DM210575 270715 LWP en C

LWP
Wrap-around case-packers
Use and maintenance manual
Registration n°...................................... Year of construction...................
Manual code: DM210575

Revision C - Creation date: 30/08/2010
Latest updating date: 27/07/2015
Summary
Summary
1 – GENERAL INFORMATION 11
1.1 How to read and use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Keeping of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Use of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Documents provided with the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Reading the manual and symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Operators to whom the manual is addressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Warranty and disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7 Relevant directives and laws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.8 Instructions for service requests and to order spare parts . . . . . . . . . . . . . . . . . . . . . . . . 15
1.9 Terms and abreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.10 Instructions to contact the service centre (INTERNET) . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.11 Instructions to activate the on-line service (INTERNET) . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.12 Method for manual updates in case of machine modifications . . . . . . . . . . . . . . . . . . . . . 17
2 – PRELIMINARY INFORMATION ON THE MACHINE 19

2.1 Machine description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Machine units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Standard painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Glue characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Cardboards specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8 Pneumatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.9 Use environment destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 – SAFETY AND ACCIDENT-PREVENTION 31

3.1 General warnings and rules of behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Safety pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 Prohibitions and precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
It is forbidden: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
It is compulsory: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4 Individual protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5 Buttons on the control panel (Posyc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.6 Safety systems and protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.7 Work, command and dangerous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.8 Residue risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.9 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.10 Instructions for emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3
Summary
4 – UNLOADING OPERATIONS AND STORAGE 41

4.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2 Transport and handling of packaged/unpackaged machine . . . . . . . . . . . . . . . . . . . . . . . 41
4.3 Weight and dimension machine module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.4 Handling the machine module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.5 Handling the infeed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.6 Pictograms found on the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.7 Examples of packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.8 Unpacking and content check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.9 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5 – INSTALLATION 47
5.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Conditions and place of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Positioning in the installation place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 Positioning and levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.5 Connection to the energy sources and relative checks . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6 Equipment supplied together with the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6 – COMMISSIONING 51
6.1 Premise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Warnings for the users: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2 Controls and signalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.3 Machine description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.4 Summary of the pages making up the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.5 Meaning of the light column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.6 Preliminary system tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.7 Switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.8 Start up after switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.9 Direct commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.10 Machine operating modes and states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.11 Machine control buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Restart after emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.12 Running of the machine and control during operations . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.13 Procedure for axes recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.14 Servo motors phase search procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.15 Start up after an alarm or emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.16 Problems/faults (ALARMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
The signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
The general operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
The electrical/mechanical maintenance operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.17 Operating the subsystems switch on timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7 – INSTRUCTIONS FOR FORMAT CHANGE 57

7.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4
Summary
Qualified personnel: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.2 Blank magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.3 Cardboard climb unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.4 Adjusting the guides of the infeed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.5 Adjusting the "push-down" arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.6 Channeler guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8 – REGULATION AND ADJUSTMENTS 63

8.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.2 Phase-setting - Lower cardboard case/tray-forming unit . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.3 Phase-setting - Upper cardboard case/tray-forming unit . . . . . . . . . . . . . . . . . . . . . . . . . 65
9 – CLEANING AND MAINTENANCE 67

9.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.2 General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.3 Maintenance state procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.4 Extraordinary maintenance - maintenance state procedure . . . . . . . . . . . . . . . . . . . . . . . 70
9.5 Notes on cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.6 Notes on lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.8 Key to maintenance symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.9 Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.10 Maintenance interventions coupon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10 – REPLACEMENTS 83
10.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.2 Periodic replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.3 Blank magazine unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.4 Cardboard separator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.5 Cardboard ramp unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.6 Separator conveyor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.7 Separator bar unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.8 Carton feeding unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.9 Flap folder unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.10 Bottom former unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.11 Upper former group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.12 Inlet belt group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.13 Battery replacement (Every five years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
11 – DISMANTLING AND DEMOLITION 119
ANALYTICAL TABLE OF CONTENTS 121
5
Summary
6
FOREWORD
In thanking you for the preference given to, SMI S.p.A. is glad to welcome you to its wide circle of
Clients and hopes that the use of this machine satisfies you completely.
This manual has been prepared to enable you to intervene on the various machine parts and to
clarify the various maintenance and intervention operations.
The respect of the prescriptions of Periodical Programmed Maintenance, can optimize the
machine performance and prevent the customer from losing the Guarantee right, due to
failure to carry out the operation required by the Manufacturer and indicated in detail in this
Operating and Maintenance manual.
To get the best performance, use SMI original spare parts, and always contact our servicing centres
for each maintenance operation. Electrical motors, electric/electronic components and auxiliary
equipment which are not manufactured by SMI, are guaranteed with the same modes nad
extensions provided by the Manufacturer.
This manual contains the descriptions of the most complete model. In some systems, though, all
the functions shown may not present.
In order to guarantee a satisfactory level of efficiency, life and performance of the machine, we urge
you to scrupously observe the instructions contained in this manual.
The characteristics, data and drawings published are and will remain the exclusive property of SMI
S.p.A. The reproduction and distribution to Third Parties, even partial, is forbidden, and
punisheable by law.
7
CE DECLARATION OF CONFORMITY (Directive 2006/42/EC - Attachment IIA)
FAC SIMILE
The Manufacturer of the Products covered by this Declaration:
SMI S.p.A. Via Ceresa, 10
24015 S. Giovanni Bianco - Bergamo (Italia)
Phone: +39 0345 40111 Fax: +39 0345 40209
Person authorized to write the technical dossier:

SMI S.p.A., Via Ceresa 10 - 24015 S. Giovanni Bianco - Bergamo (Italia) - Tel.: +39 03 45 40372
Fax: +39 03 45 40209
The manufacturer hereby declares that the machine model: LWP......................

Serial number: PC......................
Equipment purpose and application: Wrap-around case-packers
complies with the directive 2006/42/EC and with the norms following the provisions of
directives 2004/108/EC (Electromagnetic compatibility)
The product also complies with the harmonized norms:

• UNI EN ISO 12100:2010;
• ISO 13849-1:2008 + AC:2009;
• CEI EN 60204-1:2006;
• CEI EN 61439-1:2012;
S. Giovanni Bianco, 13/03/2012
SMI S.p.A.
Legal Representative
8
Statement of no risk of vibration transmission to operators working on SMI packag-
ing machines.
SMI S.p.A., situated in S.Giovanni Bianco, Via Ceresa n° 10 I-24015 Italy, declares that the
mechanical and non-mechanical components of the machines models:
LSK
SK
SR
ECOBLOC®
PSHA - HA
CM - LCM
MP - RD
WP - LWP
DV200 - DV500
ST
TF
LINE
OUTLET CONVEYOR BELT
AUTOMATIC PALLETISING
do not generate any risk of vibration transmission to operators, either by direct or indirect contact .
As a consequence, the present harmonized norms about the evaluation and the measurement of
the vibrations (UNI EN 28662-1:1993, UNI EN 28662-2:2003, UNI EN 28662-3:2003, UNI EN
28662-5:2003, UNI EN 30326-1:2009) are not applicable to SMI S.p.A. machines.
SMI S.p.A.
PAOLO NAVA
9
10
General Information
1 GENERAL INFORMATION
1.1 How to read and use this manual

Keeping of this manual
• This manual constitutes integral part of the machine and must be kept for as long as the machine
is in the user's possession or, if that be the case, handed over to any other user or subsequent
owner.
• Use this manual in a way that will not damage all or part of it.
• Do not remove, tear or re-write parts of this manual for any reason.
• Make sure that any update received is included in the manual.
Use of the manual

The consultation of this manual is easy as the insertion, in the first pages, of a summary, allows
those consulting it to immediately locate the topic required. The chapters are put in order following
a structure that facilitates the research of the required information.
The manufacturer has designed the machine with the aim of guaranteeing safe use conditions. The
exclusion of the electric safety systems or the removal of the protections envisioned by the
manufacturer, seriously jeopardises the safety conditions of the operator or of the exposed
persons.
Said conditions are also subject to the compliance with the indications in this manual and in those
attached.
This manual was drafted by SMI S.p.A. in its original language and translated into various
languages from the original Italian. Should conflicts emerge owing to the different language
versions, please refer to this manual in the manufacturer's language.
1.2 Documents provided with the machine

- Use and maintenance manual
- Operator interface manual
- Wiring diagram manual
- Spare parts manual
1.3 Purpose of the manual

This manual and the attached documentation must be carefully read before carrying out any
operation on the machine in order to avoid possible damages to the same machine, to
persons and to things.
Pay particular attention to Chapter 3 , as it contains important and detailed information and
warnings relating to safety. The same information will be briefly recalled in the operational situations
where the described risk re-arises.
It is important to keep the manual and all attached documents in a place with easy access, near the
machine and known to all users (operators and maintenance personnel). The operators and
maintenance personnel must be able to rapidly find and consult said documentation, in any
situation.
11
General Information
SMI S.p.A. declines all liability for any faults, accidents or various inconveniences due to the non-
compliance with the prescriptions contained in this manual. The same is valid for the unauthorised
modifying, varying and/or installing of accessories.
1.4 Reading the manual and symbols used

This manual is composed of:
- an introductory page;
- an index of the topics;
- Texts and warnings divided into chapters, paragraphs and subparagraphs;
WARNING!
It indicates the risk situations for persons, it recalls accident-prevention Standards, it
suggests behavioural procedures.
WARNING!
It indicates the risk situations for the machine and/or for the product being processed.
NOTICE!
It indicates the useful information for manual consultation machine good functioning.
1.5 Operators to whom the manual is addressed
First level plant conductor.

Unqualified personnel able to carry out only simple tasks, like the running of the plant through the
use of commands on the push button control panels and operations during production, with the
protections installed and active.
Second-level system operator.

Unqualified personnel capable of performing the duties of first-level system operators; previously
trained to perform operations when the machine is in EMERGENCY status, exclusively aimed at
restoring the production cycle after the jamming of any products in transit on the conveyors. For this
procedure, refer to the "CLEANING AND MAINTENANCE" chapter in this manual.
Mechanical operators.
Qualified technician able to run the plant in normal conditions, to make it work in AUTOMATIC
mode, in case of machine in state of EMERGENCY, to intervene on the mechanical parts to carry
out all adjustments, maintenance and repair interventions. He is not usually enabled to intervene
on powered electrical plants.
12
General Information
Electrical maintenance technicians.

