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Operation and Maintenance Manual-C140-18 PDF
Operation and Maintenance Manual-C140-18 PDF
EN
0 - Intro
U0G00214
WRAPMASTER C140/18
Serial number
U0G00214
Manual code
Stampato il 23/04/2015
Codice
U0G00214
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Data
23/04/2015
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0.2 Copyright
This manual is an essential part of the machine. Always ask for an additional copy if this one is ruined or no longer
legible without delay.
Carefully read all the maintenance and operating instructions as well as the warnings regarding safety.
bielomatik s.r.l. shall not be held responsible for improper use of the machine and any consequential damage, or
when operations which are not dealt with in this manual are carried out.
Use of the machine to process elements not foreseen by the manufacturer is considered improper use. In this case,
the manufacturer cannot be held liable for any damages to property and/or persons and the warranty is considered
null and void.
Any changes to the work-cycle or machine structure must be duly authorized by bielomatik s.r.l.
Only use original spare parts; bielomatik s.r.l. is not liable for personal injury or damages caused by the use of
unoriginal spare parts, voiding the warranty.
The content of this manual is of strictly technical nature and property of bielomatik s.r.l. and thus the reproduction,
distribution or full or partial modification of its content without written authorisation is prohibited. All rights reserved.
This manual was drafted as per Machine Directive 2006/42/EC (Appendix I, paragraph 1.7).
The original version of this manual was drafted in Italian and translated into other languages if necessary. Therefore,
the Italian version is the ORIGINAL INSTRUCTION MANUAL while versions in other languages are to be
considered TRANSLATIONS OF THE ORIGINAL INSTRUCTIONS.
If you believe that any part of the translation is incorrect or poor, please contact bielomatik s.r.l. who will provide
you with the necessary clarifications and correct the translation.
bielomatik s.r.l. - Via Marzabotto, 280 - 40050 Funo di Argelato (Bo) - Italy
Tel. (051) 6647444 - Fax (051) 866021
World Wide Web: http://www.bielomatik.com e-mail: bielomatik@bielomatik.it
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Contents
0.1 Customer information and machine serial number ........................................................................... 0 - 2
0.1.1 Previous documentation ........................................................................................................ 0 - 2
0.2 Copyright .......................................................................................................................................... 0 - 3
0.3 Important warnings ........................................................................................................................... 0 - 9
0.4 Document organisation ................................................................................................................... 0 - 10
0.4.1 Installation, instruction and maintenance manual ................................................................ 0 - 10
0.4.2 Spare parts and code=>unit correspondence ...................................................................... 0 - 10
0.4.3 Retail mechanical parts ....................................................................................................... 0 - 10
0.4.4 Retail electrical parts ............................................................................................................0 - 11
0.4.5 Electrical part list ..................................................................................................................0 - 11
0.4.6 Electrical part calibration tables, Motor list, Wiring diagram ..................................................0 - 11
0.4.7 Machine management program manual. ..............................................................................0 - 11
0.5 Description of the icons .................................................................................................................. 0 - 11
0.6 Qualification levels of the machine operators ................................................................................. 0 - 12
0.7 Use of the icons.............................................................................................................................. 0 - 13
0.8 How the documentation is revised .................................................................................................. 0 - 13
1 Safety ...................................................................................................... 1 - 1
1.1 General information .......................................................................................................................... 1 - 2
1.1.1 Personnel training ................................................................................................................. 1 - 2
1.1.2 Applied directives and technical reference regulations .......................................................... 1 - 3
1.1.3 Machine certification .............................................................................................................. 1 - 3
1.1.4 Intended use and operating restrictionsh ............................................................................... 1 - 7
1.1.5 Hazardous areas ................................................................................................................... 1 - 7
1.1.6 Environmental operating conditions ....................................................................................... 1 - 8
1.1.7 Vibration ................................................................................................................................ 1 - 8
1.1.8 Noise ..................................................................................................................................... 1 - 8
1.1.9 Electromagnetic emissions .................................................................................................... 1 - 9
1.2 Used material disposal ..................................................................................................................... 1 - 9
1.2.1 Instructions for special waste ................................................................................................ 1 - 9
1.2.2 Important information for the user as per directive 2012/19/EU on waste of electric and
electronic equipment (WEEE), which annuls directives 2002/96/EC and 2003/108/EC ....... 1 - 10
1.3 Safety devices installed on the machine ......................................................................................... 1 - 11
1.3.1 Emergency stop ................................................................................................................... 1 - 11
1.3.2 Fixed guards ....................................................................................................................... 1 - 12
1.3.3 Mobile guards ...................................................................................................................... 1 - 12
1.3.4 Cutting off electrical energy ................................................................................................. 1 - 14
1.3.5 Cutting off pneumatic energy ............................................................................................... 1 - 14
1.4 Personal protection devices ........................................................................................................... 1 - 15
1.5 Residual risks ................................................................................................................................. 1 - 16
1.5.1 Collision and crushing ......................................................................................................... 1 - 16
1.5.2 Shearing / cutting ................................................................................................................ 1 - 17
1.5.3 Electrocution ....................................................................................................................... 1 - 17
1.5.4 Fire ...................................................................................................................................... 1 - 17
1.5.5 Burns and scalding .............................................................................................................. 1 - 18
1.5.6 Explosive atmosphere ......................................................................................................... 1 - 18
1.5.7 Blinding ............................................................................................................................... 1 - 19
1.5.8 Falling, projecting objects .................................................................................................... 1 - 19
1.5.9 Slipping ............................................................................................................................... 1 - 19
1.5.10 Whiplash ............................................................................................................................. 1 - 19
1.5.11 Tripping ............................................................................................................................... 1 - 19
1.5.12 Circuit faults ........................................................................................................................ 1 - 20
1.5.13 Lighting ............................................................................................................................... 1 - 20
1.5.14 Noise ................................................................................................................................... 1 - 20
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3 Installation .............................................................................................. 3 - 1
3.1 General information .......................................................................................................................... 3 - 2
3.2 Supply conditions ............................................................................................................................. 3 - 2
3.2.1 Packaging and transport ....................................................................................................... 3 - 2
3.3 Work site preparation ....................................................................................................................... 3 - 3
3.3.1 General information ............................................................................................................... 3 - 3
3.3.2 Site selection and installation requirement checks ................................................................ 3 - 4
3.3.3 Lifting and handling procedures ............................................................................................ 3 - 5
3.4 Assembly and positioning ................................................................................................................. 3 - 7
3.4.1 Unit assembly and positioning ............................................................................................... 3 - 7
3.5 Electrical connections ..................................................................................................................... 3 - 14
3.6 Pneumatic connections .................................................................................................................. 3 - 16
3.7 Machine part lubrication ................................................................................................................. 3 - 16
3.8 Checks and inspections before start-up ......................................................................................... 3 - 17
3.8.1 General machine unit checks .............................................................................................. 3 - 17
3.8.2 Electrical system inspection ................................................................................................ 3 - 18
3.8.3 Safety system inspection .................................................................................................... 3 - 19
3.9 Decommissioning ........................................................................................................................... 3 - 20
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6.7
6.8
6.9
6.10
6.11
6.12
6 - 36
6 - 39
6 - 40
6 - 41
6 - 42
6 - 43
6 - 43
6 - 44
8 Maintenance ........................................................................................... 8 - 1
8.1 Overview .......................................................................................................................................... 8 - 2
8.2 Maintenance personnel .................................................................................................................... 8 - 3
8.2.1 Communications with customer service ................................................................................ 8 - 4
8.3 General safety precautions ............................................................................................................... 8 - 5
8.3.1 Hazard notes ......................................................................................................................... 8 - 5
8.3.2 Warning notes ....................................................................................................................... 8 - 8
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9 Troubleshooting ...................................................................................... 9 -1
9.1 Fault messages ................................................................................................................................. 9 -2
9.1.1 Description of the Alarms and warnings ............................................................................... 9 -2
9.2 Fault indication .................................................................................................................................. 9 -3
10 Timing diagrams................................................................................... 10 - 1
10.1 Timing diagrams ............................................................................................................................. 10 - 3
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1 Chapter heading
1.1 Paragraph title
1.1.1 Sub-heading
1.1.1.1 Any additional sub-headings
Pages are numbered by chapter. Therefore, pages are numbered with a prefix indicating the chapter followed by
the progressive page number that starts from 1 at the beginning of each chapter.
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Operator:
Personnel trained and authorized to operate the machine for production purposes to carry out the activities
it has been built for.
They must be able to perform all the operations necessary to ensure the proper operation of the machine,
ensuring the safety of themselves or of potential collaborators.
They must have a proven expertise regarding the proper use of these types of machine/equipment and
be trained and informed about it.
In case of doubt they must report any anomaly to the responsible person.
They are not authorized to carry out any maintenance operation.
Manufacturers technician:
Engineers qualified by the manufacturer or its dealer to carry out complex operations since he/she knows
production cycle of the machine/equipment.
B the
This technician operates on the basis of the agreement made with the user.
Depending on the situation, the technician has mechanical, electrical, electronic and/or software skills.
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Important!
The number of persons required to run the machine as well as carry out maintenance or other operations is indicated in the "Specifications", given in this
manual. If the presence of other persons is required to carry out a specific
operation it will be indicated in the description.
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1
Safety
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Hazard!
Tampering or the unauthorised replacement of one or more machine parts, the use
of accessories that vary machine use and the use of spare parts other than those
recommended could cause safety hazards.
1.1.1 Personnel training
Warning!
The machine is intended for professional use.
The purchaser must ensure that machine operators and maintenance technicians are suitably educated and trained.
For this reason, upon request the manufacturer provides a training course held by its qualified personnel at
commissioning.
The following subjects must be covered during the training course for machine operators and maintenance
technicians:
THEORETIC ASPECTS
PROFESSIONAL QUALIFICATIONS AND DUTIES
MACHINE TYPE TECHNOLOGY
THEORETIC ASPECTS
MACHINE COMMISSIONING AND DECOMMISSIONING
DEVICE USE AND SAFETY REGULATIONS
OPERATING CRITERIA
INSPECTION, MAINTENANCE
MANUAL CONTENT KNOWLEDGE
PRACTICAL ASPECTS
OPERATING EXERCISES
MOVEMENT EXERCISES
USE, TEST AND MAINTENANCE EXERCISES
EMERGENCY SITUATIONS
Note:
The regulations in this manual may not cover special situations that may occur
during the different work phases.
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The machine was designed, constructed and tested in accordance with the following community directives:
Note:
certification.
Any modification made to the machine immediately null and voids
In this case, the manufacturer cannot be held liable for any reason.
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Warning!
Use of the machine to process elements not foreseen by the manufacturer is
considered improper use. In this case, the manufacturer cannot be held liable for
any damages to property and/or persons and the warranty is considered null and
void.
The manufacturer cannot be held liable in the event of tampering with the machine
for unauthorised modifications or for maintenance conducted by personnel who
were not suitable informed, educated and trained.
Hazard!
In the event of abnormal machine operations, duly trained maintenance technicians are in charge of any intervention.
Hazard!
Mark work areas with no entrance signs.
Hazard!
To access hazardous areas, work in safety conditions and conduct all the
operations and procedures set in this chapter and in chapter 8 Maintenance.
Access to hazardous areas is reserved to specialised personnel, authorised to
conduct the interventions.
In order to limit risks in hazardous areas, adequate prevention and protection measures were taken. Follow the
procedures and instructions on Personal Safety Devices indicated hereto.
Hazard!
various risk factors in the maintenance phase were assessed during machine
design and the relevant prevention and protection measures taken.
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1.1.7 Vibration
If the machine is used in conformity with the prescriptions of use and according to the regulations in force,
the vibrations produced by the machine, according to use, are not harmful to operator health.
Warning!
Excessive vibrations may only be caused by a mechanical fault that must be
immediately indicated and eliminated to avoid jeopardising machine and operator
safety.
1.1.8 Noise
Noise was measured in accordance with that set by regulation ISO 3746.
Operator exposure to noise during work cycles exceeds 70 dB, remaining, in any case, under 80 dB.
The actual noise level of the machine during its working cycle at the site is different from the one measured because
the noise level is affected by different factors, such as:
type and features of the site;
other adjacent machines in operation;
type of material being processed.
We recommend personal noise protection devices are worn (headphones) by the operator working near the machine.
Warning!
The user must assess noise risks and apply consequent preventive and protective
measures in accordance with the rules in force in the country where the machine
is installed.
Hazard!
Hearing protection devices must be work during machine adjustments.
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Warning!
Any non-compliant maintenance on electrical equipment or incorrect part replacements may compromise the efficiency of adopted solution.
Warning!
Please observecurrent mineral oil and glue disposal regulations.
Additional information!
Additional information on hot melt glue, oil and other substance disposal procedures can be found on the substance safety sheets.
Toxic waste disposal collection, transport and processing phases considered as operations necessary for recycling
as well as ground storage and disposal, are considered of public interest and must meet the following general
principles:
a) All public and private health and safety damages or hazards must be avoided.
b) Observance of hygienic-health regulations must be guaranteed an all risks of air, water, ground and substrate
pollution must be avoided.
In observance of economic and efficiency criteria, material and energy recovery and recycling systems must be
promoted.
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1.2.2 Important information for the user as per directive 2012/19/EU on waste of electric
and electronic equipment (WEEE), which annuls directives 2002/96/EC and 2003/108/EC
As per directive WEEE 2012/19/EU, if purchased equipment is marked with the
means that the product must be separated from other waste upon disposal at the end of its working life.
The manufacturer organises and manages the recycling and disposal of this equipment. Users who wish to dispose
of this equipment should thus contact the manufacturer and follow the system the manufacturer has adopted for the
separate disposal of this equipment at the end of its working life.
Adequate separate collection for subsequent equipment delivery to recycling, processing and environmentally
compatible disposal contributes to avoid potential negative effects on the environment and health and promotes the
reuse and/or recycling of equipment parts.
Warning!
Abusive product disposal by the holder is punishable by current law.
Important!
If the barred waste bin symbol is not found on equipment it means that the
manufacturer is not in charge of its disposal. In this case, current waste disposal
regulations apply.
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Fixed guards.
Mobile guards.
Electrical supply cut-off device.
Pneumatic supply cut-off device.
