This machine has been designed and manufactured by MESSERSI’ PACKAGING S.R.L.

to
ensure the best performance as well as the maximum economy and effective operation,
providing that it is correctly used.
Before the delivery, this machine has been carefully tested and inspected at factory level, in
order to confirm the best conditions.
To keep these conditions and to assure a regular operation, you are kindly requested to
carry out all the maintenance operations specified within this manual.
This manual has been written to assist you during the use and periodical maintenance; it
will be your responsibility to follow the instructions provided herein.
The instructions contained in this manual are not intended for training of inexperienced
operators; all the descriptions contained herein are based on the assumption that the
operators have the necessary skill and experience.
Keep this user and maintenance manual on board of machine, for ready consultation.
Prior to operate the machine, carefully read this manual.
This machine complies with the definition stated on section 3.12.3.1.2 of the UNI EN 415-1
standard.

2
3
TABLE OF CONTENTS
TABLE OF CONTENTS ________________________________________________________________ 4

1. MACHINE’S CHARACTERISTICS _______________________________________________________ 6

1.1 MACHINE INTENDED USE __________________________________________________________ 7

1.2 MACHINE SUPPLY AND PREPARATION _______________________________________________ 8
1. 3 OVERALL DIMENSIONS ___________________________________________________________ 10
1.4 TECHNICAL CHARACTERISTICS____________________________________________________ 11
1.5 INSTALLED SAFETY DEVICES ______________________________________________________ 12
1.6 GENERAL SAFETY PRESCRIPTIONS ________________________________________________ 17
1.7 WARNING SIGNS ON BOARD OF MACHINE ___________________________________________ 24
1.8 IMPROPER MACHINE USE ________________________________________________________ 25
1.9 MACHINE USAGE RESTRICTIONS __________________________________________________ 26
1.10 WORK AREAS AND OPERATOR TASKS _____________________________________________ 26
1.11 RESIDUAL RISKS _______________________________________________________________ 28

2. TRANSPORTATION AND INSTALLATION _______________________________________________ 34

2.1 INTRODUCTION _________________________________________________________________ 35

2.2 TRANSPORTATION & HANDLING ___________________________________________________ 36
2.3 MACHINE ASSEMBLY _____________________________________________________________ 38
2.4 SECURING THE MACHINE FRAME __________________________________________________ 39
2.5 MOUNTING THE GUARDS FOR DANGEROUS AREAS __________________________________ 39
2.6 ELECTRICAL CONNECTIONS ______________________________________________________ 41
2.7 PNEUMATIC CONNECTIONS _______________________________________________________ 42

3. MACHINE STARTUP _________________________________________________________________ 44

3.1 INTRODUCTION _________________________________________________________________ 45

3.2 STRAPPING MACHINE STARTUP ___________________________________________________ 46

4. MACHINE OPERATION AND USE _____________________________________________________ 48

4.1 INTRODUCTION _________________________________________________________________ 49

4.2 OPERATION SEQUENCE __________________________________________________________ 50
4.3 MANUAL OPERATION MODE _______________________________________________________ 52
4.4 REPLACING THE STRAPPING COIL _________________________________________________ 57
4.5 AUTOMATIC OPERATION MODE ____________________________________________________ 57
4.6 MESSAGES AND SIGNALING LAMPS ________________________________________________ 60
4.7 EXPECTED SPECIAL USE CONDITIONS ______________________________________________ 67

5. MACHINE STOP ____________________________________________________________________ 68

5.1 INTRODUCTION _________________________________________________________________ 69

5.2 MACHINE STOP __________________________________________________________________ 69
5.3 EXTENDED STOP ________________________________________________________________ 73

4
6. MAINTENANCE _____________________________________________________________________ 74

6.1 INTRODUCTION _________________________________________________________________ 75

6.2 GENERAL RECOMMENDATIONS ___________________________________________________ 76
6.3 MAINTENANCE SAFETY ___________________________________________________________ 77
6.4 MAINTENANCE SCHEDULE ________________________________________________________ 79

7. MAIN SPARE PARTS ________________________________________________________________ 84

7.1 RECOMMENDED SPARE PARTS ____________________________________________________ 85

5
 1. MACHINE’S
CHARACTERISTICS

6
1.1 MACHINE INTENDED USE

The strapping machine, model OR60, has been designed by "“MESSERSI’ PACKAGING." to
provide the horizontal application of strap PP (polypropylene) or PET (polyethylene) around
a load unit.

Any machine usage different from that specified above, is to be considered as an improper use
hence the Manufacture shall not be considered liable for possible consequential damages.

The packaging of either oversized or unstable loads if forbidden, as it may be

cause of risks.

The machine can be used exclusively with accessories, possible spare parts or modifications
supplied/made either by the Manufacturer or by third parties authorized by the Manufacturer.
The temperature range allowed for the use of this machine is:

+5°C to + 40°C

The machine can be operated and serviced exclusively by informed and trained
staff, fully aware of the usage conditions and relevant risks.

7
1.2 MACHINE SUPPLY AND PREPARATION

The horizontal strapping machine OR60 is designed to horizontally apply a strap PP

(polypropylene) or PET (polyethylene) around a load unit.

Its main characteristics are the following:

 Strapping head fitted with shift mechanism, to ensure the best positioning of the strap
band over the package;

The package overall dimensions as well as the strap characteristics are designed and agreed upon
with the Customer on the purchase contract of the horizontal strapping machine OR60.

The horizontal strapping machine OR60 is delivered complete with all the equipment, special
accessories and safety devices required for correct use, adjustment and maintenance activities,
free of risks. The horizontal strapping machine OR60 is available in two different configurations, as
indicated below (the configuration of your specific machine is indicated by the tick symbol):

 Stand alone strapping machine without conveyance line;

 Strapping machine complete with conveyance line.

For your specific supply (Stand-alone strapping machine without conveyance

line) the following qualifications apply:

 The strapping machine has its own autonomy; this means that the
machine is managed through control devices separated from those of
other machines (if any);
 The strapping machine is delivered with its own CE marking and
declaration of conformity with the applicable directives and norms;
 It is the responsibility of the Customer to integrate the strapping
machine with the conveyance line or with other machines, as well as
the installation of a fixed mechanical guard, along the machine
perimeter.

The main components of your strapping machine are the following:

 Metallic frame;
 Reel-holder;
 MS500 strapping head;
 Electrical control panel.

8
METALLIC FRAME

It is made of steel plates properly bent, machined and welded in such a way as to create a sturdy
metallic frame.

REEL-HOLDER

It consists of a metallic support frame with a 3 axes movement:

 Mobile pulleys unit;

 Fixed pulleys unit;
 Reel-holder unit.

The axis of mobile pulleys unit is driven by the strapping head during the throwing phase, while the
reel-holder unit is equipped with an brake which controls the strap unwinding speed; such speed
can be adjusted depending on the size and shape of the package or on the strap thickness.

CONTROL PANEL

The control panel contains all the devices needed to control the strapping machine and to signal
the main operation failures. In particular, it contains the following control devices:

 Main switch, used to power-on the machine;

 Emergency stop buttom;
 Operator panel with dedicated display, used for monitoring of specific machine activities, as
well as for the input of operation parameters.

9
1.3 OVERALL DIMENSIONS

FRONT SIDE

PLANT

10
1.4 TECHNICAL CHARACTERISTICS

For a correct machine installation and operation, please refer to the following technical data.

GENERAL DATA

Painting RAL 3020 for mobile parts and RAL 7035 for fixed parts

Nosiness values 67 dBA

Weight about 1250 kg

ELECTRICAL DATA

Electric supply 400 V - 3ph + N + Ground

Frequency 50 Hz

Control circuit voltage 24 V DC

Main protection device interlocked breaker

Max installed power about 1,8 kW

Protection degree IP 55

PNEUMATIC DATA

Max inlet pressure 6 Bar

Air consumption 15 Nl/cycle

11
1.5 INSTALLED SAFETY DEVICES
The strapping machine has been designed and manufactured in such a way as to operate, be
adjusted and serviced without exposing the operator to possible risks, providing that such
operations are carried out in compliance with the prescriptions specified by the manufacturer.

If requested by the customer, the machine is supplied completes with all equipment, special
accessories and safety devices in order to be adjusted, make the required maintenance procedure
and use it without any risk, in any case the customer must provide the installation of the obligatory
devices.

