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TABLE OF CONTENTS:

3) MAINTENANCE AND SAFETY

1
SUMMARY
SEW GEAR MOTOR INSTALLATION AND MAINTENANCE.............................................................................. 4
SEW GEAR MOTOR SCHEDULE .............................................................................................................................................. 5

POSTER DESIGNER MANUAL.................................................................................................................................... 6

MACHINE POSTERING ................................................................................................................................................ 8

POSTER POSITION...................................................................................................................................................... 10

SCHEDULES ................................................................................................................................................................... 11
AIR SYSTEM PARTS TABLE.................................................................................................................................................. 11
AIR SYSTEM MAINTENANCE TABLE .................................................................................................................................... 12
MOTOR REDUCER MAINTENANCE TABLE ............................................................................................................................ 13
CHAIN GUIDE AND CATENARY MAINTENANCE TABLE ........................................................................................................ 14
BELT MAINTENANCE TABLE ............................................................................................................................................... 15

NOTES ON THE ELECTRIC SYSTEM ..................................................................................................................... 16


ELECTRIC SYSTEM MAINTENANCE TABLE .......................................................................................................................... 17
UNIT: 26.A1 ( LIFTING MOTORIZATION ) ............................................................................................................ 18
UNIT : 26.A1.A ( LIFTING MOTORIZATION ) ....................................................................................................................... 19
UNIT : 26.A2 ( FORK LIFTING BLOCK )................................................................................................................. 20
UNIT : 26.A2.B ( PIN RETURN SPRING UNIT )...................................................................................................................... 21
UNIT : 26.A2.C ( SAFETY POST PINION ) ............................................................................................................................ 22
UNIT : 26.A3 ( LOADING AREA ) .............................................................................................................................. 23

UNIT : 26.A4 ( SLIDING TABLE ) .............................................................................................................................. 24


UNIT : 26.A4 ( SLIDING TABLE CAM UNIT ) ........................................................................................................................ 26
UNIT: 26.A5 ( SIDE BOARDS ).................................................................................................................................... 27

UNIT : 26.A6 ( REAR SIDE BOARD )......................................................................................................................... 28

UNIT : 26.A7 ( BELT UPPER PUSHER ) ................................................................................................................... 29


UNIT : 26.A7 ( TABLE ) ...................................................................................................................................................... 30
UNIT : 26.A7.D ( ROD SLEEVE ) ......................................................................................................................................... 31
UNIT : 26.A7.F ( CAM GROUP ) .......................................................................................................................................... 32
UNIT : 26.A8 ( PUSHER AREA BELT ) ...................................................................................................................... 33
UNIT : 26.A8.A ( PUSHER BELT MOTORIZATION )............................................................................................................... 34
UNIT : 26.A9 ( GRIPPER UPPER ROTATION )....................................................................................................... 35

UNIT : 08.B1 ( ROTATION CONVEYOR)................................................................................................................. 36

UNIT : 10.00 ( BAG FLATTENER ) ............................................................................................................................ 37

UNIT : 13.A2 ( BEND WITH ADDITIONAL CONVEYOR ) ................................................................................... 39

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UNIT : 08.A19 ( BELT CONVEYOR )......................................................................................................................... 40

UNIT : 08.A17 ( BELT CONVEYOR )......................................................................................................................... 41

UNIT : 33.00 ( ARM PALLET FEEDER )................................................................................................................... 42

UNIT : 42.A4 ( MOTORIZED ROLLER CONVEYOR ) .......................................................................................... 44

UNIT : 42.A3 ( MOTORIZED ROLLER CONVEYOR ) .......................................................................................... 45

P.I. DIAGRAM ............................................................................................................................................................... 46

EMERGENCY SWITCH .............................................................................................................................................. 47

3
SEW GEAR MOTOR INSTALLATION AND MAINTENANCE

4
SEW GEAR MOTOR SCHEDULE

1) Brake and shield


2) Sealing collar
3) Brake spring
4) Hand lever
5) Releasing screw
6) Closing piece
7) Releasing lever
9) Sealing ring/Cover piece
10) V ring
11) Conical coil spring
12) Setting nut
13) Stud
14) Fan guard
15) Grommet
16) Spiral down pin
17) Fan
18) Brake coil
19) Hexagon nut
20) Retaining screw
21) Brake coil body
22) Pressure plate
23) Pressure ring
24) Setting sleeve
25) Brake stationary disc
26) Brake disc complete
27) Carrier
28) Space bush
29) Cup spring/Equalizing ring

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POSTER DESIGNER MANUAL

This poster shows likely hazards from misuse of the machine.