251652
Emergency buttons are red mushroom-head buttons on yellow backgrounds. When pushed, these are locked
(inserted) in the lowered position and do not return to their initial positions. In order to reset buttons, turn them counterclockwise as indicated on the buttons.
Resetting the emergency button does not restart the machine.
Hazard!
Tampering with, disconnecting and bypassing safety switches is strictly prohibited.
Periodically check whether emergency stop devices are in good working order as
specified below.
Warning!
The use of the mushroom-head button is only considered as an emergency
manoeuvre, not as a normal stop manoeuvre to avoid excessive machine deterioration.
1.3.1.1 Test procedure
With the safety circuits on, check emergency button and relevant control circuit efficiency.
Press a mushroom-head emergency button and make sure the safety circuit turns off.
Restore the mushroom-head emergency button to its original position and restore safety circuits.
This operation must be repeated with the remaining emergency buttons. We suggest you record these activities in
the in-house safety test log.
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Hazard!
Restarting the machine after maintenance without correctly restoring fixed guards
is strictly prohibited.
Periodically check the integrity of the fixed guards and relevant fastenings to the
structure, with special attention to the machine mechanics access door.
1.3.3 Mobile guards
Mobile guards on the tube formation area and perimeter access doors, etc. (see layout below - Reference
C) are made up of doors with safety switches that prevent access to various machine part movements
during the operating cycle.
Hazard!
Restarting the machine after maintenance without correctly restoring MOBILE
guards is strictly prohibited.
Hazard!
Tampering with, disconnecting and bypassing the safety switches installed on
inspection doors is strictly prohibited.
Periodically check mobile guard integrity and their fastenings to the structure as
well as the integrity and operations of the safety switches installed on each
inspection door as described below.
The safety circuit immediately triggers immediately stopping the machine when one of the access doors is opened.
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C
A
A
C
B
C
265713
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Position 1
Position 2
Warning!
Cut-off switches can be pad locked in position 2 (open circuit). Please remember
to pad lock switches in the open position to cut off electrical energy (pad locks are
not supplied with the machine).
The user must provide maintenance staff with the electrical cabinet pad locks.
Warning!
Refer to chapter 4.1.1.1 Main shutoff switch for further information on cutting off
power.
1.3.5 Cutting off pneumatic energy
Connection to the pneumatic mains is controlled by a cut-off valve which can be pad locked.
A compressed air drain valve equipped with a silencer is installed downstream from the air supply valve to
drain the pneumatic circuit before maintenance.
Warning!
Main disconnecting switch of the air supply circuit can be padlocked in OFF
position (discharged circuit closed); when disconnecting the pneumatic circuit,
we recommend to padlock the air supply valve in OFF position (padlocks are not
supplied with the machine).
It is the responsibility of the user to provide the personnel responsible for the
maintenance operations with the padlocks to lock the air supply valve.
Periodically check connection pipe integrity between the pneumatic supply valve
and machine parts.
Also check pneumatic fitting seals on the machine.
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Operators who conduct the various activities admitted on the machine must use personal protection devices
that reduce all possible risks derived from conducting various activities such as:
Warning!
Clothing worn by machine operators or maintenance technicians must meet the
essential safety requirements set by community directives 89/656/EEC and 89/391/
EEC and the laws in force where the machine is installed.
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Hazard!
Personnel must wear suitable work clothing during control and maintenance
operations to prevent any accident.
in order to avoid mechanical risks such as dragging, catching and others, items
such as bracelets, watches, scarves, rings or necklaces should not be worn during
the work cycle and maintenance operations.
Hazard!
When conducting work that could cause shard or material projections that could
harm the operator or others in the near vicinity, the operator must prepare or
request the supervisor install screens or other adequate safety measures.
Warning!
Periodically check all safety device operations.
Do not remove fixed or mobile machine guards.
Do not introduce foreign objects or tools in the operating area and machine
operating area.
Although the machine is equipped with the abovementioned safety systems, some risks could not be eliminated but
were reduced by corrective measures implemented by the end user and correct operating procedures.
Following is a summary of residual machine risks during:
Normal operations.
Adjustments and fine tuning.
Maintenance.
Cleaning.
Before turning on electrical and pneumatic power supplies, make sure no maintenance is being performed
on the machine.
Residual pressure may be found in cylinders which could cause unexpected part movement during interventions.
Therefore, drain the pneumatic circuit and cut it off from the supply source using and pad locking the cut-off valve
before each intervention.
After maintenance and repairs, crushing risks persist due to unexpected movements in the direction opposite the
one required due to incorrect electrical wire or pipe connections. Therefore, run test movements in manual mode
for the parts involved, remembering to maintain safety distances from parts in motion.
In the event of a blackout, the roll pneumatic brake opens, whose pneumatic circuits are discharged causing the
roll to freely rotate for several seconds.
This situation is not hazardous to assigned personnel.
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Before turning on electrical and fluidic power supplies, make sure no maintenance is being performed on the
machine.
Shearing / cutting risks may exists during maintenance on the main gears inside the machine.
Warning!
Before conducting any routine or extraordinary maintenance, cut-off electrical and
pneumatic power supplies to avoid the abovementioned risk.
1.5.3 Electrocution
Risk of damaging or breaking electrical equipment parts following a short circuit with potential reduced
safety levels.
Before turning on the electrical supply, make sure no maintenance interventions are in progress and that
no one is working on the machine.
Warning!
Before performing connections, make sure the dc current in the installation point
is not over the one indicated on protection switches inside the switchboard.
Otherwise the user must install specific limiter devices.
Warning!
Any type of electrical modification is strictly prohibited to avoid additional hazards
and unforeseen consequent risks.
1.5.4 Fire
Risk due to production waste.
In the event of faults or malfunctions, the plastic material used (i.e.: sheaths, electrical wires) is self-extinguishing and
meets current regulations.
Since integrated in a production line, the machine is not equipped with its own fire extinguishing system.
The user facilities must evaluate the need for an adequate fire extinguishing system in the rooms where the
machine is installed in observance of fire safety and prevention regulations in effect in the user country and factory
regulations.
Do not use free flames or smoke near the operating machine.
Hazard!
In the event of fire, always immediately turn off the main power switch.
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Warning!
In case of maintenance operation following a previous energy disconnection, the
motor or the gear motor might accumulate residual thermal energy.
Wait for the disposal of that energy.
For further information, please refer to the manual of the motor/gear motor
supplier. Always use appropriate PPE (gloves for high temperatures), paying
particular attention to the residual energy.
The machine includes hot glue application devices. Therefore there is a residual risk due to the working temperature
of the glue applicator/pipe/gun unit.
During the normal operating cycle, glue guns are confined inside guards. The risk remains during the glue tank
filling phase on the applicator. Suitable protection devices should be worn during this operation (Gloves, goggles,
etc.).
A risk remains during maintenance and cleaning due to the heat inertia of the glue applicator and its components.
Therefore we suggest you wait until the system cools and wear the mandatory protection devices (Gloves,
goggles, etc.).
Warning!
Hot glue application devices require high temperatures for operations. Pay special
attention not to touch these devices with unsuitably protected body parts and
always wear a mask and goggles to protect your face when filling the glue tank or
changing glue.
1.5.6 Explosive atmosphere
The machine is not suited to work in explosive or classified environments.
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1.5.7 Blinding
This risk is mainly present in the maintenance and cleaning phases.
Warning!
The use of eye protection is mandatory.
Warning!
We suggest you use vacuums instead of compressed air to avoid moving any
residue without removing it, also reducing the risk of blinding the operator.
Warning!
Hot glue application devices require high temperatures for operations. Pay special
attention not to touch these devices with unsuitably protected body parts and
always wear a mask and goggles to protect your face when filling the glue tank or
changing glue.
1.5.8 Falling, projecting objects
Avoid even temporarily leaving work tools and objects on and above the machine to prevent them from
falling or being projected.
1.5.9 Slipping
Any lubricant and/or glue residue leaks in areas around the machine or on work platforms can cause machine
personnel to slip.
Access these areas wearing non-slip shoes and keep these areas clean.
Warning!
It is absolutely forbidden to use the machine or parts of it to climb on or to access
to some machine parts; otherwise disastrous fall or damages to the machine might
occur.
1.5.10 Whiplash
Broken or damaged pneumatic and lubrication system flexible tubes can cause tube twists.
Tubes and their anchors must be periodically checked and replaced if necessary.
Using rigid or flexible pneumatic and hydraulic tubes as support bases for feet is strictly prohibited.
1.5.11 Tripping
Disorderly material storage in general can be a source of tripping hazards and fully or partially obstruct
escape routes in the event of need.
Guarantee that operating and transit sites and escape routes are free of obstacles and compliant with
current regulations.
Pay attention to yellow/black signals on any steps on machine platforms.
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1.5.13 Lighting
The user must provide an adequate lighting system for machine maintenance areas in observance of current
regulations in the users country and according to Community Directives.
In the event of a black out, we recommend at least 400 lux average lighting.
Should, for special and rare maintenance operations, additional lighting be required, also tanking into account the
extremely rare nature of these operations, the user must provide portable safety flashlights (24 Vdc power, not
supplied).
1.5.14 Noise
We recommend personnel use suitable hearing protection devices when working near the machine.
1.5.15 Lightnings
The grounding systems must be checked at regular intervals as required by law.
The final user is responsible for the machine lightning protection; he has to arrange a proper power supply
for the machine/system with all protection systems installed, including the lightning protection, that should
be checked at regular intervals (at least every 5 years or according to the regulations in force in the country).
The residual current devices (thresholds and actuation times) has to be checked at least once every three years.
1.5.16 Dusts
The dusts produced during the cutting operations and the processing (depending on the type of paper used)
may be collected by means of a suction system, supplied and installed by the user.
1.6 Hazard
Hazard!
Safety shoes and goggles must be worn during machine operations and maintenance.
Hazard!
Only use parts, pipes and fittings that are certified for 10 bar operating pressure.
Hazard!
Never exceed the factory set operating pressures and calibrations.
Hazard!
Never conduct any routine and extraordinary maintenance when pneumatic
circuits are pressurised nor when the power supply is connected. Always deenergise all power circuits.
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1.7 Warning
Warning!
Make sure all personal assigned to machine operations are suitably trained
according to the correct machine safety and operating procedures.
Warning!
Do not conduct maintenance on the machine when it is running.
Warning!
Never perform maintenance on the machine when energy sources are connected
or on. When working on the machine, turn off switches and lock them in the open
position.
Warning!
Make sure all safety devices are connected and in good working order. Never
modify or bypass any alarm or stop device.
Warning!
Removing signal plates from the machine is strictly prohibited.
bielomatik s.r.l. is not liable for machine safety due to failure to observe these
instructions.
Warning!
After the machine is installed in the packaging line, the final installation technician
must install the necessary signs according to the identified residual risks.
Warning!
The user must replace signal plates if illegible due to wear.
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11
12
13
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Warning!
Removing signal plates from the machine is strictly prohibited.
bielomatik s.r.l. is not liable for machine safety due to failure to observe these
instructions.
Warning!
The user must replace signal plates if illegible due to wear.
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2.1 Presentation
The WRAPMASTER C140 machine is a packing machine which wraps paper reams in wrapping material
taken from a reel.
The machine has been designed and manufactured by a market leader in the paper-making industry and
high-technology solutions have been adopted in order to meet the most demanding user requirements.
Regardless of the type of service required for the machine, the quality of the C140 ensures that the reams are
handled in the best possible way at all times without being damaged. In addition, the quality of the pack produced
is of consistent good quality and the machine guarantees total reliability even in the long-term with a minimum
amount of maintenance.
The C140 machine perfectly fits the requirements of the entire production line due to its high degree of versatility both
regarding size change-over operations and speed variation in order to meet the needs of the production process.
All structural elements, connection and control parts are designed and built with a level of safety so as to resist
abnormal stresses or stresses higher than those indicated.
Best quality materials are used: their introduction in the company, their storage and use in the shop are constantly
monitored so as to ensure the absence of damages, deteriorations or malfunctions. Although design and structural
tactics have been adopted, it is essential to carefully follow the manufacturer instructions in order to ensure a proper
use, safety, durability and reliability of the machine.
The main features of the C140 making it a particularly efficient machine which stands out among the
competitition include the following:
It is an automatic machine for wrapping reams of paper (refer to the specifications for the production
features).
The reams of paper are fed directly from the cutter so that operations can be perfectly timed.
The machine is provided with a power-operated system to raise the roll of wrapping material and power-assisted
unwinding.
The reams are wrapped in pre-printed paper coming from reels provided with reference marks for synchronising
the cutting operations.
The process of cutting the sheets of wrapping material, wrapping the reams, applying the glue and closing the
pack is fully automatic.
A timed central lubricating system is provided to reduce maintenance operations and downtime.
The gears and moving mechanical parts are provided with guards and safety devices guaranteeing maximum
safety and reducing noise levels.
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2 - Preliminary information
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2.2 Work-cycle
The work cycle can be divided into four basic stages. Each stage is performed by a number of mechanical
parts which carry out all the operations required to wrap the reams:
Wrapping material infeed
1
Reel holder
2
Crosswise glue spreading (if applicable)
3
De-curling unit
4
Dancing rolls and idle rollers
5
Unwinding rollers
6
Cutter
7
Cross glue applicator
8
Tube formation unit conveyor
Wrap formation
15
Elevator
16
Wrapping material stop
17
Counter-elevator
18
Fixed hopper plate
19
Mobile hopper
20
Ream accelerator
21
Lower folders
22
Movable end-flap folders
23
Discharge conveyor belt
24
Bottom flap folders
25
Glue applicator for end-flaps
26
Top flap folders
Ream infeed
9
Ream feed conveyor belts
10
Stopping mechanism-and-synchronizer
11
Toothed belts
12
Frontal ream levelling
13
Side compactors
14
Stop plate
7 18 17 16
19
23
27a
26
25
22
24
22
21
4
3
20
21
14
13
15
12
264945
11
10
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4
9
14
13
15
12
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10
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WRAPMASTER
2 - Preliminary information
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18 17 16
19
23
27a
26
25
24
22
22
21
20
21
15
264945
27b
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WRAPMASTER C140
Machine type
Ream wrapper
Ream feed
Automatic
Operation
Electro-mechanical - pneumatic
Control system
Electronic
1 (supervisor)
strokes/min.
165
Production speed
strokes/min.
