STRETCH WRAPPING MACHINE L2500 AUTO 1. Manual and CE-instructions

Transcription

1 STRETCH WRAPPING MACHINE L2500 AUTO 1 Manual and CE-instructions MARCH 2001

2 Index 1 Nissen Stretch Wrapping Machines Machine type: NISSEN L2500 AUTO Technical specification Areas of use Guarantee Limits of responsibility Machine plate Assembly instructions Installing the machine Dismantling Dismantling Disposing of the machine Instructions for use General The control panel Operation Adjustments on operator s panel Plastic film Adjustment of stop position of turntable rotation Safety regulations Area of risk Other safety instructions Maintenance Cleaning of the pre-stretching unit Care of the drive unit Care of the turntable Other maintenance instructions...29 Nissen L2500 Auto 1 2

3 1 Nissen Stretch Wrapping Machines It is important that you read and understand this manual before starting to use the wrapper. If you have any questions, please contact your supplier and/or the manufacturer. Manufactured by: Polynova Nissen AB, Box 42016, SE Stockholm, Sweden Phone: , fax: Representative/supplier: (if different from the manufacturer) 1.1 Machine type: NISSEN L2500 AUTO 1 EG-certificate of compliance with regulations Manufactured in accordance with the council s directive 98/37 EG concerning mutual closer association of the legislation of the member states relating to machines. The machine is manufactured in accordance with following harmonised standards: SS EN , SS EN-292-1, SS EN Material: Turntable in lacquered steel (also available in hot galvanised version). Film holder and film column in lacquered steel. Drive unit in zinc plated steel (also available in galvanised version). Maximum load: kg Noise level when wrapping a load on the turntable: <70 db (A) Machine plate: Machine plate, stating the manufacturer s name, machine number, model number and CE-mark are fitted to every machine. Warning signs to ensure risk-free usage are fitted to every machine (when considered necessary). Nissen L2500 Auto 1 3

4 1.2 Technical specification A. Turntable and drive unit Turntable diameter Motor Operating voltage Turntable height Max. load Max. diag dimension of load Rotation speed B. Stretch film column Motor Operating voltage Total height Max. roll diameter stretch film Max. roll width stretch film Max. load height Ø mm 0.25 kw 220/380 V 3-phase 24 V 65 mm kg mm approx. 10 rpm 0.12 kw 220/380 V 3-phase 24 V mm standard Ø 240 mm 500 mm mm C. Top sheet dispenser supplementary equipment Min. height - from floor to centre of roll mm Max. height - from floor to centre of roll mm Max. width mm Min. width 300 mm Accepts bobbins from Ø 40 Ø 78 Nissen L2500 Auto 1 4

5 1.3 Areas of use This machine is normally used in warehouses and/or distribution centres for wrapping loaded pallets in stretch film in order to maintain stability, provide protection from the elements and protect the load during storage or distribution. The loaded pallet is positioned on the turntable of the machine with a pallet truck or fork-lift. The stretch film is attached manually by, e.g. the film being tied to the pallet. Wrapping is carried out by rotating the load whilst the film roll moves up and down the film column. Some machines are fitted with a top clamp plate, which holds light loads in place whilst the wrapping operation takes place. Neither the operator nor any other person is allowed to stand on the turntable. If the turntable has to be stepped on (during service or repairs), switch off the main power supply or press the emergency stop button. 1.4 Guarantee The guarantee is valid for one (1) year from the date of delivery, and covers material and manufacturing faults. Maintenance must have been carried out according to the instructions on pages for the guarantee to be valid. This guarantee does not cover normal maintenance, installation or regular adjustment in accordance with the instructions. Nor does the guarantee cover labour costs involved in such work. Damage caused by misuse or faulty usage will result in the guarantee no longer being valid. If the machine is to be located in a damp environment the turntable, film column and drive units should be galvanised for the guarantee to be valid. The guarantee is valid as long as the machine is not altered or added to without the manufacturer s written approval. Nissen L2500 Auto 1 5

6 1.5 Limits of responsibility The supplier accepts responsibility only for the machine and its operation in accordance with the manual, on conditions that the machine is not altered or added to without the manufacturer s written approval. 1.6 Machine plate that is fitted to the machine (fitted under the electricity box). Polynova Nissen AB Box , SE Stockholm, SWEDEN Telephone: Model Auto 1 Article no Serial no. NP xxxxx Manufacturer: LENG Pac AB, Sweden Nissen L2500 Auto 1 6

