B1/H2500mm/C7
32.212.220 FR331 OP1/B2-24V-110Ah/H2500mm/C2
32.212.240 FR351 OP1/B2-24V-110Ah/H2500mm/C4
32.212.260 FR391 OP1/B2-24V-110Ah/H2500mm/C6
32.212.270 FR401 OP1/B2-24V-110Ah/H2500mm/C7
32.213.220 FR331 OP1/B3-24V-120Ah/H2500mm/C2
32.213.240 FR351 OP1/B3-24V-120Ah/H2500mm/C4
32.213.260 FR391 OP1/B3-24V-120Ah/H2500mm/C6
32.213.270 FR401 OP1/B3-24V-120Ah/H2500mm/C7
4
MACHINE MAKE – UP
32.211.320 FR332 OP1/B1/H2800mm/C2

32.211.340 FR352 OP1/B1/H2800mm/C4
32.211.360 FR392 OP1/B1/H2800mm/C6
32.211.370 FR402 OP1/B1/H2800mm/C7
32.212.320 FR332 OP1/B2-24V-110Ah/H2800mm/C2
32.212.340 FR352 OP1/B2-24V-110Ah/H2800mm/C4
32.212.360 FR392 OP1/B2-24V-110Ah/H2800mm/C6
32.212.370 FR402 OP1/B2-24V-110Ah/H2800mm/C7
32.213.320 FR332 OP1/B3-24V-120Ah/H2800mm/C2
32.213.340 FR352 OP1/B3-24V-120Ah/H2800mm/C4
32.213.360 FR392 OP1/B3-24V-120Ah/H2800mm/C6
32.213.370 FR402 OP1/B3-24V-120Ah/H2800mm/C7
32.211.161 FR390 OP1/B1/H2200mm/C6 With cutting device

32.212.161 FR390 OP1/B2-24V-110Ah/H2200mm/C6 With cutting device


5
GENERAL
The FR3xx/FR4xx robot is an semi-automatic pallet wrapping machine.
The operator has to place the robot near the pallet, (the wheel, mounted in the reading arm, have to
follows the outline of the product) and connect the film on the pallet.
The tension or stretch can be adjusted on the operating panel or carriage.
Depending on the functionality of the machine, the operator can start the wrapping process or initially
he has to setup the wrapping cycle, speed of turntable and carriage.
The process will be activated by pressing the start button. After completing the cycle, the robot will
stop, the film can be disconnected and the operator can take away the pallet.
 This manual is only intended for a semi-automatic pallet stretch wrapping machine, mentioned at
page one, as delivered by FROMM Stretch Wrapping Division.
 FOR EVERYTHING IN THIS MANUAL IS VALID, IF APPLIED!
 THE ORIGINAL, SIGNED FACTORY MANUAL HAS TO REMAIN INSIDE THE ELECTRICAL BOX
OF THE MACHINE, TOGETHER WITH THE MACHINE ELECTRICAL PLAN AND INVERTER
MANUALS.
 Pre- stretching (Stretching out) the film prior to application on the goods reduces the costs of
packaging and is easier on the environment. (Available pre stretch depend on the model)
 Refer to chapter for the technical data, which describes the installation in detail and for the
complete size of the installation.
 Read carefully at least the chapters HANDELING AND TRANSPORT and INSTALLATION.
 For safety reasons the entire instruction manual should be read before setting in operation the
machine/installation, solving failures and executing maintenance.
 We particularly draw your attention to the chapters SAFETY INSTRUCTIONS and WARNINGS
which point out the intended use and unsafe situations that could not be prevented in the design and
manufacture of the wrapping machine.
 It is strictly prohibited to tamper with the machine It is prohibited to feed the machine with unforeseen,
corrosive or inflammable products since the machine is not the explosion-proof type.
 The duration of guarantee is provided the following are observed: the use for which the machine was
designed, built and protected, in addition to recommendations, information - including matters of
general knowledge - details plus the safety and health technical limits notified to by the Manufacturer
to the User by virtue of the operating use.
 We cannot accept any claim for warranty if non-original spare parts are utilized.
 If the machine is used beyond its operating limits and if the manufacturer's features are altered in any
way, such use is considered improper. In this case MANUFACTURER is relieved of any liability for
injury/damage caused to people/property due to failure to comply with these guidelines.
 For all the aforementioned reasons, we recommend that our customers always notify the Service
Department.
SERVICE DEPARTMENT Please contact, in case of problems:
6
SAFETY INSTRUCTIONS
ATTENTION!
The following conditions have always to be satisfied, unless otherwise indicated in other
instructions in this manual.
 This wrapping machine has been delivered by FROMM Stretch Wrapping Division and may only be
applied for wrapping of pallets / products which meet the requirements as mentioned in the
description of the machine in chapter TECHNICAL DATA.
Any other use of the machine as for the described purpose may cause danger due to damage to
the machine and/or the safety of the operator or other persons in the neighbourhood of the
machine.
 Read this manual carefully before using the machine, and be aware of the residuals risks which could
not be excluded during the development of this machine.
 In any case all the components must be disposed of by scrupulously complying with the
corresponding laws in force in the country in which the machine is used, and only by qualified
persons who are capable of assessing possible risks.
 Only personnel trained for the purpose may operate the machine
 Use the emergency stop to halt the machine immediately
 Only trained electricians may perform electrical work on the machine
 Don’t find yourself close to the carriage when the machine is in operation. Be careful especially in
the lowering phase of the carriage. (Use the emergency stop to halt the machine immediately).
 Don’t find yourself near the robot when is in operation.

(Use the emergency stop to halt the machine immediately).
 Don’t touch the pallet when the machine is in operation.

 Don’t place or insert your hand and fingers between mast and carriage.
 Don’t put your hand or fingers in the mast.

 Don’t put your hand or fingers near the wheels for the carriage movement.
 Don’t put your hand or fingers in the electrical box.

 Don’t put your finger in the space between the robot and the floor.
 When installing the machine, as a precaution, always check that the controls and safety systems are
correctly mounted and operating efficiently. If any malfunctions are noted, immediately stop the
production cycle and ask the authorized technical service to intervene
7
 Examine the data-plates. lf they are in poor condition, replace them with utmost urgency, strictly and
directly contacting the authorized technical service or the Manufacturer
 The requirements, as mentioned in chapter MAINTENANCE INSTRUCTIONS should be satisfied

during adjustment and maintenance activities
 People should not step on to means of transport, unless indicated clearly otherwise
 People should not find themselves above the means of transport
 Do not place tools and components on the machine
 Safety devices should not be bridged and put out of operation
 The manufacturer will only make the machine ready for operation, when the electrical main
connection satisfies the standards applicable in the country of delivery
 The supplier will do the training of the operating personnel. If not, the training will have to be done
properly by the company that takes care of the installation.
 The machines are designed and implemented conforming to the safety laws in force.
Consequently, no intrinsic fire risks are envisaged when the machine is used normally
 As such, the equipment provided against the possibility of fire outbreaks inside the company are
sufficient for any problems caused by the material used for the process
 In the event a fire breaks out and fire extinguishers are used, it is recommended that extinguishers
filled only with CO2 be used, so as not to damage both the equipment on the machine and the
wiring system
 In the event of flooding, it is compulsory that all the power supplies be disconnected before
entering the room in which the machine is installed
 In the event the wrapping machine was subjected to a flooding, contact the Customer technical
service of MANUFACTURER
 You are strictly recommended not to work in the machine while wearing unsuitable clothing
(unbuttoned, ample garments) or personal objects (bracelets, watches, rings, etc.)
8
ADDITONAL SAFETY INSTRUCTIONS ROBOT FR3xx
ATTENTION!
The following conditions have always to be satisfied, unless otherwise indicated in other
instructions in this manual.
 The room in which the machine is housed must not have any shadow areas, annoying bright
lights or hazardous stroboscopic effects caused by the lighting supplied by the manufacturer.
 The machine can operate in clear air conditions at ambient temperatures of + 5°C to + 40°C.
The machine must be used EXCLUSIVELY BY QUALIFIED PERSONNEL.
 Before starting work, the operator must be perfectly familiar with the position and functioning
of all the controls and machine features. Daily check all the safety devices on the machine.
 Before starting the working cycle, the operator must ensure that there are no EXPOSED
PERSONS in the HAZARDOUS ZONES.
 The areas where the operator stands must always be kept clear and free of oily residues.
Any operations that need to be carried out with some of the safety devices disabled must be
performed by one person only, and unauthorised persons may not access the machine during
this time.
 IN OBSERVANCE OF Machine Directive 2006/42/EC AND SUBSEQUENT

AMENDMENTS AND EN23741, FROMM STRETCH DECLARES THAT THE NOISE
EMITTED BY THE MACHINE IN QUESTION FALLS WITHIN THE LIMITS ESTABLISHED BY
THE ABOVE MENTIONED REGULATIONS.
 HAZARDOUS ZONES
HAZARDOUS ZONE means any zone within and/or in the vicinity of a machine in which the
presence of an exposed person constitutes a risk to the safety and health of that person.
 The MACHINE has a number of HAZARDOUS ZONES in which the residual risks have been
reduced, but not completely eliminated:
Risk of getting trapped.
Never stand in contact with the product to be wrapped, since there is a risk of falling or getting
trapped in the film winding zone.
 OPERATOR STANDING ZONE

STANDING ZONE means the zone where the OPERATOR MUST STAND during NORMAL
MACHINE OPERATION.
Once the robot has been programmed and activated, no further action is required by the operator.
Therefore, do not stand in the working area around the product to be wrapped and stabilised.
 MACHINE STATE:
STATE means the operating mode (AUTOMATIC, JOG, MANUAL, TIMED STOP, EMERGENCY
STOP ...) and the condition of the safety devices on the machine (emergency stop pressed, type
of "energy source isolation". Regarding isolation of the energy sources, it will be pointed out when
the emergency switch needs to be locked and the power connector disconnected.
9
SAFETY DEVICES
We urge on you again that all safety devices are installed for the safety of the operator
etc. and should not be bridged and put out of operation.
Refer to the drawing below for the applied references.
Survey control panel