The perimeter fixed mechanical protections to which it refers and for which is provided the layout in
the correct mounting position, if not expressly required by the contract, are charged to the
customer (perimetric mechanical protection with interlocked access doors secured with captive
screws).

The machine is provided with its own CE marking and declaration of

conformity with all the applicable directives and/or standards;

There are the following protection devices on the machine side:

 Fixed guards kept into position by means of fastening items (for protection of chains,
gears, etc.);
 Emergency stop button on control panel;
 Push-buttons with protection rings against accidental activation, located on control panel;
 Magneto-thermal relays (motor protection) against possible overloads and short circuits;
 Protection housings for electrical equipment, which can only be opened by means of
special tools or keys;
 Safety valve on pneumatic circuit;

12
 FIXED PERIMETRAL MECHANICAL SAFETY FENCES WITH INTERLOCKED ACCESS
PANELS FIXED THROUGH CAPTIVE SCREWS - LIGHT CURTAINS - MUTING

A) MACHINE EQUIPPED WITH FIXED PERIMETRAL MECHANICAL SAFETY FENCES,

LIGHT CURTAINS AND MUTING.

ATTENTION:

If the machine is equipped with the fixed perimetral mechanical safety fences, light curtains
and muting, which are not installed by the technicians of Messersì Packaging srl or from
authorized personnel from the constructor, it’s obligatory, for the proper installation, refer
to the specific instruction manuals.

ATTENTION:

THE MESSERSI’ PACKAGING SRL NOT ASSUMES RESPONSIBILITY FOR ANY DAMAGE
CAUSED TO PERSONS OR PROPERTY IN THE EVENT THAT FIXED PERIMETRAL
MECHANICAL SAFETY FENCES, LIGHT CURTAINS AND MUTING ARE NOT CORRECTLY
INSTALLED.

13
 B) MACHINE DOES NOT EQUIPPED WITH FIXED PERIMETRAL MECHANICAL SAFETY
FENCES, LIGHT CURTAINS AND MUTING.

If in the machine’s supply are not included the perimeter fixed mechanical protections (A),
the light curtain and muting devices (B) (safety devices ESPE), their positioning is however
indicated in the figure below, in order to be able to use the machine in safety conditions.

B
A
A

B
ATTENTION

MESSERSI’ PACKAGING SRL ASSUMES NO RESPONSIBILITY 'FOR ANY DAMAGE

CAUSED TO PERSONS OR THINGS IN CASE THE MACHINE IS STARTED
WITHOUT THAT HAS BEEN DONE BEFORE THE INSTALLATION OF PERIMETER FIXED
MECHANICAL PROTECTIONS (A), THE LIGHT CURTAIN AND MUTING DEVICES (B)
(SAFETY DEVICES ESPE.

14
SAFETY DEVICES

1) Fixed perimeter protections that CANNOT BE OPENED (A), fixed to the

ground around the entire machine, with exception to the pallet entrance and
exit areas.

If in the line supply are not included the perimeter fixed mechanical protections (A), the
light curtain and muting devices (B) (safety devices ESPE), their positioning is however
indicated in the figure previous, in order to be able to use the machine in safety conditions.

2) The pallet entrance and exit areas are provided with electro-sensitive anti-
intrusion barriers (B).

IF THE MACHINE IS SUPPLIED

with Electrosensible OR MUTING BARRIERS (B) follow the following:

IF THE PASSAGE OF AN OPERATOR OR FOREIGN OBJECT THROUGH THE

ABOVE-MENTIONED BARRIERS IS DETECTED DURING MACHINE
OPERATION, THE MACHINE STOPS AUTOMATICALLY.

IF THE MACHINE IS NOT SUPPLIED

with electrosensible OR MUTING BARRIERS (B) follow the following:

To manage of electrosensible barriers or muting please check the manual related to these devices
which have to be obligatory installed before to put in function the machine.

15
The machine moving mechanisms and the related operating zones, when representing a source of
hazard for the operator, have been suitably protected/isolated, or they have been fitted with
appropriate safety devices.
The protection devices used against the residual machine risks, have been chosen taking into
consideration the actual risk; moreover they are sufficiently sturdy an do not cause additional risks.

The protections have been designed in such a way that they cannot be easily by-passed or made
ineffective, and they do not limit the visibility of working cycle.
The moving mechanisms that cannot cause dangers of entanglement, dragging or crushing, are
fitted with a stop device easily reachable by the operator; moreover they are equipped with an
effective braking system allowing a quick stop time.
The gears, wheels and other toothed items (e.g. geared motor), are completely enclosed inside a
sturdy metallic housing.
The electrical equipment and other machine parts that may cause electrical shock dangers
(electrical circuits and components) are completely enclosed inside a suitable metallic case with
protection degree IP 55.

Depending on the various working processes, the operators are requested to

wear suitable personal protection devices.

THE INTERVENTIONS ON THE MACHINE MUST BE PERFORMED BY AN

OPERATOR OR MAINTENANCE IN ORDER TO PREVENT ACCIDENTAL
START-UP BY A SECOND OPERATOR.

16
DANGEROUS AREA

Before starting the work cycle, the operator must ensure there are no EXPOSED PERSONS in the
DANGEROUS AREAS.

The operator areas must always be kept free from objects and clean without any oily residues.
It is prohibited to run the line in automatic mode with the fixed and/or mobile protections removed.

It 'absolutely forbidden to inhibit the safety devices installed on the machine.

The regulation operations in conditions of reduced safety must be performed by just one person
and no unauthorized persons must access the machine when these are being performed.

The MACHINE has several DANGEROUS AREASE where the residual risks have been reduced,
but not completely eliminated:

1) Risk of entrapment

Before starting the machine, the operator must ensure that no other
operator/maintenance technician is present inside the line work area, in areas A.

OPERATOR STANDING AREA

(the area is indicated with the letter Q in the figure below)

STANDING AREA means the area in which THE OPERATOR MUST STAND
during NORMAL OPERATIONS of the machine.

17
 Q A
A

18
1.6 GENERAL SAFETY PRESCRIPTIONS

Before making the machine operational, read the instructions contained in

this manual and carefully follow the indications given.

The machine has been designed and manufactured to provide not only the best performance, but
also the highest safety level. With this assumption, the machine has been equipped with all
protections and safety devices deemed necessary and accompanied by sufficient information to be
used safely and correctly.
Despite such safety measures, however, the operator or the maintenance technician are often
liable for machine safety conditions. Many accidents occur due to the non-observance of simple
caution and safety rules.
The machine has been made in compliance with the most recent Safety Standards. It is however
good practice to remember that each moving part can constitute a danger.

For this purpose, for every man-machine interaction, when necessary the following information is
indicated:

- Minimum operator qualifications required.

- Number of operators necessary.

- State of the machine.

- Residual risks.

- Necessary or recommended PPE.

- Prevention of human errors.

- Prohibitions/obligations relative to reasonably forecastable incorrect behaviour.

Remembering that all work processes require the maximum concentration it is therefore essential
to diligently follow the indications below:

• Carefully and completely read this user and maintenance manual prior to startup,
use, service or carry out any other work on the machine.

• Keep this manual with all attached publications in a place accessible to and known
by all operators and maintenance technicians.

• The machine shall be used exclusively by operators with the minimum age allowed
by law, and properly trained and qualified.

• The transport, use, routine and extraordinary maintenance of the machine must be
performed exclusively by specialised OPERATORS/MAINTENANCE
TECHNICIANS with skill on the subject.

• Position the machine as established in the LAYOUT. If this is not the case, no
liability is accepted for any problems that should occur.

19
• Before starting the job, the operator must be thoroughly familiar with the location
and operation of all commands and features of the machine, check all the safety
devices on the machine daily.

• When using the machine, the operators must wear suitable clothing, avoiding loose
ties or other flowing parts of clothing.

• Depending on the type of required work, the operators or maintenance staff shall
wear suitable personnel protection devices (shoes, gloves, etc.).

• Carry out the expected working operation either in automatic or manual mode,
exclusively with all the protections correctly installed and perfectly efficient.

• It is forbidden to tamper with or remove the machine safety devices.

• It is prohibited to run the machine in automatic or manual mode with the fixed
and/or mobile protections removed.

• Use the machine exclusively within the expected and prescribed performance, with
particular reference to the instructions provided on paragraph “Machine intended
use”.