Qualified technician capable of running the system in normal conditions and also of operating it both
in AUTOMATIC mode and when the machine is in EMERGENCY status. This technician is in
charge of all electrical-related interventions involving adjustments, maintenance and repairs. The
electrical maintenance technician is able to work when live voltage is present inside electric
cabinets and junction boxes, only if authorized by his/her own company, in accordance with
Standard EN 50110-1 or equivalent European Standard. The electrical maintenance technician is
the person who is entrusted to keep the keys of the electrical boards.
Qualified technicians.
Personnel of the Technical Support Center (T.S.C.) of SMI S.p.A., personnel authorized by SMI
S.p.A. or customer maintenance personnel trained by the Technical Support Center (T.S.C.) of SMI
S.p.A., trained in installation, special maintenance, repairs and complex operations;
In the event the foregoing personnel are not used, SMI S.p.A. shall not be liable for any
consequences relating to personal injury or damage to the system.
The conductors must not carry out operations reserved to maintenance operators or
qualified technicians. Furthermore, the conductors must not be entrusted with the keys to
the electrical control boards.
1.6 Warranty and disclaimer

SMI S.p.A. declines every liability deriving from:
- improper use;
- use by unauthorised and/or untrained personnel;
- partial or total non-compliance with the instructions;
- energy power supply faults (electrical, compressed air);
- failure to perform maintenance;
- machine contamination from outside;
- unauthorised modifications and repairs;
- use of non-original spare parts;
- exceptional events like earthquakes or floodings, fires (unless caused directly by the machine).
The warranty conditions are defined by the agreements reached between the parties when the
contract was drawn up. When the machine is sent to the Customer, it is ready to be installed since
it has already passed all the expected tests and inspections at the factory, in accordance with the
legislation in force in the Manufacturer's country.
The machine must be started up by SMI technicians or by personnel authorized by SMI S.p.A.
Before commissioning the machine, the user must appoint at least one person who will be trained
by SMI S.p.A., normally on site, on how to run and control the system.
The Customer is in charge for routine maintenance operations on the system as indicated in this
Manual.
The warranty is only valid if the User uses SMI S.p.A. original spare parts for all maintenance
operations.
The warranty for the complete system is valid for a period of 18 months from the shipping date, as
indicated below:
13
General Information
• During the warranty period, SMI S.p.A. undertakes to remove any flaws or faults, as long as the
periodical maintenance is performed and original parts are used. Consumables, which are
sometimes supplied together with the machine, are excluded from the warranty. The Purchaser
must report in a written form such defects within 10 days after they have been discovered or
they should have been discovered;
• The warranty covers all defects of materials, components and related processing methods, as
well as the interventions required to start up the machine again. If repairs are necessary, SMI
S.p.A. will send the suitable personnel at its own expense, with no cost for the Customer. The
Customer will only have to bear the travel, room & board costs for the aforesaid personnel.
• The Purchaser will return to SMI S.p.A. the old parts replaced under the warranty. SMI S.p.A.
reserves the ownership of such old parts.
• SMI S.p.A. will replace or repair (according to its technical assessments), free of charge, all the
components that prevent the appropriate system operation, and will also restore standard
operation of the system. If repair operations are required, the User must allow SMI S.p.A. or its
authorized operators to perform such interventions providing the necessary equipment and the
relevant assistance on the site.
The warranty will be null and void with immediate effect in the following cases:
0.1 improper use of the machine
0.2 change of the process conditions
0.3 unauthorized tampering by third parties
0.4 failure to comply with the instructions contained in the manual
0.5 failure to use SMI S.p.A. original spare parts
All points indicated above must be applied unless otherwise stated by SMI S.p.A. with a written
authorization.
• The warranty does not cover any consequential damages resulting from malfunctions or
breakdown of the SMI S.p.A. system, such as a loss of production and related implications.
• The warranty also does not cover any damage caused by galvanic currents, chemical corrosion
or failure to follow the instructions provided in the SMI S.p.A. manual, failure to comply with
appropriate environmental conditions, or if the user adopts improper or unapproved conditions
or technical modifications which were not officially agreed with SMI S.p.A., even if they do not
concern the damaged part of the system.
• The repairs carried out under warranty do not interrupt or extend the warranty period.
• The warranty does not cover parts subject to normal wear and tear such as conveyors,
separator push fingers, case/tray-forming unit belts, case/tray-forming unit fingers,
1.7 Relevant directives and laws

The machine "Wrap-around case-packers" complies to the Legislative Provisions of the law that
regulates the following Directives.
European Directives on machinery and/or assemblies:
• 2006/42/CE - On the approximation of the laws of the Member States relating to machinery.
• 2006/95/CE - Low voltage directive.
• 2004/108/CE - Electromagnetic compatibility.
Technical standards applied on machinery and/or assemblies:
• EN ISO 12100:2010 - "Safety of machinery - General principles for design - Risk assessment
and risk reduction"
• EN 13849-1:2008, "Safety of machinery - Safety-related parts of control systems - General
principles for design";
• EN 60204-1: 2006, "IEC 44-5, "Safety of machinery - Electrical equipment of machines - Part 1:
General requirements"
14
General Information
• IEC EN 61439-1:2012, "Assemblies and protective devices for low voltage (BT boards) part 1"
1.8 Instructions for service requests and to order spare parts

SMI S.p.A. has formed, within its organization, a CLIENTS ASSISTANCE DEPARTMENT for any
request of information and support.
For spare part requests and to consult the manual, use the SMYCLOUD service using the User
name and Password sent via e-mail upon machine delivery. Enter your serial number in the search
box or follow the navigation items
Fig. 1 Instructions for service requests and to order spare parts
1.9 Terms and abreviations
DEL Delete
Diatermico That conduct heat
Encoder Device counting the motor revolutions for the machine position
ENTER Send/confirm
ESC Exit/quit.
HELP Help
Inverter Device that changes the current frequency.
Motor Brushless Synchronous motor without brushes
OFF Turned off
ON Turned on
Operator Person in charge of running, regulating and cleaning the machine
Packing-list List of the parts of the machine contained in the shipment case
Exposed person Any person that is entirely or partly in a dangerous zone
PLC Computer that controls the functioning of the machine
Power Power
START Start-up
Timer Timer
Utility Utility
15
General Information
1.10 Instructions to contact the service centre (INTERNET)

In the official site "www.smigroup.it" in section "Contacts" the item Contact persons is active.
According to your needs, you will find a person who will help solve your problem.
Fig. 2 service centre
1.11 Instructions to activate the on-line service (INTERNET)

In the official site "www.smigroup.it" under section "Smipass services", item "On-Line service" is
active. This service has been created to offer you an first line 24H support for problem solving. You
can access a series of data sheets, grouped per type of machine, which can be opened using
ACROBAT READER.
Fig. 3 on-line service
16
General Information
1.12 Method for manual updates in case of machine

modifications
The descriptions and drawings contained in the present manual are intended as non-refutable.
SMI S.p.A. reserves the right at any moment to modify its machines (while keeping their essential
characteristics), for the purpose of improving their functionality and commercial and aesthetics
value, without being bound to immediately update this manual.
Any possible subsequent revision of this manual will be made following modifications or functional
replacements to the machine; the whole chapter pertinent to the part of the machine or to the
functions object of the modification will be replaced.
We would like to thank you in advance for all the suggestions that you may want to forward to us in
order to bring about further improvements to the machine.
Any comment can be sent to:
SMI S.p.A. - Via Ceresa, 10 - 24015 S. Giovanni Bianco (BG) - ITALIA
17
General Information
18
Preliminary information on the machine
2 PRELIMINARY INFORMATION ON THE MACHINE
2.1 Machine description

The casepacker was designed, built and sold for the packaging of products, such as bottles,
jars, cans, bundles and other containers, in corrugated cardboard boxes.
It is also available with the optional device for the insertion of pre-assembled cardboard partitions
between the products, thus granting the best protection of the products during transportation.
The machine performances are detailed in the attached Machine Operator manual.
It is forbidden to:
• Work differently from how indicated on operator manual;
• Substitute or change the speed of the machine's components;
• Change the machine cycle;
• Use unoriginal parts;
• Modify the electric connections to bypass the internal safeties;
• Remove the installed protections.
Every other USE of the machine of the product being processed is considered improper,
unintended, therefore dangerous. The use of the machine for the processing of other
materials or to obtain production values higher than the prescribed limits, is considered
"IMPROPER USE".Therefore, the manufacturing company is exempt from the
responsibilities deriving from the non-compliance with these prescriptions.
Before performing any modification you must contact SMI S.p.A. to obtain the relevant
authorization.
19
2.2 Machine units

The machine is mainly made up of the following units:
BLANK MAGAZINE UNIT

Ensures the cardboard supply. The
cardboards are placed in groups, one side of
1 which is positioned against a reference guide.
They are conveyed by means of a motorized
belt.
CARDBOARD SEPARATOR GROUP

It pulls cartons from the magazine using
2 suction cups, powered through a Venturi
pump, and arranges them on the carton
upward movement conveyor belt.
CARDBOARD CLIMB UNIT

The carton, tray or pad is moved to meet the
product by a brushless driven chain on which
3 pushing pins are fixed at machine pitch. The
exact position and the correct number of
cartons are checked in this group.
20
INFEED CONVEYOR GROUP

A conveyor run by a brushless motor conveys
4 the product into the machine. Independent
speed regulation.
INFEED CONVEYOR SENSORS GROUP

Controls the flow of the product at the inlet by
5 modulating the speed of the machine in
accordance with the presence of the product.
OSCILLATING CHANNELER UNIT

It is on the infeed belt. It channels the product
6 according to the number of rows the format
requires.
FLAGS GROUP
7 Controls the constant presence of the product
at the inlet of the separator area.
21
VERTICAL PRESSING ROD GROUP

Divides the product in the groups required by
8 the format. In this zone the product is checked,
in order to be correctly positioned and spaced.
COMPENSATING BARS UNIT

This device is managed by a brushless motor
9 to maintain the thrust on the separator belt unit
smooth and constant. This device improves
product separation.
DIVIDING BELT GROUP

It consists of a belt equipped with a device
10 dividing the products into the required pack
collations.
DIVIDING BARS GROUP

They push the product group, after this has
been separated, through a passage plate by
loading the cardboard (tray or pad) or directly
11 onto film in the wrapping area for products
using film only. They ensure that the product is
spaced at the machine pitch . It is moved by a
brushless motor.
CONVEYOR BELT GROUP

It connects the adjustable belts to the pack
12 former, allowing the product to overlap with the
carton and the beginning of the pack closure
by means of lateral pipes.
22
LOWER CASE/TRAY-FORMING UNIT

13 Used to form boxes; made up of fingers and
lateral guides to fully close the box.
UPPER CASE/TRAY-FORMING UNIT

14 Used to form boxes; made up of fingers and
lateral guides fully close the box.
FLAP FOLDER GROUP

15 It allows folding of the front and back ends of
the carton. A brushless motorruns it.
HOT MELT UNIT

It heats the glue and pumps it into the
16 applicating guns. It is used for the melting and
for the application of the hot melt material.
23
17 ELECTRIC CONTROL BOARD
2.3 Standard painting
PAINTING
The main structure sand blasted by 2.5 SAZ grade according to SIS regulations and degreasing
by solvents.
Powder painting with kiln cooking at 160 ºC.
Painting structures with powder RAL colour 5002
Painting electric cabinet with powder RAL colour 7035.
24
2.4 Glue characteristics
We advise you to use eye protections and suitable clothing when handling the melting with a lot of
running water and recur to medical care . Do not add water or other solvents to the glue in the
melter. We advise you to keep the lid of the melter closed, to work in an open or ventilated space
and to avoid the inhalation of fumes. This glue does not contain toxic substances.
25
2.5 Cardboards specifications

The flatness and form tolerance must be < 2 %: measurement effected on an unused carton placed
on a flat surface.
Packing has to often face environmental and climatic variations, as the hygrometry changes
influence its performances, when choosing the cartons, pay attention to the their dampness
absorption resistance.
• Indications for the packing and the stockpiling of the cardboards.
The tension of the bindings must not be excessive, to avoid the deformation of the cardboards. The
palletization has to preserve and to guarantee all the characteristics necessary to the
mechanization of the packings, declared by the supplier.
1 Pallets in wood
2 Angular support cardboards
3 Metal or plastic straps
4 Cardboards
Store in a clean and dry place with a relative dampness not higher than 65-70%.
2.6 Technical data
Do not move away from the values or working limits described in this paragraph.
Every other unintended use, in that non-compliant with the project and technical
specifications, is to be considered "NOT ADMITTED".
The machine's technical data are indicated on the following identification plates:
26
1 Model
2 Serial number
3 Year of construction
1 Rated voltage
2 Rated frequency
3 Rated active power
4 Rated apparent power
5 Power factor
6 Rated current
7 Short-circuit current
8 Serial number
9 Model
If the supply voltage stated by the customer and taken as a reference for parameters
setting were different from the actual value, it will be necessary to check if the supply
voltage value is within the compatible voltage range indicated on the plate; as a
consequence, it will be necessary to check the connection of the (multi-voltage)
transformers and to set the parameters of the Cosmos drivers at the actual voltage.
2.7 Electrical system
The electrical system is composed by:

- a system management electric control board
- an operator interface on the machine;
- a series of junction boxes, wiring and electric cables on the machine.
It is realised in compliance with Standard CEI EN6O2O4-1.