A A = Acoustic signal
B = Emergency stop .
C= Light On, when

the power is On
D
D= Main switch
C B
E=
This is a mobile crush-proof guard, interlocked by means of a
micro switch.
Any time underlying foreign matter comes into contact with the
guard, it inverts the film carriage's motion and causes the
E machine to stop in phase.
E = Crush-proof guard
F = COVER
Do not remove the fixed
guards when the machine is
running and always refit them
F = Carriage guard after any maintenance
operation
WARNING: ON PARTICULARLY SMOOTH OR SLIPPERY FLOORS, THE ROBOT

MAY STOP WITH A SLIGHT DELAY
WARNING: DO NOT REMOVE THE SAFETY BUMPER AND ALWAYS REFIT IT

AFTER ANY MAINTENANCE OPERATION
DO NOT REMOVE THE FIXED GUARDS WHEN THE MACHINE IS RUNNING AND
ALWAYS REFIT THEM AFTER ANY MAINTENANCE OPERATION
10
WARNINGS
 The mean weighed noise level of the machine is less than 80 dBa. It is possible that, depending on
the applied film, during wrapping of the pallets / products incidentally a noise level with a maximum
of 80 dBa will be measured. Carrying of noise protecting devices is advised.
 One has to reckon with the possibility that the film (roll) contains an electrostatic charge.
 Utmost caution has to be taken with respect to the complete electrical installation. ONLY trained
persons may carry out activities to it, after having taken the required safety measures as mentioned
in the chapter SAFETY INSTRUCTIONS.
 One has to reckon with the European safety requirements and standards if the machine has to be
adapted and thus safety measures or protection covers also have to be adapted.
 Touching the electrical equipment will hazard your personal safety.
 Persons who carry out changes in or adaptations (function, operation or principles) to the machine
are fully responsible for those changes and/or adaptations.
 All relevant safety measures should be taken when carrying out any activity on the machine,
especially during maintenance activities and solving failures.
Take care that the main switch is switched off (position "0") and locked (If possible), or that the power
cable is disconnected in order to prevent other persons in putting in action the machine during your
activities.
All the normally valid safety measures or customs with respect to safety should also be taken during
those activities.
 Playing with or around the machine may cause dangerous situations with a machine in operation.
This playing is never allowed!
 All other prescriptions and laws with respect to working conditions and safety on the working spot
should be observed with this machine.
 An acoustic signal device has been installed in the control cabinet, which will be activated first during
a short period, as a warning every time before the machine is starting.
11
EXPLANATION IDENTIFICATION STICKER

An identification sticker with the following information has been mounted at the backside of the base-unit.
Name of the manufacturer : FROMM Wrapping Systems s.r.l.
Type : Machine type.
Serialnr. : Production number of manufacturer.
Voltage : Supply voltage.
Power : Used power
Fuse : 5 Amp
Year of manufacture : Year in which the machine has been built by manufacturer.
Besides, the CE-mark has been placed on the identification plate:
CE-mark
Machine fulfils the applied requirements as mentioned in the CE - machine directives
2006/42/EC (Directive)
2004/108/EC (Electromagnetic compatibility)
2006/95/EC (Low tension)
 It is strictly prohibited to remove the identification sticker or to replace it with any other similar one of
any type.
 Should the CE mark sticker be damaged for any reason, please notify the MANUFACTURER
immediately.
12
TECHNICAL DATA
Machine - Maximum speed machine 95 M/Min
- Maximum speed carriage 3,4 M/Min
- Capacity max. 20 pallets/hr.
- Operational hours 8 hrs/day, 5 days/week
- Sealing height FR3xx minimum of 2000mm / 78.74”
Weight - Total weight FR3xx approx. 330kg

- Total weight FR3xx approx. 335kg
- Total weight FR3xx approx. 345kg
o
Conditions - Environmental temperature + 5 to +40 C
- Environment clean, dry and non-aggressive
Electrical - Power supply 1 x 230 V 50/60Hz

- Control voltage 24 VAC
- Battery Voltage 24 Volt (2 x 12Volt)
- Battery 90-100 Ah
- Charging time 8 – 10 hours
- Installed power 1 kW / 5 Amp
- Protection class IP 54
Pallet goods - Max. Pallet dimensions (Length x width) No Maximum
- Min. Pallet dimensions (Length x width) 600 x 600 x 140mm

23.62” x 23.62” x 5,51”
- Height with load FR3xx (pallet included) min. 19,69” / max. 86,61”
- Height with load FR3xx (pallet included) min. 19,69” / max. 106,29”
- Height with load FR3xx (pallet included) min. 19,69” / max. 118.11”
- Dimensions of load outside pallet max. 20mm / 0,79” per side

- Top of load flat
Stretch-film - LLDPE Material Max 27μ / 0.0011”

- Spool core diameter 76 mm / 3”
- Outer diameter of spool Max. 250mm / 9,84”
- Film width Max. 500mm / 19,69”
Colors - Mast : Blue, RAL 5010

- Chassis : Grey, RAL 9006
- Machine Cover : Yellow, RAL 1021
- Film carriage : Yellow, RAL 1021
Should the need arise to work with products having a different nature than the above mentioned ones.
It is essential that you contact the technical service of MANUFACTURER in order to receive written
authorization.
WARNING : do not use film thicker than 27 microns without

consulting the Manufacturer
13
DIMENSIONS FR3xx/FR4xx
Refer to the LAYOUT on this page for the dimensions.
DIMENSIONS DURING WRAPPING
14
EXPLANATION OF PICTOGRAMS
ATTENTION!! (FOR EVERYTHING IS VALID, IF APPLIED!)
WARNINGS
Figure 1:
DANGER
High voltage present.
Fig 1
Figure 2:
Danger Sign
Fig 2
Figure 3:
Risk of crushing one’s hands
Fig 3
Figure 4:
Risk of crushing hands and feet
Fig 4
Figure 5:
Falling hazard
Fig 5
Figure 6:
Sharp objects
Fig 6
COMMAND PLATES
Figure 7:
It is prohibited to pass by within the lifting equipment’s ray of action
Fig 7
15
Figure 8:
Do not use bare flames and do not smoke
Fig 8
Figure 9:
Don’t access the area while the machine is working
Fig 9
Figure 10:
Don’t remove the SAFETY DEVICES
Fig 10
Figure 11:
Don’t execute any work before taking off the voltage of the machine
Fig 11
Figure 12:
Truck insertions
Fig 12
Figure 13:
Lifting points
Fig 13
Figure 14:
This identifies situations in which

THE SUPPLIER must be contacted
Fig 14
16
Figure 15:
Fig 15 Very important guidelines that must strictly be complied with. Otherwise
machine operators could be at risk, the consequence of which would be the
voiding of any form of warranty and liability on behalf of FROMM
PACKAGING SYSTEMS.
Figure 16:
Operations that must never be performed.
Fig 16
CE-MARK
Figure 17:
Machine fulfils the applied requirements

as mentioned in the CE-machine directives.
Fig 17
17
MAIN COMPONENTS
The installation as delivered consists of the following parts:
1- Mast
2- Flash Light
3- Control cabinet with control panel
4- Film carriage
5- Robot cover incl. battery compartment and electronic switch board.
18
HANDLING & TRANSPORT
ATTENTION!
All mentioned activities may only be executed under supervision of qualified personnel from the
manufacturer or his representatives!
Pay attention that proper hoisting and lifting tools are used for handling of the machine.
The machine is supplied in a wooden crate insulated by plastic air bubble film.
It is advisable that two another operators be in attendance on the ground when the machine is moved
by means of the mechanical equipment driven by the operator in charge since the size of the machine
may prevent a clear view during the various phases of the handling operations.
Depending on weight, dimensions, location of machine on the vehicle, available installation space
lifting methods and points suitable for the operations described below must be used, fully observing
the current safety and health laws and the Manufacturer's recommendations.
Lifting and handling of packing in a wooden crate by crane
- use a crane and sling of sufficient strength
- bring the vehicle near to the lifting pallet
- pass the sling (and/or ropes - chains) around the case in the positions indicated by the external
markings (1);
First check that the case - sling/hook (2) are well secured, then carefully lift the case and place it in the
designated area, moving it gently.
19
HANDLING & TRANSPORT
Lifting and handling of packing in a wooden crate by fork-lift truck

Lifting and transport must be affected by a fork-lift truck suitable to bear the weight of the machine, its
accessories and packing.
Always check in advance that sufficient space is available for the operations.
- slide the forks (1) of the truck under the casels support base, in line with the indicator-marks printed
(2).
- lift the load after ensuring it is stable, and transport it to the area in which packing is to be removed,
avoiding jerks and dangerous cambers.
Following measures have to be taken for transport and storage of the machine:
- One has to take care for a suitable storage environment respectively packaging during long-term
storage.
Drag bands etc., if used, in order to attach several parts may never be tightened over vulnerable parts,
such as control panel, ventilation grills, etc.).
Handling the unpacked machine

