Robopac Masterplat PLUS FRD Series Use And Maintenance Manual
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Robopac Masterplat PLUS FRD Series Use And Maintenance Manual

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MASTERPLAT PLUS FRD-PGS
MASTERPLAT PLUS LP FRD-PGS
MASTERPLAT PLUS TP FRD-PGS
ENG

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Summary of Contents for Robopac Masterplat PLUS FRD Series

  • Page 1 MASTERPLAT PLUS FRD-PGS MASTERPLAT PLUS LP FRD-PGS MASTERPLAT PLUS TP FRD-PGS...
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  • Page 3: Table Of Contents

    Index 1. GENERAL INFORMATION ..........................6 1.1. PURPOSE OF THE MANUAL ..........................6 1.2. MANUFACTURER AND MACHINE IDENTIFICATION ..................7 1.3. TERMS AND DEFINITIONS ..........................8 1.3.1. PICTOGRAMS INDICATING DANGER ....................... 9 1.3.2. PICTOGRAMS INDICATING PROHIBITION ..................... 10 1.3.3. PICTOGRAMS INDICATING OBLIGATION ....................11 1.4.
  • Page 4 4.4. HANDLING AND LIFTING ..........................54 4.5. INSTALLATION OF THE MACHINE ........................55 4.5.1. ELECTRIC BOX ASSEMBLY ........................56 4.5.2. SLIDE SHAFT ASSEMBLY ........................57 4.5.3. SLIDE SHAFT ASSEMBLY ........................58 4.5.4. LOADING/UNLOADING RAMP ASSEMBLY ..................... 59 4.5.4.1. LOADING DIRECTION MODIFICATION ..................60 4.5.5.
  • Page 5 7.6. AIR FILTER CLEANING ..........................111 7.7. MACHINE CLEANING ............................. 112 8. FAULT INFORMATION ........................... 113 8.1. ALARM MESSAGES ............................113 9. REPLACEMENT INFORMATION ........................114 9.1. RECOMMENDATIONS FOR REPLACING MACHINE PARTS ..............114 9.2. REPLACING THE ROTARY TABLE WHEELS ....................115 9.3.

  • Page 6: General Information

    1. GENERAL INFORMATION 1.1. PURPOSE OF THE MANUAL The manual is an integral part of the machine and is aimed at providing the operator with the “Instructions for use” in order to prevent and minimise the risks that arise from human-machine interaction. The information has been written by the Manufacturer in Italian (the original language) in full compliance with the professional writing principles and the regulations in force.

  • Page 7: Manufacturer And Machine Identification

    1.2. MANUFACTURER AND MACHINE IDENTIFICATION The illustrated identification plate is applied directly to the machine. It contains references and indispensable operating safety indications. 1) Machine model. 2) Machine serial number. 3) Year of manufacture. 4) Power supply voltage. 5) Power supply frequency. 6) Power supply phases.

  • Page 8: Terms And Definitions

    1.3. TERMS AND DEFINITIONS Some recurring terms found within the manual are described in order to complete their meaning. Maintenance: The set of operations required to maintain the machine efficient and in good working order. Normally some operations are scheduled by the manufacturer, who defines the necessary skills and methods of intervention.

  • Page 9: Pictograms Indicating Danger

    1.3.1. PICTOGRAMS INDICATING DANGER The following table summarises the safety-related pictograms which indicate DANGER. ATTENTION - GENERIC DANGER This draws the attention of the personnel concerned to the risk of physical injuries caused by the operation described if it is not carried out in compliance with safety regulations. ATTENTION - DANGER DUE TO CONTACT WITH LIVE PARTS This indicates to the personnel concerned that the described operation poses, if not carried out in compliance with safety regulations, a risk of electric shock.

  • Page 10: Pictograms Indicating Prohibition

    1.3.2. PICTOGRAMS INDICATING PROHIBITION The following table summarises the safety-related pictograms indicating PROHIBITION. GENERIC PROHIBITION NO SMOKING Smoking is not allowed in the area where this sign is located. NO NAKED FLAMES This symbol prohibits the use of naked flames near the machine or parts of it to prevent a fire hazard. NO PEDESTRIANS Pedestrians are not allowed to pass through the area where this signal is located.

  • Page 11: Pictograms Indicating Obligation

    1.3.3. PICTOGRAMS INDICATING OBLIGATION The following table summarises the safety-related pictograms indicating OBLIGATION. GENERIC OBLIGATION The presence of the symbol next to the description indicates the obligation to carry out the operation/manoeuvre as described and in compliance with current safety regulations, in order to avoid risks and/or injuries.

  • Page 12: How To Request Assistance

    1.4. HOW TO REQUEST ASSISTANCE Robopac distribution network is at your disposal for any problem regarding technical assistance, spare parts and any new requirement you might need for your business. For every technical service request regarding the machine, please indicate the data found on the identification plate, the approximate hours of use and the type of fault detected.

  • Page 13: Safety Information

    2. SAFETY INFORMATION 2.1. GENERAL SAFETY WARNINGS Caution - warning Carefully read the “Instructions for use” specified in the manual and those applied directly to the machine. It is important to dedicate a little time to read the “Instructions for use” in order to minimise the risks and avoid unpleasant accidents.

