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comarme F2010 Use And Maintenance Manual

Carton erector
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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
F2010
EN
USE AND
MAINTENANCE MANUAL
CARTON ERECTOR
mod. F2010
Code
MANT-10078-02
Rev.
3
- 05.11.2024

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  • Page 1 F2010 USE AND MAINTENANCE MANUAL CARTON ERECTOR mod. F2010 Code MANT-10078-02 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. - 05.11.2024...

  • Page 2: Table Of Contents

    5.10 Intervention record sheet ..............................89 PUTTING OUT OF SERVICE AND DISMANTLING ......................90 Temporary putting out of service ............................90 Dismantling ................................... 90 ANNEXES ....................................91 A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST 2/91 F2010...

  • 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 understood and carried out. F2010 5/91...

  • 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. F2010...

  • 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. 8/91 F2010...

  • 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 F2010 9/91...

  • 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. 10/91 F2010...

  • Page 11: Handling

    A fork lift truck can be used to handle the machine through the departments (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. F2010 11/91...

  • Page 12: 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 MODEL FORMATORE SERIAL NUMBER F2010 CONSTRUCTION YEAR POWER SUPPLY VOLTAGE FREQUENCY NOMINAL CURRENT INSTALLED POWER SHORT CIRCUIT CURRENT AIR PRESSURE CYCLE AIR CONSUMPTION...

  • Page 13: Description Of The Machine

    2.2 Description of the machine F2010 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 14 Emergency signal (red light) Flap height adjustment Box height adjustment Box width adjustment Emergency push button Box length adjustment Boxes exhaustion microswitch Box support rod Box support plate Loading unit support leg Box opening upper brushes Box opening lower brushes 14/91 F2010...

  • Page 15: Technical Features

    2.3 Technical features The table below shows the main technical features of the machine. Technical features Technical features F2010 F2010 1521 Lb Machine weight 1984 Lb Weight with packaging 551 Lb 1 kW Power installed 7 bar or 7 x 10 Max.
  • Page 16 Technical features Technical features F2010 F2010 IP54 Electrical protection The equivalent continuous (A) weighted sound pres- < 78 dB (A) sure level in the workstation is equal to Min. + 5 °C / + 41 °F Temperature of use Max. +35°C / + 95°F...

  • Page 17: Dimensions

    2.4 Dimensions The machine measures are indicated below in mm. F2010 17/91...

  • 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 equip- ment 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.

  • Page 21: Free Spaces

    "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. F2010 21/91...

  • Page 22: Component Assembly

    To position it, it is necessary to: unscrew position "A" loosen the screw in position "B" rotate the signal lamp in vertical position insert the screw in position "A" which was earlier removed tighten both screws electrical connections are already carried out 22/91 F2010...
  • Page 23 Note With the electrical connection described above, the drive belts of the taping machine will be set in motion when the vacuum circuit of the carton erector is activated. The two machines together will function as if they were one unit. F2010 23/91...
  • Page 24 (see pic, 14). When the transport line is full, the photoelectric cell is energised and the production cycle interrupted (see pic. 15). The box will stop, fully formed, inside the forming machine. 24/91 F2010...

  • Page 25: Electrical Connection

    • Make sure the motor complies with the required voltage specification (the motor voltage is indicated on the identification plate). • The machine start switch must be in the off-position. • Insert the machine plug connector into the network outlet. F2010 25/91...
  • Page 26 In order to use this device it is sufficient to connect the pedal to the connector already installed on the machine. Each pressing of the pedal corresponds to a complete machine cycle (pic. 24) and the box will stop, fully formed, inside the forming machine. 26/91 F2010...

  • Page 27: Pneumatic Connection

    • Supply the machine's pneumatic system by sliding the air cock coupling sleeve upwards (see picture 19). • Adjust the pressure to the recommended value, 6 bar or 6x10 Pa (see picture 20). F2010 27/91...
  • Page 28 • check that the safety doors are closed; • turn on the machine rotating the general switch in position “1” (see picture 21); • make sure the emergency button is not inserted by rotating it clockwise and push the following buttons: ENT-DEL-RESET (see picture 22). 28/91 F2010...
  • Page 29 24. If a three phase motor is installed, should the rotational direction be reversed, invert the two phase wire connectors on the plug. b) the vacuum circuit. To verify this, it is necessary to: • select the manual cycle; • press start; • check that the box is picked up from the loader. F2010 29/91...

  • Page 30: 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. 30/91 F2010...
  • Page 31  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. F2010 31/91...

  • Page 32: Operator Position

    The machine's main operating controls are located on the touchscreen panel. Pos. Pos. Description Description Function Function When pressed, it stops the machine working Emergency button Control panel See par. 4.5 Main switch It allows switching on the machine 32/91 F2010...

  • Page 33: Use Of The Control Panel

    • Enabling cycle with decreasing number • Box counter reset • Front and rear flap closer lowering delay • Special functions • Bypass of the vacuum pump activation control • Display of total pieces counter and hour counter • INPUT-OUTPUT check • Alarms F2010 33/91...

  • Page 34: Language Selection

    • Insert the new Eprom ensuring the mark on the Eprom meets the one on the base and correctly insert- ing all parts; • Re-install the protection cover (see pict. 27 pos. 1); • Close the control panel; • Connect the electrical cabinet to the mains supply. 34/91 F2010...

  • Page 35: Minidip Position 35

    MACCHINE STOPPED, the system software release appears. Press the key FUN. 4.5.4 Total reset of the data containment buffer In order to reset the data containment buffer it is necessary to: • Connect the electrical cabinet; • Reset the machine. F2010 35/91...
  • Page 36 • Press the key “FUN” (pict. 31), to go back to the start, the display will show: Stopped machine No. of boxes 000120 Decreasing no. • to reset the quantity shown on the display, see paragraph “L” message 02 “Box counter reset” page 78. 36/91 F2010...

  • Page 37: Machine Reset

    “ENT” - “DEL” - “RESET” (pict. 32), after releasing the EMERGENCY PUSH BUTTON (pict. 33). The system is ready to work, the red lamp will switch off and the display will show the message “MACHINE STOPPED”. F2010 37/91...

  • Page 38: Enabling The Vacuum Circuit

    34). A light signal will indicate the enabled or disabled status. To carry out the “BURN-IN” it is possible to disable the control activating the vacuum circuit. Press the key “FUN” and then the key “VACUUM CONTROL”. For further information see the chapter “SPECIAL FUNCTIONS” (par. 04.5.10). 38/91 F2010...

  • Page 39: Start Cycle

    Switching from one “START” mode to the other is only possible when the system is in “STOP” and not on “CYCLE” mode. • AUTOMATIC START Select the key “AUT” (pict. 35), then press the key “START”. The system will start continuous forming cycles until some incorrect operation occurs or until the “STOP” button is pressed. F2010 39/91...
  • Page 40 Select the key “EXT START” (pict. 37). The system will carry out only one phase of the cycle for every time the “EXT START” button is pressed. 38). For further information on the external control, see page 44. 40/91 F2010...
  • Page 41 The key “STOP” stops the cycle at the end. When pressed, the LED of this button turns on and it signals that the button was pressed (pict. 39). To start the cycle again, it is necessary to press again the button “START”. 40). F2010 41/91...

  • Page 42: Introducing The Cycle End Pause Time

    Insert the time in seconds with the numeric keyboard and confirm with the key “ENTER” (pict. 42). If this function is not required, insert “0” (zero) a pause delay time. To exit this function press again the key "PAUSE". 42/91 F2010...

  • Page 43: Guided Menu

    • by pressing once more the arrow facing upwards (pict. 44), the display shows the following message: Machine start delay 000 x 0,01 sec. • To exit the menu without selecting any option, press the key “MENU” (pict. 43). F2010 43/91...
  • Page 44 • confirm the set number by pressing the key “ENT” (pict. 42). When the count is enabled, during the work cycle boxes will be counted decreasingly, until the set number will get to “0” and then the machine will automatically stop. 44/91 F2010...
  • Page 45 The delay time is expressed in hundredths of a second. Then proceed as follows: • Press the key “ENT” (picture 42); • insert the desired value using the keyboard; • confirm the set number by pressing the key “ENT” (picture 42) F2010 45/91...

  • Page 46: Special Functions

    • DISPLAY OF THE TOTAL PIECES COUNTER AND HOUR COUNTER Press the key “FUN” and then the key “1” (pict. 46). The display shows the effective working hours of the machine and the number of formed boxes. Press the key "FUN". 46/91 F2010...
  • Page 47 (output activated); by pressing the key “DEL” the machine will reset and go back to the starting position (output deactivated). To carry out this operation it is necessary to RESET THE MACHINE. F2010 47/91...
  • Page 48 48/91 F2010...
  • Page 49 Be very careful when using this function, especially when activating the outputs. Before activating an output, it is advisable to deactivate the one activated before using the key “DEL” (pict. 48). This is necessary in order to avoid any mechanical joints. Press the key "FUN"(Fig.47). F2010 49/91...