The electrical cabinets are able to supply protection of materials against external agents (protection
degree IP 54). To access, the provided key must be inserted (assigned exclusively to authorised
personnel) in the locks on the front doors of every control board.
27
Degree of protection of the electric equipment:
Micro safety: IP 65
Solenoid valve: IP 65
Electric board: IP 54
Protection box and command: IP 55
Brushless motors: IP 65
Asynchronous motors: IP 55
Direct current motors: IP 54
Inverters: IP 55
Digate: IP 65
Agate IP 65
Photoelectric cell: IP 67
Sensors: IP 67
Glue unit: IP 54
The list of electrical components and relative connection layouts are reported in the
attached electrical layouts.
2.8 Pneumatic system
The list of components and relative connection layouts are reported in the attached
pneumatic layouts.
It is a good rule to remember that the compressed air necessary for the functioning of all
pneumatic units must be purified.
The presence of impurities contained inside the air coming from the compressor and the
condensed humidity, favour the wear of the gaskets and of the relative sliding surfaces,
jeopardising the functionality and duration of the pneumatic components.
Compressed air:
Working pressure 6 bar
Max. consumtion LWP30 460 Nl/min
Max. degree of impurity:
solid particles 40 µm
liquid particles 0.5 PPM
28
Pneumatic system
2.9 Use environment destination

The machines must work exclusively in closed environments, protected from atmospheric agents,
where there is no risk of explosion.
The work place must have sufficient natural light and must have adequate artificial light to protect
the health and safety of the operator.
The minimum lighting of the premises must guarantee good visibility of every part of the machine,
whereas the maximum must be such to avoid dazzling the operator (for normal use 250-300 lux of
artificial or natural light; for maintenance 500 lux of localised light in the point of intervention).
The width of the work place must be such to guarantee an area where the production cycle can be
controlled without risks (the operator must be able to stay inside such area while keeping at a safe
distance from the machines (minimum 800 mm, in total safety).
This area is called RESPECT AREA FOR THE OPERATOR and it must contain all WORK and
COMMAND AREAS. It must remain dry and clear of obstacles. Accesses to the work and command
areas must respect safety distance needed for the cleaning or maintenance operations (minimum
distance is 0.8 m).
It is important to pay particular attention to the environmental conditions of the work place
where a SMI machine will be installed. A cold temperature, below +10°C, may cause
problems both to the machine and to the product to be processed. The working
temperatures can vary from +10°C to +40°C, with relative humidity from 30% to 80% without
condensation.
The references relating to the horizontal and vertical signals are defined by the
manufacturer in the "use environment" layout in the "Wiring diagramas" attached; it is the
responsibility of the user to apply and integrate said signals.
29
30
Safety and Accident-prevention
3 SAFETY AND ACCIDENT-PREVENTION
3.1 General warnings and rules of behavior
Before working it is extremely important to read:

- every part of this chapter, as it contains important information on the risks the operator
may take in case of incorrect use of the machine;
- the specific descriptions on safety that are reported at the beginning of every chapter.
3.2 Safety pictograms

Safety plates are placed on the machines and on the electric cabinets, they draw the attention of
the operators on dangers and relevant precautions.
In case a plate is worn or removed, it is necessary to replace it with an identical one.
Below is a list of those present in the access areas to the machine
Pictogram Description
DANGER OF HIGH VOLTAGE WITH RISK OF ELECTROCUTION

INSIDE THE ELECTRIC SWITCHBOARD.
DANGER OF CRUSHING
DANGER OF BURNING CAUSED BY CONTACT WITH HOT

SURFACES.
DANGER! PARTS IN MOTION
PROHIBITION TO REMOVE THE PROTECTIONS
PROHIBITION TO CARRY OUT MAINTENANCE WITH PARTS IN

MOTION.
31
The risk centres are shown in the figure.
3.3 Prohibitions and precautions

It is forbidden:
• to introduce any part of the body inside the machine during functioning;
• to sit and/or lean on the machine during functioning;
• to walk on the machine during functioning;
• to climb on to the machine and stand on the covering surface;
• to carry out any maintenance or adjustment operation with machine in function or under electric
voltage;
• to use the machine when the safety systems are not working, or the protections are not installed
or installed incorrectly;
• to tamper with or alter the safety and protection devices. Panels, doors, casings, photocells,
micro switches and all other devices must not be removed;
• to tamper with or remove the safety plates from the machine;
• to modify the data on the identification plate;
• to modify the machine without the authorisation of the manufacturing company;
• to use the machine if faulty;
• to throw water on the motors or on the electric components;
• to make holes on electric cable runs or passages, to wear rings, wrist watches, jewellery, ripped
or dangling clothes (like ties, ripped items, scarves, unbuttoned jackets or open zips) that might
get tangled in the moving parts. The operator must also keep their hair tied up to prevent if from
it getting tangled. Use appropriate clothing and personal protection equipments like: accident-
prevention shoes, gloves and safety goggles when required by the operation.
32
It is compulsory:
• to read all documentation supplied with the machine before operating it;
• carry out the "maintenance state" procedure before adjusting or repairing parts on the machine;
• for interventions on the machine to be carried out by authorised personnel only;
• to use safe ladders to access the electrical switchboards and the components of the machine
positioned at a height;
• for every operator to be aware of the warnings of pertinence and of the pictograms (adhesive
plates) applied on the machine;
• to take care of the operational space and the passages around the machine. They must be clear
from obstacles, clean and adequately lit;
• to entrust the keys to open the electrical switchboard to a qualified and authorised person;
• maintain the safety systems and emergency buttons' efficiency.
Precautions
Use protection gloves, comply with the warnings reported in the manual and in the safety
pictograms placed on the machine.
During functioning always keep at a safety distance (0.8 m) from the
units.
Before working inside the electric control board remove voltage from the mains powering it.
If we limit ourselves to positioning the main switch of the electric control board on "0" (OFF) all the
above described parts remain powered.
All operators must have the necessary authorisations to work on the machines and must
carefully read all safety warnings reported in the above-said manual. The assigning of the
tasks and duties must be made by the safety manager, in compliance with the
prescriptions, the European Directives on health and safety at work.
3.4 Individual protections

WORKWEAR
Operators' workwear must be made of resistant material and must allow for perfect movement
freedom of the operator. This workwear must be perfectly adhering to the body (elastic type) in
particular around the ankles, the wrists, the neck and stomach, in order to avoid that a loose part
of the workwear comes into contact with moving parts, thus causing serious dangers.
Furthermore, the workwear must be fully waterproof.
SHOES (FOOT PROTECTION)

They must have antistress arch support soles for foot comfort and the upper part must be
impervious to the product to be used. They must cover the ankle completely, overlapping with the
trousers and must be of quick removing type to allow a quick evacuation of the foot in case of
accidental contact with the product. They must also allow for a correct perspiration of the foot.
GLOVES (HANDS PROTECTION)

They must be suitable for the hand of the operator wearing them and efficiently long to cover the
workwear's elastic cuff. They must guarantee a safe and quick grip as well as be highly resistant
to the product to be handled. They must also guarantee protection and continuous comfort against
the low and high temperatures and good sweat absorption.
33
EAR PLUGS OR MUFFS (EAR PROTECTION)

They must be suitable for the operator and comfortable to use in particularly noisy environments
that may interfere with the operators' functions.
GOGGLES (EYE PROTECTION)

These goggles must be suitable for whoever works in environments where glass bottles are
handled or when running machines that use hot glue. In fact, these goggles must repair your eyes
both from glass splinters, which may be caused by broken bottles, or from unexpected hot glue
splashes. As such, their shape should cover the entire area surrounding the eye (and adhere to
your face so that splinters or glue cannot enter your eyes from any angle). Goggle lenses must
always be kept in good condition, undamaged and clean, so as to never create discomfort or
cause any kind of visual impairment.
34
3.5 Buttons on the control panel (Posyc)
White “START” button, this button starts the machine
Black STOP button. Used to stop the machine under normal operating conditions.
Blue button. When it is ON, this means that the machine is in emergency state;
press this button to allow the machine to START and restart. When it is OFF this
means the machine is powered.
The mechanical latching emergency button with manual reset is connected to a

safety relay according to IEC standard EN 60204-1. It must be pressed to instantly
stop the system only in case of immediate danger or, if necessary, during the "set
to maintenance state" procedure.
Fig. 4 Posyc
35
3.6 Safety systems and protections
WARNING!
After every intervention, each protection device that had been disassembled must be
reinstalled. Overriding the protection micro switches is strictly forbidden.
When this system was designed, all potential risks were taken into account to which operators are
subjected when running the machine under normal conditions. As such, the following devices were
set up:
A) - FIXED PROTECTIONS
Fixed components, that have to be disassembled with a useful tool. Moving mechanical parts
protection sump. These protections are present in all machines and have different dimensions
and shapes. Their function is that to isolate and contain the mechanical parts that might create
dangerous situations for the operators.
B) - MOBILE PROTECTIONS
These are constituted by sliding doors placed on the chassis of the machine. They have safety
micro switches that interrupt the functioning of the machine.
Fig. 5 Safety systems layout
Safety microswitch located at the limit stop of the movable safety guards
36
3.7 Work, command and dangerous areas
WARNING! - This is the most important table regarding safety
CONTROL ZONE
These are zones where the user and/or other authorized operators can perform command and
control operations relating to the machines' functions, by means of the Operator Panel (Posyc).
WORK AREA
These are areas where the operator can replenish the machine with the material required to run it
and all those areas outside the safety guards, from where the operator can check proper machine
running and/or act quickly via the control panel (Posyc).
DANGER ZONE
This includes all the areas inside the electrical panels as well as the machines' operating areas. All
machine accesses are protected by safety micro-switches, except for the electrical panels which can
be accessed only using a special key kept exclusively by the Electrical Maintenance technician, see
paragraph "Operators to whom the manual is addressed (page 12)"
EMERGENCY ZONES
These are zones where the operator can stop the machine.
The operator can stop internal movements through the emergency button on the machine operator
panel (Posyc).
37
3.8 Residue risks
Due to the machine's constructive features, its make-up and the type of work cycle it is
designed to carry out, there are some risks that could not be eliminated, despite the fact
that safety measures were taken to be integrated in the design. Below is the description of
the Residual Risks, for which the necessary warnings must be provided, including related
pictograms.
RESIDUAL RISK - DANGER MOVING COMPONENTS