  • Page 14: Safety Warnings For Handling And Installation

    2.2. SAFETY WARNINGS FOR HANDLING AND INSTALLATION Danger - warning The personnel authorised to handle the machine (load and unload) must possess the necessary technical and professional knowledge and skills. Handle (load and unload) the machine according to the instructions affixed directly to the machine, to the package and in the user manual.

  • Page 15: Safety Warnings For Use And Operation

    2.3. SAFETY WARNINGS FOR USE AND OPERATION Danger - warning The operator must be trained and possess the adequate skills required to carry out the specific tasks and must be fit to use the machine safely. When using the machine for the first time, the operator must read the manual and identify the control functions and simulate some operations, especially machine start and stop.

  • Page 16: Safety Warnings Related To Misuse

    2.4. SAFETY WARNINGS RELATED TO MISUSE 2.4.1. REASONABLY FORESEEABLE MISUSE The reasonably foreseeable misuse is: “the use of the machine in a way other than that indicated in the manual, that may stem from the easily predictable human behaviour”. The machine must be used only for wrapping and stabilising products with regular shape or with a shape that ensures a stable wrapping.

  • Page 17: Safety Warnings On Residual Risks

    2.5. SAFETY WARNINGS ON RESIDUAL RISKS Danger - warning During design and manufacturing, the Manufacturer has paid particular attention to the residual risks that may affect the safety and health of the operators. The residual risks are: “all the risks that persists although all safety solutions have been applied and integrated during machine design”.
  • Page 18 Risk of body crushing: Do not stand in the machine operating area. Risk of crushing upper limbs: Do not insert your hands inside moving parts. SAFETY INFORMATION...
  • Page 19 Risk of impact and slipping: Do not approach or climb on machine parts (e.g.: rotary table) with the lifting device during machine operation. Risk of falling or ejected objects: Do not use the machine at a speed which is not suitable for the type of product to be wrapped.

  • Page 20: Safety Warnings For Adjustments And Maintenance

    2.6. SAFETY WARNINGS FOR ADJUSTMENTS AND MAINTENANCE Keep the machine in maximum efficiency conditions and perform all the scheduled maintenance operations provided for by the Manufacturer. Proper maintenance will provide the best performance, a longer life span and constant compliance with safety requirements.

  • Page 21: Information And Safety Signs

    2.8. INFORMATION AND SAFETY SIGNS The figure indicates the position of the safety and information signs affixed to the machine. For each sign the relative description is specified. 1. Electrical hazard sign Do not access the area to avoid risks of electric shock or electrocution. 2.
  • Page 22 Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP SAFETY INFORMATION...

  • Page 23: Perimeter Areas

    2.9. PERIMETER AREAS The illustration shows the perimeter working areas of the machine. 1. Operator standing area. 2. Pallet loading/unloading area. 3. Perimeter area. Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP SAFETY INFORMATION...

  • Page 24: Technical Information

    3. TECHNICAL INFORMATION 3.1. MACHINE GENERAL DESCRIPTION The machine is a semi-automatic machine for palletised load wrapping and stabilising with stretch film. The machine must be used only for wrapping and stabilising products contained in packages (in boxes, liquid containers, etc.) with regular shape or with a shape that ensures a stable palletisation. Packages containing liquids or insubstantial materials must have characteristics suitable to the product and be perfectly closed and sealed to prevent the contents from flowing out.
  • Page 25 The illustration shows, for information purposes only, the machine models, and the legend lists the parts. Legend: 1. Slide shaft 2. Table motor 3. Rotary table 4. Carriage motor 5. Control panel 6. Spool carriage 7. Base 8. Loading/unloading ramp Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP...

  • Page 26: Machine Models Description

    3.1.1. MACHINE MODELS DESCRIPTION Type of machine General features Masterplat PLUS FRD Masterplat with spool carriage of “FRD” type or “FRD” type for mesh. Masterplat PLUS TP3 Masterplat PLUS Masterplat PLUS PGS Masterplat with spool carriage of “PGS” type. Masterplat PLUS TP3 Masterplat PLUS...

  • Page 27: Description Of The Operation Cycle

    3.2. DESCRIPTION OF THE OPERATION CYCLE Phase 1 The pallet is loaded on the rotary table against the bracket on the plate and the operator ties the film ends in the striker bracket slot. Caution - warning Risk of crushing upper limbs. Do not insert the film in the gripper by hand.

  • Page 28: Safety Device Description

    3.3. SAFETY DEVICE DESCRIPTION The figure shows the position of the devices on the machine. 1. Spool carriage base microswitch: it stops the downstroke if there are obstacles under the carriage. 2. Spool carriage mechanical locking device: it immediately stops the fall of the spool carriage in case of accidental breakage of the lifting chain. 3.
  • Page 29 6. Emergency button: when pressed, it immediately stops the machine in emergency conditions. To reset, rotate the button in the direction indicated by the arrow. Danger - warning When the emergency button is pressed, the terminals of the motors may still be powered. 7.

  • Page 30: Description Of Electrical Devices

    3.4. DESCRIPTION OF ELECTRICAL DEVICES The figure shows the position of the devices on the machine. 1. Gearmotor: it activates the table rotation. 2. Gearmotor: it activates the spool carriage movement. 3. Carriage limit microswitch: it is activated when the spool carriage reaches the minimum and maximum wrapping height. 4.
  • Page 31 Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP TECHNICAL INFORMATION...