  • Page 50: Alarms

    By pressing the arrow keys (pict. 49), it is possible to scroll through the message page. After resetting the machine, press the keys “ENT” - “DEL” - “RESET” (pict. 50). For the alarm list described on the display, see par. 4.5.10. 50/91 F2010...

  • Page 51: Adjustments And First Start Up

    51 and clamp it in position, rotating the lever (picture 51 pos. "1") clockwise. After clamping the leg, push it slightly towards the machine interior so as to create a slight pressure upwards on the sup- port surface of the loader. F2010 51/91...
  • Page 52 55 posi- tion 1 to position the relative indicator on the measurement taken (pic. 55). WARNING Excessive pressure on the box by the vertical pressure roller may deform it during the ejection phase. Machine rear side 52/91 F2010...
  • Page 53 • move the side guide towards the box (pict. 58 pos. 2), without pressing on it; • tighten the two knob screws by hand; • Mount the top box support as shown in picture 58 pos. 4. Lower Box containing plate F2010 53/91...
  • Page 54 59 pos. 6 Check correct regulation of the pusher blades. WARNING Check that, during the downward movement of the pusher crosspiece, there is no interference between the box pusher and the side guide (see pic. 58 pos. 2). 54/91 F2010...
  • Page 55 (pict. 62 pos., 1, 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 simul- taneously. F2010 55/91...
  • Page 56 65 pos. 1, slide the whole assembly in the appropriate groove pict. 65 pos. 2 and lock again the knob pict. 65 pos. 1 Note For boxes of limited length, in which all suction cups cannot be used, disable the ones not required rotating the corresponding knob. 56/91 F2010...
  • Page 57 66 pos. 3 • lock again the two knobs pict. 66 pos. 1. The upper suction group can be adjusted separately using the knobs pict. 66 pos. 4, manually lowering or raising it. F2010 57/91...
  • Page 58 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 inter- ference between the side flaps and the flap closer levers. 58/91 F2010...
  • Page 59 The delay time is expressed in hundredths of a second. As a general rule the regulation varies from 30÷40 hundredths of a second. Optimum regulation is achieved when the rear and front flaps close on the inside of the box without inter- fering with the side flaps. F2010 59/91...
  • Page 60 • confirm the set number by pressing the key “ENT” (picture 69) • to exit the menu press the key “MENU” (picture 69} The delay time is expressed in hundredths of a second. The regulation varies from 0÷5 seconds. 60/91 F2010...
  • Page 61 Disengage the lock pict. 70 pos. 3, rotating it in vertical position, push the pin pict. 70 pos. 4 into a rest posi- tion. WARNING 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. Carton joint F2010 61/91...
  • Page 62 In order to regulate the speed of closure of the front and rear flap closer levers, adjust the regulator pict. 71 pos. 5 on the lower crosspiece of the machine frame. The speed of repositioning of these levers is fixed. 62/91 F2010...
  • Page 63 72 pos. 2 anticlockwise as far as the end of the slot. Clamp the two screws pict. 72 pos. 1. With this set-up the machine can form boxes with a minimum length of approximately 305 mm (approxi- mately 12 inches). The maximum length remains unchanged. F2010 63/91...
  • Page 64 • check that the brushes are parallel to the plane of the boxes and tighten the two screws pict. 73 pos. 2; • clamp the brushes according to the size of the box (see par. 4.6, point “e”, by means of the handwheel pict. 73 pos. 1. 64/91 F2010...
  • Page 65 • slide the microswitch pict. 74 pos. 2 as required; • Clamp the two screws pict. 74 pos. 1; • check that the lever of the microswitch, with the relevant roller, does not interfere with the box contain- ment plate pict. 74 pos. 3. F2010 65/91...
  • Page 66 • Switch on the machine, making sure that the regulation has been carried out correctly; • reposition the cover, pict. 75 pos. 2, of the pneumatic panel and attach it with the self-tapping screws pict. 75 pos. 1. 66/91 F2010...
  • Page 67 • regulate the vacuum switch pict. 76 pos. 1, on the suction cup support crosspiece, by adjusting the screw pict. 76 pos. 2; • rotate anticlockwise to decrease the switching point; • close the protection door and restart the machine, making sure that the regulation has been performed correctly. F2010 67/91...
  • Page 68 • operate from the loader side, loosening the handwheel pict. 77 pos. 2; • move the plate pict. 77 pos. 1 • lock again the knob pict. 77 pos. 2; • start up the machine, making sure that the regulation has been performed correctly. 68/91 F2010...
  • Page 69 • tighten the locking nut pict. 78 pos. 3; • insert the feeding tube pict. 78 pos. 2 and lock with the appropriate ring nut pict. 78 pos. 1; • start up the machine, making sure that the regulation has been performed correctly. F2010 69/91...
  • Page 70 • with a 10 mm wrench turn the rod of the cylinder, pict. 79 pos. 2, anticlockwise to increase squaring and clockwise to reduce it; • tighten the locking nut pict. 79 pos. 1; • close the protection door and restart the machine, making sure that the regulation has been performed correctly. 70/91 F2010...
  • Page 71 • check that the led on the magnetic sensor lights when the cylinder is in the front or rear end of stroke position. If necessary loosen the clip clamping the sensor and move it by hand until the led lights. F2010 71/91...

  • Page 72: Machine Start-Up

    (when this is connected to the carton erector). • press the key “STEP” (picture 82). The machine can start the manual cycle. WARNING During the manual cycle, evey time the “START” key is pressed the machine carries out some movement. (pict. 83). 72/91 F2010...

  • Page 73: Manual Step By Step Work Cycle

    84 pos. 2, and is positioned as indicated in picture 84 pos. 1. Step 2 - The squaring arm pict. 84 pos. 2, is arranged as shown in picture 85, completing the opening and squaring of the box; F2010 73/91...
  • Page 74 89 pos. 1, 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. 74/91 F2010...

  • Page 75: Automatic Work Cycle

    “STOP” in phase. After the stop in phase, press “START” to restart the ma- chine. WARNING In case of jamming of the box during the work cycle, or to stop the machine immediately, press the red emergency button. 91. F2010 75/91...
  • Page 76 • press the key RESET followed by “AUT” (pict. 92); - wait a few seconds in order for the soft start valve to deliver pressure to the pneumatic system. • the machine is ready to continue working; press the key “START” (pict. 93). 76/91 F2010...

  • Page 77: Machine Signals And Stop Conditions

    (General switch in pos. “0” and air inlet valve sleeve (par. 3.7 pict. 19) going downwards. 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. F2010 77/91...

  • Page 78: Alarms

    It indicates that, during the set time, the cylinder when activated did not reach the limit switch SQ9 or when de- Front flap-closer cylinder alarm activated it did not go back to the rest limit switch SQ1O, please remove the emergency cause and reset. 78/91 F2010...
  • Page 79 Check the conditions of the motor, place back the protec- tions and reset the alarm. Free Not used HL lamp circuit Check the connection cable. YV electrovalve circuit Check the reel or the connection cable. Serial communication interrupted Check the connection cable. F2010 79/91...

  • Page 80: Residual Risks

     At 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. 80/91 F2010...

  • Page 81: Wrong And Dangerous Uses

    BY LAW (Local law on safety at work); DO NOT USE WATER. 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 F2010 81/91...

  • Page 82: 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. 82/91 F2010...

  • Page 83: 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. F2010 83/91...

  • Page 84: 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 97 and rotate it anticlockwise; - replace the suction cup complete with the relative attachment, and tighten it again. 84/91 F2010...

  • Page 85: 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. WARNING Both the box opening brushes are the same and perfectly interchangeable. F2010 85/91...

  • Page 86: Troubleshooting

    Check that the box pick-up arm is not too quickly • Check the position of the box opening brushes The machine does not open the • Check the porosity of the boxes boxes • Check the punch of the boxes 86/91 F2010...
  • Page 87 Check that there is no burnt-out lamp are finishing 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"" F2010 87/91...

  • Page 88: Recommended Spare Parts

    CNPN-100030 574334) Connector M8x1; cable Lu=0,3mt; 3 poles; contact NO CNEN-402017 SICK: PHOTOCELL art. GL6-P4212 (cod. 1062110). CNWN-000019 COMPLETE BELLOWS F2010 CNP-11106-006 FESTO: PNEUM. CYLINDER art. DSBC-32-100-PPVA-N3 (d32 x c100mm) CNP-11106-008 FESTO: PNEUM. CYLINDER art. DSBC-32-160-PPVA-N3 (d32 x c160mm) CNP-11106-012 FESTO: PNEUM.

  • Page 89: 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 F2010 89/91...

  • Page 90: 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 RECYCLE 90/91 F2010...

  • Page 91: Annexes

    ANNEXES A01 - WIRING DIAGRAM A02 - SPARE PARTS LIST F2010 91/91...
  • Page 92 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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