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- Page 1 GEM B520 GP - PLC USE AND MAINTENANCE MANUAL TAPING MACHINE mod. GEM B520 GP - PLC Code MANT-10083-02 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...
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Page 2: Table Of Contents
5.13 Recommended spare parts 5.14 Intervention record sheet............................... 68 PUTTING OUT OF SERVICE AND DISMANTLING ......................69 Temporary putting out of service ............................69 Dismantling ....................................69 ANNEXES ....................................70 A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST 2/70 GEM B520 GP - PLC... -
Page 5: Use Of The Manual
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. GEM B520 GP - PLC 5/70... -
Page 6: Symbols Used
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. 6/70 GEM B520 GP - PLC... -
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. 8/70 GEM B520 GP - PLC...
- 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 GEM B520 GP - PLC 9/70...
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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 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. GEM B520 GP - PLC...
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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. 12/70 GEM B520 GP - PLC... -
Page 13: Transport
Any accessories or options ordered with the machine are placed on additional pallets. Storage 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%. GEM B520 GP - PLC 13/70... -
Page 14: Unpacking
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. 14/70 GEM B520 GP - PLC... -
Page 15: Handling
(see picture 5). Put the forks below the machine structure and remove it from the lower base pallet. WARNING During the handling always move very slowly. This op- eration must be assisted by an operator in charge of signalling. GEM B520 GP - PLC 15/70... -
Page 16: Description Of The Machine
Pos. Pos. CE plate data CE plate data TYPE MODEL NASTRATRICE SERIAL NUMBER GEM B520 GP - PLC CONSTRUCTION YEAR POWER SUPPLY VOLTAGE FREQUENCY NOMINAL CURRENT INSTALLED POWER SHORT CIRCUIT CURRENT AIR PRESSURE CYCLE AIR CONSUMPTION... -
Page 17: Description Of The Machine
Always check that the 6 mm and 8 mm pipes are well lubricated with some spray silicone since they endure an intense squeezing caused by the rollers of the rotor and thus have a limited duration, proportional to the operating time of the pump. GEM B520 GP - PLC 17/70... - Page 18 Pos. Description Description Box feed side belts Box inlet area Support legs Water tank for moisturising system Side belt adjustment knob (box width) Lower taping machine with gummed paper Box outlet area Control panel 18/70 GEM B520 GP - PLC...
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Page 19: Technical Features
Technical features The table below shows the main technical features of the machine. Technical features Technical features GEM B520 GP - PLC GEM B520 GP - PLC Machine weight ~ 230 kg Weight with packaging ~ 280 kg Power installed... -
Page 20: Dimensions
Technical features Technical features GEM B520 GP - PLC GEM B520 GP - PLC Temperature of use Min. + 5°C / 41°F The equivalent continuous (A) weighted sound pressure level in the 78 dB (A) workstation is equal to Max. hourly production Note: Production may vary according to 7 boxes / min. -
Page 21: 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 22 1/90M - 1/90E/W 1/120M Accepted dimensions of gummed paper reel: - Ø external max. reel 400 mm - Ø internal max. reel core ~70 mm (3”) - Min / Max paper width 50 / 80 mm 22/70 GEM B520 GP - PLC...
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Page 23: Safety Protections
Such protections are fixed to the structure through screws which can be removed only with an intentional intervention and using specific tools. DANGER PLEASE NOTE THAT SUCH PROTECTED AREAS ARE ACCESSIBLE ONLY WHEN THE MACHINE IS NOT WORKING. GEM B520 GP - PLC 23/70... -
Page 24: 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 25 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 26: Free Spaces
(see picture 9). 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. 26/70 GEM B520 GP - PLC... -
Page 27: 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 11). GEM B520 GP - PLC 27/70... - Page 28 The machine can be connected mechanically with other elements of the line (ex. box spacing units, roller ta- bles, etc.). For the mechanical connection use the proper connection kit part number 801-09-868 (see picture 13). See picture 14 for the 375x500mm roller table extension. 28/70 GEM B520 GP - PLC...
- Page 29 ROLLER CONVEYOR INSTALLATION MACHINE OUTLET SIDE MACHINE INLET SIDE MACHINE INLET SIDE Insert the supports as shown in drawing 16. GEM B520 GP - PLC 29/70...
- Page 30 Insert the connections into the suitable guides. Fix the two fastening brackets of the roller conveyor. 30/70 GEM B520 GP - PLC...
- Page 31 MACHINE OUTLET SIDE Insert the supports as shown in drawing 19. Insert the connections into the suitable guides. GEM B520 GP - PLC 31/70...
