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- Page 1 GEM 50 USE AND MAINTENANCE MANUAL TAPING MACHINE mod. GEM 50 Code MANT-10088-02 COMARME S.r.l. Quartiere Mirabella snc 20081 Abbiategrasso (MI) ITALY Tel. +39 02 9422002 Fax. +39 02 9422096 Web: www.comarmesrl.com E-mail: info@comarmesrl.it Rev. 0 - 07.11.2023...
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Page 2: Table Of Contents
Check of the drive chain tension and replacement ................49 Troubleshooting ............................ 50 5.10 Recommended spare parts ........................51 5.11 Intervention record sheet ........................53 PUTTING OUT OF SERVICE AND DISMANTLING ................54 Putting out of service ..........................54 Dismantling ............................54 2/55 GEM 50... - Page 3 ANNEXES ...............................55 A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST...
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Page 4: Declaration Of Conformity
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Page 5: Use Of The Manual
The technical features of the machine are also listed. Section 3 Installation of the machine. Section 4 Description of the controls to use the machine: general safety prescriptions, first start up, calibrations, normal use and stop. Section 5 Ordinary and extraordinary maintenance. Section 6 Dismantling. 5/55 GEM 50... -
Page 6: Symbols Used
WARNING loss or visual or auditory sensorial impairment). It indicates a potential risk situation that could cause less severe or minor CAUTION damage, if not prevented (ex. cuts, scratches, irritation). NOTICE It is used for non-physical injuries. 6/55 GEM 50... -
Page 7: Operational Role Identification
The operational roles identified also include Comarme customer service advisor. Once the plant has been installed, Comarme technicians will be at the Customer's disposal to train operators as completely as possible. They will give them technical information, and instruct them on the possible residual risks or the dangers in the line. A suitable staff training form is available at the end of the line manual. - Page 8 2. ELECTRICAL TECHNICIAN, a qualified person able to: • search for and repair faults, replacing damaged parts on electrical equipment, interpreting the wiring diagrams. The table on the following page shows the main tasks of the above-mentioned professional figures. 8/55 GEM 50...
- Page 9 • Checks the correct operation of the safety systems • Follows all the phases of the production process to make sure that all operations are carried out correctly and in compliance with the safety standards 9/55 GEM 50...
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Page 10: Informative Letter
The descriptions and the pictures it contains are not to be considered as binding. Although the main features of the machine described in this manual are not subject to change, COMARME S.r.l. reserves the right to change any part, detail and accessory it deems necessary to improve the machine or for manufacturing or commercial requirements, at any time and without being obliged to update this manual immediately. - Page 11 The original configuration of machine must not be changed at all. On receiving the machine make sure the supply corresponds to what has been ordered. In case of non-conformity, please inform COMARME S.r.l. immediately. Also make sure that the machine has not been damaged during transport. 11/55...
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Page 12: Transport And Handling
The head of the department must always follow all the standards and the legal provisions concerning accidents and safety at work, that are in force nationally, locally and in business. Some areas where to deposit materials must be identified. 12/55 GEM 50... -
Page 13: Transport
During transport and storage make sure the temperature is between -5 and 40°C. If the machine is stored, make sure the relative humidity is between 30% and 95%. CAUTION During storage never overlap the cases containing the equipment (see picture 2). 13/55 GEM 50... -
Page 14: Unpacking
Place the forks on the long side of the machine so that it rests on the supporting structure. Then rest the machine on the ground. NOTICE Dispose of the packages properly delivering them to associations in charge of their elimination and recycling. A - Use and maintenance manual with EC Declaration of Conformity. B - Toolbox. 14/55 GEM 50... -
Page 15: Handling
(see picture 6). Lift the machine a few centimetres from the ground after positioning the forks near the supporting structure. WARNING During the handling always move very slowly. This operation must be assisted by an operator in charge of signalling. 15/55 GEM 50... -
Page 16: Description Of The Machine
In such a case, the operator is the only person responsi- ble towards the relevant authorities. Pos. Pos. CE plate data CE plate data TYPE TAPING MACHINE MODEL SERIAL NUMBER GEM 50 CONSTRUCTION YEAR POWER SUPPLY 1.50 VOLTAGE FREQUENCY NOMINAL CURRENT INSTALLED POWER SHORT CIRCUIT CURRENT AIR PRESSURE... -
Page 17: Description Of The Machine
Description Description Roller conveyor Box feed side belts Lower taping head Upper taping head Piece holding carriage Support legs Side belt adjustment knob (box width) Upper taping head vertical adjustment (box height) Main switch push button panel 17/55 GEM 50... -
Page 18: Technical Features
2.3 Technical features The table below shows the main technical features of the machine. Technical features Technical features GEM 50 GEM 50 102 Kg Machine weight 3 with single phase, neutral and earth Phases 0,25 kW Power installed IP54 Electrical protection Min. -
Page 19: Dimensions
2.4 Dimensions The machine measures are indicated below in mm. 19/55 GEM 50... -
Page 20: Field Of Application
COMARME S.r.l. declines all responsibility in case of accidents due to the use of the machines by UNAUTHOR- IZED and unqualified staff, or who use them for purposes different from the above-mentioned ones, WITH- OUT THE WRITTEN AUTHORIZATION OF THE MANUFACTURER AND THE ADAPTATION OF THE TECHNICAL FEATURES. -
Page 21: Safety Protections
The electric system was built in compliance with the European standard UNI EN ISO 13849. All the components installed on the machine are supplied by primary companies which provide certifications and comply with the workplace safety standards. 21/55 GEM 50... -
Page 22: Installation
Do not install the machine without the suitable protections. DANGER COMARME S.r.l. machines are NOT conceived for working in places at risk of explosion and/or at high risk of fire. The machine installation in a plant requires special precautions: areas equipped with precise energy sources to feed the plant, some specialized and qualified staff to carry out this work and with the necessary equip- ment to position and install the machine. - Page 23 OBLIGATIONS OF THE CUSTOMER: COMARME S.r.l. declines all responsibility for damage to people, objects or animals due to the failure to in- stall protection systems or to their disassembly. The manufacturer is not to be held responsible if the plant user does not follow the instructions below.