7 2. Assembly instructions Begin by first reading through the entire assembly instructions. Make sure that the following items are available before assembly: 1. Hammer drill mm hammer bit 3. Spanners 4. Allen keys 5. Socket spanners 6. Screwdriver 7. Cable cutters and strippers 8. Vacuum cleaner (for cement dust) 9. Hammer 10. Cable clip pliers Nissen L2500 Auto 1 7

8 2.1 Installing the machine The machine must stand on a level floor of concrete, wood or equally firm material. An assembly platform must be used. (Take contact with the supplier for advice about assembly in different types of floor). The various parts (central bearing, drive unit, safety bar and column) must be fixed to the floor separately. The parts are placed in order as shown in figure 1. Make sure you remove all drill-dust before the expanding bolts are inserted in the holes Figure 1. Positioning the machine parts Direction of rotation Turntable 2 Central bearing 3 Position sensor 4 Drive unit Stretch film column 6 Cable conduit 7 Tube Nissen L2500 Auto 1 8

9 2.1.1 Assembling the various parts of the machines Mark out the positioning of the central bearing. Bolt the central bearing with three expanding bolts (enclosed in the delivery). Clean the surface from cement dust and trash. Place the turntable on the central bearing, make sure that it turns easily. Place the drive unit in position wanted along the turntable. Take good care to press the drive unit firmly against the turntable edge. The recess to be 180 in relation to the drive unit when this operation is performed. Bolt the drive unit with four expanding bolts (enclosed in the delivery). Turn the table 180 by hand (NOTE: turn clock-wise) to make the transport safety screws easily accessible in the recess. Loosen the transport safety screws. Figure 2. Figure 2. Transport safety screws Transport safety screws To be removed after turnable and drive unit have been fixed Nissen L2500 Auto 1 9

10 2.1.2 Electrical installation All electrical work must be carried out by an authorised electrician. Loosen the cable conduit. Figure 1. Insert the cables in the pre-mounted tube (mounted on the cable conduit). Connect the position sensor (make sure that the sensitivity distance between turntable and sensor is 3 5 mm). Connect according to connection instructions in figure 3. Connect the rotary motor (Turntable) according to figure 4. Re-install the cable conduit and fix the tube with staples to the floor. Depending on the position of the drive unit it may be necessary to adjust the length of the tube. Do not forget the check the direction of rotation (clock-wise). Figure 3. Connecting position sensor Adjust to a space of 3 5mm between sensor-turnable Cable from column Black Blue Brown White Blue Brown TURN- TABLE Connect sensor according to colour marking Switch on power (main switch) and check that the built-in luminous diode (sensor) shines during all the rotation however not at the recess for the fork lift. NOTE! Be careful so that the sensor does not scrape against the turntable during rotation. Nissen L2500 Auto 1 10

11 Figure 4. Connecting the rotary motor Nissen L2500 Auto 1 11

12 Figure 5. Diagram electricity box Terminal box E100 PLC R01 S0 P1 T1 N1 S02 H02 Q1 Q2 F1 S01 HB K0 K1 K2 Terminal box Nissen L2500 Auto 1 12

13 Abbreviations HB Main switch Q1 Motor protector switch Q2 Motor protector switch K01 K03 Contactor R01 Auxiliary relay F1 Automatic fuse T1 Transformer N1 Control card P1 Potentiometer S0 S01 PLC E100 E100 B1 B2 B3 B4 Push-button Lamp push-button Control system Operator s terminal Cable to display Inductive sensor Inductive sensor Inductive sensor Photocell Figure 6. Diagrams for Stretch Wrapping Machine Auto 1 Figure 6a Circuit diagram Power Page 14 Figure 6b Circuit diagram Operation Page 15 Figure 6c PLC input X0 X7 Page 16 Figure 6d PLC output Y0 Y3 Page 17 Figure 6e Layout N1, control card Page 18 Figure 6f Terminal box diagram Page 19 Nissen L2500 Auto 1 13

14 Figure 6a. Circuit diagram Power HB L1 L2 L3 N PE 3 X 400 V AC + N + PE MAX 10 AMP PEN Q A K M 3~ U V W FILM CARRIER 0.12 KW 0.40 A K2 1 A/4.0 N/ BRAKE 4 6 K M 3~ U V W TURNTABLE 0.25 KW 0.78 A BRAKE Q A Nissen L2500 Auto 1 14