When performing Suitable clothing, as
maintenance. A potential described in Paragraph 3.4,
cause may be the dragging of can avoid the risk of getting
shirt sleeves or the insertion of tangled up.
one's hands in between the
moving components when the
machine is operated manually
or when replenishing the
materials required to run the
machine.
RESIDUAL RISK - RISK OF CRUSHING

The risk of crushing also In this case it is important to
subsists while maintenance is never perform any
performed and the machine is intervention while the machine
run by hand, even if it is set to is running or under conditions
a safety state. During these other than those
movements, you could crush recommended. The use of
your limbs within its moving safety footwear and work
parts gloves can prevent possible
injury caused by crushing.
RESIDUAL RISK - RISK OF SCALDING HANDS

Risk of burns caused by glue Use protective gloves to avoid
control unit. If you work on the the risk of burns. Use goggles
glue control unit when the to protect your eyes from glue
safety sensors are de- splashes.
energized. Danger of hot glue
leaking from the spray guns to
your face and hands. Only in
case the glue control unit does
not have an automatic
discharge, exercise the
greatest caution, once you
have shut-off air in the
machine's pneumatic system,
when acting on the control unit
valve or when performing
maintenance on the guns'
hoses. In fact, in this case
there may still be the residual
risk of hot glue dripping out of
the hoses, causing burns.
38
RESIDUAL RISK - DANGER HIGH VOLTAGE

Risk of electric shock (400 V) Use a ladder that is up to
is present in the power supply standard when performing
terminal strips and in the maintenance on the electrical
master switches of the panels. All power supplies of
electrical panels. During parts that make up the system
maintenance and are equipped with circuit
troubleshooting inside the breakers coordinated with the
electrical panels with fault loop impedance to
consequent risk of direct protect the operator/
contact. maintenance technician
against indirect contact. There
are also a number of barriers
(insulation, IP2x screens) to
protect the operator/
maintenance technician
against direct contacts.
Furthermore, access to the
electric panels is allowed only
to qualified electrical
maintenance technicians.
3.9 Noise
NOISE EMISSION VALUES DECLARED ACCORDING TO DIRECTIVE ISO 4871:
LPFA = dB
ASSOCIATED UNCERTAINTY KpA = 4dB
Remember that a prolonged exposure to noise can cause:

- Temporary or permanent damage to hearing.
- Difficulty in receiving sound communications.
Therefore, the department(s) manager must:
- Supply suitable protections to personnel (muffs or noise-protection ear plugs).
- Inform the personnel about the safety standards and on the risks taken when failing to use all
the necessary precautions.
We recommend carefully analysing the possibility of moving away from the areas with maximum
noise those operators that can carry out their tasks in isolated environments and those that, after a
medical check-up, may result partially weak.
Note: to learn the noise emission values of every machine, please refer to the relevant use
and maintenance manuals. With regard to noise and exposed operators, further limiting
measures must be considered "under the responsibility of the user", following the
subsequent specific environment assessments.
3.10 Instructions for emergency situations

In the event of fire, please follow the instructions below:
1 • Disconnect the packaging machine from the mains.
2 • Use fire extinguishers or fire hoses, better if CO2. type.
3 • Move inflammable materials (wooden/plastic pallets, cardboard or else) away from the
machine.
39
40
Unloading operations and storage
4 UNLOADING OPERATIONS AND STORAGE
4.1 Warnings
Unloading from the mean of transport and unpacking must be carried out by qualified personnel.
For packaging and loading on the mean of transport, or for removal of one of the units from its
installation place, contact the manufacturing company.
4.2 Transport and handling of packaged/unpackaged machine

• During modules handling, we recommend the support of an operator to the ground.
• The hoisting and transport means must be chosen according to the dimensions, the
weights, the shape of the machine and its components.The capacity of the hoisting
means must be greater (with a safety margin) than the actual weight of the components
to be transported.
• Hoisting must be carried out without interruption, rips or sudden movements.
• No one is allowed to stay within the manoeuvring area during handling; the entire
surrounding area is to be considered dangerous area. The person in charge of handling
must check the load stability before hoisting and moving it.
• Passing or staying underneath suspended loads is forbidden.
• SMI S.p.A. does not accept liability for any damage caused by incorrect operations, by
unqualified personnel or by the use of inadequate means.
WARNING!
Before handling make sure that the hoisting equipment and its tools are suitable to lift the
load that has to be handled. Exceeding the ranges recommended by SMI jeopardises the
correct functioning of the machine.
41
4.3 Weight and dimension machine module
Model A (Lenght in B (Width in C (Lenght in D (Lenght in H (Height in Weight (in

mm) mm) mm) mm) mm) Kg)
LWP 30 8370 1950 5500 2080 2450 3000
42
4.4 Handling the machine module
Model A (in mm) B (in mm)

LWP 30 1900 1650
4.5 Handling the infeed belt
Modello A (in mm) B (in mm)

LWP 30 1200 300
43
4.6 Pictograms found on the packaging
FACE UP
FRAGILE
KEEP DRY
SLING/LIFT HERE
USE HANDLE TO LIFT
KEEP TO THE INDICATED TEMPERATURES, IF STORED IN A SHELTERED

PLACE
CENTRE OF GRAVITY
44
4.7 Examples of packaging
Fig. 6 Packing in cellophane Fig. 7 Packing in wooden box
Fig. 8 Hoisting Fig. 9 Loading
Fig. 10 Wooden base Fig. 11 Stamp
In case the machine packaged with cellophane is loaded on to a container, the stamps will be
dismantled and replaced with wooden bases, which will be removed before positioning the machine
at the client premises.
The positioning and levelling will be possible only after having replaced the original stamps
supplied.
45
4.8 Unpacking and content check

The type of packaging is defined with the client in relation to the distance and and to the mean of
transport.
If transport is carried out by means of a lorry, the components are stored and anchored directly to
the platform of the vehicle, covered with a water-proof sheet to protect them against external agents
(direct contact with humidity and/or dust).
In case shipment is carried out by ship or airplane, the components are stored and anchored inside
wooden cases.
The weight of the packaging is indicated on the shipment documents and on the water-proof sheet.
Upon receipt of the supply, ensure that the components have not suffered damages during
transport and that the packaging has not been tampered with, with the consequent removal of parts.
In case damages are verified caused by the transport, the following procedures must be carried out:
- For evident damage, report it on the transport documents and supply photographic evidence.
- In case of hidden damage, within three days for shipments via sea from the date of receipt of
the goods and within seven days for shipments via lorry or air from the date of receipt of the
goods.
Fixing costs are charged to those causing the risk.
SMI S.p.A. cannot be held liable for any damage caused to the machine when it is transported and
placed inside the plant by a third party.
4.9 Storage
In case the machine is not installed within a short time, but will have to be stored for a prolonged
time, we recommend keeping the components in their original packaging and stored in a covered
place, in compliance with the protection grade required.
Check that the characteristics of the environment correspond to:
- Temperature: +2/+35 °C;
- Relative humidity 95% Max (without condensation);
- Closed environment, sheltered from atmospheric agents.
Exceeding temperature and humidity values can seriously damage the components.
- Check that the resting surface of the machine parts is suitable to safely support them.
- Do not place boxes, cases of heavy equipment over the parts.
- Do not place the parts near flammable material.
Any event caused after delivery of the machine to the consignor, is not under SMI S.p.A
liability.
46
Installation
5 INSTALLATION
5.1 Warnings
The mounting, connecting and commissioning procedures between the SMI machines modules
must be carried out by qualified personnel authorised by the manufacturing company or by
A.S.T.A.C., consequently only the general warnings are reported in this chapter and not the
operational procedure.
For any dismantling and positioning in other place, contact the manufacturing company.
If the customer/user sells the "used system", he/she must provide all the installation instructions to
the buyer, who will be entrusted with the responsibilities pertinent to the aforesaid information.
• Avoid acting on machine parts adjusted and/or pre-set during testing. Every technical
modification that affects the functioning and/or the safety of the machine, must be carried out
only by technical personnel of SMI S.p.A. or by technicians formally authorised by the same. On
the contrary, every responsibility relating to changes or damages deriving therefrom is declined.
• Any protections which segregation barriers, electro-mechanical safety devices, key safety
selectors installed by the Client, must correspond to the accident-prevention safety Standards
in force in the country of installation of the plant.
5.2 Conditions and place of installation

The following are the responsibility of the client:
- the preparing of the premises (masonry, foundations, channelling works). The client must
prepare suitable premises according to the requisites envisioned by the European Directives
regulating the safety in the work places, in particular, it must allow for the necessary spaces for
use and maintenance.
- The area defined "respect area of the operator", must remain dry, clean and free from
obstacles;
- "Respect area of the operator" means an area, along the entire perimeter of the plant, having
a minimum width of 1 m, inside which the operators must be able to safely carry out
maintenance, adjustment and control operations of the production process.
The environmental and operational conditions must not constitute an obstacle for access
to the plant commands, in particular to the emergency stops.
- the electric systems' preparations up to the power supply points of the machine. The electric
system must be provided with earthing adequate for the power absorbed by the machine and of
insulator switches and/or safety valves upstream of the same line.
- the preparation of the auxiliary services adequate to the requirements of the machine
(compressed air). It is best to remember that the compressed air must always be dry and clean.
The presence of impurities contained inside the air coming from the compressor and the
condensed humidity, favour the wear of the gaskets and of the relative sliding surfaces,
jeopardising the functionality and duration of the pneumatic components.
47
Installation
5.3 Positioning in the installation place
All the operations described in this paragraph are the competence of the A.S.T.A.C. technician or
of the trained operator authorised by the Manufacturing company.
During the hoisting and transporting of the units, the assistance of a ground operator, as well as the
operator on the hoisting mean, is necessary for eventual signalling.
- During handling of the parts, it is forbidden to park within the action radius of the hoisting
means.
- Carry out the levelling by following the instructions reported on the geometrical testing
document supplied with the machine.
5.4 Positioning and levelling

• Position the machine in the area selected for the upstream production line.
• Make sure that the floor, in the installation area, does not present irregularities that may prevent
the normal and correct positioning of the machine.
• Make sure that the foundations are able to support the weight and that the factory's ceiling
height is sufficient.
• At this point, place a centesimal spirit level on the frame's upper part, unscrew the lock nut 1
(spanner n° 46) and level the machine using the adjustable support foot 2 (spanner n° 24), and
lock it back by tightening the lock nut 1.
The machine levelling operations must be

carried out by a SMI technician in thorough
compliance with the general test sheet
"Mechanical regulations".
5.5 Connection to the energy sources and relative checks
WARNING!
All operations of connection to the electric system have to be carried out with the tunnel
disconnected from the mains.
Qualified personnel:
• Technician trained for the installation.
• Electric maintenance operator.
To guarantee the maximum of the performances, to avoid any malfunctionings due to parts
assembled incorrectly, it is necessary to verify:
48
Installation
• That all fixing nuts are correctly fastened;