WARNING

TO WORK IN SAFETY !!!


1) STOP MOTORS
2) BLOCK COUNTERWEIGHTS BEFORE
OPERATING ON CHAINS AND BRAKES OF
LIFTING MOTORS.

This second poster shows the guards on the machine, thus indicating likely hazard if they are
removed.

WARNING

Guards with
protect sliding platform bay.
These guards must never be removed.

This third poster shows the type of check to carry out.

WARNING

Check for tensioning


rollers tightness.

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Always keep to following safety warnings when using the machine:

ENSURE THAT MACHINE IS CONNECTED TO AN EFFICIENT GROUNDING CIRCUIT.

DO NOT CHANGE FOR WHATEVER REASON ANY MACHINE PARTS TO ADAPT FURTHER
EQUIPMENT TO IT. SHOULD THIS CONDITION BE UNOBSERVED, CHRONOS WILL
NOT ANSWER FOR RESULTING MALFUNCTION OR TROUBLE. ENQUIRE FOR
CHANGE, IF ANY, AT OUR TECHNICAL DEPARTMENT.

ENSURE THAT ALL ELECTRIC MOTORS ARE CONNECTED BY SUITABLE CABLE TO A


PROPER GROUNDING SYSTEM PROVIDED WITH EFFICIENT EARTH PLATES.
GROUNDING LINE MUST BE CHECKED WITH PROPER INSTRUMENTS BY A SKILLED
INSTALLER.

EACH INTERVENTION ON SYSTEM OR ELECTRICAL EQUIPMENT MUST BE CARRIED


OUT SOLELY BY A SKILLED ELECTRICAL MAINTENANCE OPERATOR.

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MACHINE POSTERING

DO NOT USE WATER TO PUT OFF FIRE

DO NOT OPEN, DO NOT INTRODUCE YOUR HANDS

DO NOT REMOVE GUARDS AND SAFETY EQUIPMENT

DO NOT REPAIR, SET, LUBRICATE OR CLEAN WHEN MOVING

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DO NOT OPERATE THE MACHINE IN AUTOMATIC MODE WITH FIXED OR MOVING GUARDS
REMOVED

DO NOT INHIBIT SAFETY EQUIPMENT ON MACHINE

ADJUSTMENT OPERATIONS, WITH SAFETY EQUIPMENT REDUCED, MUST BE CARRIED OUT


BY ONE PERSON ONLY, WHILST ACCESS BY ALL UNAUTHORIZED PERSONS TO MACHINE
MUST BE FORBIDDEN.

EACH MAINTENANCE, CLEANING, LUBRICATION OPERATION MUST BE CARRIED OUT


SOLELY WITH MACHINE AND ELECTRICAL EQUIPMENT DISCONNECTED FROM MAINS.

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SCHEDULES

AIR SYSTEM PARTS TABLE

UNIT CYLINDER CODE SOLENOID MAKE QTY SPARE


VALVE CODE PARTS KIT
SAFETY STOP POST 26360000000 FESTO 1
SAFETY STOP POST DNU-63-160-PPV-A FESTO 1
UPPER ROTATION 26362000000 FESTO 1
UPPER ROTATION DNU-50-100-PPV-A FESTO 2
BAG FLATTNER 26362000000 FESTO 1
BAG FLATTNER DNU-63-100-PPV-A FESTO 2
ARM PALLET FEEDER 26362000000 FESTO 1
ARM PALLET FEEDER DNU-32-50-PPV-A FESTO 2
F.R.L FRL1000 METAL 1
WORK

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AIR SYSTEM MAINTENANCE TABLE

COMPONENT OPERATION PERIODICITY


Filter Condensate removal 100 BAGS x 1000
Overhaul (2) 2.500 BAGS x 1000
Pressure reducer Preset value check 100 BAGS x 1000
Overhaul (2) 2.000 BAGS x 1000
Greaser Oil level check 90 BAGS x 1000
Overhaul (2) 2.000 BAGS x 1000
Valves Overhaul (2) 2.000 BAGS x 1000
Cylinders Overhaul (2) 2.000 BAGS x 1000
Circuit Leakage (1) and proper 1.000 BAGS x 1000
functioning check

(1) This operation concerns joint and piping tightness check, visual inspection of
components, proper set up of operation. All defect found must be eliminated.

