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- Page 1 F1000 USE AND MAINTENANCE MANUAL CARTON ERECTOR mod. F1000 Code MANT-10070-02 COMARME S.r.l. Quartiere Mirabella snc 20081 Abbiategrasso (MI) ITALIA Tel. +39 02 9422002 Fax. +39 02 9422096 Web: www.comarmesrl.com E-mail: info@comarmesrl.it Rev. 22-07.2022...
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Page 2: Table Of Contents
5.9 Recommended spare parts ............................... 62 5.10 Intervention record sheet ................................. 63 PUTTING OUT OF SERVICE AND DISMANTLING .........................64 6.1 Temporary putting out of service ............................... 64 6.2 Dismantling ....................................64 ANNEXES ....................................65 A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST 2/65 F1000... -
Page 5: Use Of The Manual
The operations whose execution requires qualified or specialized staff, in order to avoid any danger, are indicated with this symbol. It is advisable to train the staff in charge of the machine and to check that what is envisaged is under- stood and carried out. F1000 5/65... -
Page 6: 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 7 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.
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Page 8: 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. 8/65 F1000... -
Page 9: Transport
Any options ordered with the machine rest on additional pallets. 1.3 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% CARTON ERECTOR LOADING UNIT F1000 9/65... -
Page 10: 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. WARNING 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. 10/65 F1000... -
Page 11: Handling
A fork lift truck can be used to handle the machine through the departments (see pic. 6). Lift the machine a few centimeters from the ground after placing the forks near the load-bearing structure. WARNING During the handling always move very slowly. This operation must be assisted by an operator in charge of signalling. 11/65 F1000... -
Page 12: Description Of The Machine
F O R M A T O R E T ipo T ype M ode llo F1000 PLC F 2 0 0 0 S L I D E M od el M atricola A nno di co struzione... -
Page 13: Description Of The Machine
The bottom can be closed with adhesive tape, gummed paper or hot-melt, depending on the connected taping machine. The card erector is controlled by a touchscreen panel located on the front of the structure. 13/65 F1000... - Page 14 Compressed air unit connection Electrical cabinet Box loading unit guide adjustment Loading unit support Box support plate Box suction cups Emergency signal (red light) Running out of cartons signal (yellow light) Running machine signal (green light) Carton erector inspection window 14/65 F1000...
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Page 15: Technical Features
EN/DE 2.3 Technical features The table below shows the main technical features of the machine. Technical features Technical features F1000 F1000 Machine weight 1069 Lb Weight with packaging ca. 1466 Lb Power installed 0,40 kW Max. allowable pressure 7 bar or 7 x 10... - Page 16 Technical features Technical features F1000 F1000 Electrical protection IP 54 The equivalent continuous (A) weighted sound pressure < 78 dB (A) level in the workstation is equal to Min. + 5 °C / + 41 °F Service temperature Max. +35 °C / + 95 °F...
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Page 17: Dimensions
2.4 Dimensions The machine measures are indicated below in mm. 17/65 F1000... -
Page 18: 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 19: Installation
Do not install the machine without the suitable protections. WARNING 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 equipment to position and install the machine. - Page 20 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 21: Free Spaces
- loosen the hexagonal nut "A" with a 24 mm wrench; - turn the screw "B" to the desired size; - lock the nut "A". WARNING Make sure that at the end of these operations the machine is levelled in both longitudinal and transverse directions. 21/65 F1000... -
Page 22: Component Assembly
For protection reasons, during shipping, the signal lamp is folded inside the machine with the front side over the control panel. With reference to picture 11, position the signal lamp and fix the support bracket using the appropriate screws "A" and "B" which are already present in the respective housings. 22/65 F1000... - Page 23 - Insert the taping machine connector in the relative connection "A" of the carton erector F1000 (see picture 13); - place the taping machine in contact with the front side of the carton erector F1000, so that the screw holes are aligned with the holes of the fixing brackets;...
- Page 24 (see picture 15). When the roller conveyor is full, the photocell is energized and the production cycle interrupted (see picture 16). The box will stop fully formed, inside the carton erector. 24/65 F1000...
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Page 25: Electrical Connection
T ype • Make sure the motor complies with the required voltage specifica- M ode llo F1000 PLC F 2 0 0 0 S L I D E M od el tion (the motor voltage is indicated on the identification plate - see... - Page 26 Only connect the machine by means of the plug provided. Do not remove the plug from its cable. • Make the electrical connections for the operation of the box presence signalling micro by connecting the respective connector "A" in picture 18. 26/65 F1000...