150
minutes
Machine weight
See chapter 3
Noise levels
dB (A)
Dimensions
approx. 2
80
kVA
28
Phases
no.
Neutral
(not provided)
Voltage
Frequency
Hz
5%
3 + earth
380
50 1%
current outlets
VAC
230
VDC
24
VDC
24
Electrical system
Siemens S7/400
User interface
Siemens MP377
bar
Air requirements
Nl/min
2 - 6/16
6
1200
WRAPMASTER
2 - Preliminary information
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RW
RW
RH
RL
RH
RL
REAMS WITH
OVERLAPPED FOLDS
261743
Ream dimensions
WRAPMASTER
261744
RW min
mm
210
RW max
mm
216
RL min
mm
279
RL max
mm
355
RH min
mm
25
RH max
mm
89
RH max
mm
50
g/m2
70
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SL
Wrapping paper
Wrapping paper basic weight
SW
261363
Kraft or bonded
min
g/m2
80
max
g/m2
120
52
Polypropylene
Roll diametre max, paper
mm
1270
mm
800
mm
70
mm
76
Roll width
SW min
mm
425
SW max
mm
880
SL min
mm
325
SL max
mm
515
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2 - Preliminary information
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MAX Recommended
120
130
99.5
Central
121
0.822
5.11
2.0
70.0
5.24
2.81
2.8
56.7
2.88
621
327
190
100
183
7.3
104
4.2
132
55
82
44
149
<0.220
0.228
0.233
<0.220
0.255
0.247
0.160
0.171
0.162
The values shown in the Recommended column refer to a type of paper which has excellent characteristics and
is easy to handle.
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min
MAX Recommended
N/mm2
N/mm2
155
265
N/mm2
N/mm2
2200
3500
%
%
175
65
C
g/m2
m
52
65
0.25
120-180
45.5
60
The specifications given here in refer to Bicor 52/MB666 polypropylene, produced by Mobil plastics Europe, or
Rayopp T710/52 produced by UCB films Gmbh Germany.
Note:
The polypropylene used in the machine may not show any signs of electrostatic
charges.
Note:
The polypropylene must not have any imprints on the areas affected by the
bonding.
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2 - Preliminary information
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SL
=
RL
RW
SW
RW
= 2 /2 +
RW
R
+2 H + 1
RH
5
+3
0
RH
261760
RW
RL
RH
SL
SW
Ream width
Ream length
Ream height
Sheet unwinding
Sheet width
261746
SL = RL + 2RH + 60
SW = 2RW + 2RH + 30
261745
SL = RL + 2 (9/10RH)
SW = 2RW + 2RH + 30
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2.5.5 Cleaning
Build ups may form on the bottom and sides of the tank that can clog the spray nozzles due to dust particles
or over-heating. If the manufacturer has not recommended a specific cleaning agent, clean the tank by
quickly melting the Termomelt 301 specially formulated detergent. As it liquifies very quickly it can be
removed easily with the dirt with a hard-bristle brush. If charring has occurred, turn off the unit and soak the parts
in question, once cooled down, in solvents such as trichloroethylene, toluol, etc for a good amount of time.
Warning!
Follow all the safety rules and precautions given in the Users Manual that deals
with the glue applicator.
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2.5.6 Pressing
The two parts in question must be glued and pressed together immediately or simultaneously. During
pressing, the two parts must never be moved to prevent the glue stitches from shifting while hardening. The
two parts to be glued must be brought together within the maximum open time. The pressure must not be
decreased when the parts are initially pressed to prevent the film of hotmelt from breaking.
2 mm.
approx. 1.5
3 mm.
approx. 3
The specific weight of the hotmelt for glueing is approximately 0.92 g/cm3.
2.5.8 Applications
Seals polyethylenes, bonded paper-aluminium.
Suitable for varnishes or hard-to-glue paints.
2.5.9 Specifications
Type of adhesive:
hotmelt
Form:
granular
Colour:
white or beige
Melting point:
Open time:
seconds
Viscosity:
90 110
24
at 150 C
> 3000
160 C
2094
170 C
1100
180 C
875
Stability:
excellent
kg/cm2
Stretching:
Odour:
26
545
odourless
Filtration:
micron
Setting time:
sec.
100
<1
Food safe; complies with Law 21/3/73 for packaging food products.
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160 - 180 C.
Use the indicated temperature ranges. At lower temperatures the amount of glue used notably increases
and the parts may not be well glued.
2.5.12 Cleaning
Clean the tanks and hoses, removing any residue of other glues handled before using the product.
Clean with the cleaning agents recommended by the glue manufacturer.
Clean the tanks with detergents or solvents recommended by the machine manufacturer.
The information given above is based on our experience in the field and result obtained. However, this does not imply
responsibility for the results obtained when using the glue. The users must make sure the indications given are
suitable for their individual production requirements and perform all the necessary tests.
bielomatik s.r.l. recommends glues whose manufacturers have offices world-wide:
HENKEL
TECHNOMELT Q 3183
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3 - Installation
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3
Installation
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3 - Installation
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264752
Warning!
Observe the following precautions and warnings to guarantee stability and avoid
risks associated with machine handling:
Do not improvise any manoeuvre that is not officially approved by skilled
personnel.
Important! cables or chains must be suited to machine load.
We suggest a crane or bridge crane is used to lift and position the machine.
Do not stand under suspended loads.
Only assign these operations to trained personnel (slingers, crane operators, etc.). If load volume does not permit
sufficient visibility, assign personnel to signal the handler to supervise all handling phases.
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3 - Installation
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With the due exceptions made in the contract, the machine user customer must prepare:
appropriate lifting means for parts in accordance with the loads to be handled;
machine power supplies, including a GROUNDING wire according to the required specifications and
tolerance specified in this manual;
pneumatic machine supply adjusted as specified in this manual.
Note:
bielomatik s.r.l. cannot be held liable for operating faults if the power supplies do
not meet the specifications provided with the machine.
Installation is provided by the manufacturers specialised personnel. The manufacturer provides the customer with
all the documentation required to prepare the necessary infrastructures before installation (see layout).
Warning!
All external power must be connected to the machine by the manufacturers
personnel during installation.
Connecting the machine to external power sources or using it before the
manufacturers personnel arrives is strictly prohibited.
Warning!
The customer must ensure that the floor supports the machines static/dynamic
load.
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3 - Installation
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The floor of the site selected for installation must be even, level and meet the application specifications. It must also
be able to support specific machine weights such as the supplied static and dynamic loads.
The room must be equipped with the electrical and pneumatic supply connections required to operate the machine.
The room must be equipped according to current safety regulations in force in the user country and guarantee correct
ventilation and equipment grounding.
The minimum clearances indicated in the following layout are required to install and use the machine. The minimum
safety distances from walls and the ceiling must be considered in order to conduct machine inspections and/or
maintenance.
2000
2000
Note:
The machine installation position is indicated in the previously delivered drawing
and enclosed with this manual.
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3 - Installation
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Follow the instructions below to lift and handle boxes and machine components.
Lifting vehicle capacities must at least meet machine weight (see technical specifications table) increased
according to safety regulations.
Note:
Only bielomatic specialised and trained personnel can lift and handle boxes.
Follow the instructions and pictograms marked on boxes and use suitable tools
and equipment to handle boxes.
Additional information
For information on lifting and handling machine parts supplied by sub-suppliers
and retail parts including in the overall system, see the relevant instruction
manuals.
Hazard!
Before use, check the status and correct installation of lifting devices and means.
Use suitable slings and equipment.
Safety gloves
must be worn.
Protective
shoes must be worn.
Transit under
suspended loads is
prohibited.
Where possible, the work are must be free of materials that could hinder or limit visibility, create impediments
or obstacles.
Machine boxes must be handled with an adequate lifting system such as a forklift, crane and bridge crane and
hooking slings/cables and lifting accessories that are approved and of suitable capacity, superior to the weight
to be lifted.
Warning!
Adequate lifting means are required to lift boxes taking into account the safety
margins set by current laws and safety regulations.
Make sure the load is correctly balanced: slightly lift the load off the ground and make sure it is level before
continuing. Otherwise, lower the load, reposition the slings and repeat the operation until satisfactorily balanced.
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Warning!
In the event obstacles and/or operating situations do not allow the handler clear
visibility, personnel should be positioned outside the lifting means range of action
to signal the handler.
Hazard!
Never pass under suspended loads.
Never move the load over people working in the factory.
Hazard!
When operating on lifted machine parts, operators must pay the utmost attention
and use adequate lifting devices and personal protection systems to avoid the risk
of falling.
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3 - Installation
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Warning!
Dispose of packaging material according to current regulations in the country of
installation. The user is in charge of packaging disposal.
Note:
The machine must only be installed c/o the user customer by bielomatik s.r.l.
specialised and trained personnel who have the experience, technical know-how,
documentation and tools required for installation (except for lifting means).
For correct machine assembly, follow the design specific technical documents
made up of:
Factory layout
General machine drawings with machine part list
Mechanical units with relevant part lists
Wiring and pneumatic diagrams
Retail part instruction manuals.
During assembly, make sure the measured quotas correspond to that indicated in drawings. In the event of faults,
problems or difficulties of any kind, contact the design engineering office.
Note:
For machine and part positioning and relevant minimum distances to be observed,
refer to the layout in paragraph 3.3.2. In any case, leave work space between and
around parts to permit easy access for maintenance operations.
3.4.1 Unit assembly and positioning
The machine is made up of a packing unit, made up of a frame, the heated belt unit (Clear Wrap), the roll
holder unit and electrical cabinet.
Machine configuration at deliver ex-works.
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264441
260050
260039
3 - 8/20
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Warning!
If the machine is not levelled to meet the indicated tolerance, guides and movement
axes may emit noise or be subject to unusual wear that can compromise the life
cycle as well as correct operations.
Warning!
Levelling must be periodically checked.
After the various units are correctly positioned, release the hooks from the lifting rings and remove the lifting rings.
Once all the above described operations are completed and any mechanical brackets removed, make sure all
guards are installed and connect the main and single unit control panels to the main switchboard.
Next connect the machine with the utilities required for operations in accordance with the supplied power
specifications (for air and electricity).
Warning!
The angle (a) created by the 2 machine lifting slings/chains must not exceed 60.
4000 kg
a
max 60
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Warning!
The angle (a) created by the 2 machine lifting slings/chains must not exceed 60.
1000 kg
a
max 60
264949
Once the above described activities are completed, lift the unit to position it, making sure the frame remains levelled
and does not swing or tip.
When perfectly balanced, lift and move the load.
The unit should be positioned on the support surface which must be suited to support its static and dynamic load.
Level the unit at this point.
Once the unit is stably and correctly positioned, the next units can be positioned.
3 - 10/20
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3 - Installation
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Warning!
The angle (a) created by the 2 machine lifting slings/chains must not exceed 60.
800 kg
251141
Once the above described activities are completed, lift the unit to position it, making sure the frame remains levelled
and does not swing or tip.
When perfectly balanced, lift and move the load.
The unit should be positioned on the support surface which must be suited to support its static and dynamic load.
Level the unit at this point.
Once the unit is stably and correctly positioned, the next units can be positioned.
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Pallet guards and platforms should be lifted with a forklift, as indicated in the following illustration, that must
be suited for this purpose with at least 1000 kg capacity.
Before lifting, make sure the unit is well-balanced on the forklift.
600 kg
264779
Once the above described activities are completed, lift the pallets to position them, making sure they remain levelled
and do not swing or tip when the lift platform is lifted.
When perfectly balanced, lift and move the load.
All guards and platforms should be installed by attaching them with the specific brackets, on the machine frame or
on the ground using suitable fasteners as per the machine layout.
Check the stability and correct installation of all platforms, guard rails and perimeter guards.
Once platforms, rails and perimeter guards are stably and correctly positioned, the next units can be positioned.
3 - 12/20
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3 - Installation
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Warning!
The angle (a) created by the 2 machine lifting slings/chains must not exceed 60.
500 kg
a 0
x6
ma
264852
Once the above described activities are completed, lift the electrical cabinet to position it, making sure it remains
levelled and does not swing or tip.
When perfectly balanced, lift and move the load.
The electrical cabinet should be positioned on the support surface which must be suited to support its static and
dynamic load. Level the unit at this point.
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Electrical connections are performed by the manufacturers specialised personnel in accordance with
B applicable regulations in the country where the machine is installed. In any case, connection instructions
are provided:
machine-electrical cabinet wires must be connected according to the manufacturers wiring diagram;
a copy of the wiring diagram is enclosed. An additional copy is located in the electrical cabinet. The position
of the electrical cabinet(s) is set by the manufacturer and indicated in the previously delivered foundation
drawing;
minimum wire section for transformation cabin-electrical cabinet connections must be selected according to
voltage, installed power and distance between source and use.
Warning!
Before performing electrical connections, make sure the machine power circuit
breaker is locked in the open position.
Hazard!
Power connections must only be performed by specialised personnel and
subject to the use of individual protection devices.
Make sure the power mains are dimensioned according to machine load.
Connect the grounding system before any other mains connections.
Make sure the voltage listed on the machine wiring diagram and type of
connection on the switchboard are correct.
Additional information
The user must install an automatic circuit breaker for all power lines (with cut-off
capacity suited to the switch in switchboards) at the start of the line to facilitate
maintenance.
In any case, the user must protect the machine switchboard connection cable.
All machine parts (transformers, drivers, etc.) are connected to the general
grounding terminal in the switchboard.
Note:
For adequate safety, we suggest you install an indirect contact protection system
coordinated with the grounding system where the machine is installed (for
example, using a circuit breaker).
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3 - Installation
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Power sires must be directly connected to the terminals on the main switch in the switchboard.
The grounding wire must be directly connected to the grounding terminal in the switchboard.
When connected, cover main switch terminals.
R
S
L1
L2 T
L3
261443
260589
All system connections were suitable marked to avoid incorrect connections upon assembly or for future
dismantling, inspections or maintenance.
All connection points are specifically marked.
There are no reference where connections are not restrictive.
Warning!
The customers grounding system must be efficient and meet current regulations.
The machine must be connected to the grounding circuit which must be free of
interferences, dispersion or harmonic currents, etc. And meet current regulations.
WRAPMASTER
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Your pneumatic connection should be directly connected to the air conditioning unit on the machine.