• During the normal operation (both in manual and automatic mode) the machine
shall never be left unattended; at least one operator must look after the machine.
If the operator must leave the working area, then it will have to de-activate the
machine.

• During the machine operation, it is forbidden to interfere or lean out with the
body inside the working zone of the machine, beyond the perimeter barriers.

• Before performing the regulation and maintenance operations, it is mandatory

to affix a sign to the control panel or on the master switch, which specifically
indicates “ATTENTION: MACHINE UNDERGOING MAINTENANCE”.

• The adjustment and maintenance operations must be carried out exclusively

with machine stationary, after having disconnected the machine itself from the
electrical and pneumatic power sources, and after having activated an adequate
protection against accidental start-ups.

• All Use and Maintenance operations of the components of the machine that can
be found on the market are not given in this manual.

• Do not remove fixed guards with the machine in movement. Always re-mount
the fixed guards at the end of any maintenance operation. It is recommended,
therefore, never attempt to work on any moving parts and make sure that no
operator is in close proximity to the machine before activating it. The guards
that can be removed or opened only via screws are protected by micro switches.
Therefore when opened, the machine stops. Before opening these protections,
stop the machine, press and emergency button and remove the voltage and
pneumatic supply to the machine.

• The room where the machine is housed must not have shadows and annoying
bright lights; dangerous for use of the machine.

20
 • It is forbidden to use extension cables or flying socket-plug couplings to power o
the machine or other machine parts.

• It is forbidden to stay on the conveyance line or on other machine parts during

the normal operation. For maintenance works, where the working areas indicated
are not sufficient, please refer to the maintenance chapter.

• During the machine operation, it is forbidden to rest or deposit material and tools
not related with the production, on the conveyance line or on other machine
parts.

• The operations performed with reduced safety must be carried out scrupulously
respecting the indications provided in the relative sections.

• After an operation with reduced safety, the state of the machine with active
protections much be restored as soon as possible.

• The washing operations must be carried out with electric and pneumatic
separation devices isolated.

• Do not modify machine parts for any reason; in case of malfunctioning, due to
failure to comply with that stated above, the manufacturer is not liable for any
consequences. It is recommended to request any modifications directly to the
manufacturer.

• Position the machine according to the layouts provided by the manufacturer. If

this is not the case, it is not deemed liable for any problems.

• Do not wear loose clothing that may become attached to machine parts.

• Do not wear large rings or bracelets, which may entangle the hands in moving
machine parts.

• The operator appointed to use and the technician appointed to maintenance of

the machine, must wear suitable CLOTHING for the work environment and the
situation in which they find themselves.

Moreover, when necessary, the Manual will state further recommendations for the user regarding
prevention measures, PPE, information for the prevention of human error and the prohibitions
relative to behaviour not allowed but reasonably foreseeable.
The user must appropriately integrate the information supplied by the manufacturer with the
additional work instructions to contribute to the safe use of the machine. Obviously, this must not
contrast that stated in this Instruction Manual.

The manufacturer is deemed relieved from any liability for damage caused by the machine to
persons, animals or objects in the case of:

• use of the machine by inadequately trained staff.

• improper use of the machine;

• electric, hydraulic or pneumatic power supply defects;

• incorrect installation;

21
 • lack of envisioned maintenance;

• unauthorised modifications or interventions;

• use of non-original spare parts for model of machine;

• total or partial failure to comply with the instructions;

• use contrary to specific national Standards;

• calamities and Acts of God.

General prescriptions

The mobile elements must always be used according to the manufacturer's prescriptions, as
indicated in this Manual, which must always be available to the operator in the work place.
In order to safeguard safety and prevent accidents, all safety devices positioned on the mobile
elements cannot be modified or removed, but must be protected.
The user must immediately inform the employer or his manager regarding any defects or
anomalies on the mobile elements.

Controls and checks

The checks must be performed by expert staff. They checks must be visual and operational, with
the purpose of guaranteeing machine safety.

These include:

• checking all of the support structures, which must not have any cracks,
breakage, damage, deformations, corrosion, wear or alterations with
respect to the original features;

• checks of all mechanical parts;

• checks of all safety devices installed on the machine;

• check of all connections with pins and screws;

• functional verification of the machine;

• verification of the machine status;

• checking the sealing and efficiency of the pneumatic and/or hydraulic

plant.

22
The results of this verification must be recorded on a relevant sheet..

If the technician appointed to perform the checks should find cracks, dangerous anomalies or
damage and deterioration, he must:

• inform the machine manufacturer immediately;

• put the machine out of order and perform the relevant checks and/or repairs;

• check that there are no objects between the machine parts;

• in this case, stop the machine, disconnect it from the electricity and
pneumatic mains and inform the maintenance manager.
If anomalies are detected, these must be eliminated before re-starting the
machine and the expert that must perform the check must make note of the
repair on the appropriate sheet, thus approving the use of the machine.

Make sure no objects are left between the moving parts after any maintenance intervention.

Whenever the worn or faulty parts are not replaced immediately, the manufacturer does not
assume any liability for damage due to accidents that could derive from the same.

In order to guarantee maximum safety of the machine, it is therefore PROHIBITED:

• to tamper with any part of the machine;

• to leave the mobile parts unattended;

• to use the machine even if not fully efficient;

• modifying the machine to change the use originally established, without

explicit authorization of the Manufacturer or without the assumption of
complete responsibility laid out by the 2006/42/CE Machinery Directive;

• to move the mobile parts with manual operations if there is a power cut.

23
1.7 WARNING SIGNS ON BOARD OF MACHINE
Special adhesive warning signs are applied to the machine; the shape color and pictogram
represented on such signs comply with the UNI EN ISO 7010.
In particular, the adhesive signs applied to the machine are the following:

24
 Failure to comply with any safety prescription, due to deterioration, loss or non-
observance of a safety sign, may cause serious accidents. The Manufacturer
rejects any responsibility for injuries or damages caused by a non-observance of
prescriptions indicated on warning signs and on this manual.

Periodically check the status of all warning signs applied to the machine, and
replace them if they are no more readable or damaged. Upon request, the
Manufacturer or your Dealer can provide a new complete set of warning signs.

1.8 IMPROPER MACHINE USE

The use of the horizontal strapping machine OR60 to carry out operations other than those for
which it has been designed and manufactured shall be considered as an improper use.

Furthermore, the following will also be considered improper uses:

 The use of this machine for handling and/or sorting of loads;

 The use of this machine with safety devices removed;
 Leaving the machine unattended after its startup;
 Operating the machine with procedures different from those described on this manual;
 Machine use by non-authorized personnel;
 Failure to comply with the maintenance schedules established by the Manufacturer;
 Altering the calibrations of pneumatic circuit valves.

Any of the above listed improper uses or negligences will involve:

 The immediate voidance of warranty;

 The relief of Manufacturer responsibility for possible injuries or damages caused to people,
animals or properties.

An improper use may damage the machine with subsequent creation of

dangerous situations for either operators or third parties.

25
1.9 MACHINE USAGE RESTRICTIONS

It is forbidden to use the machine:

 In insufficient visibility condition;

 In fire hazard areas;
 In explosion hazard areas;
 In corrosion hazard areas;
 In areas with temperature and humidity conditions harmful for the
operator health;
 In outdoor environment;
 With electrical installations non correctly grounded;
 Out of the allowed temperature range (+5°C to +40 °C);
 When the overall dimensions of the product to be packaged and/or the
strap characteristics are different from those specifically designed and
agreed upon with the Customer.

1.10 WORK AREAS AND OPERATOR TASKS

The strapping machine has been designed and manufactured considering the following aspects:

 Possibility to operate either in “automatic” or in “manual” mode;

 Presence of an operator;
 Position and/or movements of the operator at floor level.

The working area for the operator is near the electrical control panel.
For any other required task, such as machine set-up, maintenance, check, etc.,
the operator shall work either at floor level or on suitable means (self-stable
ladder, platform, etc.) allowing him to reach the relevant intervention points
under full safety condition.

The operators are requested to use the strapping machine following the instructions and
prescriptions provided by this manual and they shall carry out the indicated maintenance works.

26
 The working areas shall always be kept free of oil, grease and smudge. In
addition, they must be free of possible obstacles or hindrances.

It is the responsibility of plant manager to provide an adequate lighting of the

working areas around the machine.