Should any machine components be shipped together with the machine, handle them adopting all
safety precautions
insert the forks of the suitable lifting
equipment within the specific guides (1)
Machine storage
The machine and any components packed together with it are protected by a plastic covering that
does not guarantee long storage times.
The machine must never be stacked nor is it capable of supporting external loads.
20
INSTALLATION INSTRUCTION
ATTENTION!
FOR EVERYTHING IS VALID: IF APPLIED!
Refer to layout in SAFETY DEVICES for mentioned position numbers.
General guideline
Always check in advance that the minimum conditions for machine placing and operation are
observed, in particular: ambient conditions (suitable floor), temperature, humidity, lighting and
suitability of the designated area.
Installation in rooms subject to the risks of flooding, explosion and fire is strictly forbidden.
The area necessary for installation of the wrapping machine is the area according to the dimensions
on the layout plus enough space for installing and working on the machine.
Installation must be executed by qualified personnel, directly coordinated by the authorized Technical
Service, fully observing the instructions that follow, in addition to current safety and health laws.
As a precaution, always check for any damage caused during transport and handling work.
If necessary, contact the Manufacturer directly.
Temperature
For safety make sure the machine is operating at ambient temperature in the range +10°C to +30°C.
lf other values are measured, contact the Authorized Technical Service with utmost urgency.
Work areas
It is strictly forbidden to locate and/or use the machine if the ambient conditions are liable to cause
risks of explosion or inflammability.
Ensure that the following are not present: dust concentration, gas, dangerous fumes and particles,
electrostatic fields, excessive electro-magnetic flow, or anything else that might be harmful to persons
so exposed or to the efficient running of the machine.
In any event, observe the current safety and health laws.
The machine should be placed on a flat, rigid, vibration-free concrete floor
Never access the high parts of the machine improperly.
Energy sources
The client must provide a cable suited for the required supply voltage up to the control cabinet, of
which the diameter of the conductors can manage the total of the required power as mentioned in
chapter TECHNICAL DATA
The wrapping machine should preferably be connected to the customer's supply voltage wall socket
with a connecting cable with a standard CEE-plug, being fused with a 16A-fuse (slow).
For the correct plug check chapter TECHNICAL DATA
A main switch preceding the plug has to be provided by the customer, if necessary.
The mains supply must satisfy the applicable standards, such as permitted voltage fluctuations, ripple-
generation, reduction of high harmonics, etc.
21
INSTALLATION INSTRUCTION
ATTENTION!
During maintenance, repair or adjustment operations, the emergency buttons on the control panel must
always be activated and the battery disconnected.
FOR EVERYTHING IS VALID: IF APPLIED!
- Safety bumper unit:

Undo the screws (1), fit the bumper unit (2) as shown in the drawing and then screw the
screws (1) back in through the holes (3).
- Feeler wheel unit:

Undo the screws (4), fit the wheel unit (5) as shown in the drawing and then screw the
screws (4) back in.
4
1
5 3 2
22
ASSEMBLY SEQUENCE
1. Check the functionality of the EMERGENCY SWITCH (Fig 1)
The machine is equipped with a safety device consisting of a series of

electromechanical contacts that deactivate the motor when the
emergency button is pressed.
The machine safety devices are activated with the emergency button that
converges in this device, which by means of a REDUNDANT and
AUTOMATIC CONTROL function on the intermediate relays on which the
emergency switches rest, activates a safety circuit that stops the main
Fig 1 motor.
This assures that the machine stops immediately from all points of
operating condition.
C2 Carriage: delivers film during wrapping adjusting the film application tension. The tension is
adjusted by a roller fitted with a mechanical brake which can be manually adjusted with a knob on the
carriage.
2. Carriage C2
With this carriage, the tension with which the film is applied to the pallet can be adjusted.
The carriage C2 is composed of a rubber-coated roller (1) and a roller (2) with mechanical brake.
Operating the knob (3) the braking action is adjusted and, consequently, the film tension.
Upon starting, the film must be loaded on to the carriage. Insert the roll (5) on to the centering pin (4).
Run the film between the rollers (1) & (2), following the path shown in Figure A. Diagram A is also
shown on the carriage. The symbol with the triangles identifies the side of the film on which the
adhesive (if present) is applied.
A
A
3
2 4
1
Fig 1
5
23
ASSEMBLY SEQUENCE
C4 Carriage: delivers film during wrapping adjusting the film application tension. The tension is
adjusted by a roller fitted with an electromagnetic brake.
The tension can be adjusted via the machine operating panel.
3. Carriage C4
The film carriage 2, is composed from a rubber-coated roller (1) in combination with electromagnetic
brake and idle rollers (2).
Adjusting the OP, the braking action is adjusted and, consequently, the film tension.
Upon starting, the film must be loaded onto the carriage. Slide the roll (3) onto the core holder of the
carriage. Feed the film between the rollers (1) & (2), following the path shown in Figure A. Diagram
A is also shown on the carriage.
The symbol with the triangles identifies the side of the film on which the adhesive (if present) is
applied.
A
A 3
1
2
Fig 1
24
ASSEMBLY SEQUENCE
C6 Carriage: Carriage with one motor pre-stretch system.

The film can be pre-stretched by means of a mechanical control generated by a pair of gears (fixed
mechanical ratio). The application tension is manually adjusted and controlled by a sensor which
measures its value.
The tension can be adjusted via the machine operating panel.
4. Carriage C6
With this carriage version, the tension with which the film is applied to the pallet can be adjusted via
the Operating panel
.
This carriage allows pre-stretching the film according to fixed ratios determined by interchangeable
gears.
The pre-stretch ratios usable are:

-150% (1 metre of film is pre-stretched to a length of 2.5 metres).
The carriage is fitted with a sensor (4) connected to the out-feed roller, which measures the tension
of the film applied to the pallet, and the Operating Panel (OP) to adjust this value.
A specific circuit board integrates the signal of the sensor (4) and the adjustment set with the OP in
order to dynamically control the speed of the pre-stretch roller drive motor and thus the film tension.
The carriage is fitted with a gear-motor which drives three rubber-coated rollers (1), (2) and (3) by
means of toothed gearing. The different transmission ratios generate different speeds of the rollers
(1) , (2) and (3) creating the pre-stretch action.
The carriage also features a set of 3 idle rollers which are used to increase the winding angle of the
film on the rubber-coated rollers.
Upon starting, the film must be loaded onto the carriage.

Slide the roll (5) onto the centring pin (6). Open the door and run the film between the rollers
following the path shown in Figure A. Diagram A is also shown on the carriage. Close the door
making sure that it is properly locked.
applied.
A A
6
4
1
2
3
5
Fig 1 4
25
ASSEMBLY SEQUENCE
C7 Carriage: Film carriage with a two motor pre stretch system.
Pre-Stretch can be changed by adjusting the settings on the operating panel
The application tension is manually adjusted and controlled by a sensor which measures its value.
5. Carriage C7
With this carriage version, the pre-stretch and film tension can be adjusted via the operating panel
The pre-stretch can be variable adjusted from 150% up to 400% pre-stretch.
The carriage is fitted with a sensor (4) connected to the out-feed roller, which measures the tension
of the film applied to the pallet, and the Operating Panel (OP) to adjust this value.
A specific circuit board integrates the signal of the sensor (4) and the adjustment set with the OP in
order to dynamically control the speed of the pre-stretch roller drive motor and thus the film tension.
Upon starting, the film must be loaded onto the carriage.

Slide the roll (5) onto the centring pin (6). Open the door and run the film between the rollers
following the path shown in Figure A. Diagram A is also shown on the carriage. Close the door
making sure that it is properly locked.
applied.
A A
6
4
1
2
3
5
Fig 1 4
26
ASSEMBLY SEQUENCE
6. Adjustment reading arm
The reading arm, on which the wheel that follows the outline of the product to be wrapped is
mounted, is subject to two adjustments:
a) Wheel height
Undo the screw (1), raise or lower the wheel pin (2) as shown in the drawing, position the
wheel so that it runs around the pallet without depressions and/or protrusions, then tighten
the screw (1).
1 2
27
ASSEMBLY SEQUENCE
7. Steering force
The arm steering or closure is controlled by a spring (3) coupled to a bracket (4) secured to
the steering arm.
The bracket (4) can be set in different positions (5) to adjust the spring tension.
To change the position, release the bracket (4) pulling it by the tab (6) and reset it in the
desired position.
A more rigid spring results in:

- Greater steering force
- Greater driving arm rigidity during manual movements
- The risk of lightweight pallets moving on slippery flooring.
A less rigid spring results in:
- Reduced steering force
- Reduced driving arm rigidity during manual movements
- The risk that the robot does not correctly follow the outline of the pallet during high-speed
wrapping.
3 4 5 6
28
ASSEMBLY SEQUENCE
8. Mast H.2500 – H.2800
(Fig 1) Lift the mast (1) coupling it with a rope. Put the mast in the support (2) of the base, screw the
bolts inside the carter. Remove the rope. Connect the plug.
(Fig 2) 1.Power supply driver carriage (red wire (P or +) and black wire (M or -)
2.Power supply carriage motor up/down (wire “U2” and “V2”)
3.Carriage signals
4.Cable for red light and for phonic wheel
5.Power supply robot
(Fig 3) At the end, final result
2 1
Fig 1 Fig 2
2
P 4 3 1
M
U2 U2
V2
V2
Fig 3
ATTENTION!
After the first installation
Follow procedure below before starting the machine
- Control if the emergency button is free

- Turn on the machine
- Wait 5 seconds and than make the first run in manual mode
- If the machine is running, follow procedure below
29
After installation or maintenance of the machine follow procedure below to check the efficiency of the
safety devices, such as:
 The interlocking of the mobile shock proof guard

 Emergency button
Check for the efficiency of the interlocked shockproof flexible guard
- start the machine

- activate the interlocked operator guard
Check that the machine stops within a few fractions of a second
Check for the efficiency of the mushroom-head button
- start the machine

- press the emergency mushroom-head button
Check that the machine stops within a few fractions of a second
30
CONTROL PANEL
D E G F
H
B
A
I J
Figure 1: Console FR31x Generation V03 (Operating panel ONE)