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Page 27: Pneumatic Connection
The pneumatic unit is equipped with a solenoid valve that prevents the machine from starting if the air pressure is not correct. The same solenoid valve stops the machine working if the pressure drops below the set level. 27/65 F1000... -
Page 28: 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. 28/65 F1000... - Page 29 The safety systems must be only used as “safety stop” devices and not as machine stop control device. WARNING B efore starting the machine, all its protections must be closed 29/65 F1000...
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Page 30: Operator Position
Picture 19 indicates the area in which the operator must be during use of the machine. WARNING One operator can work on the machine. Controls The machine's main operating controls are located on the touchscreen panel (see the enclosed use instruc- tions of the control panel). 30/65 F1000... -
Page 31: Adjustments And First Start Up
- Front / rear flap closing device positioning advance adjustment i - Box loading a - Flap height adjustment Take the box, measure the height of the flap and use the appropriate handwheel indicated in picture 20 to position the relative indicator on the measurement taken. F1000 31/65... - Page 32 Measure the height of the box with an open flap and use the appropriate handwheel indicated in picture 21 to position the relative indicator on the measurement taken. WARNING Excessive pressure on the box by the vertical pushing device can deform it during the ejection phase. 32/65 F1000...
- Page 33 For narrow boxes, in case of difficulty opening them, the brush must be able to act completely on the longi- tudinal side of the box. The lower brush "C" (picture 24) must always act completely on the back side of the box. Do not pass the slit in the box. 33/65 F1000...
- Page 34 With reference to picture 25, to adjust this guide according to the dimensions of the boxes, it is necessary: loosen the two lobe knobs "A"; insert a sample box, resting it on the "B" box containment plate; place the side guide "C" against the box without pressing it; manually tighten the two lobe knobs "A". 34/65 F1000...
- Page 35 "A" rests on the sample box. Check that the thrust plate is correctly adjusted. WARNING Check that there is no interference between the box pushing unit and the side guide "C" (shown in picture 26 on the previous page) during the downward movement of the pushing device. 35/65 F1000...
- Page 36 Measure the length of the box and, using the appropriate handwheel indicated in picture 27, position the relative indicator on the measurement taken. With this operation the position of the rear flap closing device and the box squaring and ejection arm are adjusted simultaneously. 36/65 F1000...
- Page 37 The tap "C" excludes the suction cup B2, while the tap "D" excludes the suction cup In height the suction cups must be positioned at about 100 mm (4 inch) from the lower fold line, as shown in pic- ture 29. 37/65 F1000...
- Page 38 "B" (see picture 33) and remove the pipe "C" from the fitting (see picture 33); completely unscrew the handwheel "F" (see picture 34) and position the suction cup "G" (see picture 34) in the position free of punching. The possible arrangements are those shown on the following page in picture 35. 38/65 F1000...
- Page 39 WARNING When locking the handwheel "A" (see picture 36), make sure you have inserted the flat washers and the disc springs according to the original arrangement. Make sure that the suction cups A2 and B2 are not deactivated. 39/65 F1000...
- Page 40 As a general rule the regulation varies from 30 40 hundredths of a second. Optimum regulation is achieved when the side flaps close without causing excessive noise, caused by interference between the side flaps and the flap closer levers. 40/65 F1000...
- Page 41 WARNING After having carried out all the aforementioned adjustments, carry out a manual step by step cycle to check that the machine is set up correctly. 41/65 F1000...
- Page 42 "D" (see picture 40) adjusts the repositioning speed of the side flap closing levers. Use the regulator "E" to adjust the closing speed of the front and rear flap closing levers (see picture 41). The repositioning speed of these levers is fixed. 42/65 F1000...
- Page 43 "C" upwards or downwards; check that the brush is parallel to the level of the boxes and tighten the two screws "B"; lock the brush, according to the size of the box, using the handwheel "A". F1000 43/65...
- Page 44 "A" of the microswitch with a 3 mm Allen wrench; slide the microswitch "B" as needed; lock the two screws "A"; check that the microswitch lever, with the relative roller, does not interfere with the box containment plate "C". 44/65 F1000...
- Page 45 "A" on the loading device side; move the plate "B"; tighten the handwheel "A" again; start the machine making sure that the adjustment has been carried out correctly. F1000 45/65...
- Page 46 "C" (see picture 46); insert the feeding tube "B" (see picture 45) and lock with the appropriate ring nut "A" (see picture 45); start the machine making sure that the adjustment has been carried out correctly. 46/65 F1000...