  • Page 32: Remote Control Software

    3.4.1. REMOTE CONTROL SOFTWARE The Machine features a remote control Software (1). Through a sensor on the roller (2), the system controls film use, end of the spool and general info. Important For further details see the wiring diagram. TECHNICAL INFORMATION...

  • Page 33: Description Of Pneumatic Devices

    3.5. DESCRIPTION OF PNEUMATIC DEVICES The figure shows the position of the devices on the machine. 1. Pressure regulator with filter and pressure gauge To adjust the general pressure of the pneumatic system. Turn the knob to change the pressure values indicated on the pressure gauge. Important For further details see the pneumatic diagram.

  • Page 34: Description Of Accessories On Request

    3.6. DESCRIPTION OF ACCESSORIES ON REQUEST To increase the machine performance and versatility, the Manufacturer makes available the following accessories. 1. Pneumatic presser: pneumatically controlled device for load stabilisation. It is supplied with pneumatic cylinder with rod (Max. stroke 800 mm). The height must be adjusted according to the size of the product to be wrapped.
  • Page 35 3. Pallet loading/unloading ramps: one ramp (3) is supplied as a standard and can be placed in 5 positions (every 45°). It is possible to purchase a second and a third optional ramp or a 270° ramp (3A) (3 pieces) which covers all the positions.
  • Page 36 5. Film reinforcement tool: it is used to create a film reinforcement on the base of the product or on the pallet. 6. Spool shaft D = 50 and D = 76 for coreless spools . Masterplat PLUS Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS TP3 Masterplat PLUS LP...
  • Page 37 7. Roll-container stop device: this system is suitable for Roll-container (1) wrapping. In this case, infeed ramp (2) position is bound to stop device position (3), in fact the recommended ramp type is the one indicated in the figure (270°). Important If the Roll-container stop device (3) is used, set the film stretch (4) to low intensity to avoid load overturning.

  • Page 38: Masterplat Plus" Technical Data

    3.7. "MASTERPLAT PLUS” TECHNICAL DATA The illustration and the table include the machine dimensional specifications and technical data. TECHNICAL INFORMATION...

  • Page 39: Masterplat Plus Frd" Machine And Pallet Dimensions

    3.7.1. "MASTERPLAT PLUS FRD" MACHINE AND PALLET DIMENSIONS Description Masterplat PLUS FRD Standard Optional Optional Optional Shaft height 2200 2400 2800 3100 2530 2730 3130 3430 2560 2760 3160 3460 2200 2400 2800 3100 77.5 77.5 77.5 77.5 Load overall ...

  • Page 40: Masterplat Plus Pgs Usa" Machine And Pallet Dimensions

    3.7.3. "MASTERPLAT PLUS PGS USA" MACHINE AND PALLET DIMENSIONS Description Masterplat PLUS PGS Standard Optional Optional Optional Shaft height 2200 2400 2800 2865 3065 3465 2560 2760 3160 2200 2400 2800 77.5 77.5 77.5 Load overall  1650 dimensions 1650 2760.5 1745 1000...

  • Page 41: Masterplat Plus Frd" And "Pgs" Spool Characteristics

    3.7.6. “MASTERPLAT PLUS FRD” AND "PGS” SPOOL CHARACTERISTICS Masterplat PLUS FRD / PGS Masterplat PLUS FRD Unit of Description Value measurement Film spool dimensions (1) Maximum outer diameter (D) Spool height (H) Film thickness μm 17÷35 Internal diameter (d) Max. weight Mesh spool dimensions (2) Maximum outer diameter (D) Spool height (H)

  • Page 42: Masterplat Plus Lp Frd" And "Pgs" Technical Data

    3.8. “MASTERPLAT PLUS LP FRD” AND “PGS” TECHNICAL DATA The illustration and the table include the machine dimensional specifications and technical data. TECHNICAL INFORMATION...

  • Page 43: Masterplat Plus Lp Frd" Machine And Pallet Dimensions

    3.8.1. "MASTERPLAT PLUS LP FRD" MACHINE AND PALLET DIMENSIONS Description Masterplat PLUS LP FRD Standard Optional Optional Optional Shaft height 2200 2400 2800 3100 H max 2502 2702 3102 3402 2532 2732 3132 3432 2200 2400 2800 3100 Load overall ...

  • Page 44: Masterplat Plus Lp Pgs Usa" Machine And Pallet Dimensions

    3.8.3. "MASTERPLAT PLUS LP PGS USA" MACHINE AND PALLET DIMENSIONS Description Masterplat PLUS LP PGS Standard Optional Optional Optional Shaft height 2200 2400 2800 2837 3037 3437 2532 2732 3132 2200 2400 2800 Load overall  1650 dimensions 1650 2801.50 1797 1000 1200...

  • Page 45: Masterplat Plus Lp Frd" And "Pgs" Spool Characteristics

    3.8.6. “MASTERPLAT PLUS LP FRD” AND "PGS” SPOOL CHARACTERISTICS Masterplat PLUS LP FRD / PGS Masterplat PLUS LP FRD Unit of Description Value measurement Film spool dimensions (1) Maximum outer diameter (D) Spool height (H) Film thickness μm 17÷35 Internal diameter (d) Max.

  • Page 46: Masterplat Plus Tp3 Frd" And "Pgs" Technical Data

    3.9. “MASTERPLAT PLUS TP3 FRD” AND “PGS” TECHNICAL DATA The illustration and the table include the machine dimensional specifications and technical data. TECHNICAL INFORMATION...