• That the pictograms and plates applied on the plant are clearly visible;
• The functioning of the safety devices installed on the access doors of the dangerous area;
• The functioning of the emergency buttons;
• The functioning and correct position of the control systems, which: photocells, sensors and end
run micro switches.
The following instructions have to be carried out:
• Bring all electrical wires, that have been disconnected for shipping, inside the electrical panel,
and reconnect them according to the numeric code indicated on them (please refer to the
volume "Electrical diagrams").
• Connect all the earth cables of the machine.
• The connection of the machine to the electrical system must be carried out in keeping with the
norms and regulations applicable in the user's Country.
• Verify that the expected short circuit intensity at the link terminals of the general switch is
compatible with its interrupt power (see Electrical Drawing).
• Check that the frequency and supply voltage values of the machine (see plate found on the
electrical panel) correspond to the values of the supply network.
Once the electrical connection of the line has been carried out, it is necessary to verify that:
• There is continuity of the protection circuits which must have a resistance lower than 0,1 ohm (if
needed, verify according to the conditions of the Regulation IEC 17-13/1.
• The line is protected by a 300 mA automatic protection differential switch.
• The correct functioning of the differential devices in case these are provided for.
• Check the presence and efficiency of the protections and of all safety devices.
• Verify the correct rotation direction of the motors.
• Carry out a few movement trials with identical pieces to those for production (this to verify the
correctness of all set parameters)
5.6 Equipment supplied together with the machine

The following items are also provided to the Customer:
• Crank for format change adjustments
• Complete equipment for format change procedure
• Tool box
• Hose with compressed air gun
49
Installation
50
Commissioning
6 COMMISSIONING
6.1 Premise
The description of the commands and use procedures of the machine are
reported in the specific Operator Manual attached to this documentation.
Warnings for the users:

• Before starting the work cycle, ascertain there is no one inside the segregated area and near
the external conveyors.
• The permanent protections are not interlocked, if removed they must be remounted in their
place in that their absence does not prevent the machine from functioning.
• Never remove or exclude the protections or safety systems during functioning or with the
machine powered.
• At every access, verify the functioning of the emergency buttons and the micro switches located
on the access doors, ascertaining the immediate stop of the movements.
6.2 Controls and signalling

During production, the operator must be in the immediate proximity of the control panel. This, other
than giving the operator himself a good view of the various phases of production, also allows him
to quickly intervene on the controls in case of need or emergency.
When problems in the normal running occur, the machine automatically stops and indicates, on the
control panel screen, which type of alarm was engaged.
The operator panel is made up by the following elements:
• operator push-buttons board.
• TOUCH SCREEN" monitor”.
51
Commissioning
6.3 Machine description

See Chapter Chapter 1 - Operator interface manual
This file provides a theoretical description on the operator panel's composition and of the principles
on which its various functions are based.
This file is to be considered introductory to the use of all the functions offered by the operator
interface system.
Refer to the PC operator interface card that is useful for technical elaboration.
6.4 Summary of the pages making up the operator panel

See Paragraph 1.2 - Operator interface manual
This file provides a theoretical description on the operator panel's composition and of the principles
on which its various functions are based.
6.5 Meaning of the light column

See Chapter 1 - Operator interface manual
This file provides all the indications for the

operation and use of the light column present on
the machine.
6.6 Preliminary system tests

To start production follow the instructions in the given order:
• insert the general switch;
• insert the compressed air supply;
• fill the cartons magazine/s.
6.7 Switch off

This file analyses all the operations that have to be carried out to switch off the machine.
6.8 Start up after switch off

This file analyses all the operations that have to be carried out to start up a machine that has been
put in operation correctly.
52
Commissioning
6.9 Direct commands

This file contains the list of the direct commands included in the SR machine ranges.
6.10 Machine operating modes and states

This file provides all the indications concerning the machine operating modes. This file must be
consulted to acquire the necessary basic knowledge of its use.
6.11 Machine control buttons

The machine is equipped with the red mushroom-shaped button on the yellow background for the
emergency stops, located on the control panel (Posyc).
WARNING!
Only press in case of immediate danger or
mechanical trouble.
Restart after emergency stop
• Release the mushroom shaped emergency button

EMERGENCY - STOP.
• Press the power button RESET.
• If any further alarms are displayed, please press STOP to

reset.
53
Commissioning
• Press the START push button to restart production.
6.12 Running of the machine and control during operations

Check that there is enough product at the machine infeed, in order to avoid any displayed alarms
or acoustic signals. Check that the product at the machine infeed has not tipped over and
consequently lies on the conveyour. If the product tips over and prevents a correct pack formation,
please follow the procedures "Procedure for axes phase recovery" and "Procedure for axes
phase search".
6.13 Procedure for axes recovery

This file indicates the necessary operations that have to be performed for the PHASE RECOVERY
of electronic axes (brushless servo motors) present in the machine.
This procedure is necessary every time one or more servo motors block, due to an error
(positioning, voltage, internal anomaly).
It allows you to reset the servo motor synchronisation with the main movement of the machine,
without requiring its complete phase search. In this way the resetting of the error conditions of the
electronic axes is possible without having to remove the product from the machine.
From an operational point of view, the PHASE RECOVERY procedure determines a shifting of the
electronic axes from the position it is blocked into that which, theoretically, puts it back into
synchronism with the main machine movement.
For obvious reasons, PHASE RECOVERY proves to be effective when the movement that the axes
must carry out is within certain limits.
If PHASE RECOVERY does not permit resetting of the axis, it is necessary to perform its PHASE
SEARCH.
The PHASE RECOVERY operation is active from the following video pages:
- main video page
- video page dedicated to the single function unit.
The following pages will provide indications taking as an example the carrying out of the PHASE
RECOVERY procedure for the ELECTRONIC SEPARATOR. The indications provided are valid for
any other functional unit based on brushless servo motor present in the machine.
For further technical details (both theoretical and practical) read the manual file that refers to the
individual functional units.
6.14 Servo motors phase search procedure

This file indicates the necessary operations to perform the PHASE SEARCH PROCEDURE of
electronic axes (brushless servo motors) present in the machine.
This operation is necessary every time the machine is switched on and every time one or more
servo motors block due to an error (positioning, voltage, internal fault) without the possibility of
resetting them with the PHASE RECOVERY function.
54
Commissioning
It is an integral part of the MACHINE'S SWITCHING-ON PROCEDURE and its task is to restore
the synchronization, of the individual servomotor, with the machine's main movement, to make it
suitable for the production process.
From an operational point of view, the PHASE SEARCH procedure causes the electronic axis to
carry out a variable number of positioning cycles, during which, thanks to the reading of the special
phase sensor, its position is determined at zero, which means synchronisation with the main
movement of the machine.
For this operation, it is necessary to remove all products from the area of the functional unit
concerned by the PHASE SEARCH PROCEDURE.
If the whole machine needs the phase search procedure, it is necessary to remove all products.
Principally the PHASE SEARCH PROCEDURE can be utilized in two situations. The first is
fundamental as it resets the synchronisation of all the electronic axes every time the machine is
started up or at every pack format change.
The second situation occurs less frequently and is strictly linked to maintenance operations. In this
case, the phase search procedure resets the synchronisation of each electronic axis and checks
its correct functioning. Still, the phase search procedure is activated when PHASE-RECOVERY
has not proved effective.
In order to facilitate its use in the former situation, a single push-button has been devised,
identifiable as "SYSTEM PHASE SEARCH" push-button. Its selection operates an automatic
procedure independent of any further intervention from the operator, which is meant to carry out
the phase search procedure for all the electronic axes and any existing automatic format change
devices the machine may be provided with. Once this procedure has ended, the machine is ready
for production.
WARNING: the push-buttons "SYSTEM PHASE SEARCH", present in the video pages specified
here below, might not be available, if the operator password is not present.
If a single operating device is in error, though, it is possible to start its phase search procedure
through the page dedicated to each axis.
As regards the video page at the bottom of the list (electronic axis), the following pages will provide
some indications taking as an example the phase search procedure for the electronic separator.
The same indications are to be held valid for any other functional group run by brushless
servomotors.
- In some applications, after pressing the push-button Phase search, a window is displayed,
indicating that it is necessary to carry out the machine "Start" procedure, in order to operate the
command "Phase search".
For further technical information on the theoretical and practical points, refer to the manual files
specific for each functional group.
6.15 Start up after an alarm or emergency

See Chapter 4 - Operator interface manual.
This file analyses all the operations that have to be carried out to re-start the machine after an alarm
or emergency.
6.16 Problems/faults (ALARMS)

Most of the anomalies and problems that occurr during the running of the machine are promptly
signalled by the machine itself, automatically, by visualizing the current signal or emergency on the
text visual (Operator interface manual).
55
Commissioning
The signals
are only communications that the machine gives the operator, though maintaining the running
state.
Alarms
cause the machine to stop and the alarms red light found on the electrical panel to switch on; push
the START bottom to restart the machine, once the problem that has caused the emergency has
been solved.
The general operator

carries out a first search for the problem and, in case he is qualified, removes the causes of the
anomaly and restores the correct functioning of the machine.
The electrical/mechanical maintenance operator

intervenes at a later stage, in the case that the operator has not been able to identify the cause of
the problem, or when the restoring of the correct functioning of the machine requires to carry out
operations for which the general operator is not qualified.
6.17 Operating the subsystems switch on timer

This file presents all the aspects concerning the automatic operating of the subsystems switch on
and switch off timers present in the machine.
56
Instructions for format change
7 INSTRUCTIONS FOR FORMAT CHANGE
7.1 Warnings
The format change operations must be carried out by qualified personnel, paragraph "Operators to
whom the manual is addressed (page 12)"
Qualified personnel:
Mechanical maintenance personnel.
Qualified technician.
During format change, the machine must be in

safe stop state with emergency button pressed.
Before starting the format change procedure, ensure to be able to use the following
adjustment instruments:
57
• Equipment necessary for format changeover
• Crank
7.2 Blank magazine
Fig. 12 Use the crank to adjust the guides of the blank magazine. Depending on the blank
format to be used, widen or narrow the guides referring to the mm counter on either side of the
machine.
58
Fig. 13 In order to adjust the blank magazine guide, use the corresponding knobs. Depending
on the format to be used, raise or lower the guide near the blank.
7.3 Cardboard climb unit
Fig. 14 Use the crank to adjust the guides of the blank magazine. Depending on the blank
format to be used, widen or narrow the guides referring to the mm counter on either side of the
machine.
59
7.4 Adjusting the guides of the infeed belt
Fig. 15 Move and adjust the guides according to the format being processed, using the knobs
as shown in the figure.
7.5 Adjusting the "push-down" arm
Fig. 16 In order to adjust the height of the "push-down" arm, use the crank according to the
loose format being processed. Raise or lower the "push-down" arm by referring to the mm
counter.
60
7.6 Channeler guides
Fig. 17 In order to adjust the guides, turn the crank, to widen or narrow, referring to the mm
counter.
61
62
Regulation and adjustments
8 REGULATION AND ADJUSTMENTS
8.1 Warnings
The maintenance operations must be carried out by qualified

personnel "Operators to whom the manual is addressed (page 12)"
8.2 Phase-setting - Lower cardboard case/tray-forming unit