A = Board on - Cycle or alarm reset (if present)
B = Hold-down button for manual carriage descent (pressed together with button A, the
carriage automatically descends to the bottom cycle start position)
C = Hold-down button for manual carriage ascent
D = STOP button for cycle pause; the robot decelerates and stops; the cycle can be resumed
from the same point
LED On = Battery had to be charged; Hold-down button = % Battery charger
E = Value decrease button
F = Value increase button
G = 2-digit display for functions (parameters) of the selected program
H = 3-digit display for the value of the function displayed
I = START button for programmed cycle
J = EMERGENCY BUTTON
Alarms
The display V (H) is used to indicate the alarms, at the same time the LED next to the RESET
key (A) is flashing:
E01: Emergency bumper pressed

E02: Failed starting (the robot does not turn)
E04: foot crushing emergency
E08: encoder block (the carriage is not moving)
E16: carriage door open
E32: Battery flat
The right side LED of the display V (H) will flash in case an EEPROM vailure has occurred.
The EEPROM has to be substituted.
The Robot can be used in a normal way in case this occasion has occurred.
31
INDICATIONS
START-UP CYCLE ACTIVE An acoustic signal device has been installed in the control cabinet,
which will be activated first during some seconds as a warning every
time before the AUTOMATIC PROGRAM is executed.
The operator will thus be able to leave the danger zone before the
machine starts to operate.
The machine will only start to operate after this period has been
elapsed.
RESET MACHINE The automatic program of the wrapping machine is interrupted and a
failure indication will be displayed on the console, when the
emergency stop is activated or any other failure is detected.
Wrapping can only be started again after pushing reset on the
control panel. Thus, the failure is reset and the control voltage is
activated again, assuming that the mains switch still has been
switched on. The cause of the failure has to be solved first, of
cause.
32
BASIC OPERATING INSTRUCTIONS
Using the buttons (1) and (2), move the robot alongside the
product resting the reference wheel against it and make sure
that the robot is positioned parallel with one of the sides of
the pallet to be wrapped at a distance between 30 and 50
cm.
From the opposite side of the stretch carriage extract the

end of the film and attach it to the bottom of the product to
Left = 1 be wrapped.
Right = 2
On the control panel (Fig 1) set the desired number of extra

wraps around the bottom and top and press the green START
button. The wrapping operation will automatically be carried
out. (see section WRAPPING PROGRAMS)
Fig 1
Button Explanation
F01 Film carriage movement
: 01 Upwards and Downwards
: Only upwards or only downwards
: Not available with the Robot
F02 Robot rotation speed

: Selectable from 50 to 95 Mt/min;
F03 Carriage ascent speed

: Selectable from 0 to 100
F04 Carriage down speed

33
F05 Number of bottom wraps
F06 Number of top wraps
F09 Strip of film placed over the top of the product
F12 Height at which the carriage ascent stops.

Top part of the film coil is the reference point for this setting. (
By setting this parameter the photocell for reading pallet height will
be disabled,
F14 Film tension during carriage movement up of the wrapping cycle

F16 Film tension during carriage movement down of the wrapping cycle
F18 Film “pre-stretch settings during carriage movement up of the

wrapping cycle
(Only in combination with carriage 7, two motor pre-stretch)
F20 Film “pre-stretch settings during carriage movement down of the

wrapping cycle
(Only in combination with carriage 7, two motor pre-stretch)
F21 Special pallet cycle for big pallets (product perimeter)

(default value = 4.0 m)
F22 Cycle with covering film

: 1 Enabled
: 2 Disabled
34
F23 Descend distance with activation of parameter F22

: Small top-sheets, low value
: Big top-sheets, higher value
F24 Thickness of film being used

: Selectable from 10 to 35 micron
(Only in combination with carriage 6 & 7,one & two motors
pre-stretch with optional weighing kit fitted)
Entering the thickness of the film within the range 10-35 micron
means that the end of the cycle the amount of film used for the
packaging can be determined.
F25 Manual forward speed

F26 Cycle with cutting (opt)

: 0 Disabled
: 1 Enabled
F27 Cutting time after the phase

: Selectable from 0 to 200 hundredths of a sec.
Sets the position where film cutting and tensioning takes place
during cutting
F28 Film outfeed time after cutting

: Selectable from 0 to 200 hundredths of a sec.
Sets the amount of film that is fed out from the carriage after the
film has been cut
F30 Carriage ascent / descent step

: Selectable from 0 to 50 step 1
: 0 Disabled
>0 Enabled
This function is used to enable the carriage ascent / descent by

steps; the value set corresponds with the ascent distance for
each turn (in cm).
N.B.: the value set in F21 must be the same as the perimeter of
the product
35
Keyboard block:
Prevents modification of parameters by blocking the
keys V+ e V-
Hold down RESET and at the same time press
F+ and F-
The right-hand LED of the display V lights up and
stays lit.
Keyboard release:
Hold down RESET and at the same time press
F+ and F-
The right-hand LED of the display V turns off and stays
turned off.
ATTENTION: To save the parameters of the cycle you have to complete a machine cycle.
If you change the parameters and you push start button, you have to wait the completion of
the cycle if you want that the parameters be saved.
If the cycle will not be completed the machine will not save the parameters and it will reload
the parameters that had been saved at the end of the last complete cycle performed.
DISPLAY "V”
1: FLASHING : saving of parameters
2: Displays the decimal point of the parameter
3: FLASHING: EEPROM fault

ON: keyboard blocked (V+ and V- blocked)
OFF: keyboard released
1 2 3
Signals
The LED next to the MANUAL CARRIAGE RISE indicates the automatic
command of the carriage rise.
Press this button together with the RESET button and the carriage starts to
move.
The LED next to the MANUAL CARRIAGE DESCENT indicates the automatic
command of the carriage descent.
Press this button together with the RESET button and the carriage starts to
move.
36
STARTING AND STOPPING OF THE ROBOT WRAPPING CYCLE
Automatic run mode with settable cycles

Activate this run mode, after the machine has been turned on and the safety conditions have been
complied with, by pressing the START pushbutton provided that the corresponding work cycle has
been set via the pushbutton panel.
- Check for the charge condition of the battery on the control panel
- If the battery was charged beforehand, disconnect the battery charge cable from the socket
- Check that the reel is present on the corresponding reel-holding shaft and that the film's path is
correct as shown in the diagram
- Check for the position of the feeler wheel and adjust it, if need be, along the sliding shaft using the
lock screw
- Grasp the handlebar and press the forward start pushbutton
- Set the feeler wheel against the product arranged on the pallet
- Manually remove the lead edge of the film from the reel and attach to one of the pallet's corners
- Set the wrapping cycles on the control panel according to the modes outlined in
- Press the START pushbutton
- when the wrapping cycle is finished, manually cut the film and set the adhesive side against the
pallet
- the pallet is ready to be picked up
ATT. The acoustic signal is active during approximately 3 seconds before the automatic wrapping cycle
will be executed. The machine will only start to operate after this period has been elapsed.
N.B. The automatic wrapping cycle is only started, if the start conditions are fulfilled.
A failure indication is displayed, if not all start conditions are fulfilled.
The start conditions for the automatic wrapping cycle are:
- One of the WRAPPING PROGRAMS should be selected;

- Photocell "pallet height" should be activated;
- Emergency stop not activated;
- The interlocking of the mobile flexible strap;
- No failure detected;
Immediate stop
This stop is commanded as follows:

- By pressing the stop pushbutton
- By pressing the emergency mushroom-head button
- By pressure exerted on the front flexible strap
- By the presence of an alarm that commands the immediate stop.
This stop mode envisages:

- The immediate stop of machine
NOTE: with this type of stop the machine can restart from the operating point in which it had stopped
by, pressing the start button.
37
WRAPPING PROGRAMS
F01=02
1. Single wrapping
After the pre-set number of bottom wraps have been completed, while the machine is running, the film
carriage will go upwards. When the film carriage has arrived on top and the pre-set number of top
wraps has been completed, the machine will halt. The film can be cut now on top.
After pushing start again the machine restarts with an descend only program.
F01=01
2. Double wrapping
The complete (double) wrapping program will be executed with this function. After completing the pre-set
number of bottom wraps the film carriage will go upwards, then it halts to lay the top wraps, while the
machine keeps running, and then it will go downwards again. Another number of pre-set bottom wraps is
laid, after which the machine will halt. Now the film can be cut and the pallet can be transported.
F22=1
3. Double wrapping + TS
After the pre-set number of bottom wraps has been completed, while the machine is running, the film
carriage will go upwards. When the film carriage has arrived on top it first, lays approx. 1 top wrap, move
downwards and wait until the top sheet has been laid.
To change the decrease distance alter the DIGITAL VALUE-SETTING
With + or – in the chapter BASIC OPERATION INSTRUCTIONS
After pushing start the film carriage will go upwards again and wrapping in the top-sheet, after this the
film carriage will go downwards again. Another number of pre-set bottom wraps is laid, after which the
machine will halt. Now the film can be cut and the pallet can be transported
F12
4. Double wrapping
See program 2 with one exception. In this program you can pre set the pallet-height with by changing
the parameters on the control cabinet. This program is special made for goods witch cannot be read
by the photoelectric sensor.
38
ERRORS DURING OPERATION
THE ROBOT DOESN’T SWITCH ON
Problem suggestion Possible solution

- Is hold the mushroom-head button - Turn it off. Press the switch on ((Look
the “CONTROL PANEL”, letter “A”)
- Batteries disconnected - Connect the battery
- Battery charger connected with the plug - Disconnected it
- Fuse FU1 burnt - Replace it
- Fuse burnt on the Pc-Board - Replace it
- Fuse burnt on the Pc-Board - Replace it
- Pc-Board broken - Replace it
Attention: before to send the Pc-board
for the reparation, remove the Eeprom
(Fig 1). When you remove it, don’t
touch the teeth of the Eeprom
because you may delete the software
Fig 1
Should the problem persist, contact the Customer After-Sales Service of MANUFACTURER
THE CARRIAGE DOES NOT STOP AT THE LOWER OR UPPER LIMIT STOP MICROSWITCH