- Page 32 Fix the two fastening brackets of the roller conveyor. 32/70 GEM B520 GP - PLC...
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Page 33: Electrical Connection
Before connecting the machine to the mains, make sure that the main switch on the control panel is set to "OFF" and that there are no objects on the work surface. CAUTION Make sure that the line complies with the indications on the identification plate of the machine (see par. 2.1). GEM B520 GP - PLC 33/70... - Page 34 Only connect the machine by means of the plug provided. Do not remove the plug from its cable. • Start the machine by means of the main switch. • Check the correct rotation direction of the driving belts, as indicated by the arrow in picture 23. § 34/70 GEM B520 GP - PLC...
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Page 35: Pneumatic Connection
During the installation phase, it is necessary to connect the signal cable from the machine (equipped with a connector) to the socket on the cart. Next, connect the water supply and return pipes using the unions located on the cart. GEM B520 GP - PLC 35/70... -
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. 36/70 GEM B520 GP - PLC... - 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. GEM B520 GP - PLC 37/70...
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Page 38: Operator Position
One operator can work on the machine. Posizione operatore / Position opérateur Lato comandi / emergenza Posición del operador Côté commandements / bouton d'urgence Panel de mando / emergencia Machine handling area from control panel 38/70 GEM B520 GP - PLC... -
Page 39: Control Panel
RESET button It allows restoring normal operating conditions START/STOP keys They allow starting/stopping the machine Emergency push button When pressed, it stops the machine working Main switch It allows switching on the machine GEM B520 GP - PLC 39/70... -
Page 40: Adjustments
"A" until they touch (with a slight pressure) the sides of the box to be taped. CAUTION If belts are closed with an excessive pressure, the machine will be damaged and will stop especially when using thick boxes. 40/70 GEM B520 GP - PLC... -
Page 41: Reel Positioning
2-5 mm between the flange and the reel to allow unrolling the paper. 8. Reposition the reel carrier on the shaft. 9. Lock the reel carrier by means of the knob (pos.1 pict.27). Glue side GEM B520 GP - PLC 41/70... -
Page 42: Gummed Paper Centring
2. Position the reel support so that the reel centre line is aligned with the centre line of the taping head. 3. Tighten the fastening knob. NOTE: The flange must no longer be moved unless the width of the tape used is changed. Paper width +2 -5 mm 42/70 GEM B520 GP - PLC... -
Page 43: Gummed Paper Arrangement
- Remove the cut flap of paper. - Check, against the light, that on the glue side of the pa- per there is a uniform and thin film of water. GEM B520 GP - PLC 43/70... -
Page 44: Start-Up Procedure
1. Turn the main switch "A" to the ON position to power the electrical panel. 2. Check that the emergency button "B" is not pressed. 3. Press the RESET button "C". 4. Press the START button "D". NOTICE If necessary, consult the attached wiring diagram. 44/70 GEM B520 GP - PLC... -
Page 45: 4.10 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. GEM B520 GP - PLC 45/70... -
Page 46: 4.12 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 46/70 GEM B520 GP - PLC... -
Page 47: 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. GEM B520 GP - PLC 47/70... -
Page 48: Ordinary Cleaning
This allows keeping the machine in good working conditions. Some gummed paper or cardboard residues can be left near the machine or near the inlet and outlet roller conveyors. During the machine cleaning remove them. 48/70 GEM B520 GP - PLC... -
Page 49: General Rules For Maintenance
Condensate drain Drain any condensate in the accumulation filter located under the main pressure regulator (see position "A" in picture 36). GEM B520 GP - PLC 49/70... -
Page 50: Driving Belt Replacement
"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 38); tighten nut "C"; 50/70 GEM B520 GP - PLC... - Page 51 "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. GEM B520 GP - PLC 51/70...