  • Page 47: Masterplat Plus Tp3 Frd" Machine And Pallet Dimensions

    3.9.1. “MASTERPLAT PLUS TP3 FRD" MACHINE AND PALLET DIMENSIONS Description Masterplat PLUS TP3 FRD Standard Optional Optional Optional Shaft height 2200 2400 2800 3100 2540 2740 3140 3440 2570 2770 3170 3470 2200 2400 2800 3100 73.5 77.5 77.5 77.5 Load overall ...

  • Page 48: Machine Technical Features

    3.9.3. MACHINE TECHNICAL FEATURES Description Unit of Value measurement Supply voltage 220-240 1Ph 220-240 3Ph 380-415 3Ph+N 120 1Ph Power supply frequency 50/60 Installed power 1.5 (Masterplat PLUS FRD) 1.9 (Masterplat PLUS PGS) Table rotation speed C = 1650 5 - 12 C = 1800 5 - 11 Carriage upstroke / downstroke speed...

  • Page 49: Masterplat Plus Tp3 Frd" And "Pgs" Spool Characteristics

    3.9.5. “MASTERPLAT PLUS TP3 FRD” AND "PGS” SPOOL CHARACTERISTICS Masterplat PLUS TP3 FRD / PGS Masterplat PLUS TP3 FRD Unit of Description Value measurement Film spool dimensions (1) Maximum outer diameter (D) Spool height (H) Film thickness μm 17÷35 Internal diameter (d) Max.

  • Page 50: Noise Level

    3.10. NOISE LEVEL The values relating to airborne noise have been detected in compliance with standards: ISO 4871 ISO 11201 Description A-weighted emission sound pressure measured level at the operator’s position (LpA) Operation in working conditions. 69.3 dB (A) Caution - warning Prolonged exposure above 80 dB (A) can be harmful.

  • Page 51: Information On Handling And Installation

    4. INFORMATION ON HANDLING AND INSTALLATION 4.1. RECOMMENDATIONS FOR HANDLING AND LOADING Before performing any operation, the authorised operator must make sure to have understood the “Instructions for use”. Carefully read the “Instructions for use” specified in the manual and those applied directly to the machine and/or the package.
  • Page 52 Package with cardboard box Package in cage Package in cage (Masterplat PLUS LP) INFORMATION ON HANDLING AND INSTALLATION...

  • Page 53: Transport And Handling

    4.3. TRANSPORT AND HANDLING Transport, also according to the destination, can be performed with different vehicles. The diagram represents the most used solutions. During transport, in order to avoid sudden movements, adequately anchor the machine to the vehicle. Important For further transportations, recreate the initial packaging conditions for transport and handling. INFORMATION ON HANDLING AND INSTALLATION...

  • Page 54: Handling And Lifting

    4.4. HANDLING AND LIFTING The machine can be moved with a forklift truck with suitable load capacity by inserting the forks in the points indicated directly on the machine. Transport and lifting means must be operated by personnel authorised and qualified for the use of such means. Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP...

  • Page 55: Installation Of The Machine

    4.5. INSTALLATION OF THE MACHINE The machine must be installed in an area which fulfils the requirements indicated in paragraph “Installation environment characteristics”. If necessary, identify the exact position by plotting the coordinates for correct positioning. Danger - warning Authorised technical service personnel must perform installation and assembly operations. Proceed as follows: 1.

  • Page 56: Electric Box Assembly

    4.5.1. ELECTRIC BOX ASSEMBLY 1. Cut the tie (A) which gathers the electric cables. 2. Remove the mounting brackets (B). 3. Route the electric cables (C) inside the slide shaft. 4. Lift the electric box (D). 5. Fasten the electric box to the slide shaft with the screws (E). 6.

  • Page 57: Slide Shaft Assembly

    4.5.2. SLIDE SHAFT ASSEMBLY 1. In certain configurations it is necessary to lift and position the slide shaft (H) above the rotary table, in correspondence with the hinge. 2. Insert the screws (L) into the hinge without tightening them. Masterplat PLUS Masterplat PLUS TP3 3.

  • Page 58: Slide Shaft Assembly

    4.5.3. SLIDE SHAFT ASSEMBLY 1. Loosen the screws (A). 2. Lift the latch of the slide shaft (B). 3. Connect the hook of the lifting device to the bracket (C) of the slide shaft and tension (Only for slide shaft with a height of 2200-2400 mm).

  • Page 59: Loading/Unloading Ramp Assembly

    9. Loosen the screws (L) and remove the brackets (M). Masterplat PLUS LP 4.5.4. LOADING/UNLOADING RAMP ASSEMBLY Assemble the pallet loading/unloading ramp (Y) and connect the power connector (Z). Masterplat PLUS TP3 INFORMATION ON HANDLING AND INSTALLATION...