The machine is equipped with an air conditioning unit with filter unit with 40 micron filtering capacity.
The purchaser must guarantee that supplied compressed air is clean and dry without water or oil and that is has
the following specifications:
- Minimum input pressure = 6 bar (85 psi)
- Maximum input pressure not over 8 bar (115 psi)
- Temperature range = 5 C to +45 C
- Filtration level upstream from the machine at least 50 micron
- Air purity grade 2.7.3 as per DIN ISO 8573-1
- No oil in the pneumatic circuit.
Warning!
Failure to meet the above pneumatic supply conditions may compromise machine
operations and reduce average pneumatic part working life thus voiding the
warranty for these parts.
Additional information
Pneumatics must not be lubricated. Oil must not be found in the pneumatic circuit.
Air consumption required by the machine during normal work cycle is 1200 Nl/minute
Additional information
The customer must provide a pneumatic supply system that constantly guarantees this capacity.
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3 - Installation
U0G00214
Before conducting the machine start-up operations described in Chapter 4 Machine start-up and
operation, conduct a series of general checks and inspections on mechanical units and the electrical and
pneumatic systems to avoid operating risks and problems during this phase.
Hazard!
These checks and preparations for first start-up must be conducted by a specialised bielomatik s.r.l. technician.
Hazard!
Considering that sensors and actuators may have suffered alterations during
transport, handling, repairs, etc., we recommend the utmost caution in running
manual movements.
The following checks and inspections are considered normal maintenance and described in chapter 8 Maintenance.
Hazard!
The checks and inspections on mechanical units must be conducted with the
machine stopped with the electrical and pneumatic supplies cut-off.
Warning!
Pay the utmost attention when inspecting the machine, making sure the machine
operating area is free of various tools and foreign objects and that all residual
energy (pneumatic) is drained.
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After inspecting mechanical parts, generally inspect the electrical system and, specifically:
make sure all shunt boxes and ducts on the machine were closed and that all conductors were
connected.
SWITCHBOARDS
For the main switch:
test main switch operations and make sure distribution upstream from auxiliary circuit breakers is correct;
check power distribution and voltage in auxiliary circuits;
also check control unit part integrity.
For motor controls:
test motor drive direction. Check using the relevant remote controls testing their correct connection and drive
direction. If incorrect motor rotation is found, do not invert motor connection but invert the conductors on the main
switch (for all asynchronous motors);
for servo motors, make sure correct movements can be run from the control panel using the Jog functions
(described in chapter 6).
For interconnections:
check correct interconnection connections.
ON BOARD MACHINE:
For limit switches:
test inputs and limit switch adjustments, limit switch triggering with correct on-board led operations and
consequent input activated on the control unit board.
For keyboards:
test inputs by pressing control buttons/selectors to see whether the input on the relevant control unit board is
activated.
For safety circuits:
check correct ground continuity control system operations, emergency stop circuit operations, etc.
Warning!
Before conducting any movement, make sure no faults are found to prevent
machine damages.
Before resetting any fault, check the cause and eliminate it.
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3 - Installation
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Before operating the machine, make sure fixed guards and safety devices are correctly installed and in
good working order.
Safety devices and inspection procedures are described in Chapter 1 Safety.
Note:
This procedure must be adopted as a normal maintenance procedure.
Warning!
Machine safety is not guaranteed when safety devices are tampered with or
removed.
Warning!
The machine and all its structural units are equipped with safety devices integrated
in the machine main safety/emergency circuit. Any connections or parts before or
after the machine, that are not included in the delivery, are not part of this manual;
in the event they have to be carried out, the operator should follow the laws in force.
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3.9 Decommissioning
The following paragraph provides recommendations and instructions for decommissioning, dismantling
and removing the machine at the end of its working life.
The following operations are strictly reserved to authorised personnel:
create enough space around the machine to perform all the movements without operator risks.
turn off all machine power circuit breakers and lock them in the open position;
disconnect the power cable from the circuit breaker, first disconnecting the power conductors and then
the grounding conductors;
disconnect the pneumatic supply tube from the air conditioning unit, first checking whether pneumatic
power is cut-off (closed) and then releasing residual air from pneumatic actuators;
dismantle the machine from the top to the bottom, paying special attention to machine units/parts that could fall
due to gravity.
Hazard!
Pay the utmost attention since falling parts or components during the removal
phase could be seriously dangerous to operators.
remove mobile parts and separate the various components by material as much as possible. Parts must be
separated by material (plastic, metal, etc.) for recycling purposes. Hire special companies to dispose of
demolition materials;
removing and handling various machine parts from the work area adopting all the necessary precautions before
lifting large-sized parts;
make sure lifting devices are correctly secured and only use adequate slings and equipment as described in
previous paragraphs.
Note:
Specific environmental protection regulations are set in every country for the
disposal of this material.
The Customer must know the laws in force in his country and work to meet them.
Note:
In the event of difficulties when removing, demolishing and dismantling machine
parts, consult the bielomatik s.r.l. engineering design department for operating
methods that meet safety and environmental protection standards.
Warning!
Keep in mind that some large-sized and heavy parts can only be handled with
adequate lifting means.
3 - 20/20
WRAPMASTER
4
Machine start-up and operation
WRAPMASTER
4 - 1/26
P3
P3.1
P12
P13
P13.1
P14
P15
P13.1
P13
P12
P1
P3
265525
P3.1
4 - 2/26
WRAPMASTER
STD0044
Q1
265772
250497
WRAPMASTER
4 - 3/26
Start (10N1-S3H)
There is only one lighted button and, when pressed, it starts the first emergency reset cycle to then start the
machine in the operating mode selected with selector 5.
Stop (10N1-S4)
Machine stop button. When this button is pressed in AUTO mode, the machine stops in phase. When presses
twice in a row, the machine immediately stops; in manual mode, the machine immediately stops when this
button is pressed.
Warning!
When this button is pressed the Clear Wrap unit (optional) remains on to prevent
sealing belt deterioration.
4
69
Available
10
Emergency (10N1-S1)
When this self-latching button is pressed the machine immediately shuts down and the pressure in the
pneumatic system drops.
Any emergency buttons are only reset when the start button is pressed.
10
265527
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WRAPMASTER
The control panel allows the user to control machine operation and more precisely:
The panel comes with a 10" backlit liquid crystal touch-screen. Touch the buttons shown on the pages with your
finger to execute the set functions.
The control panel also has a numeric and alphanumeric keypad via software to enter data and arrow keys to scroll
the lists provided.
265527
WRAPMASTER
4 - 5/26
STD0104
4 - 6/26
WRAPMASTER
Emergency (12N1-S6)
Whenever this red mushroom head button is pressed, all the machine units immediately stop, the power
supply to the motors is cut off and the pressure in the pneumatic circuit drops. The emergency stop circuits
can be reset only by pressing the lighted start button on the main push-button panel.
WRAPMASTER
264166
4 - 7/26
Available
35
Available
Warning!
When this button is pressed the Clear Wrap unit (optional) remains on to prevent
sealing belt deterioration.
8
10
10
11
12
13
14
16
17
18
19
15
265528
4 - 8/26
WRAPMASTER
11
Warning!
Pressing the button when the machine is in AUTOMATIC mode immediately stops
the machine and turns on the dancing roller brake.
12
13
14
15
Emergency (13N1-S9)
Press this red mushroom head retained button to immediately stop the entire machine, cutting off power to
motors and depressurising the pneumatic circuit.
Emergency buttons are only reset by pressing the start button on the main control panel.
1619 Available
10
11
12
13
14
16
17
18
19
15
265528
WRAPMASTER
4 - 9/26
263895
Emergency (10N1-S7)
Whenever this red mushroom head button is pressed, all the machine units immediately stop, the power
supply to the motors is cut off and the pressure in the pneumatic circuit drops. The emergency stop circuits
can be reset only by pressing the lighted start button on the main push-button panel.
260398
4 - 10/26
WRAPMASTER
Start (15N1-S3H)
Lighted button that starts the Clear Wrap unit.
Stop (15N1-S4)
Push and hold down this button to stop the Clear Wrap unit.
The Clear Wrap unit restarts when this button is released.
Available
263896
WRAPMASTER
4 - 11/26
STD0025
4 - 12/26
WRAPMASTER
These three modes of operation differ in the way the operator has to interact with the machine.
Important!
You must repeat the procedure from the start if you wait more than 6 seconds
before pressing start button 2 again.
P1
5
STD0025
265527
WRAPMASTER
4 - 13/26
Important!
You must repeat the procedure from the start if you wait more than 6 seconds
before pressing start button 2 again.
P1
5
STD0025
265527
4 - 14/26
WRAPMASTER
In this mode, the operator runs the single operations using the jog button located on the mobile pushbutton
panel.
Turn the manual/automatic selector 5 to 1 or 2 (pushbutton panel P1).
Press the jog button 11 (pushbutton panel P3/P3.1). Light 4 (pushbutton panel P1) turns on (the
machine resets general alarms).
Wait until the siren mutes.
Press jog button 11 within 6 seconds to start the machine in jog mode.
Important!
You must repeat the procedure from the start if you wait more than 6 seconds
before pressing start button 11 again.
Important!
The machine moves for as long as button 11 is held down.
P1
265527
P3/P3.1
11
STD0104
WRAPMASTER
4 - 15/26
Warning!
Sole exception to pneumatic de-energising are the following circuits:
- Clear Wrap cooling jet supply circuit.
- Roll brake supply circuit.
- Outfeed surface jet supply circuit.
The machine should be stopped in this way only when there is an actual emergency as it may cause the reams to
be poorly packaged. The machine is also stopped in this way when one of the access doors is opened while the
machine is running.
4 - 16/26
WRAPMASTER
Important!
If AUTOMATICmode has been selected the machine is ready to start the production
cycle.
The packaging cycle starts as soon as a ream reaches the stopping mechanism-and-synchronization assembly
photocell at the machine inlet.
P1
5
250497
265527
P3/P3.1
11
STD0104
WRAPMASTER
4 - 17/26
In this case, not only the unit but the entire machine/system is in emergency conditions with the power and
pneumatic supplies cut off.
To put the unit in operating conditions, you must run the following procedure:
Remove the cause of the emergency stop (return the emergency button to off).
Make sure no objects or things are inside the concerned area.
Acknowledge any alarms or signals on the main operator panel.
To put the machine in operating conditions, run the procedure described in paragraph 4.5 on the main pushbutton
panel.
4 - 18/26
WRAPMASTER
The machine wraps the reams of paper with wrapping material drawn from a roll installed on a reel
assembly.
The following kinds of wrapping material can be used:
Paper or bonded material: with these materials glue needs to be applied in order to close the flaps and finish
the pack.
Clear Wrap: polypropylene or materials which can be heat-sealed. Glue does not need to be applied to this
kind of material but the wrapping material is heat-sealed instead.
Warning!
During the reel replacement, please use lifting and handling means suited to the
load (reel) to be lifted.
4.6.1 Putting the roll on the expanding spindle
Put the spindle A through the hole in the roll, positioning it according to the product size being handled.
To ease installation of the rolls in the future, we recommend using the side reference ring F.
Insert the wrench B and turn clockwise until the expanding sectors C are blocked on the roll shank D.
C
D
B
260699
WRAPMASTER
4 - 19/26
In order to load a new roll which is already inserted on the expanding spindle on the roll holder assembly
proceed as follows:
Make sure arms D of roll holder assembly are fully down.
Use a fork lift truck to position the ends of the expanding spindle A on bearings B. Seat C for the spindle
must be aligned with bearing E.
Turn on the machine.
By these controls on P13 push button panel, lift the reel from the floor in order to allow its free rotation.
251343
251143
E
4 - 20/26
WRAPMASTER
P12
2
251150
262690
1
251346
263897
WRAPMASTER
4 - 21/26
P12
263897
262690
4 - 22/26
WRAPMASTER
P13
12
13
263894
P13.1
1
10
251151
263895
WRAPMASTER
4 - 23/26
2
P13
9
263894
12
4.6.3.7 Changing the roll being used with a roll that has different material
With the machine shutdown, using the control panel P13 use selector 11 to secure the paper with the
retainers and block the dancing roller; cutting the paper, replacing the roll, splicing and centering the paper.
Turn the selector to position OFF to enable the dancing roller and open the retainers.
P13
263894
11
4 - 24/26
WRAPMASTER
4.6.3.8 Operations to be followed when installing a roll for the same product size
Follow the instructions below when a new roll containing the same kind of wrapping material as that
previously being used is to be installed.
When the roll being used is about to run out it should be changed for a new one before it has completely
run out. This is to avoid repeating the operations when a sheet is inserted between the belts of the unwinding
assembly.
This operation is divided into five different stages:
Lifting the roll that is almost finished
Hooking the finished roll with upper arms
Installing the new roll on the mobile roll holder assembly
Splicing and centering the wrapping material
Removing the finished roll
Before performing the operations described below the new rolls need to be installed on the roll holder spindle.
Follow the instructions indicated previously.
WRAPMASTER
4 - 25/26
With the machine running in automatic mode at reduced speed, open the access doors and make sure the
machine shuts down immediately.
4 - 26/26
WRAPMASTER
5 - Machine axes
U0G00214
5
Machine axes
WRAPMASTER
5 - 1/22
5 - Machine axes
U0G00214
F.F.2
F.F.1
F.F.2
F.F.3
F.F.2
F.F.2
F.F.3
F.F.1
F.F.2
F.F.1
5 - 2/22
263919
WRAPMASTER
5 - Machine axes
U0G00214
Product size parameters: these determine the size of the reams to be handled.
Machine drive axes: these are electrically controlled mechanical parts used to position the units according to
the ream size being handled.
Ream height
Ream length
Ream width
Sheet length (unwinding length)
Sheet width (roll width)
REAM WITH
END FOLDS
RW
RL
RH
RL
REAM WITH
OVERLAP FOLDS
261743
WRAPMASTER
RW
RH
RH
RL
RW
SL
SW
261744
5 - 3/22
5 - Machine axes
U0G00214
SL = RL + 2 (9/10RH)
Ream with overlap folds
SL = RL + 2RH + 60
SL
RL
RW
SW RW/
=2 2+
RW RH
+
+2
RH 15
+3
0
RH
261760
RH
RL
RW
SL
SW
Ream height
Ream length
Ream width
Sheet length (unwinding length)
Sheet width (roll width)
261746
5 - 4/22
261745
WRAPMASTER
5 - Machine axes
U0G00214
Elevator 1 lateral
Elevator 2 central
Counter plate
Lower folder
Lower counterfolder
Left aligner
Right aligner
Folding device for top fold
Movable hopper
End damper
Ream accelerator
Phaser stop in the feeding area (gate)
Ream feed
Transport finger, outfeed
Knife
Sheet conveyor belts
Unwinding rollers
Infeed rolls on unwind unit
The values determined from the individual measurements of distances of the mechanical components after
positioning the axles are target dimensions that result when possible offsets are added to the required parameters
required for the calculation.