- Micro switches are not connected properly - Check the wiring
- Micro switch malfunctioning - Control the distance Micro – bracket
on the mast (Fig 1)
- Replace the Micro switch N5.2373
- Carriage doesn’t wrap at floor level - Check for the position of the lower
bracket by adjusting the respective
screws
Fig 1
39
THE ROBOT START TO WORK BUT THE CARRIAGE GO UP ONLY FOR A FEW CENTIMETER
AND COMPLET THE CYCLE

- The photocell don’t read the pallet - The pallet is low
- Clean the photocell
- Cover the photocell and look the Led
on it and the LED for the wire 03 JP3
(Switch on)
- Work with F12 (Control Panel)
- Photocell for black film?
THE ROBOT START TO WORK BUT THE CARRIAGE GO UP OVER THE TOP OF THE PALLET

- The photocell read reflection of light - Clean the photocell
- Decreases the sensitivity of the
photocell
CHARGE THE BATTERY FOR 8-10 HOURS AND AFTER A FEW PALLET THE BATTERY
CHARGER SHOW ORANGE LED

- The battery is not completely charge - Check all the connections (battery-
battery charger)
- Check the “Dip Switch Configuration”
in Version 03 (Fig 1 & Fig 2)
- Discharger completely the battery.
Charger again the battery for 8-10
hours (finally shows=green led, in
Version 03 and 100% in Version 04,
Fig.3)
Check with the tension meter the
voltage of the two batteries, max
voltage must be 27 Volt.
The tension between the two batteries
must be the same, if isn’t so, the
battery that has less voltage has a
part in “short-circuit”.
Look the “Operating manual” for the
“Electronic battery charger”.
Fig 3
Fig 1 Fig 2
40
THE FILM TENSION DOES NOT CHANGE WITH CARRIAGE 2

- Film feed in the wrong way - Guide the film through the brake
system according to the drawing
on top of the carriage (Fig 1)
- Friction not connected properly - Friction has to be repositioned or
- Carriage makes noise at the top part replaced (Fig2) FR3.1095
- Hand-wheel not connected properly - Check the thread of the screw
(Fig3)
- Replace the Hand-wheel
FR3.1188
Fig 1 Fig 2 Fig 3

- Tension on the film doesn’t work properly - Check the value for the tensioning
on the Pc-board (F13-F16)
- Check of the black roller can be
moved by hand. (Fig 2)
- Check the quality of film.
- Electromagnetic brake doesn’t work properly - Check the wiring
- Check the electromagnetic clutch
(Fig 3)
- Replace the electromagnetic
clutch FR3.1101
- Check the power supply (Fig 3)
- Replace the power supply
FR3.1103
Fig 1 Fig 2 Fig 3
41

- Tension on the film doesn’t work properly - Check the value for the
tensioning on the Pc-board (F13-
F16)
- Check the wiring (Fig 2a)
- Check if the screw/black plastic
magnet is at the correct distance
(10-15mm) from the power
supply (Fig 2a)
The plastic magnet has a right
side and when it approaches at
the sensor, the pulley (Fig 2b) on
the motor rotates.
- Check the power supply (Fig 2c)
- Replace power supply FR3.1153
- The pulley on the motor for the tension is blocked - Approach the dancer roller at the
sensor (Fig 3a) and at the same
time read how many flash light
makes the “Diagnostic” of the
inverter (Fig 3b)
If the led blinks 4 times:
Check the connection;
Check the brushes of the motor.
- Replace the motor (Fig 3b)
N51.1114
Fig 2a
Fig 3a
Fig 2b
Fig 1
Fig 2c Fig 3b
42

on top of the carriage (Fig 1 C6)
- Pre-stretch on the film doesn’t work properly - Check the value for the pre-
stretch on the Pc-board (F17-
F20)
- Check the wiring
- Check if the screw/black plastic
magnet is at the correct distance
(10-15mm) from the power
supply
The plastic magnet has a right
side and when it approaches at
the sensor, the pulley (Fig 1) on
the motor rotates.
- Check the power supply
- Replace power supply FR3.1153
- The pulley on the motor for the pre-stretch is blocked - Approach the dancer roller at the
sensor and at the same time read
how many flash light makes the
“Diagnostic” of the inverter
If the led blinks 4 times:
Check the connection;
Check the brushes of the motor.
- Replace the motor (Fig 2)
N51.1113
Fig 1 Fig 2
ATTENTION: IN THE CARRIAGE 6 AND CARRIAGE 7 PROPERLY CLOSE THE DOOR
Be careful to properly close the doors at the bottom and the top of the carriage. The sprockets must be
perfectly aligned and the teeth stuck well,otherwise you can damage the teeth of the sprockets (Fig 3).
CARRIAGE 6 CARRIAGE 7
Fig 1 Fig 2 Fig 3
43
POSSIBLE ERRORS AT THE FIRST TIME INSTALLATION!

- The Robot shows the error E01 - The micro switch under the
(Emergency bumper pressed) robot is not positioned in the
correct way Fig 1).
The tip of the micro switch has to
be positioned at the center of the
cam. To fix the micro switch to
the robot.
- The Robot shows the error E08 - Check all the connections
(Encoder block, the carriage is not moving) (Fig 2a e Fig 2b)
- The charging cycle does not start and the message “bat” - Check the connection to the
is displayed battery and the polarity (Fig 3)
Fig 1 Fig 2a
Fig 2b
Fig 3
44
ALARMS
The V display is used for showing the alarms, noted at the same
time by the flashing LED next to the key RESET:
The right side LED will ONLY flash if there is a fault in the non-volatile
parameters memory; if the alarm remains after turning on and off the
device several times, it is necessary to substitute the EEPROM.
Meanwhile the machine functions normally, however parameters cannot
be saved.
E01: Emergency bumper pressed

E02: Failed starting (The robot does not drive)
E04: Foot crushing emergency
E08: Encoder block (the carriage is not moving)
E16: Carriage door open
E32: Battery flat
E01- EMERGENCY BUMPER PRESSED

- An obstacle has stopped running the robot - Remove the obstacle in front of the
robot and press reset.
- The micro switch doesn’t work properly - The micro switch under the
robot is not positioned in the
correct way Fig 1).
The tip of the micro switch has to
be positioned at the center of the
cam. To fix the micro switch to
the robot.
- Check all the connections.
E02- FAILED STARTING (The robot does not drive)

- Proximity doesn’t work properly - Check the LED for the wire 103 JP6
- Check the LED for the wire 07 JP7
(switch on, the proximity read)
- Adjust the distance between the
proximity and the phonic wheel (2-
3mm)
- Check the connections.
- Replace the proximity.
- In the manual function “forward/backward - Check the LED for the wire 104 JP11
traction”, the robot doesn’t move (switch on-24V)
- The motor brake is off, but the motor doesn’t start - Check the tension on the inverter U1-
V1
- Check the tension between inverter
and motor
- Check if the tension reaches the
inverter
When switch on the robot, the
“Diagnostic” in the inverter blinking
- The motor brake is off, the tension reaches the - Check the motor brushes
motor, but the motor doesn’t start - Replace the motor
- Replace the gearbox
45
E04- FOOT CRUSHING EMERGENCY (Function not available with the robot)
- Foot crushing emergency doesn’t work properly - Check the bridge between JP8 and
JP9
E08- ENCODER BLOCK (The carriage is not moving)

- Proximity doesn’t work properly - Check the LED for the wire 100-101
JP6
(switch on, the proximity read)
- Adjust the distance between the
proximity and the phonic wheel (2-
3mm)
- Check the connections.
- Replace the proximity.
- The motor doesn’t work - Check the tension on the inverter U1-
V1
- Check the tension between inverter
and motor
- Check if the tension reaches the
inverter
When switch on the robot, the
“Diagnostic” in the inverter blinking
- The tension reaches the motor, but the motor - Check the motor brushes
doesn’t start - Replace the motor
- Replace the gearbox
E16- CARRIAGE DOOR OPEN

- The Carriage 2 and 4 are without door - Check the bridge on the connection
XC1 poles 5 and 7
- The door in the Carriage 6 and 7 is open - Check if the door is properly closed
(switch on, the micro switch read)
- Micro switch doesn’t work properly - Check the tension between wire 09
JP9 and pole P1
- Replace the micro switch
E32- BATTERY FLAT

- Battery flat - Check the led on the OP (Look the
“CONTROL PANEL”, letter “D”)
THE BATTERY CHARGER SHOWS THE WORD “bat”

- The charging cycle does not start and the - Check the connection to the battery
message “bat” is displayed and the polarity
Look the “Errors first installation”
Look the “Operating manual” for the
“Electronic battery charger”
46
INSERTING THE FILM

Place the new film reel (direction of unwinding depends on the side on which the cling is
found).
Guide the film through the brake system according to the drawing on top of the carriage.
Arrows on the inside of the roll means:

CI = CLING INSIDE
The film has to be guided through the brake system in this way when applying a "differential cling"-film
with the cling on the inside of the film when unwinding the film from the film reel.
Arrows on the outside of the roll means:

CO = CLING OUTSIDE
The film has to be guided through the brake system in this way when applying a "differential cling"-film
with the cling on the outside of the film when unwinding the film from the film reel.
The way of guiding the film through the brake system when applying a "double sided cling"-film is
basically not relevant.
Stretchfilm - LLDPE Material Max 27 μ / 0,000106”