  • Page 60: Loading Direction Modification

    4.5.4.1. LOADING DIRECTION MODIFICATION A. Remove the chain cover base (1) by loosening the fastening screws (2). Remove the guards (3) and (4) that cover the loading ramp photocell, by loosening the fastening screws (5). B. Disconnect the cable of photocell (6) and (7), for the emitter and the receiver. Masterplat PLUS TP3 308-508-708 C.
  • Page 61 E. Remove the connector cable (6) from the chosen side (in this case, LH 10) and from the connection guards (12). F. Slide the photocell receiver connector cable (16) out from the opposite side of the ramp position. G. Remove the guard (10) from the initial position and reposition it on the front side, fastening it with the screws (14).
  • Page 62 Fasten the connection guard (12) with the screws (14) and insert the cable inside it. J. Refit the upper guard (10) and the upper connection guard (12) with the fastening screws (14). K. Position the upstroke ramp (9) on the side and screw the supporting knobs (8). L.
  • Page 63 M. Refit the guard (1) that covers the base. N. Unscrew the reflector (18). O. Turn the plate clockwise until the reflector (18) is positioned on the opposite side of the loading area. P. Press the “Home position” button to turn the plate clockwise and position it in the loading point. INFORMATION ON HANDLING AND INSTALLATION...

  • Page 64: Pneumatic Presser Assembly (Optional)

    4.5.5. PNEUMATIC PRESSER ASSEMBLY (OPTIONAL) 1. Fasten the guide (P) to the slide shaft with the suitable screws (Q). 2. Fit the arm (R) on the guide and fasten it with the screws (S). 3. Fit the presser plate (T) on the arm. Important The pneumatic connections have already been performed by the Manufacturer if the presser is delivered with the machine.

  • Page 65: Machine Fixing

    4.6. MACHINE FIXING Once the units have been assembled and levels, squaring, parallelism and orthogonality have been checked, it is necessary to fix the machine body to the floor. Depending on the floor type, it may be necessary, before laying the machine, to lay foundations in correspondence of the various supporting legs.

  • Page 66: Recommendations For Connections

    4.8. RECOMMENDATIONS FOR CONNECTIONS Important The connections must be made in accordance with the specifications supplied by the Manufacturer in the enclosed diagrams. The person authorised to carry out said operation must have the skills and experience acquired and acknowledged in the specific sector, must perform the connection in accordance with the best practice and take into account all the regulatory and legislative requirements.

  • Page 67: Electrical Connection

    4.10. ELECTRICAL CONNECTION Proceed as follows for the electrical connection. 1. Check that the line voltage (V) and frequency (Hz) correspond to those of the machine (See identification plate and wiring diagram). 2. Turn main switch to pos. 0 (OFF). 3.

  • Page 68: Information On Adjustments

    5. INFORMATION ON ADJUSTMENTS 5.1. RECOMMENDATIONS FOR ADJUSTMENTS Before performing any operation, the authorised operator must make sure to have understood the “Instructions for use”. Activate all the safety devices provided, stop the machine and assess whether there is any residual energy before carrying out the operations.

  • Page 69: Spool Carriages Of "Pgs" Type (Pre-Stretch Gear Replacement)

    5.2.2. SPOOL CARRIAGES OF "PGS" TYPE (PRE-STRETCH GEAR REPLACEMENT) 1. Stop the machine in safety conditions. 2. Remove the guard (A). 3. Slacken the belt (C) using the tensioner (B). 4. Slide the belt out of the pulley (D). 5. Loosen the screws (E). 6.
  • Page 70 The table indicates the pre-stretch values which can be obtained with the relevant transmission gear set. Important Set the pre-stretch according to the film resistance and quality in order to obtain a low consumption. Pre-stretch Gear code (L) No. of gear teeth (L) Gear code (N) No.

  • Page 71: Spool Carriages Of "Frd For Mesh" Type

    5.2.3. SPOOL CARRIAGES OF "FRD for mesh" TYPE 1. Work on the handwheel (C) until reaching the value displayed on the index (E). The brake shaft for mesh is an accessory that can be mounted on the carriage later on. This optional allows the system to use a mesh spool with an “FRD”...

  • Page 72: Spool Carriage Lifting Chain Adjustment

    5.3. SPOOL CARRIAGE LIFTING CHAIN ADJUSTMENT 1. Lift the spool carriage (with the machine operating in “manual mode”) until it reaches the “upper” limit switch. 2. Switch the machine off. 3. Loosen the screws (A) and tilt the pole resting it on the plate. 4.

  • Page 73: Tp" Rotary Table Chain Adjustment

    5.5. “TP” ROTARY TABLE CHAIN ADJUSTMENT 1. Loosen the screw (C) completely. 2. Remove the cover (A). 3. Loosen the fastening screws (B) of the reduction unit. 4. Tighten the screw (C) with a torque wrench (not supplied) to the rated torque of 3Nm. 5.

  • Page 74: Adjusting Rotary Table Gear Wheels

    5.6. ADJUSTING ROTARY TABLE GEAR WHEELS 1. Remove the cover (A). 2. Loosen the fastening screws (E) and correctly position the gearmotor / gear wheel. 3. Loosen the fastening screws (D) of the gear wheels (B) and (C) 4. This adjustment must be performed at the operator’s discretion by using the proper tools. Danger - warning Any maintenance operation in this area must be carried out with machine stopped, with electric switch set to OFF and with no other operator near the machine.

  • Page 75: Adjusting The Table Guide Wheels

    5.7. ADJUSTING THE TABLE GUIDE WHEELS 1. Remove the cover (A). 2. Loosen the fastening nuts (B). 3. Loosen the screw (E). 4. Tighten the screw (D) so that the wheel (C) is pressed against the rotary plate by approximately 4 mm. 5.