Important!
If mechanical parts have been replaced in an axle (pull rod), be sure to check that
the mechanical installation complies with the description in Chapter 10 of this
manual with regard to the specified pull rod lengths of the axles. After replacing
electrical components (sensor original setting), reference the axles. This setting is
to be performed with empty machine and in manual mode.
Proceed as follows to reference a servo axle (for a detailed description of each axle, see the following paragraphs):
In JOG mode check the machine direction (see chapter 6 Machine control through operator interface):
Reference the axle by using the sensor for 0 position (see chapter 6 Machine control through operator
interface). If referencing does not occur, set the 0 position sensor.
Determine the value Home_position of the axle and enter in the axle parameter mask.
Reset again.
WRAPMASTER
5 - 5/22
5 - Machine axes
U0G00214
F.F.2
F.F.3
F.F.3
F.F.2
263906
5 - 6/22
WRAPMASTER
5 - Machine axes
U0G00214
F.F.2
F.F.3
X
F.F.3
F.F.2
263907
WRAPMASTER
5 - 7/22
5 - Machine axes
U0G00214
F.F.2
F.F.3
X
F.F.3
F.F.2
263908
5 - 8/22
WRAPMASTER
5 - Machine axes
U0G00214
F.F.2
F.F.3
F.F.3
X
F.F.2
263909
WRAPMASTER
5 - 9/22
5 - Machine axes
U0G00214
F.F.2
Z
X
F.F.3
F.F.3
F.F.2
5 - 10/22
265529
WRAPMASTER
5 - Machine axes
U0G00214
F.F.2
F.F.1
F.F.2
F.F.1
263911
WRAPMASTER
5 - 11/22
5 - Machine axes
U0G00214
Note:
The value of measurement between F.F.2 and the head folder is only reliable if the
machine is mechanically in A4 format.
G1
F.F.2
F.F.3
F.F.3
X
F.F.2
263912
5 - 12/22
WRAPMASTER
5 - Machine axes
U0G00214
F.F.2
F.F.3
X
F.F.3
F.F.2
263913
WRAPMASTER
5 - 13/22
5 - Machine axes
U0G00214
F.F.2
F.F.3
F.F.3
X
F.F.2
263914
5 - 14/22
WRAPMASTER
5 - Machine axes
U0G00214
F.F.2
F.F.3
F.F.3
F.F.2
WRAPMASTER
263915
5 - 15/22
5 - Machine axes
U0G00214
F.F.2
Note:
When reference teeth N are in line with the notch, both sensors (for A4 and A3
formats) should be obscured.
F.F.3
F.F.3
F.F.2
5 - 16/22
263914
WRAPMASTER
5 - Machine axes
U0G00214
F.F.2
X
O
F.F.3
F.F.3
F.F.2
263915
WRAPMASTER
5 - 17/22
5 - Machine axes
U0G00214
251833
5 - 18/22
WRAPMASTER
5 - Machine axes
U0G00214
SL
=
Axle A24
F.F.1
263805
WRAPMASTER
5 - 19/22
5 - Machine axes
U0G00214
SL
RL
RW
SW RW
= 2 /2 +
RW
R
+2 H +
RH 15
+3
0
RH
261760
RW
RL
RH
SL
SW
Ream width
Ream length
Ream height
Sheet length (unwinding length)
Sheet width (roll width)
261746
5 - 20/22
261745
WRAPMASTER
5 - Machine axes
U0G00214
SL
RL
RW
SW
RW
= 2 /2 +
RW RH
+2
+
RH 15
+3
0
RH
261760
RW
RL
RH
SL
SW
Ream width
Ream length
Ream height
Sheet length (unwinding length)
Sheet width (roll width)
261746
WRAPMASTER
261745
5 - 21/22
5 - Machine axes
U0G00214
5 - 22/22
WRAPMASTER
6
Machine control through
operator interface
WRAPMASTER
6 - 1/44
A touch screen is provided that allows the user to interact with the operator panel by touching an area on its screen.
The machine performs the processings of the packaging process in automatic cycle following the selection of a work
order.
With the automatic cycle and in synchronism with the system located before the machine/equipment, all the
parameters regarding the work order are set in the order database (those values are subject to a confirmation); the
operator responsible for the production can not modify the parameters (such as speed, acceleration etc.) of the
various actuators on the machine/equipment but can only implement a work according to the required format.
Any change of the machine/equipment speed can be carried out only in manual cycle and for maintenance purposes
(always under safety conditions and with all protections enabled) so as to test the machine/equipment idling
operation or during the machine test phase or adjustment.
266056
6 - 2/44
WRAPMASTER
Warning!
Password access should be used only by qualified technical staff in case of maintenance operations or in special cases such as encoder, drive replacement etc...
The misuse of this section (access with password) regards the entry of data that
do not meet the actual physical characteristics of the process, which may cause
damages or injuries to things or people; this is prohibited and falls under the direct
responsibility of the technical staff responsible.
6.2.1 Calling up the pages in OPERATOR mode (no password required)
266055
WRAPMASTER
6 - 3/44
266054
6 - 4/44
WRAPMASTER
3
3M
265534
3B
WRAPMASTER
3A
3X 3C
3D
3E 3H
3L 3G
6 - 5/44
263306
263305
264985
6 - 6/44
WRAPMASTER
1
2
3
4
5
6
X
Order: this opens the format data management and order production page.
Overview: this opens the page where production order data is displayed.
Messages and diagnostics: this opens a window where service or alarm messages are displayed.
Report: this opens the page where production data logs are displayed (optional).
General settings: this opens the operator interface settings management page (password required - level 8).
Clear screen: clear screen of any electrostatic discharges.
Simulation cycle: key that simulates a ream between the infeed phasing unit photocells. When the key is
pressed, the machine starts the automatic cycle as if the set format was to be packaged (sheet cut and
unwinding). The key lights up. The cycle continues until the key is pressed again.
2
3
4
E
5
F
266056
WRAPMASTER
6 - 7/44
1
2
3
4
5
6
7
8
266057
6 - 8/44
WRAPMASTER
11
12
13
14
G1
11
12
13
14
264998
WRAPMASTER
6 - 9/44
1
2
3
4
5
6
7
8
266058
6 - 10/44
WRAPMASTER
11
12
13
14
G2
11
12
13
14
H
I
264996
WRAPMASTER
6 - 11/44
1
2
3
4
5
6
7
8
266057
6 - 12/44
WRAPMASTER
264995
1 4 5 6
WRAPMASTER
6 - 13/44
266058
6 - 14/44
WRAPMASTER
Movement parameters: this opens the sub-pages where machine parameters are managed.
Service: this opens the maintenance management page.
Ream control: this opens the page where ream controls are managed (optional).
Report: this opens the page where production data logs are displayed.
Clear Wrap: this opens the page where Clear Wrap parameters are managed (optional).
Roll holder: this opens the page where roll holder parameters are managed.
I/O Test: access to the sub-page where the PLC inputs and outputs can be checked.
Profibus: access to the sub-page where the Bus-Profibus can be checked.
Hot-melt Service: service: this opens the Hot-melt maintenance management page.
Syncro Overview: this opens the page where the synchronization data of the Wrapper/Cutter are displayed.
Some working machine data can be displayed from the OVERVIEW page:
A
B
C
D
E
F
Cutter speed
Machine phase.
Machine speed.
Ream acceptance phase on gate.
Blade synchronism error value.
Mark reading error value.
Use the buttons X to change the ream count between the gate and the elevator, following the intervention of the
operator for the removal and/or arrangement of the reams.
The buttons turn white if the ream is present, otherwise they are coloured in blue.
If other reams are placed again, press the corresponding button to delete them.
This operation can be performed only if the machine is stopped.
B
2
C
3
E
F
10
266059
WRAPMASTER
9
6 - 15/44
2
3
4
266060
6 - 16/44
WRAPMASTER
Axle A11
Axle A12
Axle A13
Axle A14
Axle A15
Axle A16
Axle A36
Axle A17
Axle A18
Axle A19
Axle A20
Axle A37
Axle A21
Axle A22
Axle A23
Axle A24
Axle A25
Axle A26
Elevator 1: touch button for activating the parameters for the axle of the first elevator.
Elevator 2: touch button for activating the parameters for the axle of the second elevator.
Counter plate: touch button for activating the parameters for the axle of the counter plate.
Lower folder: touch button for activating the parameters for the axle of the lower folder.
Lower counterfolder: touch button for activating the parameters for the axle of the lower counterfolder.
Left aligner: touch button for activating the parameters for the left aligner axle.
Right aligner: touch button for activating the parameters for the right aligner axle.
Folder for top fold: touch button for activating the parameters for the axle of the folding devices for
the top fold.
Movable hopper: touch button for activating the parameters for the axle of the movable hopper.
End damper: touch button for activating the parameters for the axle of the end dampers.
Ream accelerator: touch button for activating the parameters for the axle of the ream accelerator.
Gate: touch button for activating the parameters for the axle of the Gate.
Ream feed: touch button for activating the parameters for the axle of the ream feed.
Transport finger, outfeed: touch button for activating the parameters for the axle of the outfeed
transport finger.
Knife: touch button for activating the parameters for the knife axle.
Wrapping paper belt: touch button for activating the parameters for the axle of the wrapping paper belt.
Second infeed roll: touch button for activating the parameters for the axle of the second infeed roll.
First infeed roll: touch button for activating the parameters for the axle of the first infeed roll.
On each side of the axle are two fields. The first contains the value of the actual position, the second any pending
error codes. The error code appears in the field only if the axle stops due to a fault. To clear this code, the operator
must look it up in the warning list supplied by the motor manufacturer.
Pressing the Axle parameter 2 touch button accesses the parameters for the selected axle (required: password,
level 8). The selected axle is indicated by a flashing yellow marker next to the axle name.
The table for checking the axles has the following columns:
Blue
Yellow
Violet
Red
Green
Orange
Axle moving.
Axle is incorrectly positioned based on the setting in the size data.
Axle is not referenced; axle position values not reliable because no correct referencing has taken place.
Axle with warning.
Axle corrected by referencing or positioning; no pending warnings and the axle is correctly positioned.
Axle not enabled.
266061
265722
WRAPMASTER
2
6 - 17/44
1
2
Pressing the touch button for the axle to be selected displays all parameters.
The available fields contain the following:
MDI position: shows the angle position which defines the zero point of the axle in manual mode.
MDI speed: shows the speed of the axle during manual mode.
The commands are carried out using the following touch buttons:
3
Start MDI: starts manual mode.
4
Stop MDI: stops manual mode.
5
Homing: carries out the axle reference run.
6
Jog +: enables inching mode and increases the angle.
7
Jog -: enables inching mode and decreases the angle.
8
Brake: controls actuation and release of the brake of the selected axle. This function is activated if the
machine is at a standstill as a result of an Emergency Stop.
9
Sim: accessible only to the manufacturer.
Note:
Some touch buttons may be deactivated for some axles or deactivated due to the
state of the axles (white lettering).
3
2
4
7
6
5
8
9
264992
6 - 18/44
WRAPMASTER
2
3
4
5
6
7
8
9
Feed constant: this value (in millimetres) shows the linear development for each rotation of the movement
(value present only for some axles).
To change the value, switch the machine off and then on again.
Home position: this dimension (in millimetres) specifies the value for referencing the selected axle (see
chapter 5 Machine axes).
Home offset: this value (in millimetres) specifies the distance between the proximity switch of the starting
position and the actual starting position.
Home velocity: this value (in millimetres/second) specifies the speed of the axle during referencing.
Not used
Overload limit: this value (in Nm) specifies the value of the electronic overload protection.
Software position limit +: this shows the largest value which the movement can reach (software limit switch).
Software position limit -: this shows the smallest value which the movement can reach (software limit
switch).
Jog/MDI maximum velocity +: this value specifies the highest possible speed of the axle of the movements
in manual mode.
The boxes A allow to display the activation status of the selected axis (green = OK, red = error); for further details,
please refer to the manufacturers manual.
1
2
3
4
5
6
7
8
266062
WRAPMASTER
6 - 19/44
Warning!
Changing these parameters may compromise the proper functioning of the
machine; therefore, changes should be performed only after a thorough analysis
and when the movement is adequately known. Our Customer Service will be glad
to provide you with further information if required.
3
4
5
6
7
The touch buttons in the screen mask have the following functions:
1 General parameters: opens the mask where you can manage the parameters for machine movements.
2 Switchcam parameters: opens the mask for managing the parameters for actuating the solenoids,
photocells etc.
Glue parameters: opens the mask for the control system responsible for glue application assemblies.
Switch system parameters:opens the mask where you can manage the parameters for actuating the axles.
Syncron parameters: opens the mask for managing the general parameters for synchronisation with the
cross cutter.
Syncro displacement parameters:opens the mask for managing the parameters for synchronising with the
cross cutter based on size.
Print mark control parameters: opens the mask for controlling the reference mark (print mark) on the
packaging material.
2
3
4
5
6
7
266063
6 - 20/44
WRAPMASTER
1
2
3
4
5
6
7
8
9
10
11
265723
12
13
14
15
16
264987
WRAPMASTER
6 - 21/44
1
2
3
4
5
B
C
6 7 8
265724
265539
264985
10
6 - 22/44
WRAPMASTER
1
2
3
4
Offset glue ON: indicates the value in millimetres that is added to the Start glue parameter set in size data.
Offset glue OFF: indicates the value in millimetres that is added to the Stop glue parameter set in size data.
Glue spray delay ON: indicates the glue spray start delay to proportionally compensate for the change in
machine speed.
Glue spray delay OFF: indicates the glue spray stop delay to proportionally compensate for the change in
machine speed.