- Spool core diameter 76,2 mm / 3”
- Outer diameter of spool Max. 250 mm
- Film width Max. 500 mm
47
BATTERY CHARGER / BATTERY “Version 03”
GENERAL INFORMATION AND WARNINGS

 Electronic automatic battery charger with microprocessor suitable for any battery type;
 Fully automatic charging cycle with electronic setting: protected against overload, short-circuit at
clamps and reversed polarity;
 Never disconnect the battery while charging: this could cause sparks;
 Never use the equipment in the rain, in areas used for washing or in damp areas;
 Before starting to charge, make sure the voltage of the equipment suits the voltage of the battery,
that the charging current suits the capacity of the battery and that the selected charging curve (for
lead-acid batteries or airtight gel batteries) is correct for the type of battery to be charger. In
addition, make sure the rated input voltage of the charger suits the avaible supply voltage and the
system is equipped with grounding;
 If necessary, replace the fuse with another of the same type and value as indicated on the rating
plate;
 Use battery chargers only in well ventilated areas;
 Pay attention to any remarks of the battery manufacturer.
For lead-acid batteries with liquid electrolyte:

 Control the water lever after each charging process;
 Refill with distilled water only;
 Caution! The gases generated during charging are explosive. Do not smoke in the vicinity of the
batteries. When working with cables and electrical equipment, avoid open lames and sparks;
 Attention: use protective glasses and gloves during battery maintenance. Battery acid causes
injuries. In case of contact with battery acid, wash the affected parts with a lot of fresh water and
consult a doctor if necessary.
TECHNICAL FEATURES OF THE CBHF1-SM SERIES (Robot FR3xx/FR4xx)
The innovative characteristics of the CBHF1-SM range of battery charger are the following:
1. Advanced Mosfet technology with high frequency and insulation transformer.
2. Charging process fully controlled by microprocessor.
3. Visualization on a lit display of the charging current, of the battery voltage, of the charging time, of
the electric charge supplied in Ah’s and of the electric energy absorbed in KWh’s.
4. Possibility to change the charging curve by means of microswitches (DIP-switches), choosing from
16 standard pre-programmed curves for lead-acid, Gel and VRLA batteries.
5. Possibility to change the battery voltage and the charging current by means of the relevant
microswitches.
6. Charging process starting in the “soft start” mode, storing of the data of the cycle just finished and
automatic reset upon connection of a new battery.
7. Protection against polarity inversions, short-circuits, over-voltages or anomalies by means of an
output relay.
8. Battery to battery charger connection without sparks on the output terminals with obvious
advantages for the active safety, thanks to the recognition of the battery voltage downstream the
normally opened output relay.
9. Alphanumeric signals of possible anomalies.
10. Insensitive charge parameters in case of 10% network voltage
11. Efficiency > 85%.
12. Output ripple at maximum charge lower than 100mV.
13. Start of the charge cycle also with 2V batteries.
14. Thermal protection against over heating.
15. An auxiliary relay that permits the partial or total disconnection of an electric traction machine is
available in should the batteries have to be re-charged with the battery charger placed on board the
machine. In this way the relay prevents the machine from starting while the battery charger is
operating. This is a safety device.
48
OPERATING PRINCIPLE
On switching on a new battery charger of the CBHF1-SM series, programmation data are displayed
(these parameters depend on internal dipswitch configuration).
After the “SPE” logo you can see on display the version of software installed on the machine. At this
time the following programmed parameters are displayed on sequence according to internal dipswitch
configuration (see tables on page n. 4):
battery voltage, charging current, number of charging curve and is displayed the message “GEL” if
programmed charging curve is suitable for gel batteries or “Acd” if programmed charging curve is
suitable for Lead-Acid (Wet) batteries. After these operations the charger is ready to check the battery
voltage and to decide whether to start the charging process. If the battery is not connected to the
battery charger, the message ’bat’ will be displayed. The same message is displayed also in case of
negative result of the testing (for example, reversed polarity or battery having a wrong voltage). If the
result of the testing is positive, the value of the battery voltage is displayed for about 5 seconds, with
output relay open. After 5 seconds the charging of the battery can start. The output relay closes and
the current of the first phase rises slowly till it reaches the nominal value programmed.
If the user disconnects the battery from the battery charger during the charging process, after a few
seconds the battery charger will re-initialize and prepare to start a new charging process.
The display always shows the charging current of the battery. The battery voltage, the time since the
beginning of the charge, the charge yielded in Ah’s and the energy consumed in KWh can be seen
only by pressing the button S.
The progress of the charging process is shown by three LED’s: red, yellow and green, as in the whole
range of the battery chargers.
The green LED indicates the stop of the charging or the last phase in case of deep charging process;
in the former case, the relay is opened to disconnect galvanically the battery from the battery charger.
Technical remarks
 When the maximum voltage admissible for a specific battery is reached (value given by the
manufacturer) the error message ‘E01’ is displayed, and the process is terminated.
 By using an internal thermostat, the charging can be interrupted in case of excessive battery
charger over-temperature. In this case the error message ‘E02’ is displayed.
 Possibility of setting each single charging phase. On exceeding this time, the charge will be
interrupted and the error message ‘E03’ will be displayed.
 The display of the message ‘SCt’ indicates safety timer operation.
 The message ‘Srt’ will be displayed in case of internal short circuit.
TRAXION BATTERY
www.exide.com
12ELEM.2EPZS100 24VAH5 (100Mah)

12/2 EPzS 120, 24 V, 120 Ah/5h (120Mah)
Dimensions: 580 x 215 x 390 L x W x H (Battery housing has to be an steel box)
AGM BATTERY
www.exide.com
AGM ZENITH BATTERY 2x 12V 106Ah

Dimensions: 307 x 169 x 237 L x W x H
Do you want to change the battery?

Here below the instructions (from AGM batteries to Traxion battery).
The connections of the traxion battery are the same those of the AGM battery.
When you remove the AGM batteries, also remove the bridge between them.
So, in the robot you have only 2 cables (+ and -) and the clamps are ok also for the traxion battery.
You have only to change the charging curve (look at the next pages).
49
BATTERY CHARGER CBHF1-V2
By setting up 8 dipswitches it is possible to change the charging curve and it is possible to customize
the charging profile with the specifications of battery manufacturers.
The battery voltage (12V or 24V) and the charging current (4A or 8A or 10A or 14A) can be setup.
The set of 8 dipswitch is easy to find and is s located under the front label of the charger, lifting the
corner on the bottom-left, without opening the charger.
In the following tables you can find the explanation for different positions of the dipswitches, enabling
you
to program CBHF1-V2 battery chargers.
ON
ON ON ON ON ON ON ON ON
OFF OFF OFF OFF OFF OFF OFF OFF

DIP1 DIP2 DIP3 DIP4 DIP5 DIP6 DIP7 DIP8
 DIP1 / DIP2 / DIP3 / DIP4 for the selection of the CHARGING CURVE GEL / AGM (Check also next
page!)
DIP1 DIP2 DIP3 DIP4 CHARGING CURVE
ON OFF OFF ON Lead-acid and GEL batteries
 DIP5 / DIP6 / DIP7 for the selection of the CURRENT I1

DIP5 DIP6 DIP7 CURRENT
OFF OFF ON 14A
 DIP8 for the selection of the battery voltage

DIP8 VB
OFF 12
 DIP1 DIP2 DIP3 DIP4 for the selection of the CHARGING CURVE TRACTION (Check also next page!)
DIP1 DIP2 DIP3 DIP4 CHARGING CURVE
ON ON OFF ON Lead-acid (Wet) traction batteries)
 DIP5 DIP6 DIP7 for the selection of the CURRENT I1

DIP5 DIP6 DIP7 CURRENT
OFF OFF ON 14A
 DIP8 for the selection of the battery voltage

DIP8 VB
OFF 24
50
PRE-PROGRAMMED CURVES FOR CBHF1-SM
CURVE CURVE TYPE DIPSWITCH

DP1-DP2-DP3-DP4
00 IUa SO (IUa + float charge 2,30VPC) = IUUo ON-ON-ON-ON
Technology for charging DRYFIT TRACTION BLOCK (TRACTION
GEL batteries). In compliance with the DIN 41773 regulations.
01 IUIa Lead-Acid OFF-ON-ON-ON
Technology for charging TRACTION Lead-Acid batteries.
02 IUUa (2,45VPC) ON-OFF-ON-ON
A Technology for charging SEALED LEAD-ACID batteries.
03 IUUa (2,40VPC) OFF-OFF-ON-ON
Technology for charging Sealed Lead-acid and GEL batteries
batteries from Trojan and other manufacturers.
04 IUIa Lead-Acid + float charge at 2,30VPC ON-ON-OFF-ON
Technology for charging TRACTION lead-acid batteries.
05 IUUa (2,45VPC) + float charge at 2,30VPC OFF-ON-OFF-ON
B Technology for charging SEALED LEAD-ACID batteries.
06 IUUa (2,40VPC) + float charge at 2,30VPC ON-OFF-OFF-ON
Technology for charging Sealed Lead-acid batteries and GEL
batteries from Trojan and other manufacturers.
07 IUIa PzV OFF-OFF-OFF-ON
Technology for charging large capacity DRYFIT PzV (A800) GEL
batteries. In compliance with the DIN 41773 regulations.
08 IUIa GNB ON-ON-ON-OFF
Technology for charging GNB Sealed Lead-Acid batteries.
09 IUo (2,35VPC) OFF-ON-ON-OFF
Technology for charging Lead-Acid start-up batteries.
10 IUIa drysafe (HAGEN) ON-OFF-ON-OFF
Technology for charging DRYSAFE HAGEN batteries.
11 IUIa per TRACTION BLOCK + float charge 2,30VPC OFF-OFF-ON-OFF
Technology for charging DRYFIT TRACTION BLOCK batteries from
Sonnenschein, DETA and other manufacturers.
In compliance with the DIN 41773 regulations.
(This curve is an alternative of curve 00)
12 IUa for Lead-Acid batteries (2,40VPC) ON-ON-OFF-OFF
Technology for charging Lead-Acid starting batteries with stop.
13 Iua for Lead-Acid batteries (2,60VPC) OFF-ON-OFF-OFF
Technology for charging Lead-Acid starting batteries with stop.
14 --- ON-OFF-OFF-OFF
15 --- OFF-OFF-OFF-OFF
NOTES:
A: charging curves with charge stop.