  • Page 76: Information About The Use

    6. INFORMATION ABOUT THE USE 6.1. RECOMMENDATIONS FOR OPERATION AND USE When using the machine for the first time, the operator must read the manual and identify the control functions and simulate some operations, especially machine start and stop. Make sure that all safety devices are properly installed and efficient. Only carry out the operations foreseen by the Manufacturer and do not tamper with any device to obtain different performance levels.

  • Page 77: Description Of The Controls

    6.2. DESCRIPTION OF THE CONTROLS 1) Emergency stop button: it is used in case of imminent risk to stop, with a voluntary action, the machine parts which may pose a risk. For more details, see the paragraph “description of safety devices”. 2) User interface: it is used to set or modify the machine operating parameters.

  • Page 78: Description Of User Interface

    6.3. DESCRIPTION OF USER INTERFACE The user interface is equipped with a multi-function selector (1), which is used to view and set the machine functions, and a display (2), which shows recipes, parameters, etc. To view and/or set the functions, turn or press the multi-function selector. Functional logic diagrams show the navigation modes.

  • Page 79: Main Menu" Page

    6.4. "MAIN MENU" PAGE Ref. Button Description Wrapping cycle Table rotation speed (rpm) Carriage speed Wrapping end delay Access to “Manual Controls” Menu. (See “Manual Controls Menu”) Access to “Film Tensioning” Menu (See “Film tensioning menu) Access to “Other” Menu (See “Other Menu”) Intermediate wrapping turns Intermediate and upper wrapping turns Access to “Settings”...

  • Page 80: Wrapping Cycle

    6.4.1. WRAPPING CYCLE Activation mode Button Description abbreviation “Double wrapping” cycle “Single wrapping” cycle “Double wrapping with feeder” cycle INFORMATION ABOUT THE USE...
  • Page 81 6.4.2. TABLE ROTATION SPEED (rpm) Activation mode Button Description abbreviation Display the table rotation speed (rpm) INFORMATION ABOUT THE USE...

  • Page 82: Carriage Speed

    6.4.3. CARRIAGE SPEED Activation Ref. mode Button Description abbreviation Display carriage speed Display carriage upstroke speed Display carriage downstroke speed INFORMATION ABOUT THE USE...

  • Page 83: Wrapping End Delay / Pallet Height

    6.4.4. WRAPPING END DELAY / PALLET HEIGHT Activation Ref. mode Button Description abbreviation View the distance of the wrapping end delay in cm View the dimension of the offset from the ground in cm View the set pallet height View the dimension of the offset from the ground in cm INFORMATION ABOUT THE USE...

  • Page 84: Manual Controls

    6.4.5. MANUAL CONTROLS Activation mode Button Description abbreviation Press the button (5) to access the “Manual controls” Menu. Activation mode Button Description abbreviation If “JOG” is pressed, the carriage (hold to run) rises until reaching the upper limit switch If “JOG” is pressed, the presser (hold to run) rises until reaching the upper position If “JOG”...

  • Page 85: Film Tensioning

    6.4.6. FILM TENSIONING For PGS version only Activation Ref. mode Button Description abbreviation View the film tensioning value View the lower film tensioning value View the film upstroke tensioning value View the upper film tensioning value View the film downstroke tensioning value INFORMATION ABOUT THE USE...

  • Page 86: Other

    6.4.7. OTHER Activation mode Button Description abbreviation Press the button (7) to access the “Other” Menu. Activation mode Button Description abbreviation Presser function enabling “Ergonomic upstroke” function “Phase angle adjustment” function “Copy recipe data” function Return to the Home page Code Icon activation...

  • Page 87: Settings

    Selection of the carriage stop height in cm at the end of the cycle Selection of the phase angle height Selection of the recipe to copy 6.4.8. SETTINGS Activation mode Button Description abbreviation Press the button (10) to access the settings Menu. Activation mode Button...
  • Page 88 Function to change the panel lock password (Available depending on to the login status and with unlocked panel) Motor parameters - Assistance page Machine parameters - Assistance page Input/Output status - Assistance page Load cell settings (PGS only) Info - Assistance page Return to the previous menu Activation Icon...
  • Page 89 Page for entering the password to change the user; Turn to select the digit and press to confirm. Select “C” to delete the password. Select the “Checkmark” to confirm the password. Enter the password (default 9999) to lock the panel. When the panel is locked, the edge of the screen is yellow.

  • Page 90: Recipe

    6.4.9. RECIPE Activation mode Button Description abbreviation Programme Code Icon activation Page Description ref. mode Programme “1” Programme “2” Programme “3” Programme “4” Programme “5” Programme “6” INFORMATION ABOUT THE USE...
  • Page 91 Manual cycle (See “Manual Cycle”) “ECO” cycle (See “Eco Cycle”) INFORMATION ABOUT THE USE...

  • Page 92: Manual Cycle

    6.4.10. MANUAL CYCLE Activation mode Button Description abbreviation Press the button (12) to access the manual cycle menu Home page Set the table rotation speed, the carriage upstroke/downstroke speed and the film stretch as previously indicated in programmes from 1 to 6. Activation mode Button...
  • Page 93 When the “START” button is pressed, the table starts to turn and the Home page looks as follows. Activation mode Button Description abbreviation Table rotation speed Carriage upstroke/downstroke speed “Double wrapping with feeder” cycle Film stretch (for PGS version only) allow to modify the parameters just listed.