- Page 47 If necessary, loosen the clip clamping the sensor and move it manually until the led lights. 47/65 F1000...
- Page 48 Turn the main switch to position "1"; Make sure that the emergency button is disengaged by turning it clockwise; Make sure there are boxes on the loading device; For the start-up see the enclosed use instructions of the control panel. 48/65 F1000...
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Page 49: Manual Step By Step Work Cycle
(see picture 48), and is positioned as indicated in position "B" (see picture 48); Step 2 - The squaring arm "A" (see picture 48) is arranged as shown in picture 49, completing the opening and squaring of the box; 49/65 F1000... - Page 50 During the closing movement of the levers "B" (see picture 51), the two levers "C" (see picture 51) return to rest position to avoid interferences between them and the side flaps. The return point of these levers is adjustable; 50/65 F1000...
- Page 51 "B" (see picture 53) pushes the box out of the carton erector. Step 7 - Ejector return and machine repositioning for a new cycle. Check the correct adjustment of the machine during the step-by-step forming cycle. 51/65 F1000...
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Page 52: Automatic Work Cycle
With the machine in emergency conditions, the cylinders are without pneumatic supply. Before placing your hands inside the machine, for any operation, push the side flap closing levers downwards. To restart the machine after any emergency, refer to the enclosed use instructions of the control panel. 52/65 F1000... -
Page 53: Machine Signal And Stop Conditions
For each maintenance operation, always disconnect the machine power supply and its pneumatic feed. Never carry out maintenance work with the machine in emergency conditions. When the machine is in emergency conditions it always has a part of the electrical system which is live. 53/65 F1000... -
Page 54: Residual Risks
A t the end of the work, even after stopping the machine, some components such as the motors can keep high temperatures. Therefore, at the end of the operations, make sure that nobody touches these parts until the heat is dissipated below a temperature of about 40-50°C. 54/65 F1000... -
Page 55: Wrong And Dangerous Uses
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. WARNING IN CASE OF FIRE TURN OFF IMMEDIATELY THE POWER SUPPLY 55/65 F1000... -
Page 56: 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. 56/65 F1000... -
Page 57: Ordinary Cleaning
The ordinary cleaning of the machine must be carried out every day in compliance with the specific quality procedure and with the machine disabled. This allows keeping the machine in good working conditions. Some cardboard residues can be left near the machine. During the machine cleaning remove them. 57/65 F1000... -
Page 58: General Rules For Maintenance
To replace them, proceed as follows: unscrew the suction cup by inserting an Allen wrench into the central slot "B" in picture 57 and rotate it anticlockwise; replace the suction cup complete with the relative attachment, and tighten it again. 58/65 F1000... -
Page 59: Box Opening Brushes
- remove the brush "D" and insert the new one, making sure that the seat for the head of the socket head screw is turned towards the loading device; - lock the brush with the screws "C" which were removed previously. WARNING Both the box opening brushes are the same and perfectly interchangeable. 59/65 F1000... -
Page 60: Troubleshooting
Check the punch of the boxes • Check the position of the front-rear flap closing levers The machine cannot close the • Check the punch of the boxes bottom of the boxes • Check the length adjustment of the box 60/65 F1000... - Page 61 Check that there is no burnt-out lamp The machine interrupts the au- • Check the previous conditions and if necessary call the Technical Sup- tomatic cycle port System. In case of malfunction contact the Technical Service Centre (see par. "Informative letter"). 61/65 F1000...
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Page 62: Recommended Spare Parts
Recommended spare parts F1000 CODE Q.TY DESCRIPTION MAGNETIC SENSOR FOR CYLINDER (FESTO) 851-05-445 MAGNETIC SENSOR COD.SME-8-S-LED-24 (FESTO) 851-03-502 FESTO: SOLENOID FOR VALVE 5/2 851-03-404 TRANSDUCER (FESTO) 851-03-202 SOLENOID VALVE (FESTO) 851-03-508 SUCTION CUP DIAM. 60 851-01-656 SUCTION CUP DIAM. 85... -
Page 63: Intervention Record Sheet
5.10 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 63/65 F1000... -
Page 64: 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 64/65 F1000... -
Page 65: Annexes
ANNEXES A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST F1000 65/65... - Page 66 COMARME S.r.l. Quartiere Mirabella snc 20081 Abbiategrasso (MI) - ITALIA Tel. +39 02 9422002 Fax. +39 02 9422096 Web: www.comarmesrl.com E-mail: info@comarmesrl.it...
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