15 Figure 6b. Circuit diagram Operation 3.8/A F1 4 A T1 230/24V D 6.5 D0 24 Vdc supply to brake card film brake S01 MACHINE STOP S02 OPERATION TO H02 OPERATION TO X1 X R R01 A1 OPERATION A2 C0NTACTOR /N E A E A/4.8 B/6.0 N/4.8 Nissen L2500 Auto 1 15

16 Figure 6c. PLC input X0 X /A 6.0/N N L + SS PLC CPU PE 0V E 100 TEXT DISPLAY S0 X 0 START IMPULSE B1 B2 B3 B X 1 X 2 X 3 X 4 TURN- TABLE 0-POSITION FILM CARRIER DOWN FILM CARRIER UP FILM CARRIER TOP OF PALLET X 5 RESERVE Nissen L2500 Auto 1 16

17 Figure 6d. PLC output Y0 Y3 COM 0 Y K 0 A1 A2 TURNTABLE ROTATION COM 1 Y K K 1 A1 A2 FILMCARRIER UP COM 2 Y K K 2 A1 A2 04 FILM CARRIER DOWN 4.3 D 4.3 D0 COM Y CONTROL FILM BRAKE P1 5 K /B 5.0/N FILM BRAKE Nissen L2500 Auto 1 17

18 Figure 6e. Layout N1, Control card BRAKE CARD NL EL001 BRAKE 0V +24V SUPPLY 24Vac P 1 Nissen L2500 Auto 1 18

19 Figure 6f. Terminal box diagram TERMINAL BOX IN CABINET BOTTOM TERMINAL BOX IN CABINET TOP INCOMING SUPPLY 3 x 400Vac+N+PE MAX 10 A MOTOR ROTATION B 1 SENSOR TURNTABLE POSITION B 2 FILM CARRIER DOWN MOTOR FILM CARRIER FILM BRAKE B 3 FILM CARRIER UP B 4 FILM CARRIER AT TOP OF PALLET L1 L2 L3 N PE PE PE PE Nissen L2500 Auto 1 19

20 3. Dismantling 3.1 Dismantling In order to dismantle the machine follow the instructions under point 2.1, but in the reverse order. 3.2 Disposing of the machine When, after many years service, your machine is finally ready for disposal it should be done in a way that is not detrimental to the environment. NISSEN STRETCH WRAPPING MACHINES are manufactured from recyclable and, therefore, environmentally friendly materials. Nissen L2500 Auto 1 20

21 4. Instructions for use 4.1 General The management responsible for the machine shall make sure that the operator checks to see that there is nobody close to the machine who could be injured before the machine is started. A safety area of at least 800 mm from the edge of the turntable must always be kept free of people, goods etc. 4.2 The control panel Figure 7. Control panel 1 Start: Impulse button for start of wrapping 2 Operation: Switch PLC etc Stop: Stop of movements by cutting voltage on outputs on PLC etc. 4 Operator s panel: For adjustment of wrapping program etc. 5 Film brake: Adjusts the film brake force 6 Main switch: Switch electricity box Operator s panel E100 Nissen L2500 Auto 1 21

22 4.3 Operation 1. Position the pallet on the turntable 2. Attach the film to the pallet 3. Choose wrapping program on the operator s panel. This adjustment will be stored and need not be repeated 4. Push start button and follow possible instructions shown on the operator s panel 5. When wrapping is completed, cut the film and remove the pallet. 4.4 Adjustments on operator s panel PUSH START P:Down 1=Pr 2=Adj 3=M 4=? PUSH START Main menu (MENU) Shows action to be taken or state of operation P: Down Shows wrapping program chosen (F1) F1 (Pr) F2 (Adj) F3 (M) F4 (?) Choice of function by means of F1 4 Programming of program choice regarding type of wrapping cycle Adjustment of wrapping program (type, number of turns etc.) Manual operation of the machine Information Nissen L2500 Auto 1 22