B: charging curves equivalent to group A but with a float charge of 2,30VPC (maintenance
charge).
51
KIT EXTERNAL ELECTRONIC BATTERY CHARGER V02 (optional, FROMM code 16.8288)
This kit can be used for AGM / GELL and TRAXION batteries of all brands. It is important to check the
charger settings “dipswitches”. The settings need to be correct, in order to guarantee a correct
charging curve. Every type of battery has its own curve!
Check the document CHARGER CONFIGURATION below. (You have to be logged in at our website
to download this information.
http://www.fromm-stretch.com/Pages/Download.aspx?DownloadID=759
Set 16.8288 existing of:

1x FR3.1293 Charger
1x FR3.1292 Cable
1x FR3.1291 Cable
Item FR3.1293 Item code FR3.1293

Battery charger CBHF1 V2 24V 14A
Item FR3.1292 Item FR3.1291

Long “optional” cable to be used in combination Short cable for battery connection in the Robot.
with the kit external (Standard cable supplied with the machine, this
battery charger Code. 16.8288 code is not a part of the kit 16.8288)
52
BATTERY CHARGER / BATTERY “Version 04”
GENERAL INFORMATION AND WARNINGS

 Electronic automatic battery charger with microprocessor suitable for any battery type;
 Fully automatic charging cycle with electronic setting: protected against overload, short-circuit at
clamps and reversed polarity;
 Never disconnect the battery while charging: this could cause sparks;
 Never use the equipment in the rain, in areas used for washing or in damp areas;
 Before starting to charge, make sure the voltage of the equipment suits the voltage of the battery,
that the charging current suits the capacity of the battery and that the selected charging curve (for
lead-acid batteries or airtight gel batteries) is correct for the type of battery to be charger. In
addition, make sure the rated input voltage of the charger suits the avaible supply voltage and the
system is equipped with grounding;
 If necessary, replace the fuse with another of the same type and value as indicated on the rating
plate;
 Use battery chargers only in well ventilated areas;
 Pay attention to any remarks of the battery manufacturer.
For lead-acid batteries with liquid electrolyte:

 Control the water lever after each charging process;
 Refill with distilled water only;
 Caution! The gases generated during charging are explosive. Do not smoke in the vicinity of the
batteries. When working with cables and electrical equipment, avoid open lames and sparks;
 Attention: use protective glasses and gloves during battery maintenance. Battery acid causes
injuries. In case of contact with battery acid, wash the affected parts with a lot of fresh water and
consult a doctor if necessary.
INSTRUCTIONS MANUAL CHARGER
You must read this manual carefully and follow the instructions when charging the batteries or starting
up vehicles.
MARS SERIES DESCRIPTION

The high-frequency battery chargers MARS-SERIES are designed for use in industrial environments.
Particular attention was paid to meeting the needs different market applications require.
The battery chargers MARS-SERIES comply with the following European Directives:
89/336 EEC (electromagnetic compatibility)
72/23 EEC (safety of electrical equipment)
Installation
Use the battery charger inside an environment with the features that can warrant user safety and
correct opeartions for the device. It has to be: dry, ventiled and not dusty .
According to its protection degree IP, the battery charger, cannot be used under rain or water sprays.
The battery charger must not be installed in unsafe areas for the presence of other activities, like:
- chemical industries and wood industries: risk of flammable material.
- ceramics industries, due to the great quantity of dust.
- food and meat transformation industries, due to the great quantity of water and humidity.
In these cases it is necessary to install the battery charger in protected areas.
Recommendations:
Do not close the input and the output for forced ventilation in order to allow a correct cooling of the
unit.
For the same reason, do not store materials near the device and do not put liquid containers on the
battery charger.
53
Operation, commands, and views.

The chargers MARS-SERIES come with a backlit LCD display and three touch-sensitive buttons
(touch) that enable the data exchange between the device and the user.
At power on, the display lights up and gives information on the model and software release
housed on the microprocessor inside the charger. Ex:
Firmware 1.0 (software release 1.0) on MARS 2415 model.
It then provides compared to the options chosen. Ex:
Voltage 15V, 12A current
Pb battery liquid, end of charge equalized.
Then you see the flashing battery symbol which means that the device is not connected to a
battery.
When you connect a battery, the battery charger automatically begins to charge according to the
options. The state of charge is symbolized by a progressive scale and displayed numerically in%.
The charger can be stopped by tapping the start/stop button on the left for 3 seconds. Pressing it
again for 3 seconds the charger starts again and so on. The middle button is used to view, in
sequence, the battery voltage, amps provided instantly and the Ah loaded up to that point. The right
button turns on the power supply.
FRONT BUTTON COMANDS
V key: The left button "V" sets the voltage between 12V and 24V. Press again to alternate between
the two allowed values on the panel. When the charger is started (automatically) to load, becomes key
Start / Stop. In this case, keeping the finger pressed for 3 seconds, the charger stops and allows you
to disconnect the battery. After 5 seconds, if the battery is still attached, starts to load it.
MODE: The middle button "MODE" sets the mode of the device among those permitted and described
in the instruction manual.
A button: The button on the right "A" sets the current model of the allowed values for the model.
Pressures repeated successively bring the allowed values on the panel. When the charger has been
programmed as a power supply (Power Supply) assumes the function of the Start / Stop button. In
this case a pressure of 3 seconds ago from the power supply, the next press 3 seconds it stops and
so away. In this operating mode, the output current depends on the load and arrival at the maximum of
size (15A MARS 2415 50A MARS 2450, MARS 24100 100A).
54
CHARGING CURVES
The charging process is divided into 5 phases:

1 - Analysis. At battery connection, there is the analysis of the battery.
2 - Bulk. Phase of initial charge at constant current.
3 - Absorption. Charging, constant voltage which decreases the current drawn from the battery.
4 - Conditioning. Optional step of charging the batteries.
5 - Floating. Charging in the final buffer, an optional alternative to equalization.
CONNECTION TO THE MAINS
For connection to the mains use the outgoing cable from the unit to the end of which will be sufficient
to connect a suitable plug together with an earth terminal.
Avoid the use of extension cords.
The socket outlet to which you connect the battery charger must be proportionate to its power and
shall have built-in fuses or other protections.
Check the rating plate data with respect to:
V - (Supply voltage), KVA - (power) and A - (current)
Ensure correct earthing.
The replacement of the power supply cable must be carried out by competent and authorized
personnel.
CONNECTION TO THE BATERRY
For the connection to the battery, there are two cables coming out of one positive (+) marked in red.
Be careful not to reverse the cables connected to the battery terminals: to this end, we reccomend the
use of special, one direction connectors, supplied by the manufacturer.
PROTECTION DEVICES
The MARS Series chargers are protected from :

- Reverse polarity, with a fuse on the DC circuit;
- Accidental breakage, with a fuse on the power circuit;
- Overload and short circuit on the output, via electronic protection;
- Charger overheating due to special environmental conditions, with thermal protection device
that excreting pause the charger and restores only when the temperature of its components
back to normal.
55
MAINTENENCE
Maintenance must be carried out only by specialized and authorized personnel.

Control inspection and verification depend on the environment and on the operating conditions.
Before beginning any inspections or maintenance, make sure that the battery and the power
supply are disconnected.
We recommend that all internal electrical connections are periodically checked to make sure that the
wires and the lugs do not show signs of overheating due to a poor contact. Remove all accumulated
dust.
WIRING DIAGRAM
TRAXION BATTERY
www.exide.com
12ELEM.2EPZS100 24VAH5 (100Mah)

12/2 EPzS 120, 24 V, 120 Ah/5h (120Mah)
Dimensions: 580 x 215 x 390 L x W x H (Battery housing has to be an steel box)
AGM BATTERY
www.exide.com
AGM ZENITH BATTERY 2x 12V 106Ah

Dimensions: 307 x 169 x 237 L x W x H
Do you want to change the battery?