This operation allows you to make the phase search procedure for the tray forming group.
Please, follow the below procedure:
Loosen the screw 4.
Position the screw indicated at point 1 in the

drawing, perpendicularly to the axis of the
shaft and centered as to the hole in the flap
1 folder lever.
After removing the pulley, place the pin

indicated at point 2 in the drawing in axis with
the hexagonal shaft.
63
Use the hole in the grease gun indicated at

point 3 in the drawing as a reference for
positioning the bearing inside the cam.
2
Tighten the screw indicated at point 4 in the
drawing.
Keeping the flap folder lever and the cam

blocked, position the bucket, indicated at point
5 in the drawing, so that the indicated plane is
on axis with the hexagonal shaft.
3 After refitting the pulley, position it as indicated

at point 6 in the drawing, keeping the screws
centered as compared to the loops.
Position the belt and tension it, as indicated at

point 7 in the drawing.
64
8.3 Phase-setting - Upper cardboard case/tray-forming unit

This operation makes it possible to adjust the distance between the front and back bucket of the
moulding machine every time it is necessary to change format.
Proceed as follows:
1 • Lock the disc, indicated at point 1 in the drawing, using the spring piston indicated at point 2
in the drawing.
2 • Loosen the screws indicated at point 3 in the drawing.
3 • Adjust the shaft using the specific knob (indicated at point 4) positioning the buckets (indicated
at point 5) to the optimal size for closing the package from the new format change.
4 • Tighten the screws (point 3), remove the knob and unlock the disc (point 1) using the spring
piston (point 2).
5 • Carry out the phase search of the case/tray-forming unit through the Operator Panel (Posyc)
before restarting the machine.
65
66
Cleaning and maintenance
9 CLEANING AND MAINTENANCE
9.1 Warnings

9.2 General precautions

The cleaning, routine and extraordinary maintenance operations must be entrusted only to qualified
personnel expert of the machine (mechanical and/or electrical maintenance operator, each for his
competences)
We recommend, to avoid interference risks with other operators present in the work areas, to pre-
emptively interdict the area by means of installation of signal straps and by moving persons foreign
to the operations in progress away.
To obtain maximum duration and the best working economy, we recommend scrupulously following
the instructions contained in this chapter:
• In replacing spare parts use exclusively ORIGINAL SPARE PARTS. To contact the after-
sales technical assistance centre, see Paragraph "Instructions for service requests and
to order spare parts (page 15)"
• A table called "MAINTENANCE INTERVENTIONS COUPONS" is envisioned in paragraph
"Maintenance interventions coupon (page 82)" that will have to be filled in by a manager
in charge of the machine or by the operator carrying out the indicated interventions. We
recommend always keeping it updated, in particular during the warranty period. In case
of lacking intervention and filling in, the warranty on the machine becomes void.
• Before carrying out any maintenance or lubrication operations, carry out the
"maintenance state procedure" described in Paragraph "Maintenance state procedure
(page 68)"
• It is forbidden to carry out maintenance, lubrication, repair operations when the machine
is in motion and/or electrically powered.
• After every intervention always remount the eventually removed protection, bringing the
machine back in initial state.
• It is forbidden to use matches, ciarette lighters, torches, naked flames as means of
illumination.
• Unauthorised persons must keep at due distance from the machine.
• No untrained person can operate or stand near the machine during functioning.
67
• Always keep the area set-up for maintenance interventions clean and dry. Always
eliminate any oil stains.
• Before any intervention on electrical components, ascertain that the power supply line is
disconnected.
• After every intervention on the control board, always close it and lock it with the main
switch door lock, before restoring power supply and starting the plant.
• The lacking in inspections and maintenance can cause serious damages to the machine.
9.3 Maintenance state procedure

The procedure envisions the isolation of the machine from all energy sources and consists in:
1 Pressing the machine stop button at cycle end;
Switching off the program (see Operator

2 Manual supplied with the machine);
Bringing the main switch of the electric control

3 board in position "0" (OFF);
68
4 Pad-locking the main switch;
WARNING!
For any type of maintenance operations the
general switch must be locked with a padlock in
the open position
WARNING!
Note for the electrical/mechanical maintenance personnel:
There are some circuits in the electric box that are not disconnected by the selectioning
device of the electrical supply. These circuits have a warning tag and are covered with an
orange coloured wire.
69
• Pneumatic system disconnection

For safety reasons, before beginning maintenance be sure to lock the pneumatic valve
located in the zone, shown in the figure, using a padlock.
9.4 Extraordinary maintenance - maintenance state procedure
The special maintenance operations concern the breakage of parts and components for which a
specific knowledge of the faults is required. As a rule, these operations can be carried out by
suitably trained personnel or by SMI S.p.A. personnel.
Contact SMI S.p.A. if the problem was not fixed
9.5 Notes on cleaning

To optimise the performances of the machine, it is necessary to always keep it clean. Only on a
clearly accessible and clean machine is it possible to identify and repair any faults, prevent
malfunctionings and work in safe conditions.
To keep the machine perfectly efficient, do as follows:
• At the end of each production batch, leave the machine free from all objects.
• Do not use jets of water, in particular on electrical parts.
• During cleaning of the safety systems and protections, pay particular attention not to
move them from their position.
9.6 Notes on lubrication

Lubrication must be carried out within the time intervals reported in the Paragraph "Preventive
maintenance ".
• Temperature and functioning conditions of the various parts are burdensome and it is
sometimes good to act anticipating the time intervals. In particular, we recommend the
full maintenance, every time production has to be suspended. Depending on the
environment temperature, the viscosity of the lubricants to be used also varies.
• In any case, never exceed the interval limits prescribed. The manufacturing company
recommends using the lubricants indicated below.
70
9.7 Lubrication
The transmission chains, supports and organs and the rotary shaft support must be
checked and lubricated monthly.
LIST OF RECOMMENDED LUBRICANTS

ARAL ARALUB HLP 2 FINA MARSON EP 2
ALVANIA EP Fett 2 AVILUB SPEZIALFETT EP 2
CALITHIA EP Fett T2 AVIA MEHRZWECKFETT
SHELL AVIA
ALVANIA EP Grease 2 AVILUB Special grease EP 2
CALITHIA EP Grease T2 AVIA Multipurpose grease
HTF 4020/220-2
NILS TRIBOL
FOOD 2 4020/460-2
KLUBER MICROLUBE GL 262 OLISTA LONGTIME 2
ESSO BEACON EP 2 OPTIMOL LONGTIME BLANC
MOBILUX EP 2 OLIT CLS
MOBIL
MOBILGREASE HP ELKALUB GLS 75/N2
When lubricating with grease, use lithium soap grease.
9.8 Key to maintenance symbols

Listed in the table below are the mechanical components on the machine on which it is necessary
to periodically carry out maintenance interventions.
To indicate the type of operation to carry out on the various components a cross reference system
with the following symbols is used:
It identifies a visual check on the wear state or on the good functioning of a

component.
Cloth. It identifies a cleaning intervention performed using a cloth
Air gun. It identifies a cleaning intervention performed by a compressed air

gun
Pump. It identifies a lubrication intervention with grease.
71
Brush.It identifies a lubrication intervention using grease.
It identifies a mechanical intervention (tensioning) to be carried out on the

component.
Oil. It identifies a lubrication intervention using synthetic oil
It is best to remember that the temperature and functioning conditions of the various parts
(even if studied and abundantly dimensioned) are burdensome and it is sometimes
opportune to intervene, anticipating the time intervals; should the environmental and
operational conditions be such to induce the decreasing of the same intervals reported in
the following table in work hours (h) (that correspond to European Standards). In
particular, we recommend the complete maintenance, every time that production has to be
suspended for a prolonged period of time.
9.9 Preventive maintenance

By preventive maintenance we mean all of those controls which must be performed on the
components subject to wear or consumption. They are listed hereafter, to facilitate correct
functioning of the machine.
Before proceeding with any maintenance or controls, suspend flow of the product and let
the machine keep going until it empties.
Have maintenance and inspections performed by authorised personnel with knowledge of

these instructions, especially when concerning electrical and pneumatic parts. Use the
tools and equipment suitable for each type of work.
ATTENZIONE! Prima di procedere con qualsiasi operazione di manutenzione, effettuare la

procedura di Messa in Stato di Manutenzione descritta al Paragrafo "Maintenance state
procedure (page 68)"
La SMI S.p.A. declina ogni responsabilità per danni causati a persone o cose dovuti alla
inosservanza delle suddette indicazioni.
Frequency of maintenance operations is calculated based on:

24 hours' machine operation = 1 day
125 hours' machine operation = 1 week
250 hours' machine operation = 2 week
500 hours' machine operation = 1 month
1.500 hours' machine operation = 3 months
72
Frequency of maintenance operations is calculated based on:

6.000 hours' machine operation = 1 year
12.000 hours' machine operation = 2 years
BLANK MAGAZINE UNIT

(EVERY 8 WORKING HOURS)
MACHINE STATE: Machine stationary

FREQUENCY: Every 8 working hours
NECESSARY MATERIAL: Air gun
PROCEDURE: Remove any cardboard residues.
SUCTION CUPS

NECESSARY MATERIAL:
PROCEDURE: Check the suction cups. Check wear and tear.
73
BEARINGS AND GEARS


NECESSARY MATERIAL: Brush/Grease
PROCEDURE: Apply grease on the picker's bearing
CARDBOARD BLANK RAMP UNIT


PROCEDURE: Use an air jet to remove any cardboard
residues from the cardboard ramp
CARDBOARD RAMP LUBRICATION


NECESSARY MATERIAL: Oil
PROCEDURE: Use oil to lubricate the chains of the cardboard
ramp.
74
LUBRICATING THE CARDBOARD RAMP SHAFTS


NECESSARY MATERIAL: Brush/grease
PROCEDURE: Use a rag to remove any residues. Then apply
grease.
TENSIONING THE CHAINS OF THE CARDBOARD RAMP

(EVERY 3,000 WORKING HOURS)

NECESSARY MATERIAL: Allen wrench CH17
PROCEDURE: Use the wrench to tension the chains on a
regular basis.
LUBRICATING THE SEPARATOR CHAINS


PROCEDURE: Lubricate the separator chains on a regular
basis
75
TENSIONING THE SEPARATOR CHAIN


PROCEDURE: Use a wrench to check and tighten the
separator's lower tensioning screw

MACHINE STATE]: Machine stationary

PROCEDURE: Use a wrench to check and tighten the
separator's lower tensioning screw


PROCEDURE: Use a wrench to check the tension of the upper
screw. Only with this screw can you adjust the chain's tension.
76
CONVEYOR BELT

PROCEDURE: Blow in the vicinity of the conveyor belt to
remove any residues.
CONVEYOR BELT

NECESSARY MATERIAL: Rag
PROCEDURE: Clean the belt on a regular basis to remove
any residues
CARDBOARD FEEDING BELT


PROCEDURE: Clean the belt on a regular basis to remove
any residues
77
CHAINS OF THE LOWER CASE/TRAY-FORMING UNIT


PROCEDURE: In order to adjust chain tension, use the two
lateral screws as shown in the figures below
Use the wrench to loosen the four screws

1 shown in the figure.
After loosening the screws, push the case/

tray-forming unit down; this will tauten the
2 chain. Tighten all the screws after having
tensioned the chain.
78
BRUSHLESS MOTORS BELTS


PROCEDURE:Tighten the belts of all the machine's brushless
motors. The figures below show the belts on the various
motors.
Fig. 18 Separator motor belt Fig. 19 Case/tray-forming unit motor belt
Fig. 20 Cardboard ramp motor belt Fig. 21 Separator belt motor belt
79
PHOTOCELL AND REFLECTORS