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Page 24: Free Spaces
(see picture 11). We recommend checking the suitability to carry loads near the supports. NOTICE WARRANTY AND RESPONSIBILITY DECAY IN CASE the machine is not installed ac- cording to the indications provided for by the manufacturer. 24/55 GEM 50... -
Page 25: Component Assembly
- pull out legs "B" to the required length (max. 100 mm) and tighten screws "A" . Make sure that at the end of these operations the machine is on a level in both directions, lengthwise and crosswise (see picture 14). 25/55 GEM 50... - Page 26 The machine can be connected mechanically with other elements of the line (ex. box spacing units, roller tables, etc.). For the mechanical connection use the proper connection kit part number cod. 801-09-868 (see picture 16). For the 375x500mm roller table (complete) part number cod. 801-10-021 (see picture 17). 26/55 GEM 50...
- Page 27 ROLLER CONVEYOR INSTALLATION MACHINE OUTLET SIDE MACHINE INLET SIDE MACHINE INLET SIDE Insert the supports as shown in drawing 19. 27/55 GEM 50...
- Page 28 Insert the connections into the suitable guides. Fix the two fastening brackets of the roller conveyor. 28/55 GEM 50...
- Page 29 MACHINE OUTLET SIDE Insert the supports as shown in drawing 22. Insert the connections into the suitable guides. 29/55 GEM 50...
- Page 30 Fix the two fastening brackets of the roller conveyor. 30/55 GEM 50...
- Page 31 27, and sliding the four pins "D" as far as they go into the grooves. Then lock the taping head by retightening the locking pins "C" (see picture 25). 31/55 GEM 50...
- Page 32 "A" and the corresponding nuts "B" fastening the columns to the frame from holes "C" and position them 30 mm below, using holes "D" (see picture 28). CAUTION This operation should be performed by specialized mechanical maintenance technicians. 32/55 GEM 50...
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Page 33: Electrical Connection
Before connecting the machine to the mains, make sure the main switch "A” is in "0" position. CAUTION Make sure that the line complies with the indications on the identification plate of the machine (see par. 2.1). 33/55 GEM 50... - Page 34 • The machine can be supplied with three phase motors and single phase motors, with different voltages and frequencies (see wiring diagrams in pictures 30 and 31). SINGLE PHASE MOTOR WIRING DIAGRAM THREE PHASE MOTOR WIRING DIAGRAM 34/55 GEM 50...
- Page 35 If a three phase motor is installed, should the rotational direction be reversed, invert the two phase wire connectors on the plug. For single phase motors supplied by COMARME, the correct connection for the box feed is the one indicated in the wiring diagram on page 29.
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Page 36: Normal Use
Use the machine for purposes that are different from the ones described in this use and maintenance manual. Allow unauthorized personnel to operate on the machine. Clean the machine while it is running. 36/55 GEM 50... - Page 37 The safety systems must be only used as “safety stop” devices and not as machine stop control device. WARNING Before starting the machine, all its protections must be closed. 37/55 GEM 50...
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Page 38: Operator Position
The main operating machine controls are located on the left side of the machine. Pos. Pos. Description Description Function Function Start-up push button If it is pressed, it allows starting the machine Emergency button When pressed, it stops the machine working 38/55 GEM 50... -
Page 39: Adjustments And First Start Up
UPPER TAPING HEAD ADJUSTMENT With the box positioned as in picture 36, lower the taping head carriage using handle "B" until the lower part of the front chute slightly touches the upper surface of the box to be taped. 39/55 GEM 50... - Page 40 Too much closing pressure of the arms will block the machine and damage it, especially when using thick boxes. SIDE PRESSURE ROLLER ADJUSTMENT Move the side pressure rollers "C" against the surfaces of the box to be taped and lock them by tightening knobs "D" (see picture 38). 40/55 GEM 50...
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Page 41: Working Cycle
(side belts and taping machines). The affected areas cannot be isolated or blocked by some guards, since this would compromise the machine operating principle. Therefore, the staff who use the machine and who work in the department where the machine is installed must be suitably trained on these risks. 41/55 GEM 50... -
Page 42: Wrong And Dangerous Uses
BY LAW (Local law on safety at work). DO NOT USE WATER. Staff members should be trained to deal with such accidents. The machine can NOT work in areas at high risk of fire. DANGER IN CASE OF FIRE TURN OFF IMMEDIATELY THE POWER SUPPLY 42/55 GEM 50... -
Page 43: Maintenance
Do not wear rings, watches, chains, bracelets, etc. during maintenance operations. Always wear individual protective devices (gloves, goggles, safety shoes, etc.). Do not use naked flames, pointed instruments or pins for cleaning operations. Do not smoke. 43/55 GEM 50... -
Page 44: Ordinary Cleaning
This allows keeping the machine in good working conditions. Some tape or cardboard residues can be left near the machine or near the inlet and outlet roller conveyors. During the machine cleaning remove them. 44/55 GEM 50... -
Page 45: General Rules For Maintenance
"C" fixing the front pulley "D" so that the pulley can be moved inwards; replace belt "E"; insert a screwdriver into the suitable housing "F" by levering it so as to tighten the belt (see picture 42); tighten nut "C", 45/55 GEM 50... - Page 46 "B" back on and lock it with screws "A" (see the previous page). CAUTION This operation should be performed by specialized mechanical maintenance technicians. In any case, it is advisable to replace the belts at least once a year. 46/55 GEM 50...
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Page 47: Lubrication
To carry out this operation do as follows (see picture 45): loosen screws "B" and remove the protective guards "C" on the belts, loosen stop nut "D" on the front pulley "E" so that it may be moved towards the inside of the machine, remove belt "F", 47/55 GEM 50... - Page 48 (see picture 46), fasten the locking screw as tightly as possible using a 5 mm hexagon socket head cap screw wrench "H", reassemble the belt by checking its correct tension as indicated in par. 5.5. 48/55 GEM 50...
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Page 49: Check Of The Drive Chain Tension And Replacement
To replace the drive belt, do as follows: loosen screws "A" and remove the belt guard "B"; loosen locking nuts "D" and replace belt "C"; readjust the belt tension by tightening locking nuts "D"; reassemble guard "B". 49/55 GEM 50... -
Page 50: Troubleshooting
Check that the socket is plugged in The machine interrupts the au- • Check the previous conditions and if necessary contact the tomatic cycle Technical Service Centre. In case of malfunction contact the Technical Service Centre (see par. "Informative letter") 50/55 GEM 50... -
Page 51: Recommended Spare Parts
5.10 Recommended spare parts GEM 50 CODE RECOMMENDED DESCRIPTION QUANTITY Single phase motor 120V 60Hz gr.71C 4 B14 Pn=0,37kW Shaft/ CNEN-100032 CNEN-100032 flange dim.: D.14/105 mm CNE-13042-016 SCREW REDUCER S.F.NMRV040 R=1:15 PAM 71 B14 SQUARE FLANGED BEARING SUPPORT art. UCF 202 for shaft D. - Page 52 EMERGENCY STOP MUSHROOM PUSH BUTTON (art. 3SU1000- CNEN-600002 1BH20-0AA0) SCHNEIDER: UNDERVOLTAGE RELEASE 380÷400V 50Hz / 440V 60Hz CNE-10011-012 (art. GVAU385) UNDERVOLTAGE RELEASE 110V/50HZ - 120V60Hz (art. 3RV2902- CNEN-501003 1AF0) CNEN-501004 SIEMENS: MAGNET. SWITCH 4.5÷6.3 A (art. 3RV2011-1GA10) CNE-11056-008 (QUICK) FUSE D.5x20mm - 2A 52/55 GEM 50...
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Page 53: Intervention Record Sheet
5.11 Intervention record sheet Fill in the table below with the features of the maintenance intervention carried out on the machine. DATE MACHINE PART OPERATION OPERATION TIME NOTES SIGNATURE 53/55 GEM 50... -
Page 54: Putting Out Of Service And Dismantling
If the machine must be put out of service and dismantled, follow the standards to safeguard the environment as well as those on the recovery of recyclable materials. The parts to dismantle must be given to specialized companies with the regular authorization to transport and dispose of them. RECYCLE 54/55 GEM 50... - Page 55 ANNEXES A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST 55/55 GEM 50...
- Page 56 COMARME S.r.l. Quartiere Mirabella snc 20081 Abbiategrasso (MI) - ITALY Tel. +39 02 9422002 Fax. +39 02 9422096 Web: www.comarmesrl.com E-mail: info@comarmesrl.it...
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