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- Page 1 F2000 USE AND MAINTENANCE MANUAL CARTON ERECTOR mod. F2000 Code MANT-10060-02 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. 1 - 16.05.2024...
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Page 2: Table Of Contents
Intervention record sheet ..............................81 PUTTING OUT OF SERVICE AND DISMANTLING ......................82 Temporary putting out of service ............................82 Dismantling ....................................82 ANNEXES ....................................83 A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST A03 - USE INSTRUCTIONS OF THE CONTROL PANEL 2/83 F2000... -
Page 4: Declaration Of Conformity
4/83 F2000... -
Page 5: Use Of The Manual
Description of the machine and of its field of application. The technical features of the machine are also list- 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. F2000 5/83... -
Page 6: Symbols Used
(ex. amputations, severe burns, loss of vision or hearing loss or visual or auditory sensorial impairment). It indicates a potential risk situation that could cause less severe or minor damage, if not prevented (ex. cuts, scratches, irritation). It is used for non-physical injuries. 6/83 F2000... -
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. - 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. 8/83 F2000...
- 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 F2000 9/83...
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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.
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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. 12/83 F2000... -
Page 13: 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 F2000 13/83... -
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. 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. 14/83 F2000... -
Page 15: 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. During the handling always move very slowly. This operation must be assisted by an operator in charge of signalling. F2000 15/83... -
Page 16: Description Of The Machine
T ype SERIAL NUMBER M o d e llo G E M F 5 2 0 -G P M ode llo F2000 M od el F 2 0 0 0 S L I D E M od el CONSTRUCTION YEAR... -
Page 17: Description Of The Machine
2.2 Description of the machine F2000 is a carton erector that automatically prepares the boxes with the four folded lower flaps, by taking them from the magazine located on the side of the machine. The formed box is sent to the line after the automatic taping of the bottom by means of a taping machine connected to the carton erector. - Page 18 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 18/83 F2000...
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Page 19: Technical Features
2.3 Technical features The table below shows the main technical features of the machine. Technical features Technical features F2000 F2000 Machine weight 1025 Lb Weight with packaging ca. 1428 Lb Power installed 0,40 kW Max. allowable pressure 7 bar or 7 x 10... - Page 20 Technical features Technical features F2000 F2000 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 21: Dimensions
2.4 Dimensions The machine measures are indicated below in mm. F2000 21/83... -
Page 22: 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 23: Safety Protections
COMPLIANCE WITH THE STANDARDS The electric system was built in compliance with the European standard UNI EN ISO 13849-1:2016. All the components installed on the machine are supplied by primary companies which provide certifications and comply with the workplace safety standards. F2000 23/83... -
Page 24: Installation
Do not place the machine near heat or water sources or other free liquids. Do not install the machine without the suitable protections. COMARME S.r.l. machines are NOT conceived for working in places at risk of explosion and/or at high risk of fire. - 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
- loosen the hexagonal nut "A" with a 24 mm wrench; - turn the screw "B" to the desired size; - lock the nut "A". Make sure that at the end of these operations the machine is levelled in both longitudinal and transverse directions. 26/83 F2000... -
Page 27: 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 12, position the signal lamp and fix the support bracket using the appropriate screws "A" and "B" which are already present in the respective housings. F2000 27/83... - Page 28 14, so as to move the loader manually, gripping the two outer, sloping walls in the points indicated in the picture 14. rest the loader on the ground as indicated in the picture 15, supporting it in this position. 28/83 F2000...
- Page 29 M8x70 hexagonal head screw, ø 8 spring washer and special ø 40, thickness 3, washer. C - Special ø 40 thickness 3, washer D - ø 8 spring washer E - M8x70 hexagonal head screw F - M8 flat washer F2000 29/83...
- Page 30 20 "B" in the clamps, picture 20 "C" (insert on the side along the guard) and make it slide to the end of the fixed guard, picture 20 "D"; tighten the screws, picture 20 "A". 30/83 F2000...
- Page 31 ASSEMBLY OF THE HANDWHEELS FOR RAISING THE LOADER AND BOX PRESSURE ROLLER Mount the above handwheels as indicated in picture 21 and tighten the TSPEI M6x12 socket button head screw. Box loader front side Box presser rear side Machine shaft Handwheel Washer Socket flat head screw TSPEI M6x12 F2000 31/83...
- Page 32 2 TE M8 x 16 hexagonal head screws from the front end of the bed of the taping machine (pic. 23 "A") place the taping machine in contact with the front side of the carton erector F2000, so that the screw holes (pic. 23 "A") are aligned with the holes of the fixing brackets (pic. 23 "B");...