More precisely, the operator tasks depend on the machine operation mode:

AUTOMATIC OPERATION

In automatic mode, the machine is managed by PLC according to the signals provided by sensors.
In such operating mode the operator’s task is limited to the regular machine operation control.

MANUAL OPERATION

In manual mode, the machine is completely managed by the operator through the devices
available on control panel. The manual operation mode is usually requested for ordinary and
extraordinary maintenance operations.

27
1.11 RESIDUAL RISKS

It’s necessary put attention to the following residual risks which are present at the use of the
machine and which cannot be deleted.

ATTENTION: DANGEROUS MOVEMENTS

Around the machine must not stand persons other than the operator.
In the presence of third persons, immediately stop the movements and
force them to leave.

ATTENTION: ELECTRICAL RISKS FOR THE PARTS UNDER TENSION

The operations on the general electrical panel of the machine have been
effectuated only from competent personnel and, in any case, with the
sectioned machine feeding device.

ATTENTION: ELECTRICAL RISKS FOR THE RESIDUAL TENSION

Pls. see the notes put in the description of the electrical equipment.

ATTENTION: HIGH TEMPERATURE RISK

For maintenance operations, the burns risk remains relative to the blade
welding of the strapping head.

ATTENTION: CRUSHING RISK

This danger remains in the proximity of moving pallets and the mobile
elements of the machine in general. In the loading and unloading area, in
transport and in installation.

When the machine is isolated from the mains electric and pneumatic power, it remains mechanical
energy stored in the springs of block of tools and in pre-loaded springs of the electromechanical
brakes of some motors actuators of axes movements; and it’s present, moreover, energy due to
gravity on the vertical axis.
This can be caused residual risk for the maintainer.

Moreover, other residual risks are present for the operator and/or maintenance technician:

1) Residual risks remain due to machine maintenance operations.

28
2) If the work area lighting fails, a residual risk develops in the equipping phase for the operator,
who would have to work with insufficient lighting; in this case, the operator must interrupt his
job and inform the maintenance service for replacement of one or both bulbs.

3) The lifting and conveying operations are manual that always include a residual risk especially due
to blows and/or crushing. These operations require a high level of attention by the employees;
the transport operations manager must inform the staff suitably regarding these risks and
provide suitable means pfor individual protection, such as helmets and protective gloves.

4) When the machine is isolated from the mains power supply, mechanical energy remains
accumulated in the tools blocking springs and in the pre-loaded springs of the electromechanical
brakes of some axes movement actuator motors.
This can lead to residual risks for the maintenance technician.

5) During load/unload operations of the pieces and tools, as it is a manual operation that requires
the use of suitable equipment, there is always the residual risk present regarding a falling piece
or part of the equipment used; along with the prescriptions that the operator must follow.

Moreover, other residual risks are present due to surfaces, edges and corners and
connected with the load-unload operations of the pieces and tools: these must be
eliminated by the user that is responsible for said operations (e.g. making suitable
PPE available).

6) For any eventuality, the operator must never try to open a mobile guard in the
working phase or a fixed guard envisioned for the maintenance service. The user is
responsible for informing the operator and the fitter regarding this requirement and
to make sure that the instructions implemented have been suitably transposed.

7) To prevent the upper part of the body striking external fixed parts of the machine
during normal handling, the operator must always use a protective helmet.

8) To prevent dangers of slipping, slipping and falls on the reference surface (walkway),
the operator must use accident-prevention shoes, especially during all manual
operations that lead to residual risks.

9) The user must keep the area surrounding the machine suitably aired with apertures and safety
devices.

29
10) Under the operating conditions provided for and those reasonably foreseeable and in
“manual” mode, there is a residual risk for the personnel, due to the possibility to
access the dangerous work area of the machine with operating elements in motion and
with other movable elements activated by maintained operation controls, in addition to
the two-position enabling device with the use of both of the operators hands or with the
maintained operation control only (if the dangerous elements cannot be reached with the
second hand).

It should be noted, however, that putting any part of the body in those areas or
keeping the movements active in the presence of exposed people, is prohibited and
not allowed.

11) Under the operating conditions provided for and those reasonably foreseeable and
in “manual” mode, there is a residual risk for the personnel, due to the possibility to
access the dangerous work area of the machine with operating elements in motion in
case, because of a failure, with the movable guards open, the axes should move and
stop immediately, thanks to the presence of the associated safety function.
It should be noted, however, that putting any part of the body in those areas or
keeping the movements active in the presence of exposed people, is prohibited and
not allowed.

12) For the residual risk due to the development of a file, the user must provide suitable
fire protection systems (also portable).

13) There are still residual risks due to the rupture of the piping during maintenance
operations in the other areas of the machine.

14) There are also residual risks connected to the impact of the keys of the selectors
and of the keys that activate the interlocking safety micro-switches, mounted onto
the internal parts of the movable guards.

15) There are also risks of scalding and burning due to contact with the external part of
the hydraulic unit (if present).
The hydraulic unit features a high temperature and measures must be taken in
accordance with the requirements of standard EN 563:1994/A1:1999/AC:2000 (mainly

30
 personal protective equipment PPE, such as heat resistant gloves for the operator
and the maintenance personnel).

16) The presence of drops of hydraulic fluid outside the machine may represent a
residual risk for the operator and the maintenance personnel due to the possibility of
slipping and falling.

17) The cleaning operations of the internal parts of the machine must be carried out by
the maintenance service while the machine is off and, if necessary, with parts of the
machine open; these operations involve residual risks and also require the use of
personal protective equipment PPE.

It is the user’s responsibility to teach the operators and the maintenance personnel about
this need and to make sure that the instructions given are properly understood.

When necessary, it is the responsibility of the user to activate a training course, if possible in
cooperation with the manufacturer of the machine, so that the operators and the maintenance
personnel are suitably trained and learn about risks in general and about the residual risks
indicated in this manual.

In its normal and reasonably foreseeable use, the machine can only be used:

a) for the activity indicated in the technical specification for normal operation (catalogue data
and contract specifications) described in the manual;

b) with the use of the materials (and substances) provided for and listed in the technical specification
(materials required for normal operation) and not for other materials (and substances).

The machine must not be used in an improper way; in particular it cannot be operated with
parameters different from those indicated in the specification and with materials of a size or weight
exceeding the capacity of the machine.

The machine must not be used in an incorrect way; in particular:

- it must not be operated with the fixed and movable safety guards open, not properly
secured or removed;

31
 - it must not be operated with the micro-switches and the safety interlocks deactivated and, in
general, with any safety and/or protection device (mechanical, electrical) turned off and/or
not working;

- it must not be operated if the user has not taken all the measures regarding the elimination
of the residual risks indicated.

The user must eliminate the residual risks indicated above

Moreover, the machine has sticky safety signs; therefore the type of residual risk to which the
operator and maintenance technician are subjected are indicated in every point of the machine.
The signs make the operator and maintenance technician take particular precautions to prevent
facing the risk represented by this sign.

32
33
2. TRANSPORTATION AND
INSTALLATION

34
2.1 INTRODUCTION

The strapping machine shall be installed in a sufficiently wide environment, free of obstacles,
suitable to the correct machine operation and maintenance works. Not only the overall machine
dimensions should be taken into consideration, but also the size of packages to be processed, as
well as the space required for loading/unloading operations. The installation site shall be suitably
lighted, free of dust, and far from heat sources; the machine shall not be installed in explosion
hazard areas.

Prior to start the machine installation, the Customer must comply with the following requirements:

 Make sure that the machine rest surfaces are perfectly cleaned;
 Observe the positioning indicated on machine layout;
 Make sure that the electric and pneumatic supply points are correctly positioned and that
the supply lines are suitably dimensioned.

The installation must be carried out exclusively by qualified technicians, in

compliance with all the applicable standards and local regulations concerning
the electric and pneumatic installations. The involved staff must be perfectly
aware of the safety regulations in force within the installation country; in
addition they shall be familiar with the instructions, safety warnings and
prescriptions related to the machine and contained in this manual.

35
2.2 TRANSPORTATION & HANDLING

The machine is sent by truck, ship, railway or aircraft. The painted surfaces are carefully protected
to avoid damages.
The various components are separated in such a way as to obtain homogeneous packages in
terms of size and weight.
The unloading of packages from the truck used for transport to the installation site should possibly
take place using a forklift truck.