(2) This operation concerns disassembly and cleaning of each component; replacing
worn out parts, if the need be. Re-mount component lubricating the gaskets
with silicon grease; check for proper operation1of same.

1Note: A set of spares for parts that more easily wear, such as valve and cylinder gaskets, is recommended.
(Refer to technical Enclosures for more information).

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MOTOR REDUCER MAINTENANCE TABLE

COMPONENT OPERATION PERIODICITY


Pallet lifting Brake check (1) 4500 hours
Lubrication (2)
Loading area Brake check (1) 4500 hours
Lubrication (2)
Sliding table Brake check (1) 4500 hours
Lubrication (2)
Side board Brake check (1) 4500 hours
Lubrication (2)
Rear side board Brake check (1) 4500 hours
Lubrication (2)
Layer pusher motorization Brake check (1) 4500 hours
Lubrication (2)
Rod lifting motorization Brake check (1) 4500 hours
Lubrication (2)
Pusher area belt Brake check (1) 4500 hours
Lubrication (2)
Gripper upper rotation Brake check (1) 4500 hours
Lubrication (2)
Rotation conveyor Brake check (1) 4500 hours
Lubrication (2)
Bag flattener Brake check (1) 4500 hours
Lubrication (2)
Bend with additional conveyor Lubrication (2) 4500 hours
Belt conveyor L=4500 Lubrication (2) 4500 hours
Belt conveyor L=4000 Lubrication (2) 4500 hours
Lifting Arm pallet feeder Brake check (1) 4500 hours
Lubrication (2)
Motorized roller conveyor L=2750 Brake check (1) 4500 hours
Lubrication (2)
Motorized roller conveyor L=2500 Lubrication (2) 4500 hours

MOTOR REDUCER MAINTENANCE TABLE

(1)This operation concerns brake guard disassembly, brake lining dust


removal, air gap check.

(2) This operation concerns visual check for lubricant leakage, oil level
check and oil refill or replacement, if needed 2.

2 Note: A set of spares for parts that more easily wear, such as brake disks and brake coils, is recommended.
(Refer to technical Enclosures for more information).

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CHAIN GUIDE AND CATENARY MAINTENANCE TABLE

COMPONENT OPERATION PERIODICITY


Pallet lifting chains Lubrication (1) 500.000 BAGS
Chain tightness and state check (2) 200.000 BAGS
Chain replacement 7.500.000 BAGS
Loading area chain system Lubrication (1) 500.000 BAGS
Chain tightness and state check (2) 200.000 BAGS
Chain replacement 7.500.000 BAGS
Bend with additional Lubrication (1) 500.000 BAGS
conveyor catenary Chain tightness and state check (2) 200.000 BAGS
Chain guide/chain replacement 7.500.000 BAGS
Pallet feeder lifting catenary Lubrication (1) 500.000 BAGS
Chain tightness and state check (2) 7.500.000 BAGS
Chain link roller conveyor Lubrication (1) 500.000 BAGS
catenary L=2750 Chain tightness and state check (2) 200.000 BAGS
Chain guide/chain replacement 7.500.000 BAGS
Chain link roller conveyor Lubrication (1) 500.000 BAGS
catenary L=2500 Chain tightness and state check (2) 200.000 BAGS
Chain guide/chain replacement 7.500.000 BAGS

(1) This operation consists in lubricating the chain system with a product
suiting the environment in which the palletizer works (see Schedules)

(2) This operation consists in weekly checking the clearance, if any,


between the chain system and the relevant chain guide to see it does not
exceed that specified (see notes on specific units description) and check
of proper tightness of the same