23 P:Step Down P:Normal F4=MENU P:Stop Down (Stop Up) P:Normal (Top sheet) Change of program choice Wrapping program (F1=Pr) Choice between wrapping completed at top or bottom of pallet Choice between wrapping between with or without top sheet Move the twinkling marker on the text to be changed by means of the arrow keys, then push enter F4 (MENU) Return to main menu Turns:N2 U2 St 2.0 Fc 2.0 Change of adjustment Wrapping program (F2=Adj) Following adjustments can be made: N:2 Number of turns on lower part of the pallet U:2 Number of turns on upper part of the pallet St:2.0 Fc:2.0 Overlap between turns upwards Overlap on top of pallet Move the twinkling marker to the value to be changed by means of the arrow keys. Then push NUM-button at the same time as new value is chosen via the number keys. To write decimal numbers the key with an 0 must be activated by double push. Then push enter F1=Store F4=MENU F4 (MENU) Return to main menu Nissen L2500 Auto 1 23

24 MANUAL OPERATION Turntable Up Down Menu F1 F2 F3 F Manual operation (F3=M) Turntable rotation Film carrier up Film carrier down Return to main menu Machine type: 2500L A1 F4=Menu F4=MENU Information (F4=?) Information about type of machine Return to main menu 4.5 Plastic film Width: 500 mm Max diameter: Inner core: Thickness: Quality: 240 mm 76 mm micron Contact your supplier for right choice of film Figure 8. Thread the film, Auto 1 NOTE: When film with sticky outside is used Nissen L2500 Auto 1 24

25 4.6 Adjustment of stop position of turntable rotation Adjustment is made by a timer that starts the rotation sensor and runs the time that has been set and finally stops the turntable. Control for this function is placed on the PLC of the machine in the electricity box. Figure 9. Timer for turntable rotation timer Nissen L2500 Auto 1 25

26 5. Safety regulations NISSEN STRETCH WRAPPING MACHINE These safety regulations must be read by everyone who will use the machine. 5.1 Area of risk Min 0.8 m Min 0.8 m Min 0.8 m Under no circumstance may anyone stand within the area of risk whilst the machine is in operation. The area of risk must be clearly marked on the floor. (Warning tape is supplied.) Nissen L2500 Auto 1 26

27 5.2 Other safety instructions Great care must be taken to see that nobody comes between the loaded pallet and the turntable when the pallet is driven onto the turntable. The operator must not stand near the film carrier when it travels up the film column. The risk area including the film carrier is marked with warning tape to avoid risk of the operator putting a foot under the film carrier. Warning tape is supplied. Great care should be taken to ensure that no hand or arm gets caught between the top clamp and the load when a top clamp is used. The machine must be shut off if it is not used during an extended period or when the operator is not present. All electrical installation and repair work must be carried out by an authorised electrician. After servicing or repairs, check that the safety bar, lift wire and all switches, including the emergency stop switch, are fully operational. IN CASE OF EMERGENCY: PRESS THE EMERGENCY STOP BUTTON. IMPORTANT! The maximum load is kg The turntable must not be stepped on by any person. Ensure that the fully loaded pallet is positioned in the centre of the turntable for the best possible stability. Nissen L2500 Auto 1 27

28 6. Maintenance To ensure that your stretch wrapper works efficiently it is important that you regularly carry out maintenance in accordance with the instructions below. Service and repairs may only be carried out when the machine is totally disconnected from the power supply. 6.1 Cleaning of the pre-stretching unit Both rollers of the pre-stretching unit must be kept clean to enable the film to run freely. Clean with spirit. 6.2 Care of the drive unit The drive station is equipped with automatic chain tension. However, it may be necessary, after some time of operation, to exchange the chain (see separate instructions delivered together with the spare chain). Besides, the drive station is equipped with two drive wheels which may have to be exchanged after some time of operation (see separate instructions delivered together with the spare chain). Check yearly both chain and drive wheels. The chain is to be oiled regularly, 2 4 times yearly depending on operation conditions. NOTE! Lubrication is to be made with care to avoid oil stains on the drive wheels NOTE! When the covering plate on the drive unit is being removed, be careful as the drive station contains chain tensioner which can cause damages if carelessly handled. Nissen L2500 Auto 1 28

29 6.3 Care of the turntable Keep the turntable free of dust. Do not use cleaning fluid, since this can cause the drive wheel to slip if cleaning fluid is left on the periphery of the turntable. 6.4 Other maintenance instructions Electrical connections: Check all connections and repair any damage or wear found. Replace with new parts when necessary. Nuts and screws: Check that all nuts and screws are tightened thoroughly. Notice plates: Check that all warning plates are firmly fixed and clearly legible. They are there for your safety. Nissen L2500 Auto 1 29