Two eyebolts on the vertical posts, allow an easy and safe handling, in case of assembled
machine.

To unload and transport the machine to its installation site the Customer is recommended to follow
the procedures described hereunder:
When using a crane or gantry, observe the following precautions:

 Disengage the machine from the truck support frame.

 Hook the lifting ropes to the eyebolts.
 Position the crane to the machine side or, if you are using a gantry, position the gantry
hook over the machine, then secure the lifting ropes to the hook of crane or gantry.
 Slightly tension the ropes and, if necessary, correct the balancing.
 Slowly lift the machine from the truck platform, trying to keep it balanced and avoiding
excessive oscillation, with a aid of a guide-rope.
 When the machine is sufficiently lifted, move away the truck.
 Lower the machine up to about 30 cm from the floor, and move it to the installation site,
always keeping it to vertical position.
 Rest the machine on the floor and remove the lifting means.

When using a forklift observe the following precautions:

 The forklift truck shall be driven by a qualified and authorized operator;

 During the transportation path, the forks shall be lowered as much as possible;
 The chosen path shall be smooth, to keep the machine stable;
 The load shall be correctly balanced over the forks, to avoid accidental falling.

36
 Example of machine lifting, taking
into consideration the total weight
indicated on the machine
nameplate. During the lifting
movement, make sure that the
ropes do not damage the
unprotected machine parts

The machine weight is engraved on the nameplate.

To lift the machine use a lifting equipment with suitable lifting capacity.
Use exclusively ropes approved and suitable to the load to be lifted; the rope
lifting angle shall not exceed 90°.
Make sure that the machine lifting eyebolts are not damaged.
Make sure that all people not directly involved in the lifting operations are at
safety distance, far from the handling path.
Do not stay under suspend loads
Properly secure the machine to the truck if you must move it to another place.

37
2.3 MACHINE ASSEMBLY

The only machine component which is separately packed, thus requiring an assembly work is the:

 Electrical control panel if not on the machine;

 Reel-holder positioning.

ELECTRICAL PANEL ASSEMBLY PROCEDURE

If the machine is provided with a separate self-standing electrical panel (console type), it will be
necessary to:

 Position the self-standing panel near the work area, however outside the perimetric
protection.
 Connect the electrical panel to the strapping machine, as indicated on the enclosed
electrical diagrams. To correctly carry out the electrical connections, please read the safety
prescription paragraph, at the end of this chapter.

The electrical panel must be positioned in a safe area, outside the machine
perimetric protection.
The operator work area shall ensure a good visibility of the machine operation.
The connection between electrical panel and strapping machine, must be carried
out following the instructions provided by this manual, in compliance with the
local regulations in force.

38
2.4 SECURING THE MACHINE FRAME
The machine positioning must be carried out taking into account the available spaces, evaluating
the building characteristics and considering the machine processing phases: loading, strapping,
unloading.

SECURING PROCEDURE

 Position the machine frame on a leveled floor. If the floor does not offer sufficient solidity
guarantees, we recommend to provide suitable foundations.
 Secure the machine frame to the floor on the designated points, using suitable screw
anchors and bolts on the post base plates.
 Before completing the machine fastening operation, check (using a precision spirit level) the
machine leveling and adjust it, if necessary, through the adjustment nuts (if present).
 Position the remaining system components and check again the leveling (on both direction)
of the strapping machine and conveyance roller units.
 Tighten all the fastening bolts on the post base plate, to avoid vibrations.

The machine installation environment must be properly lighted (without shade

zones) and it must guarantee acceptable temperature and humidity values, etc.)

Before completing the machine fastening

operation, check (using a precision spirit
level) the machine leveling and adjust it, if
necessary, through the adjustment nuts (if
present).

39
2.5 MOUNTING THE GUARDS FOR DANGEROUS AREAS

Complete assembly of the machine by positioning and fixing the perimeter protections (for correct
positioning, refer to the LAYOUT).

The machine is available in two different configurations, as indicated below (the configuration of
your specific machine is indicated by the tick symbol):

 Stand-alone strapping machine without conveyance line;

 Strapping machine complete with conveyance line.

The machine is fitted with accurate protections that guarantee a high degree of safety to staff
appointed during machine operations, in agreement with international accident-prevention
Standards in force.
The machine is also fitted with safety devices with the essential task of protecting it completely.
These devices start to operate when an anomaly is detected such to require machine shutdown
and successive maintenance intervention.

For this supply (strapping machine without conveyance line), it is the

responsibility of the Customer to integrate the strapping machine with other
conveyance lines or with other machines, as well as the installation of a fixed
mechanical guard, along the machine perimeter.

For the installation of mandatory safety devices, refer to paragraph 1.5

Prior to start the machine test at the Customer’s premise, it is necessary to

install the fixed mechanical guard, along the machine perimeter.

40
2.6 ELECTRICAL CONNECTIONS
The electrical connections between machine and electrical panel (when this is not on-board), as
well as the strapping machine connection to the electrical supply line and any other electrical
connection such as protection guard wires and equipotential bonds on board of machine, must be
carried out exclusively by expert electricians, in compliance with the applicable safety regulations
in force.
The machine connection to the mains, carried out as indicated herein, does not cause any
movement of machine parts

Use the enclosed electrical diagrams to connect the strapping machine to the separate electrical
panel (X1 power clamps and X2 auxiliary circuit clamps). The connection wires shall be
properly protected with a suitable isolated sheathing and they shall be routed inside pipes or
runners, to avoid mechanical damages.

The connection between electrical panel (X1 power clamps) and electrical supply line shall be
carried out using an isolated electrical cable, with wire cross-section calculated taking into
consideration the following parameters:

 Absorbed power;
 Length of power cord;
 Type and characteristics of power cord;
 Laying and connection modes.

Pay particular attention to use a YELLOW-GREEN wire for ground connection (PE clamp) and a
BLUE wire for neutral connection (N clamp).

After every connection, make sure that the clamps and cable glands are securely tightened.

Components and harnesses of the electrical equipment shall never be tampered with. The
manufacturer will not acknowledge possible damages caused by a failure to comply with
this prescription.

The electrical connections must be carried out by a skilled electrician, in

compliance with the technical standards and local safety regulations in force.

Confirm that the mains voltage (V) and frequency (Hz) meet the specifications.

All metallic parts of the machine must properly be connected to the Protective
Earth system according to the local regulations.
Make sure that the machine is powered through a magneto-thermal main switch
(preferably of differential type) with a suitable short-circuit breaking capacity.

Turn the main switch to OFF position and lock-it with a suitable padlock prior to
connect the machine to the mains.

41
2.7 PNEUMATIC CONNECTIONS
The connection of strapping machine (pressure reducer valve) to the compressed air line of the
plant shall be carried out by the Customer.

The following target requirements apply:

 Max. inlet pressure: 10 bar

 Nominal operating pressure: 6 bar

The pneumatic supply line must be suitable to support the operating pressure and it must have a
minimum diameter of 8 – 10 mm.
Once you have connected the supply pipe to the pressure-reducer valve, turn the knob (A) until
reading a nominal pressure of 6 bar on be pressure gauge.

The pneumatic connection must be carried out by a skilled technician in

compliance with the technical standards and local safety prescriptions.
Prior to connect the supply pipe, make sure that the inlet valve is “closed”.

42
43
3. MACHINE STARTUP

44
3.1 INTRODUCTION

Once you have completed all the adjustments and preliminary checks described on chapter 5 of
this manual, the strapping machine is ready for startup.

Turn the main switch to ON position, to power-on the

control panel (as shown on the figure).

The startup and subsequent machine management shall be carried out by

trained operators.

45
3.2 STRAPPING MACHINE STARTUP
The strapping machine can be started up only with intentional action on the designated control
device.

The required operations, described below, refer to the control panel figure.
To activate the strapping machine turn the operation switch on control panel to position "ON-0".

The "POWER SUPPLY" white lamp turns on to indicate that the strapping machine is powered.
Once the control panel is powered-on, to use the strapping machine you must carry out the
following three simple operations:

 Make sure that the emergency button is not pressed (otherwise rotate the red button to
counter-clockwise direction to release it);

 Press the blue reset button to restore the machine and the emrgency;

 Press the green run button for to operate the machine.

WHITE light indicator to RED light indicator to signal

signal that the electrical malfunctions or alarms.
panel is powered.

Digital thermoregulator
(only for strapping heads
model "MS")
For the adjustment and
programming of the
thermo-regulator, refer to
the Instruction Manual of
STRAPPING HEAD.

RESET button to
reset the machine
and the emergency.

EMERGENCY
button to stop
the machine.

RUN button to enable STOP button to stop the

the machine to machine during its
operate. operation.
46
When the green lamp of Run button and the blue lamp of Reset button are on, it means that the
strapping machine is active.

47
4. MACHINE OPERATION
AND USE

48
4.1 INTRODUCTION
By “machine operation”, we mean all the actions usually requested, depending on the type of
intended use.

The normal operation, as well as all the subsequent stages of machine use, must be carried out by
the Customer; it will not be necessary to involve the Manufacturer.

The information required to the operators for a correct machine use are listed on this manual.

Prior to start the normal machine operation:

 Make sure that the working area is correctly lighted;

 Make sure that the safety devices installed on the strapping machine have
not been removed or by-passed;
 Depending on the actual working process, wear suitable personal
protection devices.

49
4.2 OPERATION SEQUENCE
The machine is equipped with a SIEMENS TP177A touch panel (like that shown on the figure
below), on which you may setup the following parameters.
Turning the "MANUAL/AUTOMATIC" selector on control panel, you may activate the desired o
peration mode:

From this page is possible:

 View the status of the machine;

 View and choose the program number;
 Activate the automatic or manual operation mode;
 Start the automatic strapping cycle with the button “START CYCLE” (in this case the
strapping quantity to effectuate on the pack can change in relation to the programme
chosen);
 Start the “START STRAPPING” (if the machine is making the “START CYCLE”, and then it
was performing a complete cycle and for an anomaly it crashes is necessary to proceed as
follows:

1) Reset the alarm;

2) If required, recycle and remove the strap from the arch of strapping,
3) Put the machine in "AUTOMATIC” mode,
4) Press the "START STRAPPING" to restart the machine from where it was stopped, in
practice it resets the block of the machine.

The button "START STRAPPING" performs a single strapping in the position where the
machine is located.

50
The softkeys available on the left side of touch screen allow you to easily navigate through the
various program pages, such as:

 Home page;
 Manual controls;
 Setup;
 Programs;
 Alarms;

51
4.3 MANUAL OPERATION MODE
To activate the manual operation mode, press the “MANUAL/AUTOMATIC” selector switch on
control panel.
In this operation mode, the machine is fully managed by the operator.

Once selected the manual operation mode, it is possible to enter on the pages:

 Home page;
 Manual controls;
 Setup;
 Programs;
 Alarms;

52
MANUAL CONTROLS

Press the “Manual” softkey to select the manual control page.

1) “FEED” button: press this button to carry out the strap throwing; the throwing movement
goes on as long as you keep the button pressed.

2) “TAKE UP” button: press this button to carry out the strap recovery; the recovery movement
goes on as long as you keep the button pressed.

3) “RECYCLING” button: this button allows you to adjust the strapping head phase; it provides
two operating modes: Extended pressure (more than 2 seconds): the head performs the
recycling and returns to zero phase; this is a mandatory position for the head, to enable the
strapping cycle;
Pulse pressure: the head stops at each characteristic step of the strapping cycle.

4) Button “MACHINE RESET”: this button allow reset the machine;

5) “HEAD UP/DOWN” button: these buttons allow you to either raise or lower the strapping

head and the arch. Press the button to move the head and arch up. Press the  button
to move the head and arch down.

53
SETUP

Press the “Setup” button to choose the desired working options.

By means of this page you may setup the following options:

 Choose the strap type: PP/PET;

 Machine included: when it receives the relevant signal, the machine will carry out the
strapping cycle, providing that it is set to automatic operation mode;
 Machine excluded: when it receives the relevant signal, the machine will not carry out the
strapping cycle, even if it is set to automatic operation mode;
 Language Selection; push on the desired language;
 To control screen contrast;
 Start the cycle of welding blade cleaning.

54
STRAPPING PROGRAMS

The machine can set 10 programs, each of which has 5 possible strapping positions.

This page displays the following parameters, which can be modified:

1. Number of the program selected;

2. Strapping quotas of the program in use (can be modified using the keys).

The height of the arc that is shown now and again is just a display:

To modify the program, click on the program number . A screen keypad

will open; introduce a number between 1 and 10.

55
To modify the arc quota of the program: click on the button until the desired quota is
obtained.

At this point, by clicking on (example ), the desired quota is introduced

into the program.
“Once all the necessary strapping quotes are programmed, press the “save” button to save
the program, until you see a pop-up window with the words "program saved."
The saving function is active only in manual mode and it will be notified by a signal in the
alarms page.

It is visualized also the current position of the strapping arch, the position (numerical value)

can be changed by the following button .

If you want to insert a new quote for the arch press the panel
which has the numerical value, at this point you will see a numeric keypad in which you
can digit the new value.
Press “Enter” to confirm the new entered value.
Press at the end “SAVE” on the programming page.

START CYCLE

With the arch at the maximum height starts the complete strapping cycle of the pack under
the same arch.

ATTENTION: the quotes have to be included in ascending order in order to optimize

the working time of the machine.
56
4.4 REPLACING THE STRAPPING COIL
The replacement of strapping coil must be carried out following the procedure and the sequence
described hereunder.

 Set the machine to MANUAL operation mode;

 Put the machine in the state of emergency stop or make the request for access to get
inside the working area of the machine;
 Access to the work area of the machine;
 Unscrew the knob shown on the following figure, that keeps the discs tight;

DISCH TIGHTENING KNOB

 Remove the external disc and the old strapping band coil from the relevant supports;
 Raise the lower pulley and hitch it to the chain fastened to the upper cross-beam. Like this
the strap coil is not braked; make sure that the coil doesn’t unreel by accident;
 Insert the new strapping band coil paying particular attention to the direction shown on the
following figure; then re-install the disc and turn the knob until the coil is correctly tight
between the two discs;
 Release the lower pulleys previously attached to the chain;
 Thread the strap inside the two sets of pulleys, following one of the two paths indicated on
the figure below (note that in both cases, the natural bending of the strap follows that of
the pulleys), in this way the strap will not get in collision with the strapping machine
mechanisms or with other frames or devices. Sometimes it is necessary to install special
strap counter-rollers.

57
 Insert the strap into the strapping head, taking pulled the knob (A) and making sure that
the curvature respects the value indicated by the arrow;
 Once you have insert the strap, please release the knob (A);

KNOB (A)

 Exit the work area of the machine;

 Activate the manual throwing of the strap until the strap itself comes out of the strapping
head, then carry out a recycle and free the arc;
 At this point the strapping machine is ready to run.

58
ATTENTION: ONLY FOR CLAMPS ARCH

Every time that you want to free the arch, pull the strapping following the arch profile and
not in the orthogonal direction of it. If the arch is with flaps, if the strapping come not pull
out in the correct mode, the springs of the flaps arch are subject to stretching and tend to
loosen.

Horn
(Prealarm End of strap)

YELLOW COLOR
(Anomaly)

59
4.5 AUTOMATIC OPERATION MODE
Prior to start the automatic operation, while the machine is running in manual mode, make sure
that:

 The strapping band coil is not in run out condition;

 The strap is correctly inserted into the strapping head;
 The ""FAULT" red lamps on control panel are both OFF
 All the photocells and sensors are correctly oriented;
 The operator display does not show alarm messages;
 The air pressure in the pneumatic circuit is properly adjusted.

In automatic operation mode, the strapping machine ignores the commands given by the operator
with the various buttons and selectors of control panel, except the “START CYCLE” command; the
machine is automatically managed by the PLC and its correct operation is controlled through the
sensors installed on board of machine.

Check the correct alignment of the photocells with the relevant mirrors and
check that the proximity sensors are positioned in such a way as to guarantee a
correct distance between the sensor heads and the relevant cams.

To activate the automatic operation mode, push the “MAN / AUT” bottom on control panel.
If no alarm condition has been detected, then the operator display will show the "AUTOMATIC"
message.

60
Once selected the automatic operation mode is possible to select the program and start the cycle
or strapping required.

 CYCLE START

When the arc is in position (maximum ascent) it can start the strapping cycle on the pallet inside
the arc.

 START STRAPPING

It can start the single strapping on the pallet.

61
4.6 MESSAGES AND SIGNALING LAMPS
The main title page of the electrical and control cabinet shows the following signaling interfaces
with the operator :

 display;
 signaling lamps.

ALARM MESSAGES SHOWN BY THE DISPLAY

From the home page of the panel, clicking “alarm” button it is possible to access to the alarm
messages display.

62
The following sketch shows all the main alarm signals that can be displayed.

MESSAGE DESCRPTION

Means that the head launch clutch has been

indicated for a longer time than the one
STRAP FEED TIMEOUT
forecasted; therefore it is not possible to
complete the strapping cycle. .

Means that the head recovery clutch in the

STRAP TAKE UP TIMEOUT signal is still activated for a time longer than the
time limit set .

Means that the head did not complete the

tensioning; the tensioning clutch has been
TENSIONING TIMEOUT
activated for a time longer than the time limit
set .

Means the head did not complete the

SYNCHRONIZATION TIMEOUT
synchronization and the tensioning .

Means the head carried out the maximum

MAX NUMBER OF STRAP FEED TRIALS number of launch forecasted and no one
reached the good result.

Means an anomaly occurred in the AZ1 inverter

ALARM INVERTER (AZ1)
functioning

Means the head is not in phase and it is not

HEAD NOT IN PHASE 0
ready to start a new cycle .

It indicates that the cam shaft reduction clutch

CAMS REDUCTION GEAR TIMEOUT remained active for a time exceeding the
maximum set time.

It indicates that the machine cannot move the

HEAD AND COMPACTORS NOT FULLY
strapping head up or down, because the
BACK
compacting devices are not fully open.

It indicate that the machine has received the

SELECT PROGRAM IS VOID
start cycle but the program is not selected.

It indicates that you have exceeded the

maximum time allowed for the advance and
HEAD AND COMPACTORS FW/BW TIMEOUT
retreat of the head and compactors device,
without that there has been handling.

63
 Means the machine is carrying out the clearing
BLADE CLEANING CYCLE IS RUNNING
of the sealing blade.

Means the machine is excluded by the line,

MACHINE EXCLUDED therefore packages pass under it without being
stripped .

The sensor detected a slackening of chains;

check that no obstacle prevents the lowering
movement; if necessary, remove the obstacle
after having moved up the machine. If the path
ARCH AND CHAIN SAFETY INTERVENTION is free, check for correct operation of the
sensor. If necessary, replace the sensor.
Intervention of the photocell safety arch, check
that there are no problems of possible collisions
between the package and the arch.
It indicates that the air pressure into the
pneumatic system is too low, pls. check the
AIR PRESSURE TOO LOW
regulation or that there is some loss.

Check the motor related to the upwards /

ALARM THERMAL PROTECTION UP/DOWN downwards of the head and restore the use of
MOTOR the motor. At this point you can re-enable the
thermal protection device.

It indicates that the machine is not ready to

MACHINE NOT READY
make a work cycle.

It indicates that you have exceeded the

MECHANICAL BLOCKS OPENING TIMEOUT maximum time allowed for the open self-locking
device, without that there has been handling.

It indicates that on the operator panel it’s

present a message of pre-alarm which indicates
PREALARM END OF STRAP
the end of the strapping.

It indicates that has been performed with

RESET DONE
success the reset of the machine.

It indicates that there is an anomaly in the

UP/DOWN ENCODER FAULT
translation encoder.

It indicates that you have exceeded the

BLADE WARMING TIMEOUT maximum time allowed for the heating the
sealing blade relative to the strapping head.

64
 The sensors positioned on the cylinders don’t
detect the opening of mechanical blocks, the
MECHANICAL BLOCKS NOT OPENED sensors could be not properly settled or the
blocks could effectively have opening problems.

MESSAGES SHOWN BY THE DISPLAY

The following table shows all the messages that can be displayed in the “machine status” line, and
a brief description of their meaning.

MESSAGE DESCRIPTION

Means the machine is in manual functioning

MANUAL MODE
mode.

Means the machine is in automatic functioning

AUTOMATIC MODE
mode. .

Means the machine is in emergency stop

EMERGENCY
status, restore the functioning.

Means the machine is excluded by the line,

MACHINE EXCLUDED therefore packages pass under it without being
stripped .

Means the machine is carrying out the clearing

BLADE CLEANING
of the sealing blade.

65
SIGNALING LAMPS

The signaling lamps on control panel turn-on to indicate the following conditions:

 Operation failures (alarms) – red color;

 A machine status (condition) – green color;
 Security module is ON – blue color.

ALARM LAMPS

 FAULT” – it signals a machine operation failure;

CONDITION LAMPS

 “POWER SUPPLY”: it indicates that the control panel is powered.

 “RUN”: it indicates that the machine is not in emergency stop status, i.e. it is ready for
normal operation, providing that no alarm message is displayed.

66
4.7 EXPECTED SPECIAL USE CONDITIONS

The intended use of the machine is defined on this manual. The intended use also includes the
compliance with the technical instructions provided by this manual as well as the knowledge of
usage restrictions.

OPERATION IN COLD ENVIRONMENT

The strapping machine operation in excessively cold environments may be

critical due to the plastic material of the strapping band.

OPERATION IN DUSTY ENVIRONMENT

The strapping machine operation in dusty environments requires a special care

during the maintenance operation. In particular: the machine shall be carefully
cleaned and it is advisable to establish a service procedure specifying the
cleaning intervals and required cleaning degree; the lubrication intervals shall be
shortened.

67
5. MACHINE STOP

68
5.1 INTRODUCTION

The stop devices can be easily located through the following color codes and indications:

 Red color, for push-buttons;

 Red/yellow color for the main switch;
 Mushroom shape for emergency buttons;
 Label with "emergency" indication.

The operator work area is fitted with an emergency stop device (mushroom button) located on the
electrical control panel; this allows a complete stop of the machine in safety condition.

An emergency stop order has a higher priority with respect to any startup order.

The machine restart after an emergency stop, may only occur after an intentional reactivation of
the emergency button.

5.2 MACHINE STOP

The machine stop devices are located outside the dangerous zones.
The stop devices are:
 Clearly visible, easily reachable and marked with a suitable indication;
 Arranged in such a way as to guarantee a safe, univocal and quick action;
 Arranged in such a way as to prevent supplementary risks;
 Resistant to predictable stresses.

NORMAL STOP

The machine is equipped with a control device that allows a general machine stop under safety
conditions (red STOP button).
The machine has been designed and manufactured to operate either in manual or automatic
mode; the machine stop depends on the current operation mode:

Manual operation

 Press the red “STOP” button on control panel to stop the machine
 The machine is equipped with a safety solenoid valve on pneumatic plant; whenever you
stop the machine the inlet air supply is interrupted and the pressure of machine pneumatic
circuit is discharged.

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 STOP

Automatic operation

If possible, wait for completion of the current cycle, then act as described for manual operation
mode.

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EMERGENCY STOP

Press the red mushroom button on control panel available in the operator working area. As an
alternative, you may also turn-off the red/yellow main switch on control panel.

EMERGENCY

If, for any reason, you have pressed the emergency button, then to restart the
machine, operate as follows:

 disengage the emergency button, turning it to counterclockwise direction;

 restart the machine.

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STOP DUE TO ELECTRIC OR PNEUMATIC BLACK OUT

In case of sudden blackout of ELECTRICAL POWER, operate as follows:

 turn the main switch to “OFF” position;

 wait for the normal restoration of electric power;
 restart the machine.

In case of sudden interruption of PNEUMATIC SUPPLY, operate as follows:

 press the Stop button to interrupt the machine operation;

 restore the correct pressure of pneumatic circuit;
 restart the machine.

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5.3 EXTENDED STOP

If the machine shall remain inactive for a long time, it will be necessary to:

 disconnect it from energy supply sources (electric and pneumatic);

 adopt suitable precautions to prevent crashes or mechanical damages (perimetric
protections, fences, etc.);
 properly protect it against dust, humidity, splashes, etc.;
 do not leave the machine out of the allowed temperature range (+5° to + 40°C).

To move the machine without disassembling it, please refer to chapter 2 for
details about lifting devices and lifting points.

To resume the normal operation, after an extended stop, observe the prescriptions provided on
chapter “Maintenance” chapter, in particular:

 Thoroughly clean the whole machine;

 Lubricate the mobile items and the transmission chains;
 Check the correct operation of the automatic breaker used to power-on the strapping
machine;
 Check that all the safety devices on board of machine are correctly installed and operating
(perimetric protection interlock switches, emergency stop button, etc.)

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6. MAINTENANCE

74
6.1 INTRODUCTION

For a long life and a correct operation of your strapping machine, you are recommended to
periodically carry out the maintenance operations described on this manual.
By “maintenance” we mean all the ordinary and extraordinary service works, as well as the repairs
which are fully or partially in charge of the Customer; this manual does not deal with the
maintenance works which must be carried out by the Manufacturer and that do not involve
Customer resources.

The maintenance operations also include the machine cleaning, which must be carried out
periodically out of the normal working cycle.

Prior to start any maintenance work on the strapping machine you are kindly
recommended to carefully read the instructions contained in this manual and to
strictly adhere to the indications provided by the warning signs on board of
machine.

Not authorized personnel shall not be allowed to carry out maintenance works.
Do not start any maintenance work without specific authorization.
Always follow the maintenance and service procedures provided by this manual.

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6.2 GENERAL RECOMMENDATIONS

Any maintenance work on the machine, must be carried out in compliance with
the local accident prevention regulations in force.
Not qualified or not authorized personnel cannot carry out maintenance works.
Use suitable personal protection devices depending on the operation to be
carried out.
To reach the machine parts subject to maintenance, use suitable means (self -
table ladders, platforms, etc.) allowing to operate under full safety condition.
Never execute temporary repairs; in order not to compromise the machine
integrity, use exclusively original spare parts and/or accessories, like those
currently installed, or in any case approved by the Manufacturer.
You are recommended to record all the ordinary and extraordinary maintenance
works on specific ordinary and extraordinary maintenance log.
The staff in charge of maintenance activities shall ensure the compatibility
between the maintenance schedule provided by this manual and the local
regulations in force, taking into consideration the actual machine use.

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6.3 MAINTENANCE SAFETY

The checks and maintenance operations on electrical components must be

carried out with the machine switched off.
Lock the main switch to OFF position using a suitable padlock.
All the adjustment, lubrication, cleaning, part replacement, control and repair
operations must be carried out with machine stationary and under safety
condition.
The maintenance staff must use suitable Personal Protection Devices and
wear appropriate clothing, avoiding or paying attention to: fluttering clothes,
wide sleeves, hanging ties or scarves, necklaces, bracelets and rings, long
hair (if necessary, wear a cap).
The protections and safety devices installed on the machine, should never be
removed. If this is impossible, they must be reinstalled at the end of the
maintenance work and, in any case, prior to startup the machine.
Never insert parts of your body into holes or zones subject to cutting risks,
with relevant guards removed, without having firmly locked in advance the
movable parts.
Prior to start any maintenance works, on machine parts subject to
movements, lock such movements with suitable safety devices. Never use
unsuitable tools.
Never carry out maintenance works on moving parts.

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The machine is equipped with an additional safety “Self locking device for vertical
movement“ which is applied for a major security of the maintainer.
The mechanism is composed from a pneumatic and electro-mechanic device which acts
on a wedge. This wedge is inserted onto a steel comb integrated with the structure of the
machine or directly on the holes present in the machine frame.
This device is applied to the mobile suspended parts of the machine and comes into
operation whenever they stop.
During the vertical stroke up and down of the suspended elements, the device is not
used and when these elements stop, the device comes into action.
The activation of the device with the machine stopped allows the maintainer to can
perform maintenance operations avoiding, in the event of a mechanical failure, that the
suspended part of the machine may fall.

Self locking
device for
vertical
movement

COMB STEEL
UNITED TO THE
STRUCTURE IN
WHICH ITS
CATCHED THE SELF
LOCKING DEVICE
FOR VERTICAL
MOVEMENT.

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6.4 MAINTENANCE SCHEDULE

To maintain the safety and efficiency of the machine and prevent undesired "out of order
situations", it is advised to scrupulously follow the maintenance operations given in the program, in
accordance with the frequency.

Scrupulously follow the instructions below when performing maintenance and/or repairs:

• Before starting any job, display the sign indicating "MACHINE UNDERGOING MAINTENANCE"
in a visible position;

• Do not use solvents and inflammable materials;

• Do not dispose of coolants in the environment;

• Use suitable devices for the operations to be performed on high parts of the
machine;

• Do not climb onto machine parts, as they have not been designed to support persons;

• At the end of the job, restore and correctly fix all protections and guards removed, opened or
deactivated.

The manufacturer is not deemed liable for the failure to comply with theabove-
mentioned recommendations and for any other incorrect use or use not
mentioned in these instructions.

Before performing any type of intervention, the machine must be isolated from the electric
power supply and other energy sources.

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 OPERATION TO
FREQUENCY INDICATIONS
PERFORM

Carefully eliminate all traces

of dirt on all work and
transport surfaces of the
machine which could cause
friction and therefore running
problems on said surfaces.
Use isopropyl alcohol and a
non-fraying cloth only. If not
CLEANING THE necessarily requested, only
DAILY
MACHINE use a cloth dampened in
warm water.
Where stretch films and
pneumatic surfaces are
present, clean the cutting
wire from deposits of film and
drain the condensate from
the compressed air filter

Carry out the following

checks every day before
using the machine:
control the outside of the
machine and its equipment,
checking for any breakage or
damage of components or
the structure;
CONTROLLING
GENERAL MACHINE check for any loose screws,
STATUS DAILY nuts and bolts;
check that all pins are
present and locked correctly
in position;
visually check whether there
are any fluid leaks and, if
necessary, inform a
specialised technician who
will eliminate said leaks.

Check the status, electric

CONTROLLING connection and operation of
EVERY the photocells, of the
MACHINE
THREE proximity sensors and end
ELECTRICAL SET-UP runs.
MONTHS
Check the electric cables are
connected correctly

80
 (particularly the terminal
boards of the control boards
and electric components
installed on the machine) and
control if they or loose or
damaged.
Control operation of the
LEDs and buttons on the
electric control board, as well
as the cleanliness and
connection of the
components inside the
control board itself.
Check that the protection
rating (IP) of the electric
control board and other
electric components is
maintained.
Check the tightness,
connection and metallic
continuity of the protection
and equipotential wires.

Check for any traces of

corrosion or mechanical
damage present on the
CONTROLLING machine structure.
MECHANICAL Check that the external
COMPONENTS MONTHLY temperature of the motors
and gear boxes is not too
high (below 60 °C). Also
check that there are no
lubricant leaks from the
gearbox.

Remove the guards and

check chain lengthening.
This must not exceed 3% of
CONTROLLING the initial length.
MOVEMENT AND MONTHLY Also check wear of the chain.
DRIVE PARTS

Check the tensioning of the

chain.

MOST
UNFAVORAB
LE
Lubricate with spray or brush
LUBRICATING CHAIN CONDITION applied grease
BETWEEN
200
WORKING

81
 HOURS AND
2 WEEKS

MOST
UNFAVORAB
LE
CONDITION
LUBRICATING DRIVE Lubricate with spray or brush
BETWEEN applied grease
PINIONS
200
WORKING
HOURS AND
2 WEEKS

LUBRICATING
LATERAL RUNNING
GUIDES

MOST
UNFAVORAB
LE
CONDITION
Lubricate with spray or brush
BETWEEN applied grease
200
WORKING
HOURS AND
2 WEEKS

Where
LUBRICATING THE Fill the grease nipples
present, mounted on the rails.
BALLSCREW
MONTHLY

82
 Fill the relevant greasing
Where nozzles mounted on the
GREASING RUNNING
present, guides.
GUIDES
MONTHLY

83
7. MAIN SPARE PARTS

84
7.1 RECOMMENDED SPARE PARTS

To face the ordinary and extraordinary maintenance works and to avoid long machine downtimes,
we recommend you to order the following spare parts.

The spare parts shall be stored in dry environment.

Recommended spare parts for basic machine

For spare parts:

- EDE005
- EDE032
- EDE033

refer to the eletric diagram attached.

85
For spare parts:

- IBO001
- ICA013

refer to the pneumatic diagram attached.

EFT 014100

86
EPR009400

87
 MML012 MGM002

MNY002

88
MZZ018 - MZZ019

89
IBO001 - ICA013

90
Recommended spare parts for strapping head

91