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BELT MAINTENANCE TABLE

COMPONENT OPERATION PERIODICITY


Sliding table Tightness check Monthly
Replacement 4.500.000 BAGS
Sliding table cams Tightness check Monthly
Replacement 4.500.000 BAGS
Upper pusher Tightness check Monthly
Replacement 8.000.000 BAGS
Upper pusher cams Tightness check Monthly
Replacement 9.500.000 BAGS
Pusher area belt Tightness check Monthly
Replacement 9.500.000 BAGS
Upper rotation Tightness check Monthly
Replacement 3.000.000 BAGS
Pusher area belt Tightness check weekly
Replacement 9.000.000 BAGS
Rotation conveyor Tightness check weekly
Replacement 9.000.000 BAGS
Bag flattener (upper and lower Tightness check weekly
belt) Replacement 8.000.000 BAGS
Belt conveyor L=4500 Tightness check weekly
Replacement 8.000.000 BAGS
Belt conveyor L=4000 Tightness check Weekly
Replacement 8.000.000 BAGS

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NOTES ON THE ELECTRIC SYSTEM

In executing the electric system, all efforts have been made to simplify the circuits
so easing the maintenance and check work.

Coding and identification of components

All components, both in-field and in the cabinet, have been identified by a code
marked on the wiring diagram. This coding corresponds to the component
location in the diagram and the corresponding coordinates (page - column).
To further ease component state check (i.e., whether a PLCs input is powered or
not), the component has been identified with the initial of its PLCs input.

Control and supply voltage

Supply voltage to Control Panel must be 380 V 3-phase with a 10% maximum
variation. A 5% adjustment may be made on power units input of auxiliary
circuits.
Control voltages are as follows.
24 VDC for limit switches, push-buttons, sensors, photocells and pilot lamps
110 VAC for contactors and solenoid valves
220 VAC for PLCs supply

Cabinet inner lighting and service plugs must be powered separately via a 220
Volt single-phase line.

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ELECTRIC SYSTEM MAINTENANCE TABLE

COMPONENT OPERATION PERIODICITY


Photocells Cleaning (1) Beginning of weekly
Alignment check shift
Sensors - Limit switches State check (2) monthly
Push-button panels State check (2) monthly
Electrical cables State check (3) monthly
PLC battery Replacement yearly
Contactors State check (4) monthly
Replacement 9.000 BAGS x 1000
Relays State check (4) monthly
Replacement 9.000 BAGS x 1000
Terminals Tightness check yearly
Cabinet General cleaning, dust removal yearly

(1) This operation consists of dust removal from lens and reflectors. Do not use
abrasive cloth

(2) The operation consists of checking the mechanical tightness of sensors and
limit switches and checking the intervention gap from the corresponding cams

(3) The operation consists of checking the electric cables to see they are not being
damaged from shock against mechanical parts

(4) The operation consists of checking the contactors contacts and relays good
conditions.3

3 Note: Refer to technical enclosures for more information.

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UNIT: 26.A1 ( LIFTING MOTORIZATION )

POS UNIT FUNCTION MAINTENANCE AND CHECKS

26.A1.A LIFTING MOTORIZATION controls pallet vertical Chain tightness and


movement lubrication check
Keep motor fan clean
Motor brake check
26.A1.B LIFTING ENCODER

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UNIT : 26.A1.A ( LIFTING MOTORIZATION )

WARNING
after chain tensioning, check
parallelism of motor with shaft

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UNIT : 26.A2 ( FORK LIFTING BLOCK )

POS UNIT FUNCTION MAINTENANCE


CHECKS
26.A2.A FORK LOCK PIN comb-type pin support bush sliding check
COUPLING
26.A2.B PIN RETURN SPRING UNIT safety activation spring tightness check

26.A2.C FORK LOCK PINION DRIVE fork safety release Cylinder seals check
CYLINDER

20
UNIT : 26.A2.B ( PIN RETURN SPRING UNIT )

SENSORS FUNCTION

Pos. 01
Ref. electrical pattern E 14.1
INDICATES FORK LOCK POSITION

21
UNIT : 26.A2.C ( SAFETY POST PINION )

LIMIT SWITCH FUNCTION

Pos. 01
Ref. electrical pattern E 8.2
EMERGENCY PALLET LIFT DEV. DOWN

Pos. 02
Ref. electrical pattern E 8.1
EMERGENCY PALLET LIFT DEV. UP

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UNIT : 26.A3 ( LOADING AREA )