  • Page 94: Eco Cycle

    6.4.11. ECO CYCLE Activation mode Button Description abbreviation Press the button (12) to access the self-learning cycle Home page. Activation mode Button Description abbreviation Start logging mode Manual controls Film stretch (for PGS version only) Other menu Settings Synchronisation of the machine INFORMATION ABOUT THE USE...
  • Page 95 Activation mode Button Description abbreviation Press the “Start logging mode” button (1) to access the logging mode. Set the table rotation speed, the carriage upstroke/downstroke speed and the film stretch as previously indicated in programmes from 1 to 6. Once any of these control buttons has been pressed, these values can no longer be modified.
  • Page 96 Activation mode Button Description abbreviation When the button is pressed, the table starts to turn. Use the buttons to perform the required movements. Press the jog button to confirm the selected control. Press the “STOP” button to end the logging. INFORMATION ABOUT THE USE...

  • Page 97: Miscellaneous

    6.4.12. MISCELLANEOUS 1. Press the “Reset” button. 2. Press the "Cycle Start" button. Restart from feeder cycle. 3. Home page if the film stretch function is absent. 4. Emergency bypassed. The carriage can be lifted (using the “start” button) even in case of carriage emergency. 5.

  • Page 98: Machine Switching On And Off

    6.5. MACHINE SWITCHING ON AND OFF 1. Turn the main switch (A) to “I” (ON) to activate the power supply. The displayed icon indicates that the “Reset” button (B) must be pressed. For “FREEZER” and “INOX” versions only: Turning the main switch (A) on automatically activates the electric control panel heating. The panel heating phase is signalled by the lighting up of the indicator (L).

  • Page 99: Description Of The Wrapping Cycles

    6.7. DESCRIPTION OF THE WRAPPING CYCLES 6.7.1. SINGLE WRAPPING CYCLE Turn the jog control to enable the wrapping cycle page. Press the jog control and select the single wrapping. Press the jog control to confirm. The spool carriage starts moving from the pallet base and stops when it reaches the upper end, after having performed the required number of wrapping turns at the base and at the upper end of the pallet.

  • Page 100: Wrapping Cycle With Feeder

    6.7.3. WRAPPING CYCLE WITH FEEDER To select the cycle. Turn the jog control to enable the wrapping cycle page. Press the jog control and select the wrapping with feeder. Press the jog control to confirm. The machine performs a cycle aimed at making it easier for the operator to completely cover the pallet and ensuring the higher possible level of protection.

  • Page 101: Cycle Start And Stop

    6.8. CYCLE START AND STOP Proceed as follows. 1. Place the pallet on the rotary table and move the loading device away. 2. Lock the film end to the pallet. 3. Set the wrapping mode. For more details, see the paragraph “Description of user interface”. Caution - warning Do not stretch or pre-stretch the film excessively and do not wrap the product with too many wrappings in order to prevent damaging the packages and the products contained in them.

  • Page 102: Presser Height Change

    6.9. PRESSER HEIGHT CHANGE Presser unit can be supplied with pneumatic (stroke 800) or mechanical cylinder version. The illustrations show the machine with the presser unit in the available versions. See tables to find the minimum height of the pallet to be wrapped in accordance with the version of the presser installed on the machine.

  • Page 103: Spool Loading

    6.11. SPOOL LOADING 1. Insert the film spool into its seat on the spool carriage. 2. Gather the film to make a thin cord and make it pass between the double-cone surfaces. Important Unwind the film following the path engraved on the spool carriage plate. 3.
  • Page 104 To allow film unwinding on carriages of “PGS” type, it is necessary to press the roller rotation button (C) on the spool carriage. Masterplat PLUS Masterplat PLUS TP3 Masterplat PLUS LP INFORMATION ABOUT THE USE...

  • Page 105: Maintenance Information

    7. MAINTENANCE INFORMATION 7.1. RECOMMENDATIONS FOR MAINTENANCE Proper maintenance will allow a longer life span and constant compliance with safety requirements. Before performing any operation, the authorised operator must make sure to have understood the “Instructions for use”. Pay attention to the safety warnings, do not misuse the machine and assess the possible residual risks. Carry out the interventions with all the safety devices enabled and wear the required PPE.

  • Page 106: Periodical Maintenance Intervals

    7.2. PERIODICAL MAINTENANCE INTERVALS Important Keep the machine in maximum efficiency conditions and perform all the scheduled maintenance operations provided for by the Manufacturer. Proper maintenance will provide the best performance, a longer life span and constant compliance with safety requirements. Maintenance interval table Frequency Component...
  • Page 107 Extraordinary maintenance Frequency Component Type of intervention Intervention mode Reference Every 5 years “Reset” button Replacement Replace (Masterplat PLUS TP3) Reduction units and gearmotors can be lubricated with grease, oil or for life, depending on their type. Topping up and/or change must not be performed in case of life-lubed reduction units and gearmotors. Cycle timings have been defined on the basis of the standard cycle.

  • Page 108: Lubrication Point Diagram

    7.3. LUBRICATION POINT DIAGRAM The diagram shows the main parts concerned by the lubrication interventions and their intervals. Masterplat PLUS Masterplat PLUS TP3 Spread grease over it. Check the lubricant level. Do not top up and/or change in life-lubed reduction units and gearmotors. MAINTENANCE INFORMATION...
  • Page 109 Masterplat PLUS LP Spread grease over it. Check the lubricant level. Do not top up and/or change in life-lubed reduction units and gearmotors. MAINTENANCE INFORMATION...