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Page 52: Lubrication
(see picture 42); fasten the locking screw as tightly as possible using a 13 mm Allen wrench "E"; reassemble the belt by checking its correct tension as indicated in par. 5.5. 52/70 GEM B520 GP - PLC... -
Page 53: 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". GEM B520 GP - PLC 53/70... -
Page 54: Ordinary Maintenance Table For The Taping Heads
5.10 Ordinary maintenance table for the taping heads GEM B520 GP - PLC CHECK WITH POSSIBLE MATERIAL ADJUSTMENT/REPLACEMENT OF: Lubrication of the peristaltic electric pump pipes Silicone spray Lubrication of idle return/paper passage rollers Silicone spray Paper passage check/cleaning in the... -
Page 55: Maintenance Operations For The Taping Heads
- tighten a knob or a screw (M6) on the suitable threaded insert in the centre of the sleeve to extract it - extract the sleeve - remove the three sponges and rinse them thoroughly with water - rinse thoroughly the net under running water without disassembling it from the sleeve. GEM B520 GP - PLC 55/70... -
Page 56: Sponge And Net Check/Replacement
- if the net is torn or broken, replace it - if the sponges are worn with a slight patina, replace them. NOTE: Otherwise follow the instructions given in paragraph “sponge and net washing". 56/70 GEM B520 GP - PLC... - Page 57 - reposition the small tank in the taping head. NOTE: Before repositioning the lower small tank in the taping head, clean the latter with some compressed air to remove any water leaks during overturning. Pay special attention to the dispensing unit. GEM B520 GP - PLC 57/70...
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Page 58: Replacement Of The Peristaltic Electric Pump Pipes
- take the pipe and fix it to the pipe fitting - repeat this operation for the other pipes. NOTE: The delivery pipe diameter must be of 4/6 mm while the return pipe diameter must be of 6/8 mm. 58/70 GEM B520 GP - PLC... -
Page 59: Check/Replacement Of Blade Push Pins
- reposition the small tank in the taping head. NOTE: Before repositioning the lower small tank in the taping head, clean the latter with some compressed air to remove any water leaks during overturning. Pay special attention to the dispensing unit. GEM B520 GP - PLC 59/70... -
Page 60: Cutting Blade Check/Replacement
- open the machine pneumatic supply. NOTE: Before repositioning the lower small tank in the taping head, clean the latter with some compressed air to remove any water leaks during overturning. Pay special attention to the dispensing unit. 60/70 GEM B520 GP - PLC... -
Page 61: Counterblade Check/Replacement
- make sure the dispenser corrugated roller turns freely. NOTE: Before repositioning the lower small tank in the taping head, clean the latter with some compressed air to remove any water leaks during overturning. Pay special attention to the dispensing unit. GEM B520 GP - PLC 61/70... -
Page 62: Paper Guide Plate Check/Replacement
NOTE: Before repositioning the lower small tank in the taping head, clean the latter with some compressed air to remove any water leaks during overturning. Pay special attention to the dispensing unit. Cutting counterblade support 62/70 GEM B520 GP - PLC... -
Page 63: Reel Carrier Brake Functionality Check
In order to obtain a correct gummed paper unwinding, position the flanges of all return rollers so that they always keep the paper centred on the taping head centre line. Moreover, the distance between the flanges must be slightly higher (1-2 mm max) than the width of the paper used. GEM B520 GP - PLC 63/70... -
Page 64: Check Of The Lower Paper Non-Return Ball Functionality
In order to avoid any backward movement of the paper, make sure that there are three stop balls (pos.3 pict.54) in the paper stop device assembled on the lower head (pos.4 pict.54), and the balls are not jammed. STOP BALLS 64/70 GEM B520 GP - PLC... -
Page 65: 5.12 Troubleshooting
The machine interrupts the au- • Check the previous conditions and if necessary call the Technical Ser- tomatic cycle vice Centre In case of malfunction contact the Technical Service Centre (see par. "Informative letter"). GEM B520 GP - PLC 65/70... -
Page 66: 5.13 Recommended Spare Parts
5.13 Recommended spare parts GEM B520 GP - PLC CODE RECOMMENDED Q.TY DESCRIPTION MSNC-84001-82 Roller L = 180 mm MSNC-84001-84 Roller = 516 mm Spring MSNC-85065-81 Pressure adjustment filter unit CNN-56002-075 Bearing Ø32x15x9 (SKF 6002-2RS1) CNN-70033-153 Closed chain 3/8”x 40 pitches... - Page 67 RECOMMENDED SPARE PARTS FOR THE TAPING HEAD GEM B520 GP - PLC - HEAD MECHANICAL MATERIAL CODE RECOMMENDED Q.TY DESCRIPTION 02620 4649/4/A upper paper retainer 03900 1545/4/A dispenser roller 49405 Spheres D13/32" AISI 420 MC500002_0 Gasket OR 156 Ø3.53 - Øint.52.39 mm NBR-70SH-A...
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Page 68: 5.14 Intervention Record Sheet
5.14 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 68/70 GEM B520 GP - PLC... -
Page 69: 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 GEM B520 GP - PLC 69/70... -
Page 70: Annexes
ANNEXES A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST 70/70 GEM B520 GP - PLC... - Page 72 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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