PHOTOCELL FUNCTION
WARNING

Pos. 01
Ref. electrical pattern E 12.6 Guards with protect
PHOTOCELL PALLET LIFTING chains.
EMERGENCY These guards must not be
removed.
Pos. 02
Ref. electrical pattern E 12.4
PHOTOCELL LOADING AREA PALLET
POSITION

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UNIT : 26.A4 ( SLIDING TABLE )

SENSORS FUNCTION

Pos. 01
Ref. electrical pattern E 12.3
INDICATES THE LAYER LEVEL

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UNIT : 26.A4 ( SLIDING TABLE )

POS UNIT FUCTION MAINTENANCE AND CHECKS

26.A4.A SLIDING TABLE Sliding table


MOTORIZATION opening/closing
26.A4.B SLIDING TABLE CAM UNIT Sliding table movement
control
26.A4.C SLIDING TABLE COUPLING

26.A4.D TENSIONING UNIT

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UNIT : 26.A4 ( SLIDING TABLE CAM UNIT )

SENSORS FUNCTION
Pos. 01
Ref. electrical pattern E 8.4
SLIDING TABLE OPEN
INDICATES OPENING OF SLIDING TABLE.

Pos. 02
Ref. electrical pattern E 8.3
SLIDING TABLE CLOSED
Indicates closing of sliding table.

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UNIT: 26.A5 ( SIDE BOARDS )

SENSORS FUNCTION WARNING


Pos. 01
Ref. electrical pattern E 8.6-8.5
Guards with
LEFT AND RIGHT SIDE BOARDS OPENING
protect chains.
Stops side boards opening phase.
These guards must never be
removed.

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UNIT : 26.A6 ( REAR SIDE BOARD )

SENSORS FUNCTION
Pos. 01
WARNING
Ref. electrical pattern. E 8.7
REAR SIDE BOARD OPENING
Stops rear side board opening phase. Guards with
protect chains.
These guards must never be
removed.

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UNIT : 26.A7 ( BELT UPPER PUSHER )

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UNIT : 26.A7 ( TABLE )

POS UNIT FUNCTION MAINTENANCE


CHECK
26.A7.A LAYER PUSHER Layer inserting into Motor brake check
MOTORIZATION sliding table Motor reducer oil check
26.A7.B BELT LAYER PUSHER Chain tightness check
TRANSMISSION
26.A7.C LAYER PUSHER GUIDE Guides pusher sliding

26.A7.D ROD SLEEVE Rod sliding guide Dust seal check

26.A7.E ROD LIFTING Pusher vane Motor brake check


MOTORIZATION ascent/descent Motor reducer oil check
26.A7.F CAM GROUP Belt upper pusher Sensor fixing check
movement control

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UNIT : 26.A7.D ( ROD SLEEVE )

SENSORS FUNCTION
Pos. 01
Ref. electrical pattern. E 9.5
PUSHER DOWN.

Pos. 02
Ref. electrical pattern. E 9.4
PUSHER UP.

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UNIT : 26.A7.F ( CAM GROUP )

SENSOR FUNCTION SENSOR FUNCTION

Pos. 01 Pos. 04
Ref. electrical diagram. E 10.0 Ref. electrical diagram. E 10.3
Pusher forward. Pusher backward.

Pos. 02 Pos. 05
Ref. electrical diagram. E 10.1 Ref. electrical diagram GE 10.4
Pusher low speed forward Ok to infeed bags.

Pos. 03
Ref. electrical diagram. E 10.2
Pusher low speed backward

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UNIT : 26.A8 ( PUSHER AREA BELT )

POS UNIT FUNCTION MAINTENANCE AND CHECKS

26.A8.A PUSHER BELT Motor lubrication check


MOTORIZATION
26.A8.B BELT PRESSING GUIDE Belt tightness check
PULLEY
26.A8.C CHAIN STRETCHER
PULLEY

PHOTOCELLS FUNCTION

Pos. 01
Ref. Electric diagram. E 12.2
SAFETY PHOTOCELL
Blocks pusher if a bag is found at
beginning of conveyor.