The connections of the traxion battery are the same those of the AGM battery.
When you remove the AGM batteries, also remove the bridge between them.
So, in the robot you have only 2 cables (+ and -) and the clamps are ok also for the traxion battery.
When change type of battery you have to change the charging curve.
FOR THIS OPERATION PLEASE CONTACT FROMM DISTRIBUTOR.
56
MAINTENANCE INSTRUCTIONS FOR OPERATORS
SAFETY!
- First switch off the main switch and lock it before carrying out maintenance on the installation.
- Take care, that other persons cannot put the installation in action.
- Take care, that the protection covers, etc. are remounted when putting the installation in action again.
The installation will have a long operational life due to preventive maintenance. This means, that the
various parts of the installation have to be monitored on a weekly, monthly, semi-annually or annually
schedule.
The operational lifetime is influenced by the environmental conditions. The indicated maintenance
frequency is valid for normal operation conditions (8 hrs per day, 20 C, clean environment).
One is advised to increase the maintenance frequency under more severe conditions.
Keep rotating parts free from dirt.
REMAINDER OF THE FILM

The machine has to be cleaned every day
Never use solvents to clean the machine. To remove dust or particles deposited during the size
changeover operations, never use compressed air: only use rags and aspirators.
Check if any film and packaging remainder are present in the brake system and remove it.
57
DAILY
Particular attention must be given to the charging of the Robot battery in order to ensure a long
lifetime. The electronic control unit also incorporates the battery charger which operates under a tight
control of the main electronic control unit.
The frequency with which the battery charger must be charged depends on the machine. The most
important rules to preserve battery life are:
- Do not leave the batteries half charged or fully discharged for a long period.
- Charge the batteries when the operating panel indicates that the battery is discharged.
Extended use when batteries are discharged can cause irreparable damage.
How to recharge:
Connect the tension cable to the machine (Fig 1)
and next to the electrical socket. Leave the Robot
under charging.
Figure 1
After connecting the plug the process of charging

will start in a few seconds. If the charging will be
interrupted, the charging will re-start from the
initial point of charging, when the connection is
re-stored.
The green LED (Version03) or 100% (Version04)

indicates that the charging has been finished with
success.
Figure 1
For any other reporting refer to the technical manual of the charger.
WEEKLY
Cleaning. Using only isopropyl alcohol and a non-stringy cloth, thoroughly clean off any trace of dirt
from all the working and transport surfaces of the machine, as dirt may cause surface friction and
sliding problems. Where appropriate use only a cloth soaked in hot water.
58
HALF YEARLY
1 2
Fig. 1
Fig. 2
Check that the feeder wheel arm (1) always returns in HOME position. If not replace the spring.
Check the status for wear and tear of drive and guide wheels and the rubber coated roller of the roll-
holder carriage; if necessary replace them.
7
2
Figure 3
5 6
59
Turn off the machine and check the play of the roll-holder carriage. (Fig 3)
If the carriage (1) can be freely lifted with a few centimetres, the chain (2) must be tensioned in the
following way.
- Loosen the screw (5), tighten the screw (6) until the oscillation of the slow branch, measured
at the half height of the column, is contained in 2 cm. Tighten the screw (5).
- Lubricate the chain with grease.
6
ALIGNMENT SPROCKET CARRIAGE 7:
After the replacement of the three sprockets you have to check that the pinions:
gearmotor, roller 2 and 3 are all aligned (picture 4):
- Close the door and lock it well with the screws (picture 1 and 2), check that there are no
oscillations;
- Check that the rollers are parallel between themselves (picture 3) and with the frame;
- Check that the toothed faces of the sprockets are aligned between themselves;
- Check the backlash / the space between the tooth of the sprockets (usually a tenth of a mm)
After 15 days of work on the operation of the machine check that all the above points.
Fig 1
Fig 2
Fig 3 Fig 4
60
MAINTENANCE SCHEME
MAINTENANCE FREQUENCY
8 hr 40 hr 100 hr 200 hr 500 hr 1000 hr 2000 hr
Daily cleaning X
Cleaning eye of photocell X
Shaft chain 4
Bearings X
Friction discs X
Proximity and limit switches X
Electrical system X
Sliding wheels X
Support wheels X
The numbers in the maintenance scheme refer to lubricants, which are to be applied in the table with
lubricants (hereunder).
The symbol "X" in the maintenance scheme refers to remarks concerning the maintenance of or
checking on the relevant part or system.
LUBRIFICANTS
No. LUBRIFICANT
SHELL BP ESSO MOBIL OIL TEXACO
1 OMALA 220 ENERGOL SPARTAN MOBILGEAR 630 MEROPA 220
GR-XP 220 EP 220
2 OMALA 680 ENERGOL SPARTAN MOBILGEAR 636 MEROPA 680
GR-XP 680 EP 680
3 TONNA T68 MACCURAT 68 FEBIS K 68 VACTA.4 WAX LUBRI-
EP220 CANT X68
4 ALVANIA R ENERGREASE BEACON 2 MOBILUX 2 MULTIFAK EP2
L2
5 TELLUS 46 HPL 46 NUTCO H46 DTE 26 RANDO HD46
6 TORCULA 32 ENERGOL AROX EP 56 ALMOBIL 1 ARIES 32

RD-E 80
7 TELLUS 15 RANDO HDZ 15
8 RETINAX WB STARPLEX
PREMIUM 1
(depending on
the application)
61
MANIFACTURER
FROMM Wrapping Systems S.r.l.
Viale del Lavoro, 21
37013 Caprino Veronese (VR)
Italia
Tel. +39 0452057300

Fax +39 0452057373
P.IVA 04146150232
[email protected]
DOCUMENTATION
For the spare parts, check the separately delivered spare-parts booklet.
Or download directly from our website:
http://www.fromm-stretch.com
Or contact your Fromm Distributor.
62
CE-Declaration of Conformity
(CE machine directive 2006/42/EC - Annex IIA)
Manufacturer FROMM Wrapping Systems S.r.l.

Italia
Declare under our responsibility that the product
Model: FR3xx/FR4xx
Item number: 32.21X.XXX
Serial number: 04. XXXXX
Production year 2015
Type of machinery Pallet Stretchwrapping machine
Following the provisions of directive:

2006/42/EC (Directive)
2004/108/EC (Electromagnetic compatibility)
2006/95/EC (Low tension)
Harmonized standards, national standards and other normative documents refer to Legislative Decree
17/2010 point 7.
Technical file at: FROMM Wrapping Systems S.r.l.

Italia
Written in: Caprino Veronese (VR)

Date: 2015
Name: Sig. Fromm Reinhard
Function: Legale Rappresentante
63
WARRANTEE CONDITIONS
FROMM Distributor to End-user.
Warranty over a period of 12 months, using the machine in operation

8 hours a day, 40 hours a week. The warranty includes all deficiencies clearly resulting from poor
manufacturing or faulty materials.
The warranty excludes:

a) wearing parts.
b) deficiencies resulting from improper stocking, incorrect handling and use as well as from using
strapping / stretch film qualities not recommended by FROMM.
c) deficiencies resulting from improper repair work made by the customer.
Warranty lapses as soon as the installation is not maintained according to supplied maintenance- and
operating instructions.
The warranty concerns the parts to be replaced, inclusive the necessary repair hours.
Damage claims as a result of production shutdowns and claims for damage to persons and to property
resulting from warranty deficiencies cannot be asserted by the customer.
Maintenance costs
Ask your local distributor / supplier for the maintenance cost per year / service period.
Service will be provided according FROMM service conditions / contracts.
64
SERVICE LOGBOOK
Service / Maintenance executed Service / Maintenance executed

Date: Date:
Engineer: Engineer:

Date: Date:
Engineer: Engineer:

Date: Date:
Engineer: Engineer:
65
SERVICE LOGBOOK

Date: Date:
Engineer: Engineer:

Date: Date:
Engineer: Engineer:

Date: Date:
Engineer: Engineer:
66

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FR3.1413-Manual-32.21X.XXX.03.04-EN-Version01.

11 Handeling & Transport

16 Basic operating Instructions

17 Start wrapping Cycle

19 Errors during operation

20 Possible errors during first installation

22 Insering the film

23 Battery charger / Battery

24 Kit external electronic battery charger (optional)

26 Maintenance sheme & Lubrificants

27 Mandatory & Manufacturer / Documentation

32.211.220 FR331 OP1/B1/H2500mm/C2

32.211.320 FR332 OP1/B1/H2800mm/C2

32.211.161 FR390 OP1/B1/H2200mm/C6 With cutting device

32.211.261 FR391 OP1/B1/H2500mm/C6 With cutting device

32.211.361 FR392 OP1/B1/H2800mm/C6 With cutting device

 FOR EVERYTHING IN THIS MANUAL IS VALID, IF APPLIED!

SERVICE DEPARTMENT Please contact, in case of problems:

 Use the emergency stop to halt the machine immediately

 Only trained electricians may perform electrical work on the machine

 Don’t find yourself near the robot when is in operation.

 Don’t touch the pallet when the machine is in operation.

 Don’t put your hand or fingers in the mast.

 Don’t put your hand or fingers in the electrical box.

 The requirements, as mentioned in chapter MAINTENANCE INSTRUCTIONS should be satisfied

 People should not find themselves above the means of transport

 Do not place tools and components on the machine

 Safety devices should not be bridged and put out of operation

ADDITONAL SAFETY INSTRUCTIONS ROBOT FR3xx

 IN OBSERVANCE OF Machine Directive 2006/42/EC AND SUBSEQUENT

Risk of getting trapped.

 OPERATOR STANDING ZONE

Refer to the drawing below for the applied references.

Survey control panel

C= Light On, when

WARNING: ON PARTICULARLY SMOOTH OR SLIPPERY FLOORS, THE ROBOT

WARNING: DO NOT REMOVE THE SAFETY BUMPER AND ALWAYS REFIT IT

 Touching the electrical equipment will hazard your personal safety.

EXPLANATION IDENTIFICATION STICKER

Name of the manufacturer : FROMM Wrapping Systems s.r.l.

Type : Machine type.

Serialnr. : Production number of manufacturer.

Voltage : Supply voltage.

Power : Used power

Besides, the CE-mark has been placed on the identification plate:

Machine fulfils the applied requirements as mentioned in the CE - machine directives

Weight - Total weight FR3xx approx. 330kg

Electrical - Power supply 1 x 230 V 50/60Hz

Pallet goods - Max. Pallet dimensions (Length x width) No Maximum

- Min. Pallet dimensions (Length x width) 600 x 600 x 140mm

- Dimensions of load outside pallet max. 20mm / 0,79” per side

Stretch-film - LLDPE Material Max 27μ / 0.0011”

Colors - Mast : Blue, RAL 5010

WARNING : do not use film thicker than 27 microns without

DIMENSIONS DURING WRAPPING

Risk of crushing one’s hands

Risk of crushing hands and feet

It is prohibited to pass by within the lifting equipment’s ray of action