  • Page 110: Lubricant Table

    7.4. LUBRICANT TABLE The table includes the specifications of the lubricants recommended by the Manufacturer on the basis of reference components and/or areas. Use lubricants (oils or grease) recommended by the Manufacturer or with similar chemical-physical features. Lubricant characteristics Masterplat PLUS - Masterplat PLUS TP3 - Masterplat PLUS LP Lubricant type Code Parts to be lubricated...

  • Page 111: Condensate Drainage

    7.5. CONDENSATE DRAINAGE 1. Close the tap (A) and check the level of condensation in the container (B). 2. Unscrew, if necessary, the valve (C) to drain the condensation. 3. Push the valve (C) upwards until all condensation is let out. 4.

  • Page 112: Machine Cleaning

    7.7. MACHINE CLEANING General cleaning of the machine is fundamental to guarantee its efficiency over time. The whole machine must be kept free from dust, dirt and foreign bodies. The chrome-plated shafts must be cleaned with a cloth and slightly lubricated with a cloth soaked in Vaseline oil. The parts in plastic material (1) must be cleaned with a slightly damp cloth;...

  • Page 113: Fault Information

    8. FAULT INFORMATION 8.1. ALARM MESSAGES In the event of a breakdown during operation the machine stops automatically and alarm messages appear on the display. The table lists the displayed messages, the type of problem, the causes and possible solutions. Important For these operations a precise technical expertise or ability is required;...

  • Page 114: Replacement Information

    9. REPLACEMENT INFORMATION 9.1. RECOMMENDATIONS FOR REPLACING MACHINE PARTS Before performing any operation, the authorised operator must make sure to have understood the “Instructions for use”. Carry out the interventions with all the safety devices enabled and wear the required PPE. Demarcate the surrounding areas and put in place adequate safety measures, as provided for by the standards on workplace safety, in order to prevent and minimise the risks.

  • Page 115: Replacing The Rotary Table Wheels

    9.2. REPLACING THE ROTARY TABLE WHEELS 1. Loosen the screws (A). 2. Fit the eyebolts (B) and remove the upper plate (C). 3. Lift the table and place it on the ground. 4. Replace the wheels (D). 5. Reposition the table on the base and fasten it with the screws. Masterplat PLUS LP Masterplat PLUS TP3 REPLACEMENT INFORMATION...

  • Page 116: Replacing The Rotary Table Rollers

    9.3. REPLACING THE ROTARY TABLE ROLLERS 1. Loosen the screws (A). 2. Fit the eyebolts (B) on the rotary table (C). 3. Lift the table and place it on the ground. 4. Replace the rollers (D). 5. Reposition the table on the base and fasten it with the screws. Important Should it not be possible to lift the rotary table using the eyebolts as indicated in point 2, position the support (E) and screw it into the rotary table central seat using the screws (F).

  • Page 117: Replacing The Guiding Rollers

    9.4. REPLACING THE GUIDING ROLLERS 1. Loosen the screws (A). 2. Fit the eyebolts (B) on the rotary table (C). 3. Lift the table and place it on the ground. 4. Remove the snap ring (D). 5. Replace the rollers (G). 6.

  • Page 118: Replacing The Rotary Table Gear Wheels

    9.5. REPLACING THE ROTARY TABLE GEAR WHEELS 1. Remove the cover (A). 2. Loosen the fastening screws (D) of the gear wheels (B) and (C). 3. Replace the gear wheels. Danger - warning Any maintenance operation in this area must be carried out with machine stopped, with electric switch set to OFF and with no other operator near the machine.

  • Page 119: Recommended Spare Parts List

    9.6. RECOMMENDED SPARE PARTS LIST List of the spare parts that wear easily and that should be always available to avoid long machine downtimes: No․ 14 double wheels for base. No․ 8 carriage supporting wheels. No. 1 braked roller pad (Only for spool carriages of "FRD” type). No․...

  • Page 120: Machine Decommissioning And Scrapping

    9.7. MACHINE DECOMMISSIONING AND SCRAPPING 9.7.1. MACHINE DECOMMISSIONING Cut off any supply to the machine (power, pneumatic, etc.) so that it cannot be restarted and position it in a place that cannot be easily accessed. Empty the systems, which contain hazardous substances, in a proper manner and in compliance with the laws in force at workplaces and with those on environmental protection.

  • Page 121: Annexes

    Robopac S.p.A. will in no case be held responsible for any losses due to lack of production or injuries to persons or damage to things caused by malfunctions or forced downtime of the machine covered by the warranty.

  • Page 122: Presser Pneumatic Diagram

    10.2. PRESSER PNEUMATIC DIAGRAM Legend: A. Filter/regulator unit B. Solenoid valve C. Flow regulator D. Silencer E. Unloading regulator F. Presser actuating pneumatic cylinder ANNEXES...
  • Page 123 EC DECLARATION OF CONFORMITY (Annex IIA DIR. 2006/42/EC) Robopac S.p.A. Via Fabrizio da Montebello, 81 - 47892 Gualdicciolo Republic of San Marino DECLARES THAT THE MACHINE IS IN CONFORMITY WITH DIRECTIVES DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 17 May 2006 on machinery, and amending Directive 95/16/EC.

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