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UNIT : 26.A8.A ( PUSHER BELT MOTORIZATION )

WARNING

Guards with protect belts.


These guards must not be
removed.

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UNIT : 26.A9 ( GRIPPER UPPER ROTATION )

SENSORS FUNCTION
Pos. 01
Ref. electrical pattern. E 9.3
ROTATION STEP

Pos. 02
Ref. electrical pattern. E 9.2
ROTATION PHASE

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UNIT : 08.B1 ( ROTATION CONVEYOR)

PHOTOCELLS FUNCTION

Pos. 01
WARNING
Ref. electric diagram E 12.1
First pusher safety.
Guards with protect belts.
Pos. 02 These guards must not be
Ref. Electric diagram E 11.7 removed.
Photocell light conveyor bag turner area

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UNIT : 10.00 ( BAG FLATTENER )

POS UNIT FUNCTION MAINTENANCE


CHECKS
10.00.A PRESS ADJUSTMENT INCREASE/REDUCE BAG GAP

10.00.B BELT MOTORIZATION BELT MOTORIZATION Motorization check


Belt center. check
10.00.C PRESSING FORCE DRIVE INCREASE/REDUCE BAG Air seal check
CYLINDERS PRESSURE

FUNCTION OF PHOTOCELL

Pos. 01
Ref. Electric diagram E 11.5
PHOTOCELL BAG FLATTENER

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UNIT : 10.00 ( BAG FLATTNER )

WARNING

Guards with protect belts.


These guards must not be removed.

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UNIT : 13.A2 ( BEND WITH ADDITIONAL CONVEYOR )

WARNING

The guard with protect the


chain.
The guard must not be removed.

39
UNIT : 08.A19 ( BELT CONVEYOR )

WARNING

Guards with protect


belt.
These guards must never be
removed.

40
UNIT : 08.A17 ( BELT CONVEYOR )

PHOTOCELL FUNCTION
WARNING

Pos. 01
Ref. El. diagram E 15.4 Guards with protect
MAX ACCUMULATION PHOTOCELL belt.
Signals the maximum pile-up of bags onto the These guards must never be
conveyor removed.

41
UNIT : 33.00 ( ARM PALLET FEEDER )

POS UNIT FUNCTION MAINTENANCE


CONTROL
33.00.A LIFTING MOTORIZATION Control lubrication gear
motor
33.00.B CYLINDER RELEASE
PALLET

42
UNIT : 30.00 ( ARM PALLET FEEDER )

FUNCTIONING OF SENSORS AND


PHOTOCELL

Pos. 01
Ref. electrical pattern. E 13.4
PALLET FEEDER UP
Stops the lifting frame from going up

Pos. 02
Ref. electrical pattern. E 13.5
1/2 RUN FEEDER
Stops downward movement.

Pos. 03
Ref. electric diagram E 13.6
PALLET FEEDER DOWN
Stops downward movement.

Pos. 04
Ref. Electric diagram E 13.7
LEVEL PALLET

Pos. 05
Ref. electric diagram E 15.6
RIGHT ARM CLOSE

Pos. 06
Ref. Electric diagram E 15.5
LEFT ARM CLOSE

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UNIT : 42.A4 ( MOTORIZED ROLLER CONVEYOR )

PHOTOCELLS FUNCTION
WARNING
Pos. 01
Ref electric diagram E 12.5 Guards with protect
FIRST OUTFEED ROLLER CONVEYOR rollers.
These guards must not be
Pos. 02 removed.
Ref electric diagram LC661-LC662
LIGHT CURTAIN

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UNIT : 42.A3 ( MOTORIZED ROLLER CONVEYOR )

PHOTOCELLS FUNCTION
WARNING
Pos. 01
Ref electric diagram E 12.7 Guards with protect
CHECKS PRESENCE OF PALLET ON rollers.
CONVEYOR. These guards must not be
removed.

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