- Page 33 In order to use this device it is sufficient to connect the pedal to the connector already installed on the ma- chine, as indicated in picture 24. Each pressing of the pedal corresponds to a complete machine cycle (pic. 24) and the box will stop, fully formed, inside the forming machine. F2000 33/83...
- Page 34 (see pic, 26). When the transport line is full, the photoelectric cell is energised and the production cycle interrupted (see pic. 27). The box will stop, fully formed, inside the forming machine. 34/83 F2000...
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Page 35: Electrical Connection
• The machine can be supplied with three phase motors, with different voltages and frequencies (see wir- ing diagram). • Make sure the motor complies with the required voltage specification (the motor voltage is indicated on the identification plate - see par. 2.1) • The machine start switch must be in the off-position. F2000 35/83... - Page 36 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 29. 36/83 F2000...
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Page 37: 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. F2000 37/83... -
Page 38: 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. 38/83 F2000... - Page 39 The safety systems must be only used as “safety stop” devices and not as machine stop control device. B efore starting the machine, all its protections must be closed F2000 39/83...
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Page 40: Operator Position
Picture 30 indicates the area in which the operator must be during use of the machine. 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). 40/83 F2000... -
Page 41: Adjustments And First Start Up
- Box side guide adjustment g - Box thrust plate adjustment h - Box length adjustment i - Box width adjustment l - Suction cups position adjustment m - Front / rear flap closing device positioning advance adjustment n - Box loading F2000 41/83... - Page 42 - Release of loader leg In order to release the loader leg, rotate the lever (pic. 31 "A") clockwise. 42/83 F2000...
- Page 43 - Regulation of flap height Take the box, measure the height of the flap as shown in picture 32 and, by means of the handwheel, position the relevant indicator on the size measured. F2000 43/83...
- Page 44 Position the leg slightly tilted towards the machine exterior, as shown in picture 31 and clamp it in position, rotating the lever (31 "A") clockwise. After clamping the leg, push it slightly towards the machine interior so as to create a slight pressure upwards on the support surface of the loader. 44/83 F2000...
- Page 45 Measure the height of the box with an open flap (pic. 33) and use the appropriate handwheel indicated in picture 34 to position the relative indicator on the measurement taken. Excessive pressure on the box by the vertical pressure roller may deform it during the ejection phase. F2000 45/83...
- Page 46 (long side) of the box. The lower brush "C" (see pic. 37), must always act on the whole of the rear side of the box. Do not go beyond the slot in the box. 46/83 F2000...
- Page 47 "A"; insert a sample box, resting it at the box containing plate "B"; move the side guide "C" towards the box without pressing on it; tighten the two knob screws "A" by hand; mount the top box support. F2000 47/83...
- Page 48 "A" at the sample box. Check correct regulation of the pusher blades. Check that, during the downward movement of the pusher crosspiece, there is no interference between the box pusher "C" (see pic. 38). 48/83 F2000...
- Page 49 Measure the length of the box and, by means of the handwheel (pic. 40), position the relevant indicator on the measurement taken. By this operation the position of the rear flap closer lever and the box ejection and squaring arm are regulated simultaneously. F2000 49/83...
- Page 50 - Adjustment of the box width Measure the width of the box and, by means of the handwheel (see pic. 42) position the relevant indicator on the measurement taken. By this regulation the box is centred with the axis of the machine. 50/83 F2000...
- Page 51 The "C" tap disables the B2 suction cup, while "D" tap disables the A2 suction cup. The suc- tion cups should be positioned at a height of around 100 mm (4 inches) from the lower fold line, as shown in picture F2000 51/83...
- Page 52 "B" (see pic. 47) and remove the tube "C" from the connector (see pic. 47); unscrew the handwheel "F" (see pic. 48) completely and position the "G" suction cup assembly (see pic. 47) in the area free from dinkings. The possible arrangements are those shown in picture 52/83 F2000...
- Page 53 During locking of the handwheel "A" (see pic. 50), make sure that the flat and Belleville washers have been insert- ed according to the original arrangement. Make sure that the suction cups A2 and B2 have not been disabled. F2000 53/83...
- Page 54 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. 54/83 F2000...
- Page 55 Disengage the lock (pic. 52 "C") rotating it into a vertical position, and push the pin (pic. 52 "D") into a rest position. After having performed all the adjustments mentioned above, carry out a step-by -step manual cycle in order to check the correct set-up of the machine. Giunzione cartone / Jonction carton/ Unión del cartón F2000 55/83...
- Page 56 In order to regulate the speed of closure of the front and rear flap closer levers, adjust the regulator "E" (pic. 55), on the lower crosspiece of the machine frame. The speed of repositioning of these levers is fixed. 56/83 F2000...
- Page 57 (pic. 56 "B"), anticlockwise, as far as the end of the slot. Clamp the two screws (see pic. 56 "A"). With this set-up the machine can form boxes with a minimum length of approximately 220 mm (approximately 8 11/16"). The maximum length remains unchanged. F2000 57/83...
- Page 58 "C" upwards or downwards; check that the brushes are parallel to the plane of the boxes and tighten the two screws "B"; clamp the brushes according to the size of the box by means of the handwheel "A". 58/83 F2000...
- Page 59 "A" of the microswitch by means of a 3 mm Allen wrench; slide the microswitch "B"as required; tighten the two screws "A"; check that the lever of the microswitch, with the relevant roller, does not interfere with the box contain- ment plate "C". F2000 59/83...
- Page 60 By rotating the screw clockwise the switching point is increased. WARNING: Switch on the machine, making sure that the regulation has been carried out correctly; reposition the cover of the pneumatic panel and attach it with the self-tapping screws. 60/83 F2000...
- Page 61 (pic. 59, "A") on the suction cup support crosspiece, by adjusting the screw (pic. 59, "B"); rotate anticlockwise to decrease the switching point; close the protection door and restart the machine, making sure that the regulation has been performed correctly. F2000 61/83...
- Page 62 "A"; move the "B" plate; clamp the "A" handwheel again; start up the machine, making sure that the regulation has been performed correctly. 62/83 F2000...
- Page 63 - about 3/32 inch); tighten the locking nut "C" (pic. 62); insert the feed tube "B" (pic. 61) lock with the appropri- ate ring nut "A" (pic. 61); start up the machine, making sure that the regulation has been performed correctly. F2000 63/83...
- Page 64 If necessary loosen the clip clamping the sensor and move it by hand until the led lights. 64/83 F2000...
- Page 65 Make sure that there are boxes on the loader; For the start-up see the enclosed use instructions of the control panel. F2000 65/83...
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Page 66: Manual Step By Step Work Cycle
"A" (see pic. 64), and is positioned as indicated in position "B" (see pic. 64); Step 2 - The squaring arm "A" (see pic. 64) is arranged as shown in picture 65, completing the opening and squaring of the box; 66/83 F2000... - Page 67 During the closing movement of the levers "B" (see pic. 67), the two levers "C" (see pic. 67) return to rest position to avoid interferences between them and the side flaps. The return point of these levers is adjustable; F2000 67/83...
- Page 68 "B" (see pic. 69) 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. 68/83 F2000...
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Page 69: 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. F2000 69/83... -
Page 70: 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. 70/83 F2000... -
Page 71: Residual Risks
The manufacturer's written consent must be previously obtained to work special materials different from the one indicated in this manual. The voluntary action by which the operator does not follow the working rules indicated in this manual is an im- proper use. F2000 71/83... -
Page 72: Clothes
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. IN CASE OF FIRE TURN OFF IMMEDIATELY THE POWER SUPPLY 72/83 F2000... -
Page 73: 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. F2000 73/83... -
Page 74: 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. 74/83 F2000... -
Page 75: 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 73 and rotate it anticlockwise; replace the suction cup complete with the relative attachment, and tighten it again. F2000 75/83... -
Page 76: Box Opening Brushes
"D" brush, and insert the new one, making sure that the housing for the head of the socket head T.C.E.I. screw is turned towards the loader; clamp the brush with the "C" screws removed previously. Both the box opening brushes are the same and perfectly interchangeable. 76/83 F2000... - Page 77 F2000 77/83...
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Page 78: 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 78/83 F2000... - Page 79 • Check that there is no burnt-out lamp The machine interrupts the • Check the previous conditions and if necessary call the Technical Sup- automatic cycle port System. In case of malfunction contact the Technical Service Centre (see par. "Informative letter"). F2000 79/83...
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Page 80: Recommended Spare Parts
Recommended spare parts F2000 CODE Q.TY DESCRIPTION PNEUMATIC SPARE PARTS 851-01-745 Festo DSNU-25-350-PPV-A Pneumatic cylinder 851-03-191 Festo DSNU-25-160-PPV-A Pneumatic cylinder CNPN-100030 Magnetic limit switch (FESTO) 851-03-502 SME limit switch 8-S.-LED-24 (FESTO) 851-03-198 Festo GRLA-1/8-QS6-RS-B flow regulator 851-03-199 Festo GRLA-1/4-QS8-RS-B flow regulator 851-03-404 Festo CPV 14-M1H-5LS-1/8"... -
Page 81: 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 F2000 81/83... -
Page 82: 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 82/83 F2000... -
Page 83: Annexes
ANNEXES A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST A03 - USE INSTRUCTION OF THE CONTROL PANEL F2000 83/83... - Page 85 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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