PROCEDURE: Clean the surface of the photocells and the
reflectors (present throughout the machine) to remove any
dust.
Fig. 22 Photocell in separator belt zone Fig. 23 Reflector in separator belt zone
Fig. 24 Photocell in cardboard feeding belt zone Fig. 25 Reflector in cardboard feeding belt zone
80
LUBRICATING THE LIFTING BLOCK CHAIN


PROCEDURE: Lubricate the lifting block's chain on a regular
basis
81
9.10 Maintenance interventions coupon

We recommend making a note below of all routine and extraordinary maintenance operations.
Date Type of intervention Time taken Signature
82
Replacements
10 REPLACEMENTS
10.1 Warnings

10.2 Periodic replacements

Lifecycle of the components after which their replacement is strongly recommended
10.3 Blank magazine unit

S001 • For replacing the conveyor belt, indicated at point 1 in the drawing, proceed as follows:
1 • Remove the guards and the plate indicated respectively at points 2 and 3 in the drawing.
2 • Loosen the tensioning device placed upstream from the conveyor belt indicated in the drawing
at point 4.
3 • Unhook the belt using the pins between the conveyor belt handles.
4 • Remove the belt and replace it with the new one, making sure the path shown in the drawing
is followed.
5 • Manually tension the belt using the tensioning device shown in point 4.
83
Replacements
Fig. 26 Blank magazine unit
84
Replacements
S002 • Depending on wear - Proceed as follows to replace the drive pinions indicated in the drawing
at point 1:
1 • Carry out the procedure S001 to replace the belt
2 • Remove the two supports indicated at point 2
3 • Remove the two tensioners indicated at point 3
4 • Loosen the stop rings and slide out and sideways the drive shafts indicated at point 4
5 • Replace the bushing of the central supports indicated at point 5 in the drawing.
6 • Proceed with replacing worn pinions with new ones.
7 • Reassemble following the procedure in reverse, making sure that the belt correctly engages
with the pinions.
Fig. 27 Blank magazine unit
85
Replacements
10.4 Cardboard separator unit

S003 • Depending on wear - For replacing the suction cups, indicated at 1 in the drawing, proceed
as follows:
1 • Loosen the screw inside the suction cup, indicated at point 2 in the drawing.
2 • Replace the suction cup and tighten so that it does not leak air.
Fig. 28 Cardboard separator unit
86
Replacements
S004 • Every 16,000 hours - Proceed as follows to replace the picker's belt indicated at point 1 :
1 • Slacken the tensioners indicated at point 4
2 • Unscrew the screws indicated at point 2
3 • Unscrew the screws and open the small side panel indicated at point 3
4 • Replace the drive belt
5 • Reassemble in reverse order and phase-set again (subsequent operation)
6 • Tension the belt by tightening the tighteners in working position
Fig. 29 Cardboard separator unit
87
Replacements
• BELT PHASE-SETTING POSITION

In order to phase-set the belt, be sure that when the lever indicated at point 1 is vertical with respect
to the work surface and that the tie rod indicated at point 2 is horizontal.
Fig. 30 Belt phase-setting position
88
Replacements
10.5 Cardboard ramp unit

S005 • Every 12,000 working hours - Proceed as follows to replace the chain as indicated at point
1 in the drawing:
1 • Slacken the chains through the tightener's screw indicated at point 2
2 • Release the chains by acting on the appropriate coupling
3 • Slide out the chains from the guides and install the new ones according to the moving direction
indicated in the drawing
4 • Tension the chains through the tightener's screw
Fig. 31 Cardboard ramp unit
89
Replacements
S006 • Every 12,000 hours - Proceed as follows to replace the guides:

1 • Carry out the procedure S005 to replace the chains
2 • Remove the guides indicated at point 1 by unscrewing the screws indicated at point 2
3 • Re-assemble following the procedure in reverse order.
Fig. 32 Cardboard ramp unit
90
Replacements
10.6 Separator conveyor unit

S007 • Every 16.000 working hours - In order to replace the transmission belts, proceed as follows:
2 • Remove the motor-holding plate indicated at point 3
3 • Slide out the worn-out belts and replace them with the new ones
4 • Reassemble in reverse order
5 • Tension the chains through the tensioners indicated at point 2
Fig. 33 Separator conveyor unit
91
Replacements
S008 • Every 16,000 hours - Proceed as follows to replace the passage plate indicated at point 1
in the drawing:
1 • Unscrew the nuts, located under the plate support, indicated at point 2
2 • Slide out the plate and replace it with the new one
3 • Re-fasten the plate in reverse order
92
Replacements
S009 • Every 8,000 working hours - Proceed as follows to replace the belt indicated at point 1 in
the drawing:
1 • Follow the steps S008 to replace the passage plate
2 • Remove the plate indicated at point 2
3 • Slacken tension of the roller located upstream of the belt indicated at point 3, by loosening the
screw
4 • Release the belt by acting on the pins between the belt's links
5 • Slide out the belt and replace it with the new one, according to the path shown in the drawing
6 • Tension the belt by acting on the roller and secure it in working position
93
Replacements
S010 • Depending on wear - Proceed as follows to replace the guides and the polizene pen:
1 • Follow the steps S009 to replace the belt
2 • Unscrew the nuts that secure the guides indicated at point 1
3 • Remove the support indicated at point 2
4 • Replace the pen indicated at point 3 by unscrewing the nuts under the support
5 • Replace the guides indicated at point 4 by riveting the new ones to the support sheets
6 • Reassemble in reverse order by replacing the guides indicated at point 1
94
Replacements
S011 • Depending on wear - Proceed as follows to replace the drive pinions indicated at point 1 in
the drawing:
1 • Follow the steps S010 to replace the guides and pen
2 • Remove the support indicated at point 2
3 • Loosen the stop rings and slide the drive shaft out and sideways indicated at point 3
4 • Replace the worn-out pinions with the new ones
5 • Reassemble in reverse order, carefully engaging the belt on the pinions
95
Replacements
S012 • Depending on wear - Proceed as follows to replace the transmissions indicated at point 1
in the drawing:
1 • Slacken chain tension by following the steps S015
2 • Unscrew the nuts indicated at point 2
3 • Replace the transmissions with the new ones and lock the nuts
96
Replacements
10.7 Separator bar unit

S013 • Every 16,000 working hours - Proceed as follows to replace the belts indicated at point 1
in the drawing:
2 • Remove the motor-holding plate indicated at point 3
3 • Slide out the worn-out belts and replace them with the new ones
4 • Reassemble following the procedure in reverse order.
5 • Tension the chains through the tensioners indicated at point 2
Fig. 39 Separator bar unit
97
Replacements
S014 • Every 12.000 working hours - In order to replace the dragging pinions indicated at point 1
in the drawing, proceed as follows:
1 • Slacken chain tension through the tie rods indicated at point 2
2 • Slide out the belts indicated at point 3 by following the steps S013
3 • Remove the supports indicated at point 4
4 • Unscrew the pinion's dowels, slide out the shaft indicated at point 5 and replace them with the
new ones
5 • Reassemble following the procedure in reverse order.
98
Replacements
S015 • Depending on wear - In order to replace the transmissions indicated at point 1 in the draw-
ing, proceed as follows:
1 • Slacken chain tension through the tie rods indicated at point 2
2 • Replace the transmission pinions with the new ones
3 • Tension the chains and fasten the tie rods in working position
99
Replacements
S016 • Every 12.000 working hours - In order to replace the chains indicated at point 1 in the draw-
ing proceed as follows:
1 • Extract the dividing bars, by acting on the pivot indicated at point 2 in the drawing.
2 • Follow the steps S015 to slacken chain tension
3 • Release the chains through the coupling indicated at point 3
4 • Slide out the chains and fit the new ones, checking the correct position of the coupling as
compared to the moving direction
5 • Tension the chains and set them back to working position
100
Replacements
S017 • Every 12.000 working hours - In order to replace the chain sliding guides indicated at point
1, proceed as follows:
1 • Complete procedure S016 to replace the chains.
2 • Loosen the screws indicated at point 2 in the drawing.
3 • Remove the guide from the profile.
4 • Insert the new guide and lock using the screws.
101
Replacements
10.8 Carton feeding unit

S018 • Every 8,000 working hours - Proceed as follows to replace the belt indicated at point 1 in
the drawing:
1 • Slacken the tensioning rollers indicated at point 2
2 • Release the belt by acting on the pins between the belt's links
3 • Slide out the belt and replace it with the new one, according to the path shown in the drawing
4 • Tension the belt and fasten the tensioning rollers in working position
Fig. 44 Carton feeding unit
102
Replacements
S019 • Depending on wear - Proceed as follows to replace the drive pinions indicated at point 1 in
the drawing:
1 • Slide out the drive belt indicated at point 3 by following the steps S022
2 • Unscrew the pinions' and supports' dowels and slide out the shaft sideways, indicated at point
2
3 • Replace the worn-out pinions with the new ones
4 • Reassemble in reverse order
103
Replacements
S020 • Depending on wear - Guides replacement:

1 • Follow the steps S018 to replace the belt
2 • Unscrew the nuts that fasten the guide indicated at point 1 and replace it with the new one
3 • Replace the guides indicated at point 2 by riveting the new ones to the support sheets
4 • Replace the guides indicated at point 3 by unscrewing the nuts located under the sheet
5 • Reassemble the belt in reverse order
104
Replacements
10.9 Flap folder unit

S021 • Every 16.000 working hours - In order to replace the drive belt indicated at point 1 in the
drawing, proceed as follows:
1 • Slacken the tightener indicated at point 2
2 • Remove the worn belt and replace it with a new one.
3 • Tension the belt manually, by following the path indicated by the drawing.
4 • Tighten the tensioning device in the right working position.
Fig. 47 Flap folder unit
105
Replacements
10.10 Bottom former unit

1 • Slacken the tightener indicated at point 2
3 • Remove the worn belt and replace it with the new one
4 • Refit the plate and manually tension the belt, making sure to follow the path shown in the
drawing
5 • Tighten the tensioning device in the work position
Fig. 48 Bottom former unit
106
Replacements
S023 • Every 16.000 working hours - In order to replace the drive belt indicated at point 1-2 in the
1 • Slacken the tensioners indicated at point 3 and 4
3 • Slide out the pulley indicated at point 6
4 • Slide out the belt indicated at point 2 and replace it with the new one, making sure to follow
the path shown in the drawing
5 • Refit the pulley, replace the belt indicated at point 1 making sure to follow the path shown in
the drawing
6 • Refit the plate and manually tension the belts
7 • Tighten the tensioning devices in the work position
107
Replacements
1 • Loosen the screws on the tensioning plates indicated at point 2 both on the lower and upper
case/tray-forming units
2 • Release the chains indicated at point 1 through the appropriate coupling
3 • Extract the chains from the guides and install the new ones, according to the direction of
rotation indicated in the drawing
4 • Manually tension the chain and close the screw indicated at point 2
108
Replacements
S025 • Every 12,000 working hours - Proceed as follows to replace the drive pinions indicated at
point 1 in the drawing:
1 • Follow the steps S024 to remove the chains
2 • Follow the steps S023 and S024 to slacken the drive belts
3 • Unscrew the screws of the supports indicated at point 2 and slide out the entire transmission
block indicated at point 3
4 • Slide out the hex shaft inserted in the flanges, taking care not to lose the references printed on
the flanges and on the shaft itself
5 • Unscrew the screws of the flanges indicated at point 4
6 • Release the snap ring indicated at point 5
7 • Use a puller to remove the pinions indicated at point 1 from the forks indicated at point 6
8 • Reassemble everything in reverse order
109
Replacements
S026 • Every 12.000 working hours - In order to replace the sliding guides indicated at point 1 in
the drawing, proceed as follows:
1 • Follow the steps S024 to remove the chains
2 • Remove the pins indicated at point 2
3 • Slide out the guide indicated at point 1
4 • Fit the new guides in the appropriate slot
5 • Put in the pins
110
Replacements
1 • Follow the procedure indicated in point S024 to disassemble the chains.
2 • Unscrew the screws indicated at point 2
3 • Slide out the guides indicated at point 1
4 • Assemble the new guides in reverse order
111
Replacements
10.11 Upper former group