F.F.2 and left glue gun distance: indicates the distance measured on the machine in the inspection phase
between the F.F.2 and nozzle that applies glue on the left head flap.
F.F.2 and right glue gun distance: indicates the distance measured on the machine in the inspection phase
between the F.F.2 and nozzle that applies glue on the right head flap.
Hot melt longitudinal glue gun blade distance: indicates the distance between the blade and the hot melt
application nozzle.
Longitudinally spread glue gun blade distance: indicates the distance between the blade and the glue
spreading nozzle.
1
2
3
4
264983
264982
WRAPMASTER
6 - 23/44
HP
SC
HP
262647
PC
Ream width
Ream length
Packing paper length
Flap height
Distance between the Machine zero-point and the glue gun
Side glue offset ON
Side glue application delay On
FS=PC+HP-A-ON-TOn
SIDE GLUE APPLICATION STOP =FT
A
B
SC
HP= (SC-B):2
PC
OF
TOff
Ream width
Ream length
Packing paper length
Flap height
Distance between the Machine zero-point and the glue gun
Side glue offset OFF
Side glue application delay OFF
FT=PC-HP+OF-TOff
If the parameter is varied or fields FS or FT are set to zero, the PLC calculates the equations (for each program step)
and, as a result, will update the fields.
6 - 24/44
WRAPMASTER
HP
PC
B
SC
262648
Ream length
Packing paper length
Flap height
Lengthwise glue application offset ON
Lengthwise glue application delay On
FS=PC-SC+HP-ON-TOn
LENGTHWISE GLUE APPL. STOP = FT
B
SC
HP = (SC-B):2
PC
OF
TOff
Ream length
Packing paper length
Flap height
Distance between blade and glue gun
Lengthwise glue application offset OFF
Side glue application delay off
FT=PC-HP+OF-TOff
If the parameter is varied of fields FS or FT are set to zero, the PLC calculates the equations (for each program step)
and, as a result, will update the fields.
WRAPMASTER
6 - 25/44
Determining the lengthwise glue application parameters - spiral shape or smeared (optional)
HP
B
SC
SC
HP
PC
262649
Ream length
Packing paper length
Flap height
Lengthwise glue application offset ON
Lengthwise glue application delay On
FS=HP-ON-TOn
LENGTHWISE GLUE APPL. STOP = FT
B
SC
HP = (SC-B):2
PC
OF
TOff
Ream length
Packing paper length
Flap height
Distance between blade and glue gun
Lengthwise glue application offset OFF
Side glue application delay off
FT=SC-HP+OF-TOff
If the parameter is varied of fields FS or FT are set to zero, the PLC calculates the equations (for each program step)
and, as a result, will update the fields.
6 - 26/44
WRAPMASTER
1
2
3
4
5
6
7
8
265725
22
264980
WRAPMASTER
6 - 27/44
This parameter sets linear belt movement at wrapper infeed for each encoder revolution.
This value sets the acceleration degree of the axis that allows the synchronism correction.
This value sets the maximum acceptable speed that allows gate operations.
This value sets the wrapper speed increase to correct ream synchronism.
This value sets minimum admitted machine speed to correct synchronism, according to the minimum format.
This value sets maximum admitted machine speed to correct synchronism, according to the maximum format.
This value sets the maximum speed, calculated according to values 5 and 6.
This value sets minimum admitted machine speed to correct synchronism.
This value sets minimum machine acceleration to correct synchronism.
This value sets how many machine degrees are needed to correct synchronism.
1
2
3
4
5
6
7
8
9
10
266064
6 - 28/44
WRAPMASTER
11
12
13
14
15
16
50
51
52
A
This value sets the distance between the cutter synchronous photocells and the wrapper synchronous photocell.
This value sets the maximum distance required after the synchronism photocell to correct synchronism.
This value sets minimum correction error.
This value sets the maximum distance with reference to optimal correction.
This value sets the distance between the wrapper synchronous photocells and the gate synchronous
photocell.
This value permits correct ream transit to be calculated from the cutter conveyor to the wrapper conveyor,
compensating the step difference between the two conveyors.
This data sets encoder rotation direction.
This value sets the reading direction of the wrapper synchronous photocell on the ream.
This value sets the reading direction of the cutter synchronous photocell on the ream.
These values indicate the linear blade speed.
11
12
13
14
15
16
50
51
52
266065
WRAPMASTER
6 - 29/44
Ream width.
Offset value for the synchronous reference phase of the cutter photocell.
Distance of the reams on the cutter belt, according to the ream width.
Distance of the reams on the gate belts, according to the ream width.
Offset value for the synchronous reference phase of the wrapper photocell.
Synchronous reference phase of the cutter photocell, according to the ream width.
Synchronous reference phase of the wrapper photocell, according to the ream width.
1
2
3
4
5
9
10
266066
6 - 30/44
WRAPMASTER
This value identifies the distance between the blade and the spot reader photocell.
This value identifies the spot reading area.
This value identifies the maximum admitted spot reading error.
This value sets the maximum correction on the single packaging sheet to correct the spot read error during
the production cycle.
This value sets the maximum correction on the single packaging sheet to correct the spot read error during
empty machine operations.
1
2
3
4
5
264975
WRAPMASTER
6 - 31/44
8
9
265726
10
6 - 32/44
WRAPMASTER
6.6.4.1 Parameters of the suction pump on the conveyor belts page description
1 Motor constant: this value refers to the ratio between the frequency and the axis current speed.
2 Reference speed: this value corresponds to the reference speed.
50 Direction: use this key to reverse the axis direction.
1
2
50
266068
8
10
50
1 Motor constant: this value refers to the ratio between the frequency and the axis current speed.
2 Reference speed: this value corresponds to the reference speed.
7-9 Reference speed 1-2: min. and max. machine speed range, within which the pump increases its speed
proportionally.
Reference freq. 1: pump minimum speed, with reference to parameter 7.
Reference freq. 2: pump maximum speed, with reference to parameter 9.
Direction: use this key to reverse the axis direction.
1
2
7
8
9
10
50
266069
WRAPMASTER
6 - 33/44
4
5
6
266070
6 - 34/44
WRAPMASTER
3
4
A
264973
WRAPMASTER
6 - 35/44
This key opens the sub-page where some Clear Wrap motor variables can be managed.
This value sets minimum Clear Wrap operating speed.
This key enables/disable all Clear Wrap resistances.
This key loosens the lower Clear Wrap conveyor to facilitate replacement (key only enabled when the machine
is stopped).
Press the resistance keys to open the single temperature regulators.
A
B
C
D
264969
6 - 36/44
WRAPMASTER
Resistance on selector.
Current temperature.
Set temperature.
Set temperature tolerance.
Range settings keys.
Working temperature settings keys.
Directly touch the set temperature or range field to open the number pad you can use to enter the required data.
264968
263306
WRAPMASTER
6 - 37/44
A
B
1
2
50
264967
6 - 38/44
WRAPMASTER
This value refers to the number of sheets cut, following the photocell reading.
This value refers to the unwounded length, following the photocell reading.
This value determines the number of sheets cut after which, following the photocell reading, the alarm appears
on the operator panel.
This value determines the number of sheets cut after which, following the photocell reading, the machine is
decelerated and the corresponding message appears on the operator panel.
This value determines the number of sheets cut after which, following the photocell reading, the synchronism
is disabled.
This value determines the number of sheets cut after which, following the photocell reading, the machine is
stopped.
This value identifies the deactivation time of the upper brake on the almost empty reel during the splice phase
at low and high speed.
This value identifies the actuation time of the upper brake on the almost empty reel during the splice phase.
This value identifies the cutter speed during the splice phase.
1
2
3
4
5
6
7
8
9
266071
WRAPMASTER
6 - 39/44
1
2
3
4
Online messages: a page opens listing current machine service signals and alarms.
Message log: a page opens listing all machine service signals and alarms in the buffer.
Print service: prints service signals and alarms if the machine is connected to a printer.
Delete messages: deletes all messages accumulated in the service signal and alarm buffer.
Alarm messages that stop machine operations are displayed in a popup window on the operator panel that displays
the alarm message and a key:
A HELP: displays online help for the message displayed in the window.
1
2
3
4
264972
264971
6 - 40/44
WRAPMASTER
1
2
3
4
5
Note:
The password is set to 1234 by default.
1
2
3
4
5
264970
WRAPMASTER
6 - 41/44
265089
6 - 42/44
WRAPMASTER
266074
Reference value
Average value of the last data detected
Value of the last reading
Values of the readings preceding the last reading.
1
2
3
266075
WRAPMASTER
6 - 43/44
1
2
3
4
Actual data:
Last data:
Time frame data:
Shift Setup:
1
2
3
4
265728
6 - 44/44
266072
266073
265731
265732
WRAPMASTER
7
Operation and format change
WRAPMASTER
7 - 1/62
7.1 Introduction
This chapter provides all the information needed to understand machine operations, instructions for format
changes and adjustments.
All information that concern the same machine unit or section are grouped and only marked by the icons
indicated the operation they run.
Warning!
Before performing any type of operation on the machine, the user must first read
and fully understand the entire Instruction Manual.
7.1.1 Size change-over
The machine is adjusted in all its parts by our engineers before it is delivered. However, the user should
know how to carry out these adjustments or replace the parts to optimize the quality of the product according
to its variables. In addition, after maintenance has been performed the machine can be brought back to
its initial state by simply following the directions given.
7 - 2/62
WRAPMASTER
260527
hRH
Ra
W
b
RL
260010
WRAPMASTER
7 - 3/62
Position the new packing sheet using the buttons on pushbutton panel P12.
A
B
C
D
7 - 4/62
WRAPMASTER
Adjust the lateral Clear Wrap unit belts (optional unit) according to ream width (see paragraph 7.7.2.1).
Adjust the upper Clear Wrap unit belt (optional unit) according to ream height (see paragraph 7.7.2.1).
Adjust the glue guns according to flap length (see paragraph 7.6.9), which depends on ream height and
the type of package to be created (heat or underneath folds).
Adjust and/or replace the rear head folders according to ream height (see paragraph 7.6.7.1).
Adjust and/or replace the front fixed head folders according to ream height (see paragraph 7.6.7.1).
This operation must be performed at the same time as step F.
Adjust and/or replace the helical folders according to ream height (see paragraph 7.6.8.1). This
operation must be performed at the same time as step E.
Adjust sheet feed guides according to packaging sheet dimensions (see paragraph 7.4.8.1).
Adjust front head folders according to ream width (see paragraph 7.6.7.2).
Adjust side pressing units according to ream length (see paragraph 7.5.4.2).
Adjust the outfeed conveyor according to ream length (see paragraph 7.6.11).
Adjust the bottom stop and lower hopper according to ream width (see paragraph 7.5.4.1).
Adjust the width of the aligner chains and teeth according to the ream length (see paragraph 7.5.3.1).
Adjust the phasing stop unit belts according to ream length (see paragraph 7.5.2.1).
Replace the ream support slats in the phasing unit stop area (see paragraph 7.5.2.2).
Replace squaring unit teeth (see paragraph 7.5.3.2).
Replace lateral slats on the ream infeed conveyor in the squaring unit area according to ream length
(see paragraph 7.5.3.3).
Replace lift plates (see paragraph 7.6.1.1).
Replace the upper mobile hopper according to ream length, correctly positioning it according to ream
width (see paragraph 7.6.5.1).
Replace the counter-lift according to ream width and length (see paragraph 7.6.3.1).
Insert the ream support slats in the outfeed surface area (see paragraph 7.7.1.1).
Launch the new format using the operator panel (see paragraph 6).
To switch from large to small format, steps 1 through 5 remain the same while the sequence in point 4 changes. Thus
format part replacement and/or adjustments must be performed in reverse order.
Important:
This operation must be performed with the machine in manual mode.
The above format change operations refer to a complete format change meaning
all ream dimensions change (width - height - length).
One only one ream dimension changes, only some of the above operations are
required.
WRAPMASTER
7 - 5/62
1.1
1.2
1.3
1.6
1.5
1.4
1.8
1.7
263892
1.9
7 - 6/62
WRAPMASTER
Ream wrapper
3.1 Elevator
3.2 Paper stop
3.3 Counter-elevator
3.4 Upper hoppers
3.6 Lower folder and counter-folder assembly
3.7 Mobile and fixed end folder assembly
3.8 Plough folders
3.9 End flap glue applicator
3.10 Ream accelerator
3.11 Pushers
2.2
2.1
3.7 3.10
3.6 2.4
2.2
3.1
2.1
3.8
3.8
263892
2.3
WRAPMASTER
3.2
3.8
7 - 7/62
Common parts
5.1 Electrical cabinet
5.2 Pneumatic system
5.3 Hotmelt unit
(*1)
4.1
4.2a
5.1
5.3
263892
5.2
7 - 8/62
4.1
4.2a
WRAPMASTER
263898
WRAPMASTER
7 - 9/62
Warning!
When replacing the roll, using lifting and handling vehicles suited to the load (roll)
to be lifted.
251343
7 - 10/62
WRAPMASTER
251460
F
E
251348
WRAPMASTER
251910
7 - 11/62
Warning!
Before attempting to carry out any operations on the machine, make certain the
main shutoff switch on the electrical control cabinet is turned to position 0 and
that the machine is disconnected from the pneumatic system.
7.4.1.2 Changing the roll
Change the roll before it is completely finished to avoid having to insert the sheet between the unwinding
unit belts a second time.
The operations for changing the roll are described in chapter 4 at paragraph 4.6 "Wrapping material".
7 - 12/62
WRAPMASTER
Danger!
Hand crushing hazard due to the unwinding rollers opening and closing during the
packaging paper insertion phase.
251378
251460
WRAPMASTER
I
7 - 13/62
Note:
This device does not provide to eliminate the cross curling
7.4.3.1 Adjusting the de-curling unit
De-curling unit L should be adjusted according to the type of wrapping material handled and roll diameter.
To adjust, proceed as follows:
loosen handle O;
manually adjust the device by working on lever N;
re-tighten handle O.
Danger!
Cutting hazard during the yield adjustment phase, wear protective gloves.
251689
7 - 14/62
WRAPMASTER
Danger!
Hand crushing hazard during the wrapping paper feed phase.
251834
WRAPMASTER
7 - 15/62
251690
7 - 16/62
WRAPMASTER
251911
WRAPMASTER
7 - 17/62
AREA WHERE
PAPER IS CUT
WRAPPING MATERIAL
AREA WHERE
PAPER IS CUT
265719
7 - 18/62
WRAPMASTER
251691
WRAPMASTER
7 - 19/62
P12
4
251380
264166
251690
7 - 20/62
251462
WRAPMASTER
Danger!
Cutting hazard during the wrapping paper feed phase and during operations in
manual or jog mode due to the accessible cutting blade. Wear protective gloves.
263899
WRAPMASTER
7 - 21/62
251380
251381
7 - 22/62
WRAPMASTER
The conveyor belts are operated by brushless motor which is controlled by the machines logic system. This ensures
accurate positioning according to the size of the sheet. The sheet is placed centrally along axis F.F.1. Motor is
referred to as electric drive and its operating principle is described in chapter 5.
Photocell G assures the sheet is present on the conveyor belts.
251835
WRAPMASTER
7 - 23/62
251380
251693
251694
XC = RH + 1/2RW - 35
XD = RH + 3/2RW - 35
XC
1520
XD
1520
RH
35
35
262126
30
RW
B
RH
262161
RW
RL
262119
7 - 24/62
WRAPMASTER
Danger!
Hot glue application devices require high temperatures for operations. Pay careful
attention to avoid hitting or touching these devices with unprotected body parts.
Wear protective gloves, goggles and masks for protection when working near glue
nozzles.
Important!
Glue does not need to be applied if polyethylene wrapping material is used. In fact,
the wrapping will be sealed by the molten polyethylene.
251463
WRAPMASTER
7 - 25/62
Danger!
Hot glue application devices require high temperatures for operations. Pay careful
attention to avoid hitting or touching these devices with unprotected body parts.
Wear protective gloves, goggles and masks for protection when working near glue
nozzles.
7.4.9.2 Glue applicator position adjustments
The spread glue applicator can be positioned crosswise along rods C to adjust to packaging sheet width:
Loosens the fastening screw B.
Move the unit long the rods C and read the position on the linear scale D.
Tighten the fastening screw B.
251385
7 - 26/62
WRAPMASTER
265532
WRAPMASTER
7 - 27/62
Warning!
Keep hands away from belts during normal operations to avoid dragging hazards.
B
A
C
251913
7 - 28/62
WRAPMASTER
251913
251914
WRAPMASTER
7 - 29/62
251913
hRH
Ra
W
L
Rb
260010
7 - 30/62
WRAPMASTER
251915
WRAPMASTER
7 - 31/62
251873
hRH
Ra
W
L
Rb
260010
7 - 32/62
WRAPMASTER
7.5.3.2 Equipping the squaring unit with two or three teeth (only for machine with A3-format)
To equip the squaring unit with two or three teeth, identify the fixed tooth, marked by paint, that should not
be replaced.
Once the fixed tooth has been identified, follow the specific procedure below:
Two-teeth (for A3- Format and similar) or three-teeth (for A4-formats or similar) installation
Remove teeth F to be replaced, by unscrewing screws G and remove the internal fastening slat.
Install teeth F: for the two-teeth installation, teeth will have an opposite position with respect to the fixed tooth
on belt H, for the three-teeth installation, the teeth will be installed in the other two assembling positions, by
screwing screws G on the belt by means of the internal fastening slat.
251874
WRAPMASTER
7 - 33/62
251873
7 - 34/62
WRAPMASTER
A
D
251873
WRAPMASTER
7 - 35/62
F
D
B
M
C
251840
Adjust the lateral pressing units G accordino to the ream length RL:
Release the screws H.
Move the pressing units until they reach the required position, checking the quota on the linear scale I.
Fix again the screws H.
I
H
251875
7 - 36/62
WRAPMASTER
263902
WRAPMASTER
7 - 37/62
G
F
E
A
E
251873
263903
E
A
7 - 38/62
WRAPMASTER
External plates C - E move down so that the lower folder and lower counter-folder can take their place
holding up the ream and folding the wrapping paper under it in the mean time. The middle plate D moves
down to complete this operation.
In addition, the elevator is equipped with an air blower that creates a cushion between the table and ream
to ease movement.
The air blower can be adjusted according to the characteristics of the reams being handled. Use pressure
regulator to make any required adjustments. The blower is activated when solenoid valve found in the
battery valve pack opens.
Calibration pressure: 2.5 bar
251875
WRAPMASTER
7 - 39/62
263903
7 - 40/62
WRAPMASTER
7.6.3 Counter-elevator
The counter elevator A has the function to carry the ream during the elevator B lifting to avoid its
misplacing during the lifting jeopardizing the well done packing.
The counter elevator is a plate A to be replaced according to the size, connected to the support E,
vertically moving by means of guide C, a spring system grant the right pressure e on the ream by lifting,
compensating possible speed differences between elevator and counter elevator.
The counter elevator takes the motion from a servomotor controlled by the machine logic able to make the
correct timing according to the worked size.
The motor action is defined as electric axis and its features are explained in chap. 5.
251873
263903
WRAPMASTER
7 - 41/62
251842
7 - 42/62
WRAPMASTER
251841
251873
hRH
Ra
W
L
Rb
260010
WRAPMASTER
7 - 43/62
A
G
hRH
263903
Ra
W
L
Rb
260010
251843
7 - 44/62
WRAPMASTER
263903
WRAPMASTER
7 - 45/62
251841
7 - 46/62
WRAPMASTER
251873
h
RH
Ra
W
WRAPMASTER
L
Rb
260010
7 - 47/62
B
A
251844
7 - 48/62
WRAPMASTER
C
D
251844
hRH
Ra
W
L
Rb
260010
WRAPMASTER
7 - 49/62
Danger!
Hot glue application devices require high temperatures for operations. Pay careful
attention to avoid hitting or touching these devices with unprotected body parts.
Wear protective gloves, goggles and masks for protection when working near glue
nozzles.
Adjust the position of spray-gun A to apply the glue on the top flap of the ream.
Place the wrench supplied on the hexagonal pin C and then turn it according to the height of flap P until
the pointer is positioned on the measurement shown on plate D.
Make the same adjustment for the spray-gun on the other side of the machine.
D
A
251844
260023
7 - 50/62
WRAPMASTER
7.6.11 Pushers
The formed tube is moved by a set of rods connected to a chain named conveyor fingers B.
This group will withdraw the product from the elevator and bring it up to the outlet.
The outfeed drawing unit takes the motion from a servomotor controlled by the machine logic able to make
correct timing, according to the worked size.
The motor action is defined as electric axis and its features are explained in chap. 5.
The unit is adjusted according to ream length RL using the key clamp C that adjusts all movements at the same
time thus adjust according to RL (head and helical folders, pressure belts) and reading the quota on the specific
numerator D.
251873
251847
WRAPMASTER
7 - 51/62
263904
7 - 52/62
WRAPMASTER
260032
251845
WRAPMASTER
7 - 53/62
251851
7 - 54/62
WRAPMASTER
This optional unit is placed after the discharge unit and can be used to:
seal polypropylene;
heat up the glue applied on the sheets of paper beforehand to close the wrapping;
heat up the glue applied by theby the spreading glue unit.
251400
A
263987
WRAPMASTER
7 - 55/62
E
G
H
251400
hRH
263986
Ra
W
L
Rb
260010
7 - 56/62
WRAPMASTER
B
A
251916
WRAPMASTER
7 - 57/62
263905
7 - 58/62
WRAPMASTER
Q1
263984
The wiring diagram is provided along with this documentation to aid in better understanding the functions of the
components.
WRAPMASTER
7 - 59/62
A
C
B
251845
A pneumatic diagram is supplied with this documentation to help the user understand how the various parts work.
7 - 60/62
WRAPMASTER
251408
WRAPMASTER
7 - 61/62
7 - 62/62
WRAPMASTER
8 - Maintenance
U0G00214
8
Maintenance
WRAPMASTER
8 - 1/34
8 - Maintenance
U0G00214
8.1 Overview
This chapter, intended for the customers maintenance technicians, describes the maintenance operations
to be performed on the machine.
The purpose of the maintenance operations described below is to keep the machine efficient and in good working
order and prevent any faults or breakdowns.
Maintenance includes the following activities:
Preventive maintenance
The group of interventions conducted at set intervals or in accordance with set criteria and aimed to reduce the
possibility of faults or deteriorated machine operations; preventive maintenance includes inspection, control,
adjustment, cleaning and lubrication activities.
Special maintenance
Special maintenance is the group of activities conducted at set intervals or following faults or breakdowns to
restore machine operations. Special maintenance includes overhaul, repairs, the restoration of nominal
operating conditions or replacement of faulty, defective or worn units.
Note:
Preventive and special maintenance activities can be conducted by the user
customer of bielomatik s.r.l. technicians according to the instructions listed in the
sheets.
Due to their complexity, some particular special maintenance operations were
intentionally omitted from the manual and can only be conducted by bielomatik
s.r.l. technicians who have the technical know-how, documentation and tools
required to conduct these activities.
Machine Directive 2006/42/EC defines the operator as the Person qualified to install, run, adjust, clean and
maintain the machine (Appendix I, point 1.1.1).
Note:
Repair frequency must be:
A) According to wear: Repairs are conducted after analysing the results of a
preliminary revision in order to avoid damaging the unit in question.
B) Following a fault or deterioration: A revision, during which the fault or deterioration is identified, precedes repairs.
Repairs must be conducted after analysing the revision results.
Please remember that correct maintenance can reduce downtime after faults to a minimum.
Prompt repairs avoid additional deterioration.
Use original spare parts and accurately repair faulty parts to restore them to nominal status.
Use original spare parts and accurately perform the indicated maintenance activities.
Note:
The manufacturer cannot be held liable for faults or malfunctions during the
machine warranty period in the event of poor maintenance, lack or lubrication,
machine parts replaced with non original or unauthorised parts and machine use
other than that indicated in this instruction manual.
8 - 2/34
WRAPMASTER
8 - Maintenance
U0G00214
Know the directives in force in the users country concerning workmans safety during machine work,
and be able to apply them.
Have fully read and understood this instruction manual.
Know how to correctly use and consult the design technical documentation, including the machine diagrams,
mechanical units with part lists, mechanical drawings and wiring and fluidic diagrams.
Perform the authorised operations (Mechanical, Electrical, Fluidic).
Be able to use the most appropriate and adequate troubleshooting instruments and know which equipment is
best suited for the maintenance operations.
Warning!
Only trained and authorised personnel can conduct maintenance, adjustment and
tuning operations.
Warning!
The need to place the machine in operating conditions with the guards bypassed
requires adequate skills and knowledge and the maintenance technicians utmost
care.
Warning!
If unit, equipment or system malfunctions or defects are found during the normal
operating cycle, stop the machine and immediately inform the customer service
centre.
WRAPMASTER
8 - 3/34
8 - Maintenance
U0G00214
Leuze Group
Neuffen
Bologna
Bielomatik S.r.l.
Via Marzabotto, 280
I - 40050 Funo di Argelato (Bo)
Tel. +390518650711
Fax +39051866021
bielomatik@bielomatik.it
www.bielomatik.com
8 - 4/34
WRAPMASTER
8 - Maintenance
U0G00214
Hazard!
Protections and safety devices must be turned off and guards opened to perform
certain maintenance operations.
In this case, operating personnel are in hazardous conditions and, therefore, the
following rules must be strictly observed: Personnel assigned to perform maintenance must be authorised and specifically trained on the safety and operating
procedures to be conducted, on the hazardous situations that may occur and on
the correct methods to avoid them.
During these operations, personnel must work with the utmost care and extreme
caution.
Place specific warning signs such as: MAINTENANCE IN PROGRESS DO NOT TURN ON, WORK IN
PROGRESS DO NOT RUN or DO NOT TURN ON (see illustration) near the main switch and machine access
areas.
Hazard!
Before starting maintenance operations, place signs indicating machine maintenance status.
WRAPMASTER
8 - 5/34
8 - Maintenance
U0G00214
Touching live wires may be fatal. Always work with the utmost caution and according to applicable workmans
safety regulations.
When the machine is running, parts are in motion that could cause serious personal injury. For this reason,
maintenance and relevant checks, part dismantling and replacement on the machine or control unit must
be conducted with the system off. Therefore, main switches must be in the OFF position (OPEN) and
locked with a safety pad lock that prevents them from being switched ON. The shutter must be on.
Even if the control unit is not powered (main switch off), interconnected voltage may still be present.
In case of maintenance operations and/or access to internal parts of the machine, following a previous
disconnection of the electric and pneumatic power, motors/ gearmotors, glue applicator and relative pipings and
spray guns might accumulate residual thermal energy.
Warning!
Avoid contact with the hot metal surfaces of the guns, of the pipes, of some
components of the melting unit and of the motors/gearmotors.
If contact is unavoidable, wear gloves, protective equipment for high temperature
and face shield when working near the heated equipment.
Unprotected contact with hot metal surfaces can cause injuries.
Before performing maintenance, make sure the pneumatic system is not pressurised. Before beginning
work, maintenance personnel must make sure that the pneumatic supply is turned off and that pressurised
systems are drained. For this reason, before working on pressurised parts, reduce pressure in the system
concerned by work to room pressure.
Hazard!
Before starting maintenance or removing jammed machine parts or units, cut-off
and pad lock all energy sources and drain fluidic systems.
Keep away from drain holes and taps when releasing system pressure.
Keep away from any part that could be moved by pneumatic pressure when the system is not fully drained.
Make sure all fittings and joints are correctly tightened before pressurising systems after repairs.
Make sure units with vertical movements are lowered to idle positions or, in alternative, supported with adequate
lifting system to prevent accidental movements or falls, especially when actuators or drives require replacement.
Before performing maintenance on moving parts, make sure shutters are correctly inserted.
Hazard!
Before starting maintenance, place vertical units with moving or fall risks in safety
conditions.
Never exclude safety and protection devices installed on the machine. If this is necessary, signal this conditions
with suitable warning signs and work with the utmost caution. Restore all safety and protection devices as soon
as possible.
Failure to ground equipment may cause serious personal injury. Always make sure grounding
connections are complete and compliant with regulations.
Before starting the machine after maintenance, make sure that maintenance personnel are at safety distance
and that tools or materials were moved away from devices.
8 - 6/34
WRAPMASTER
8 - Maintenance
U0G00214
Equipment must always be installed in accordance with workmans safety regulations. All parts in motion and
transmission devices must be protected against accidental contacts. Always make sure that all protections are
installed, correctly positioned and closed before starting equipment.
Prolonged overloads or faults may cause electrical equipment to overheat generating toxic fumes. Immediately
cut-off the power supply and stay clear of equipment until these fumes are removed by adequate ventilation.
Avoid inhaling fumes that remained inside equipment during repairs.
Do not spray water to extinguish fires, especially on electrical equipment: immediately cut-off all power supplies
and use CO2 extinguishers. Warn the factor fire fighting service or the fire department.
Wear appropriate personal protection devices during maintenance (safety shoes, goggles and gloves, etc.)
according to the work to be performed. When working on suspended parts, use fall-safe devices.
Wearing clothing or personal items such as necklaces, bracelets, etc. is strictly prohibited since they can catch
in tools and equipment and react to conductors.
Hazard!
Personnel must wear all the personal safety devices required to avoid accidents.
Make sure electrical equipment is in good working order and equipped with insulated grips. Make sure that test
equipment wiring and conductor insulation is not minimally broken or damaged.
Any temporary access platforms or supporting equipment for the maintenance of parts (such as motors and
other machine parts), that can not be easily reached by the user, that are not installed on the machine, must be
provided by the user, who has to supply any equipment (ladders, shims, belts, ropes, etc.) necessary to carry
out such maintenance operations.
Tighten all screws and nuts with correct torque. Incorrect torque could cause malfunctions or hazardous
situations.
Where possible, troubleshooting must be conducted outside protected areas. If necessary when troubleshooting, perform work with the control unit and machine powered. All the precautions required by safety regulations
when working on live parts and powered drive axles must be taken.
All excluded safety devices (panels, guards, safety limit switches, interlocks, etc.) must be restored when
maintenance and troubleshooting is completed.
Maintenance, repairs and troubleshooting must be concluded by testing correct machine and safety device
operations.
Hazard!
Before restarting the machine, pay the utmost attention and make sure no one is
still working in the machine work area marked by hazard signs.
Hazard!
Before restarting the machine, re-check the entire system according to the startup procedures. After maintenance, run a few test cycles in manual mode to check
for correct movements.
WRAPMASTER
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8 - Maintenance
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Maximum machine reliability and minimum maintenance costs are the result of a planned and meticulously
performed maintenance and inspection program during the entire machine working life. Strictly observe the set
maintenance intervals.
Make sure machine parts are correctly lubricated. Insufficient or defective lubrication can cause damages and
malfunctions.
Before beginning checks and maintenance, remove dust, processing residue and dirt in general from the
machine with a vacuum and clean with appropriate liquid detergents.
Always use perfectly dry air during cleaning at pressures not superior to 0.2 MPa (2 bar). The use of a vacuum
is preferable and recommended.
When dismantling parts, mark single parts with ID plates to ensure the subsequent correct assembly. After
maintenance that requires wiring and/or fixed or mobile parts to be removed, check number/plate consistency
with the fixed or mobile part.
When using a mega ohm meter to check electrical device insulation, make sure all electronic control devices
are disconnected to avoid damaging components.
Always use tools in good working order and specifically designed for the work to be completed. The use of
unsuitable or inefficient tools may cause serious damages.
Conduct repairs in clean rooms and, where possible, free of dust. Protect all connection lights with plastic caps
and accurately cover all dismantled part work surfaces until they are assembled on the machine.
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8 - Maintenance
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If machine operations need to be stopped for a prolonged period of time, the maintenance technician must
prepare the machine according to the following procedure:
Clean the machine removing processing material residue or dirt.
Fully clean the machine, especially sliding guides, fluidic cylinder rods and sliding parts with rags and
specific products.
Spread specific oil on processed surfaces, sliding guides, fluidic cylinder rods and parts in motion.
Clean and dry the remaining painted machine parts.
Periodically run the machine for short periods of time and, before turning it on, make sure there are no traces
of rust on sliding guides and fluidic cylinder rods.
The machine must be stored indoors. In the event of prolonged storage, cover all movement parts to protect them
from dust.
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0.17
0.33
0.58
0.94
1.39
2.05
2.83
4.74
7.54
11.50
16.0
22.2
30.0
39
56
77
0.52
1.01
1.75
2.83
4.19
6.17
8.37
14.30
22.70
34.60
48.0
66.60
90
117
170
232
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1.48
2.90
5.30
5
8
12
17.40
24.40
32
41
60
83
4.40
8.70
15.40
15
24
36
52
73
97
124
180
250
WRAPMASTER
8 - Maintenance
U0G00214
CLEANING OPERATIONS indicated in paragraph 8.6 consisting of a series of advice and general instructions
to keep the area concerned by machine activities clean and orderly.
LUBRICATION PLAN indicated in paragraph 8.7 consists of a series of advice and general instructions to keep
mobile machine element efficient.
MAINTENANCE PLAN indicated in paragraph 8.8 consists of a series of preventive maintenance and
dismantling instructions sheets that list the maintenance operations to be performed on the various machine
units and systems.
Note:
For maintenance operations to be conducted on retail machine parts, see the
relevant enclosed instruction manuals.
Note:
For cleaning operations on the sheet feeder unit and on the glue application
unit, see the relevant instruction manual provided with the machine and part of this
documentation.
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8 - Maintenance
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Do not spray cleaning liquid using pressurised tanks since its volatility does not allow it to clean and can generate
vapours in the work area. Instead, use soft damp cloths for the best results and/or manual domestic type spray
bottles.
Avoid prolonged contact with cleaning liquids and avoid inhaling their vapours. Avoid use near free flames or
heat sources. Ensure adequate ventilation in the room where used.
When cleaning, in addition to the usual caution the operator must use suitable personal protection devices such
as work overalls, goggles, gloves and shoes according to the work to be performed.
The machine and system must be cleaned with care, especially unpainted guides and sliding parts. When
finished cleaning unpainted parts, spread a thin layer of rustproof oil on them.
Note:
The machine must be cleaned at regular intervals according to use and the work
environment.
Hazard!
Before cleaning the machine, cut-off and pad lock all energy sources and safely
lock its mobile units. Place machine in maintenance - do not turn on signs near
the main switch. Removing machine guards and safety devices by cleaning
personnel is strictly prohibited.
Warning!
Machine parts must be carefully cleaned of dust or other substances. We suggest
you use cleaning liquids that have good grease solvent properties that are not
harmful to rubber seal gaskets.
During these activities, personnel must be equipped with suitable protective
clothing (gloves and goggles) and use non-fray cloths.
Warning!
Only use dry and soft cloths that do not leave frays or flexible silk brushes to clean
delicate mechanisms, references and lubricating mechanisms.
Note:
Use the types of cleaning liquids and observe the restrictions set by current
regulations in the country of use.
Hazard!
The use of cleaning liquids not permitted in the country of use and compressed air
with pressure over 0.2 MPa to clean is strictly prohibited.
Avoid prolonged personnel exposure to cleaning liquid vapours ensuring good
room ventilation.
Failure to observe these precautions may cause personal injuries.
8 - 12/34
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8 - Maintenance
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It is easy to understand the extreme importance of adequate machine lubrication. The correct use of
appropriate lubricants considerably contributes to achieving the best machine performance and reducing
faults.
If the machine is question is equipped with a centralised lubrication system, no manual controls or
lubrication are required except for the points indicated in the following chapter.
When handling lubricant, observe the following preventive measures for health reasons:
only use the amount of lubricant necessary to lubricate the concerned mechanism. Dry excess oil, grease or
graphite with a non-fray cloth;
excess lubricant, like insufficient lubricant, may, at times, compromise good machine operations;
only the recommended lubricants or greases or lubricants and greases with equivalent characteristics of known
and proven quality can be used for lubrication;
avoid prolonged, excessive or repeated skin contact with lubrication products and avoid inhaling their vapours;
protect skin by wearing appropriate protective clothing and devices (for example, overalls, goggles and
protective gloves) or by applying a protection product;
in the event of skin contact, wash with soap or specific products and rinse under running water.
Hazard!
Lubricants are inflammable products. Follow the instructions on the container
labels.
When disposing used lubricants, follow the environmental protection regulations listed below:
lubricants can pollute water and the ground. Therefore, never pour lubricant products on the ground, in water
or in sewers. Failure to follow these instructions is punishable by law. When using lubricants, keep oil binders
on hand;
carefully collect used lubricants separating mineral-based products from synthetic-based ones. Observe
current used oil disposal regulations.
Lubricants used must have good emulsion stability and resistant to aging. They should not damage the material with
which oil scrapers, joints, rubber/plastic parts and machine paint are made.
Continue using the same lubricants used for the first time to fill the machine. If this is not possible, only use the
compliant products indicated in the reciprocity tables provided by the various manufacturers.
Only the use of suitable quality lubricants guarantees safe machine operations.
Warning!
Mixing lubricants of different qualities is strictly prohibited since their composition
and additives do not have the same specifications. This rule especially applies to
mixing synthetic and mineral lubricants.
If lubricants other than those indicated must be used, check whether the two
products are compatible. In the event of doubt, the lubricant used until that time
must be fully eliminated by cleaning the entire circuit.
Warning!
To avoid the risk of contamination, careful attention must be paid to cleanliness
during lubrication procedures.
Warning!
For further information on lubrication points and procedures for retail units and
parts installed on the machine, see the relevant maintenance sheets.
WRAPMASTER
8 - 13/34
8 - Maintenance
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8.7.1 Lubrication
The machine is equipped with a central lubrication system which keeps the lubricated parts in top working
order. During its cycle the pump sends the required amount of lubricant to the lubricating circuit. The
frequency at which this operation is performed is determined by the operator according to the state of the
machine.
The operator can run a non-programmed lubricating cycle by pressing button on the control panel (optional).
Regularly check the level of lubricant in tank C and, if necessary, top up by opening filler plug B.
SHELL:
"OSSAGOL V"
BP:
"ENERGREASE ZS 00"
TAMOIL:
TAMLITH
GREASE 000 EP
BECHEM:
RHUS LIC-000
C
251698
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8 - Maintenance
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Note:
Preventive and special maintenance activities can be conducted by the user
customer of bielomatik s.r.l. technicians according to the instructions listed in the
sheets.
Due to their complexity, some particular special maintenance operations were
intentionally omitted from the manual and can only be conducted by bielomatik
s.r.l. technicians who have the technical know-how, documentation and tools
required to conduct these activities.
Hazard!
The following maintenance activities are to be conducted with the machine
stopped and power sources cut-off.
Controls that need to be conducted with power on are specifically marked with a
hazard symbol and highlighted text. In this case, pay the utmost attention.
WRAPMASTER
8 - 17/34
8 - Maintenance
U0G00214
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Intervention description
Required tools
Detailed description of the
operations to be
conducted in chronological
order.
Comments
Specifically, it is essential that the sheet illustrated above is filled out for all maintenance activities and filed by the
maintenance supervisor in a specific folder.
8 - 18/34
WRAPMASTER
8 - Maintenance
U0G00214
WRAPMASTER
8 - 19/34
8 - Maintenance
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Nr.
1
OPERATION DESCRIPTION
Check chain wear and tensioning
800 h
2
3
4
5
6
7
Check
Check
Check
Check
Check
Check
0.50
1.00
1.00
0.50
10
11
12
13
14
15
16
17
1200 h
0.50
1600 h
2400 h
0.50
0.50
1.00
1.00
0.50
0.50
1.00
1.00
0.50
0.25
0.25
0.50
0.50
0.50
0.25
0.25
0.25
0.25
0.50
0.50
1.00
0.25
0.25
1.00
0.25
1.00
0.50
0.50
0.25
0.50
0.50
0.50
Note:
In the event of prolonged machine disuse, conduct the all the checks listed in the
table above before resuming production.
8 - 20/34
WRAPMASTER
8 - Maintenance
U0G00214
8.8.3 Detailed specific procedures for machine parts that require detailed information
8.8.3.1 Replacing and tensioning the side bands
B
F
G
E
251912
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8 - Maintenance
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A
A
251913
8 - 22/34
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8 - Maintenance
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251919
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8 - Maintenance
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263899
8 - 24/34
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8 - Maintenance
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D
A
263899
WRAPMASTER
B
8 - 25/34
8 - Maintenance
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Perform a horizontal and vertical precision grinding operation by using plenty of coolant.
The coolant must be directed to the point where the grinding wheel and the piece come into contact.
Bakelite-based and soft abrasive material is to be used, typically 46H6 or 46G6/8.
If a vertical grinder is available, it is preferable to use a sectional grinding wheel instead of cup grinders.
The cutting edge along with the two respective faces of the blade is to be reground. The amount of material to
be removed from the blade is 2 mm until a fairly consistent cutting edge is obtained.
In general, in order to perform the procedure in the proper way, always straighten the piece before grinding.
32 0,1
Hardening HRc 63
6 0,1
24
50
263900
8 - 26/34
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8 - Maintenance
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B
B
260024
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251399
8 - 28/34
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8 - Maintenance
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Picture 1
251876
Picture 2
251877
WRAPMASTER
C
8 - 29/34
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B
C
251699
8 - 30/34
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263985
251402
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251918
E
D
251917
8 - 32/34
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251841
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9 - Troubleshooting
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9
Troubleshooting
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9 - 1/4
9 - Troubleshooting
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Clear messages: deletes all messages stored in the memory for warning messages.
View current messages: opens the screen mask with the list of operating messages currently active on the
machine.
View messages memory: opens the screen mask with the list of messages which have occurred on the machine
and are stored in the memory.
Print messages: prints the warning messages if the machine is connected to a printer.
The fault messages that stop the machine from operating are displayed in a window that is overlaid on top of the
window displayed on the operator panel and contains the text of the fault message and three touch buttons:
A HELP: The online help for the fault message indicated in the window is displayed.
264823
264824
9 - 2/4
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9 - Troubleshooting
U0G00214
Fault
code or
description
Day
occurred
time
WRAPMASTER
Action taken
Shut down
time
Additional
notes
9 - 3/4
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Fault
code or
description
9 - 4/4
Day
occurred
time
Action taken
Shut down
time
Additional
notes
WRAPMASTER
10 - Timing diagrams
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10
Timing diagrams
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10 - Timing diagrams
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WRAPMASTER