S028 • Every 16.000 working hours - To replace the transmission chains indicated at point 1-2 in
1 • Slacken the tensioners indicated at point 3 and 4
3 • Slide out the pulley indicated at point 6
4 • Slide out the belt indicated at point 2 and replace it with the new one, making sure to follow the
path shown in the drawing
5 • Refit the pulley and replace the belt indicated at point 1 making sure to follow the path shown
in the drawing
6 • Refit the plate and manually tension the belts
7 • Tighten the tensioners in working position
Fig. 54 Upper former group
S029 • Every 12,000 working hours - Replacing the chains:

• Follow the instructions provided at point S024 for the bottom former
S030 • Depending on wear - In order to replace the drive pinions, proceed as follows:
• Follow the instructions provided at point S025 for the bottom former
112
Replacements
1 • Complete procedure S029 to disassemble the chains
2 • Extract the pins indicated at point 2 in the drawing
3 • Remove the guide indicated at point 1 in the drawing
4 • Insert the new guides in the specific space
5 • Put in the pins
S032 • Every 12,000 working hours - Proceed as follows to replace the sliding guides:
• Complete procedure S027 to disassemble the sliding guides
113
Replacements
S033 • Every 16.000 working hours - In order to replaced the tyred roller indicated at point 1 in the
1 • Loosen the screws of the tensioning device indicated at point 2, in order to release the belt
2 • Replace the worn belt with a new one
3 • Reassemble by following the same procedure in the reverse order
4 • Tighten the tensioning device in the work position
114
Replacements
10.12 Inlet belt group

S034 • Every 12.000 working hours - In order to replace the conveyour indicated at point 1 in the
1 • Extract the plate collecting the liquids, indicated at point 2 in the drawing
2 • Loosen the tensioning device indicated at point 3 in the drawing
3 • Unhook the conveyour from the pivots among the links of the conveyour
4 • Remove the conveyour and replace it with the new one, according to the path indicated in the
drawing
5 • Manually tension the belt through the tensioning roller indicated at point 3 and lock it in working
position
Fig. 57 Inlet belt group
115
Replacements
S035 • Depending on wear - Proceed as follows to replace the guides and polizene pen:
1 • Follow the procedure indicated at point S034 for replacing the conveyor belt
2 • Remove the sheet metal indicated at point 5
3 • Remove the support indicated at point 4 in the drawing
4 • Replace the polizene guide indicated at point 3 by unscrewing the nuts located under the
support
5 • Replace the guides indicated at point 1 by unscrewing the nuts located under the sheet metal
supports
6 • Replace the guides indicated at point 2 by riveting the new ones in the pre-drilled holes
7 • Reassemble in reverse order by replacing the plate indicated at point 6
116
Replacements
S036 • Depending on wear - In order to replace the dragging pinions indicated at point 1 in the
1 • Complete procedure S034 to replace the belt
2 • Remove the side supports indicated at point 2
3 • Loosen the dowels of the stop rings and slide out the drive shaft sideways, indicated at point 3
4 • Proceed with replacing worn pinions with new ones
5 • Reassemble following the procedure in reverse order
117
Replacements
10.13 Battery replacement (Every five years)

For a good battery operation, it is recommended to replace the battery after five years.
118
Dismantling and demolition
11 DISMANTLING AND DEMOLITION
The dismantling and demolition operations must be entrusted to specialised personnel and
provided with the mechanical and electrical competences necessary to work in safe
conditions. For these operations we recommend contacting SMI S.p.A.
Keep to the safety Standards reported in this manual and in those attached.
For the handling contact SMI S.p.A.
For the legal and tax aspects (any minutes, claims, etc...) comply with the rules in force in
the country where the machine has been installed.
Dismantling procedure
(Prepare a wide work area and free from obstacles and proceed as follows:
- disconnect the machine from the mains by removing the cables from the terminal board of the
electric control board, only after having isolated the plant and using the safety measures
envisioned by Standard EN 60204-1 for such interventions;
- disconnect the connectors of the machine from the electric control board;
- depressurise the pressurised circuits (pneumatic);
- disconnect the air supply network;
- drain the lubricants in the appropriate containers;
- dismantle all machine parts and subdivide the components to reject and to reuse.
Residues disposal
The materials with which the machine is built do not cause dangers or risks for the operators.
Whereas, they may be a danger for the environment if not processed correctly.
Exhaust oil and greases drained from the cylinders and tanks, belts, rubber or plastic components,
electric motors, electric cables and electric components of the control boards must be sent to the
differential collection centres for the separation and processing of the polluting parts.
Each waste must be processed, disposed of or recycled, depending on the classification and
procedures envisioned by the legislation in force in the country of installation
- brass;
- aluminium and alloys;
- galvanized or painted steel;
- stainless steel series 300/400;
- plastic material in polythene;
- rock wool
- carbon fibre;
- gears oil;
- electrical motors;
- electrical cables and relative sheaths;
- electronical control or actuation devicese.
- foam rubber
119
Dismantling and demolition
SMI S.p.A. is absolutely not responsible for any direct or indirect consequence due to
proper or improper use of this issue or of the system software.
SMI S.p.A. has the right to make technical modification on his system and on his manual
without advising the users.
120
Analytical table of contents
Adjusting the "push-down" arm 60

Adjusting the guides of the infeed belt 60
Battery replacement (Every five years) 118
Blank magazine 58
Blank magazine unit 83
Bottom former unit 106
Buttons on the control panel (Posyc) 35
Cardboard climb unit 59
Cardboard ramp unit 89
Cardboard separator unit 86
Cardboards specifications 26
Carton feeding unit 102
Channeler guides 61
Conditions and place of installation 47
Connection to the energy sources and relative checks 48
Controls and signalling 51
Direct commands 53
Documents provided with the machine 11
Electrical system 27
Equipment supplied together with the machine 49
Examples of packaging 45
Extraordinary maintenance - maintenance state procedure 70
Flap folder unit 105
General precautions 67
General warnings and rules of behavior 31
Glue characteristics 25
Handling the infeed belt 43
Handling the machine module 43
How to read and use this manual 11
Individual protections 33
Inlet belt group 115
Instructions for emergency situations 39
Instructions for service requests and to order spare parts 15
Instructions to activate the on-line service (INTERNET) 16
Instructions to contact the service centre (INTERNET) 16
Key to maintenance symbols 71
Lubrication 71
Machine control buttons 53
Machine description 19
Machine description 52
Machine operating modes and states 53
Machine units 20
121
Maintenance interventions coupon 82
Maintenance state procedure 68
Meaning of the light column 52
Method for manual updates in case of machine modifications 17
Noise 39
Notes on cleaning 70
Notes on lubrication 70
Operating the subsystems switch on timer 56
Operators to whom the manual is addressed 12
Periodic replacements 83
Phase-setting - Lower cardboard case/tray-forming unit 63
Phase-setting - Upper cardboard case/tray-forming unit 65
Pictograms found on the packaging 44
Pneumatic system 28
Positioning and levelling 48
Positioning in the installation place 48
Preliminary system tests 52
Premise 51
Preventive maintenance 72
Problems/faults (ALARMS) 55
Procedure for axes recovery 54
Prohibitions and precautions 32
Purpose of the manual 11
Reading the manual and symbols used 12
Relevant directives and laws 14
Residue risks 38
Running of the machine and control during operations 54
Safety pictograms 31
Safety systems and protections 36
Separator bar unit 97
Separator conveyor unit 91
Servo motors phase search procedure 54
Standard painting 24
Start up after an alarm or emergency 55
Start up after switch off 52
Storage 46
Summary of the pages making up the operator panel 52
Switch off 52
Technical data 26
Terms and abreviations 15
Transport and handling of packaged/unpackaged machine 41
Unpacking and content check 46
Upper former group 112
Use environment destination 29
Warnings 41
Warnings 47
Warnings 57
122
Warnings 63
Warnings 67
Warnings 83
Warranty and disclaimer 13
Weight and dimension machine module 42
Work, command and dangerous areas 37
123
SMI S.p.A. Via Ceresa, 10 - 24015 SAN GIOVANNI BIANCO (BG) ITALY
Tel. +39 035 45 40 111 - Fax +39 035 45 40 209 - www.smigroup.it

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LWP

Registration n°...................................... Year of construction...................

Manual code: DM210575

2 – PRELIMINARY INFORMATION ON THE MACHINE 19

3 – SAFETY AND ACCIDENT-PREVENTION 31

4 – UNLOADING OPERATIONS AND STORAGE 41

7 – INSTRUCTIONS FOR FORMAT CHANGE 57

8 – REGULATION AND ADJUSTMENTS 63

9 – CLEANING AND MAINTENANCE 67

11 – DISMANTLING AND DEMOLITION 119

ANALYTICAL TABLE OF CONTENTS 121

Person authorized to write the technical dossier:

The manufacturer hereby declares that the machine model: LWP......................

The product also complies with the harmonized norms:

S. Giovanni Bianco, 13/03/2012

1.1 How to read and use this manual

Use of the manual

1.2 Documents provided with the machine

1.3 Purpose of the manual

1.4 Reading the manual and symbols used

1.5 Operators to whom the manual is addressed

First level plant conductor.

Second-level system operator.

Electrical maintenance technicians.

1.6 Warranty and disclaimer

1.7 Relevant directives and laws

1.8 Instructions for service requests and to order spare parts

Fig. 1 Instructions for service requests and to order spare parts

1.9 Terms and abreviations

1.10 Instructions to contact the service centre (INTERNET)

Fig. 2 service centre

1.11 Instructions to activate the on-line service (INTERNET)

Fig. 3 on-line service

1.12 Method for manual updates in case of machine

2 PRELIMINARY INFORMATION ON THE MACHINE

2.1 Machine description

2.2 Machine units

BLANK MAGAZINE UNIT

CARDBOARD SEPARATOR GROUP

CARDBOARD CLIMB UNIT

INFEED CONVEYOR GROUP

INFEED CONVEYOR SENSORS GROUP

OSCILLATING CHANNELER UNIT

VERTICAL PRESSING ROD GROUP

COMPENSATING BARS UNIT

DIVIDING BELT GROUP

DIVIDING BARS GROUP

CONVEYOR BELT GROUP

LOWER CASE/TRAY-FORMING UNIT

UPPER CASE/TRAY-FORMING UNIT

FLAP FOLDER GROUP

HOT MELT UNIT

17 ELECTRIC CONTROL BOARD

2.3 Standard painting

2.4 Glue characteristics

2.5 Cardboards specifications

2.6 Technical data

2.7 Electrical system

The electrical system is composed by: