Stretch wrapper model GL 1000
Stretch wrapper model GL 1000
Stretch wrapper model GL 1000
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<strong>Stretch</strong> <strong>wrapper</strong> <strong>model</strong> <strong>GL</strong> <strong>1000</strong><br />
Manual<br />
Ver. 2.1<br />
EN<strong>GL</strong>ISH
Model: <strong>GL</strong> <strong>1000</strong> Serial number:........................ Delivery date:...............................<br />
YY-MM-DD<br />
This machine is equipped with the following options on delivery:<br />
6<strong>1000</strong>1 CONVEYOR FOR BIG LOADS<br />
6<strong>1000</strong>2 CUSTOM COLOR<br />
6<strong>1000</strong>3 MAST MOVED BACK<br />
6<strong>1000</strong>4 CABINET MOVED BACK<br />
6<strong>1000</strong>5 FORMAT CONTROL<br />
6<strong>1000</strong>6 HALF PALLET<br />
6<strong>1000</strong>7 CABINET EXCLUDED<br />
6<strong>1000</strong>8 SEPARATE CABINET<br />
6<strong>1000</strong>9 ALLEN BRADLEY CONTROL<br />
610012 LIGHTBEAM, 1 PC<br />
610013 LIGHTBEAMS, 2 PCS<br />
610014 LIGHTBEAMS, 3 PCS<br />
610148 TOP PLATE, RECTANGULAR<br />
610149 TOP PLATE, ROUND<br />
610150 FREQ. CONTROL OF TOP PLATE<br />
610159 ALARM, ”FILM ALMOST AT AN END”<br />
610179 GALVANIZATION OF BOTTOM CHASSIS<br />
610184 CUSTOM MAST HEIGHT<br />
610188 CHAIN CONVEYOR, 3 CHAINS<br />
610189 CHAIN CONVEYOR, 2 CHAINS<br />
610191 INFILL CONVEYOR FOR LARGE CONVEYOR<br />
610192 INFILL CONVEYOR FOR STD CONVEYOR<br />
610194 LARGER FILM ROLL DIAMETER<br />
610198 POWERED OUTER ROLLERS<br />
610206 INCREASED TRANSP. HEIGHT, 575-700 mm<br />
610207 INCREASED TRANSP. HEIGHT, 625-750 mm<br />
610208 INCREASED TRANSP. HEIGHT, 750-875 mm<br />
610209 CUSTOM CONVEYOR HEIGHT<br />
610254 WELDING UNIT<br />
610261 90 DEGREE IN OR OUT TRANSPORTATION<br />
610324 STRING ROLLER<br />
610325 PNEUMATIC STRING ROLLER<br />
610481 PALLET GUIDING DISCS<br />
610210 AIR CONDITIONED ELECTRICAL CABINET<br />
610010 INTEGRATION CI 1110<br />
610011 CONTROL OF 1 CONVEYOR<br />
610012 CONTROL OF 2 CONVEYORS<br />
610013 CONTROL OF 3 CONVEYORS<br />
610014 CONTROL OF 4 CONVEYORS<br />
610015 CONTROL OF 5 CONVEYORS<br />
610016 FREQ. CONTROL OF CONVEYOR<br />
610199 SEPARATE START BOX<br />
610663 PASSIVE ANTISTATIC<br />
610664 ACTIVE ANTISTATIC<br />
Throughout the entire manual, the following symbols will be used to indicate particularly important information.<br />
Particularly important<br />
information<br />
Must be executed by<br />
an operator<br />
Must only be executed by a<br />
Cyklop service engineer<br />
Hazard<br />
"Fast return" to a page. To access this menu/page,<br />
press the buttons in order in the grey field. (This is an example.)<br />
Rights to make any technical modifications are reserved. This manual must not be copied or otherwise duplicated.<br />
Nor may its content be amended or passed on without our written permission. All rights reserved.<br />
© Copyright by Cyklop Teknik AB – Burseryd 2010 /mka<br />
2 EN
Contents<br />
Chapter Page<br />
Machine configuration 2<br />
Positioning of safety decals 4<br />
EC declaration 5<br />
General safety instructions 1 6<br />
Main machine parts 2 10<br />
Control cabinet 3 11<br />
• Overview 3.1 11<br />
• Explanation of buttons 3.2 11<br />
• Lamp test 3.3 12<br />
Display 4 12<br />
• Overview 4.1 12<br />
• Home menu 4.2 12<br />
• Information menu for film 4.3 13<br />
• Name program 4.4 13<br />
• Manual operation 4.5 14<br />
• Service 4.6 15<br />
• Language selection, date set 4.7 15<br />
• Alarm / Status sensor 4.8 17<br />
• Contact information 4.9 19<br />
• Setting program parameters 4.10 19<br />
• Program selection 4.11 20<br />
Operate the machine 5 21<br />
• Activation 5.1 21<br />
• Load film 5.2 21<br />
• Set prestretching of film 5.3 22<br />
• Set film tension 5.4 22<br />
• Start the machine 5.5 22<br />
• Pause automatic mode 5.6 23<br />
• Description of film patterns 5.7 23<br />
Care and daily maintenance 6 24<br />
• Cleaning 6.1 24<br />
• Service & maintanence 6.2 24<br />
Resetting 7 26<br />
• Film breakage / End of film 7.1 26<br />
• Machine stop activated 7.2 26<br />
• Emergency stop activated 7.3 26<br />
• Light beam which has tripped (optional) 7.4 27<br />
Troubleshooting 8 27<br />
Transport 9 29<br />
Technical specifications 10 30<br />
Table of set values, program parameters 11 31<br />
3 EN
EN<strong>GL</strong>ISH<br />
This user guide describes the operation, safe use,<br />
maintenance and adjustment of the machine. ATTENTION!<br />
Connection to the power grid is not included.<br />
Machine design and construction allows for safe<br />
use and maintenance. This is true provided that<br />
the installation is done as is described in this guide.<br />
The warning labels that have been applied to the machine should<br />
be kept in such condition that the content is easy to read. If not,<br />
the label must be replaced. Explanations and positioning below.<br />
Design may differ slightly on label affixed to the machine, but the<br />
meaning is the same.<br />
Part No: 400777<br />
7. HAZARD!<br />
The turn table rotates in the direction of the<br />
arrrow.<br />
18. HAZARD!<br />
Aggregate travels in the directions of the arrows.<br />
Crush hazard.<br />
2. HAZARD!<br />
Topplattans släde rör sig i pilarnas riktning. Crush<br />
hazard. (For option: Top plate)<br />
MANDATORY<br />
Outtakes for forks. Lift the machine here.<br />
9. HAZARD!<br />
Rotating rollers. Crush hazard.<br />
12. HAZARD!<br />
Sharp egdes. Risk of cutting.<br />
3. VARNING!<br />
Rotating rollers. Crush hazard.<br />
5. HAZARD!<br />
Crush hazard.<br />
8. HAZARD!<br />
Crush hazard.<br />
17. HAZARD!<br />
Dangerous electrical voltage.<br />
13. HAZARD!<br />
Hot surface.<br />
(For option: Weld)<br />
4. INFORMATION<br />
1. Tread the stretch film according to the picture.<br />
2. Gear ratio.<br />
15.<br />
10.<br />
1.<br />
14.<br />
16.<br />
4 EN
The declaration of incorporation of the partly completed machinery under the EC’s Machinery<br />
Directive 2006/42/EC, Annex 2B.<br />
We:<br />
Cyklop Teknik AB<br />
Villstadsvägen 1<br />
330 26 BURSERYD<br />
Org. Nr. 556224-0001<br />
declare under our sole responsibility that the partly completed product:<br />
Model: <strong>Stretch</strong> <strong>wrapper</strong> <strong>GL</strong> <strong>1000</strong><br />
Type designation: <strong>1000</strong>50-<strong>1000</strong>50/99<br />
Machine Number:<br />
________________________<br />
• is designed to be incorporated in a larger machinery or assembled with another machine, which<br />
together will constitute machinery covered by Directive 2006/42/EC ”Machinery Directive”<br />
and which shall be made in accordance with Directive 2006 / 42/EC.<br />
• conforms to the applicable sections of annex 1 regarding essential health and safety in the design<br />
of machines have been performed and that the relevant technical documentation is compiled in<br />
accordance with Annex 7, Section B.<br />
• Remaining items in Annex 1: 1.1.3, 1.3.1, 1.3.2, 1.3.3, 1.3.7 samt 1.5.2. At the substantiated<br />
request of national authorities relevant documents on the partly completed machinery<br />
will be presented.<br />
• and declares, moreover, that the machinery should not be put into any use until the machinery<br />
it must be incorporated in, or forming part of, has been found and declared in accordance with<br />
Directive 2006/42/EC and national legislation, namely the overall including the machine,<br />
referred to in this declaration.<br />
Covered by this declaration in conformity are the following directives:<br />
2006/42/EG Machinery Directive, Basic safety regulations<br />
2006/95/EG Low Voltage Directive (LVD)<br />
2004/108/EG Electromagnetic Compatibility (EMC)<br />
The following harmonized standards apply:<br />
EN ISO 14121 Machine safety - Principles for risk assessment<br />
EN ISO 12100-1 Machine safety - Basic terminology, methodology<br />
EN ISO 12100-2 Machine safety - Technical principles<br />
SS-EN 60204-1 Machine safety - Electrical equipment of machines<br />
SS-EN 954-1 Machine safety - Control systems<br />
SS-EN 415-6 Packaging machines safety<br />
Burseryd<br />
Place and date (YY-MM-DD)<br />
Bo Eriksson<br />
Managing director<br />
Position<br />
Burseryd<br />
Place and date (YY-MM-DD)<br />
Lars Karlsson<br />
Responsible for Technical file<br />
Position<br />
Cyklop Teknik AB<br />
Villstadsvägen 1<br />
SE-330 26 BURSERYD<br />
Ph: +46 (0)371 50800<br />
Fax: +46 (0)371 50775<br />
info@cyklopteknik.se<br />
www.cyklopteknik.se<br />
5 EN
1. General safety instructions<br />
GENERAL<br />
Machine design and construction allows for safe use and<br />
maintenance. This is true provided that the installation is done<br />
as described in this guide. The guide should be read and the instructions<br />
followed by anyone working with the machinery. It is<br />
the customer’s responsibility to ensure that the instructions are<br />
complied with by staff.<br />
In some countries or some companies more safety regulations are<br />
to be observed, mainly related to personnel. This documentation<br />
does not take account of such company-specific or national<br />
guidelines. The technical specifications in the manual shall be<br />
sufficient to base for decisions on any local safety regulations.<br />
Consult with the appropriate the authorities or with company<br />
safety representatives.<br />
This documentation distinguishes between ”normal operation”<br />
(see Chapter 3-4 Running the machine) and ”other management”<br />
(see Chapter 5 Care and daily maintenance). The reason is that<br />
they place different demands on operators and service personnel,<br />
specially in regards to security.<br />
Easier maintenance, as described in Chapter 4, may also be<br />
performed by operators. Maintenance only described in Chapter 5,<br />
only carried out by skilled service personnel.<br />
SAFETY<br />
Here are the rules to be observed: Ensure that no children or<br />
animals in the vicinity of the installation.<br />
Only people who have read and understand this manual may work<br />
with this machinery. Do not tamper with the machine while it is<br />
working or is on. Warning! Even if the machine is not working,<br />
it may be switched on. Safety devices shall not be removed or<br />
eliminated. All the protection of electrical and mechanical compo<br />
nents must be correctly installed when the installation is in<br />
operation. The safety devices are essential for safety in the work<br />
environment. Thus, it is strictly forbidden in any way ignore or<br />
circumvent them. Keep the work area clean and free of foreign<br />
objects. Make sure the lighting in the work area is adequate.<br />
UNAUTHORIZED USE<br />
Some use may lead to unnecessary security risks because they are<br />
not in conformity with the machine’s specifications and therefore<br />
unlawful. You may not:<br />
• wrap pallets that do not meet specifications<br />
• wrap pallet goods exceeding the maximum allowable weight<br />
• wrap pallet goods which have not been stacked properly.<br />
Keep in mind that even if the goods look like it is stacked<br />
properly, packages can still fall due to other causes<br />
• wrap pallets that are in poor condition<br />
• wrap pallets that extends outside the periphery of the turn<br />
table<br />
• negligering of installation specifications<br />
• wrap unpackaged foods<br />
USERS<br />
Operators<br />
The machine may be operated by any adult person who has read<br />
and understood the contents of Chapters 1-4. It is not necessary<br />
that the operators have any special knowledge. Machine operators<br />
are trained by personnel from Cyklop or by Cyklop designated<br />
dealers.<br />
• daily standard maintenance This means for example cleaning<br />
of photocells - no major tasks may be performed.<br />
• ensure that dangerous situations can not arise.<br />
• keep the work area clean and free from foreign objects.<br />
Service<br />
Specific skills, experience and / or training is required. Service<br />
personnel should also master the entire contents of this<br />
documentation. Service typically have the following types of tasks:<br />
• maintenance of the installation<br />
• repair of defects<br />
• give support to operators<br />
Service personnel shall after rectifying an error restore the<br />
machine to original state. With security in mind, this means for<br />
example, re-installation of protective caps and also return safety<br />
switch to its original position. When a service person take their<br />
own initiatives to implement changes in the installation, the<br />
customer forfeits the moment of their warranty claims in the case<br />
of any problems as a consequence of the change.<br />
PERSONAL PROTECTION<br />
Some personal protection measures are not to be taken by<br />
operators of the machine. However, a number of measures<br />
are recommended. For example shoes with steel caps, hearing<br />
protection, etc.. Some products used, however, may require<br />
protective measures - advice the documentation of those devices.<br />
When handling sheet metal take certain precautions to prevent<br />
injuries such as hand injuries and the likes. When performing<br />
service local safety regulations must be folowed. Discuss personal<br />
safety with company safety representatives.<br />
The whole installation was designed and tested to work with the<br />
specified substances. Unforeseen dangers may arise from the use<br />
of substances other than those specified. The manufacturer can<br />
not accept responsibility for the complications arising from the use<br />
of substances other than those specified.<br />
TRANSPORTATION<br />
When transporting the installation on a public road, there may<br />
be local regulations to follow. Consult with national and local<br />
authorities on these kinds of regulations and if application for a<br />
permit is needed.<br />
ENVIRONMENTAL CONCERNS<br />
Potential environmental risks are in the form of, for example, oil,<br />
grease and detergent. This type of substances are to be disposed<br />
of in accordance with national environmental regulations.<br />
DISPOSAL OF THE MACHINE / INSTALLATION<br />
If and when the machine is disposed local environmental<br />
regulations must be observed. The machine contains only material<br />
that can be considered public knowledge. All the materials in the<br />
machine was at the time of manufacture of such a nature that<br />
they could be disposed of in an environmentally sound manner<br />
and without risk of personal injury.<br />
DISASTERS<br />
Disasters include fire, flood, and the like. There are no specific<br />
rules for the conduct of disaster relief.<br />
Fire fighting can be done under the usual standards.<br />
The operator is normally involved in the following tasks:<br />
• operation of the machine<br />
6 EN
Basic operation<br />
Before use, please read the handbook and safety instructions<br />
carefully. The operator handbook is to be stored ready<br />
for use in direct machine proximity. Maintenance and inspection<br />
intervals are to be adhered to.<br />
The machine/plant must only be used in technically perfect<br />
condition in accordance with its designated use and the<br />
instructions set out in the operating manual, and only by<br />
safety–conscious persons who are fully aware of the risks<br />
involved in operating the machine/plant. Any functional disorders,<br />
especially those affecting the safety of the machine/<br />
plant, should therefore be rectified immediately.<br />
The machine/plant may be operated only for its designated<br />
use.<br />
Organizational measures<br />
In addition to the operating instructions, observe and instruct<br />
the user in all other generally applicable legal and<br />
other mandatory regulations relevant to accident prevention<br />
and environmental protection. These compulsory regulations<br />
may also deal with the handling of hazardous<br />
substances, issuing and/or wearing of personal protective<br />
equipment, or traffic regulations.<br />
For reasons of security, long hair must be tied back or otherwise<br />
secured, garments must be close–fitting and no jewellery<br />
– such as rings – may be worn. Injury may result<br />
from being caught up in the machinery or from rings catching<br />
on moving parts.<br />
Use protective equipment wherever required by the circumstances<br />
or by law.<br />
Observe all safety instructions and warnings attached to the<br />
machine/plant.<br />
See to it that safety instructions and warnings attached to<br />
the machine are always complete and perfectly legible.<br />
In the event of safety relevant modifications or changes in<br />
the behaviour of the machine/plant during operation stop<br />
the machine/plant immediately and report the malfunction<br />
to the competent authority/person.<br />
Never make any modifications, additions or conversions,<br />
which might affect safety without the supplier’s approval.<br />
This also applies to the installation and adjustment of safety<br />
devices and valves as well as to welding work on load–bearing<br />
elements.<br />
Spare parts must comply with the technical requirements<br />
specified by the manufacturer. Spare parts from original<br />
equipment manufacturers can be relied to do so.<br />
Never modify the software of programmable control systems.<br />
Replace hydraulic hoses within stipulated and appropriate<br />
intervals even if no safety relevant defects have been detected.<br />
For the execution of maintenance work, tools and workshop<br />
equipment adapted to the task on hand are absolutely indispensable.<br />
The personnel must be familiar with the location and operation<br />
of fire extinguishers.<br />
Observe all fire–warning and fire–fighting procedures.<br />
Accident preventing devices, which are not included in the<br />
scope of supply, such as protective guarding, are to be provided<br />
by the customer in accordance with the local safety<br />
regulations.<br />
Selection and qualification of personnel<br />
Any work on and with the machine/plant must be executed<br />
by reliable personnel only. Statutory minimum age limits<br />
must be observed.<br />
Employ only trained or instructed staff and set out clearly<br />
the individual responsibilities of the personnel for operation,<br />
set–up, maintenance and repair.<br />
Make sure that only authorized personnel works on or with<br />
the machine.<br />
Define the machine operator’s responsibilities – also with<br />
regard to observing traffic regulations – giving the operator<br />
the authority to refuse instructions by third parties that are<br />
contrary to safety.<br />
Do not allow persons to be trained or instructed or persons<br />
taking part in a general training course to work on or with<br />
the machine/plant without being permanently supervised<br />
by an experienced person.<br />
Work on the electrical system and equipment of the machine/plant<br />
must be carried out only by a skilled electrician or<br />
by instructed persons under the supervisions and guidance<br />
of a skilled electrician and in accordance with electrical engineering<br />
rules and regulations.<br />
Work on gas–fuelled equipment (gas consumers) may be<br />
carried out by specially trained personnel only.<br />
Work on the hydraulic system must be carried out only by<br />
personnel with special knowledge and experience of hydraulic<br />
equipment.<br />
7 EN
Safety instructions governing specific operational<br />
phases<br />
Avoid any operational mode that might be prejudicial to<br />
safety.<br />
Take the necessary precautions to ensure that the machine<br />
is used only when in a safe and reliable state. Operate the<br />
machine only if all protective and safety– oriented devices,<br />
such as removable safety devices, emergency shut–off<br />
equipment, sound–proofing elements and exhausters, are<br />
in place and fully functional.<br />
Check the machine/plant at least once per working shift<br />
for obvious damage and defects. Report any changes (incl.<br />
changes in the machine’s working behaviour) to the competent<br />
organization/person immediately. If necessary, stop<br />
the machine immediately and lock it.<br />
In the event of malfunctions, stop the machine/plant immediately<br />
and lock it. Have any defects rectified immediately.<br />
Before starting up or setting the machine/plant in motion,<br />
make sure that nobody is at risk.<br />
Never switch off or remove suction and ventilation devices<br />
when the machine is in operation.<br />
Brief operating personnel before beginning special operations<br />
and maintenance work, and appoint a person to supervise<br />
the activities.<br />
Ensure that the maintenance area is adequately secured!<br />
Lift units must be secured by mechanical fall–safety units<br />
(clamps), before entering the machine!<br />
If the machine/plant is completely shut down for maintenance<br />
and repair work, it must be secured against inadvertent<br />
starting by:– locking the principal control elements and<br />
removing the ignition key and/or– attaching a warning sign<br />
to the main switch.<br />
Carry out maintenance and repair work only if the machine<br />
is positioned on stable and level ground and has been secured<br />
against inadvertent movement and buckling!<br />
To avoid the risk of accidents, individual parts and large assemblies<br />
being moved for replacement purposes should be<br />
care-fully attached to lifting tackle and secured. Use only<br />
suitable and technically perfect lifting gear and suspension<br />
systems with adequate lifting capacity. Never work or stand<br />
under suspended loads!<br />
For carrying out overhead assembly work always use specially<br />
designed or otherwise safety–oriented ladders and working<br />
platforms. Never use machine parts as a climbing aid.<br />
Wear a safety harness when carrying out maintenance work<br />
at greater heights. Keep all handles, steps, handrails, platforms,<br />
landings and ladders free from dirt, snow and ice.<br />
Clean the machine, especially connections and threaded<br />
unions, of any traces of oil, fuel or preservatives before<br />
carrying out maintenance/repair. Never use aggressive detergents.<br />
Use lint–free cleaning rags.<br />
Before cleaning the machine with water, steam jet (high–<br />
pressure cleaning) or detergents, cover up or tape shut all<br />
openings which – for safety and functional reasons – must<br />
be protected against water, steam or detergent penetration.<br />
Special care must be taken with electric motors and<br />
switchgear cabinets.<br />
Ensure during cleaning of the machine that the temperature<br />
sensors of the fire– warning and fire–fighting systems<br />
do not come into contact with hot cleaning agents as this<br />
might activate the fire–fighting system.<br />
After cleaning, remove all covers and tapes applied for that<br />
purpose.<br />
After cleaning, examine all fuel, lubricant, and hydraulic<br />
fluid lines for leaks, loose connections, chafe marks and<br />
damage. Any defects found must be rectified without delay.<br />
Always tighten any screwed connections that have been<br />
loosened during maintenance and repair.<br />
Any safety devices removed for set–up, maintenance or repair<br />
purposes must be refitted and checked immediately<br />
upon completion of the maintenance and repair work.<br />
Ensure that all consumables and replaced parts are disposed<br />
of safely and with minimum environmental impact.<br />
Before setting the machine in motion always check that the<br />
accessories have been safely stowed away.<br />
Avoid any operation that might be a risk to machine stability.<br />
Do not step on conveying equipment.<br />
The fastening of loads and the instructing of crane operators<br />
should be entrusted to experienced persons only. The<br />
mars-holler giving the instructions must be within sight or<br />
sound of the operator.<br />
8 EN
Warning of special dangers<br />
Electric energy<br />
Use only original fuses with the specified current rating.<br />
Switch off the machine/plant immediately if trouble occurs<br />
in the electrical system.<br />
Work on the electrical system or equipment may only be<br />
carried out by a skilled electrician himself or by specially<br />
instructed personnel under the control and supervision of<br />
such electrician and in accordance with the applicable electrical<br />
engineering rules.<br />
If provided for in the regulations, the power supply to parts<br />
of machines and plants, on which inspection, maintenance<br />
and repair work is to be carried out must be cut off.<br />
Before starting any work, check the de–energized parts for<br />
the presence of power and ground or short–circuit them in<br />
addition to insulating adjacent live parts and elements.<br />
The electrical equipment of machines/plants is to be inspected<br />
and checked at regular intervals. Defects such as loose<br />
connections or scorched cables must be rectified immediately.<br />
Necessary work on live parts and elements must be carried<br />
out only in the presence of a second person that can cut<br />
off the power supply in case of danger by actuating the<br />
emergency shut–off or main power switch. Secure the working<br />
area with a red– and–white safety chain and a warning<br />
sign. Use insulated tools only.<br />
Before starting work on high–voltage assemblies and after<br />
cutting out the power supply, the feeder cable must<br />
be grounded and components, such as capacitors, short–<br />
circuited with a grounding rod.<br />
EMERGENCY OFF equipment must not be bridged nor set<br />
out of function.<br />
Close area by means of a red and white chain and a warning<br />
panel. Use voltage insulated tools only.<br />
Actuation of the sensors can trigger hazardous machine<br />
functions. Use covers, protective fence or safety light barriers<br />
to prevent access. Set up warning signs.<br />
Plug or unplug quick disconnects only when mains off.<br />
Hydraulic and pneumatic equipment<br />
Work on hydraulic equipment may be carried out only by<br />
persons having special knowledge and experience in hydraulic<br />
systems.<br />
Check all lines, hoses and screwed connections regularly<br />
for leaks and obvious damage. Repair damage immediately.<br />
Splashed oil may cause injury and fire.<br />
Depressurize all system sections and pressure pipes (hydraulic<br />
system, compressed–air system) to be removed in<br />
accordance with the specific instructions for the unit concerned<br />
before carrying out any repair work.<br />
Hydraulic and compressed air lines must be laid and fitted<br />
properly. Ensure that no connections are interchanged. The<br />
fittings, lengths and quality of the hoses must comply with<br />
the technical requirements.<br />
Noise<br />
During operation, all sound baffles must be closed. Always<br />
wear the prescribed ear protectors.<br />
Hazardous substances for humans and the<br />
environment<br />
When handling oil, grease and other chemical substances,<br />
observe the product related safety regulations. Be careful<br />
when handling hot consumables (risk of burning or scalding)!<br />
Mobile Machine<br />
For loading only use lifting gear and tackle of sufficient<br />
capacity. Appoint a competent marshaller to assist in the<br />
lifting operations. Lift machinery and equipment properly<br />
with suitable lifting gear and only in accordance with the<br />
operating instructions (fixing points for lifting tackle, etc.).<br />
Only use suitable means of transport of adequate carrying<br />
capacity. Do not stay or work below suspended loads. Fasten<br />
the loads safely using the suitable fixing points.<br />
Before or immediately after completion of the loading operations<br />
the machine/plant must be secured by means of<br />
recommended/supplied devices against unintentional changes<br />
of position and a corresponding warning sign attached<br />
to the ma-chine/plant.<br />
Before re-commissioning the machine/plant these devices<br />
must be properly removed. Carefully refit and fasten all<br />
parts to be removed for transport purposes before re-commissioning<br />
the machine/plant.<br />
Cut off the external power supply of the machine or plant<br />
even if only minor changes of place are envisaged. Properly<br />
re-connect the machine to the supply mains before<br />
re-commissioning.<br />
9 EN
CYKLOP TEKNIK AB<br />
CYKLOP TEKNIK AB<br />
2. Main machine parts<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Machine<br />
plate<br />
Mast<br />
Top plate (optional)<br />
Control cabinet<br />
Prestretch unit<br />
Weld (optional)<br />
Cutter unit<br />
Film retainer arm<br />
Conveyor<br />
(roller conveyor is shown in<br />
the illustration)<br />
Chassis<br />
10 EN
3. Control cabinet<br />
3.1 OVERVIEW<br />
<br />
Pos Type<br />
Rotary switch<br />
Function<br />
Main switch, lockable<br />
<br />
Rotary lamp button<br />
Control voltage<br />
<br />
Lamp pushbutton<br />
Start mode / Alarm reset<br />
<br />
Lamp pushbutton<br />
Automatic<br />
<br />
Pushbutton<br />
Start<br />
<br />
<br />
<br />
Pushbutton<br />
Pushbutton<br />
Machine stop<br />
Emergency stop<br />
<br />
<br />
<br />
<br />
Lamp pushbutton<br />
Control system / Display<br />
Request open door / Part-automatic<br />
Program selection/ Parameter setting<br />
<br />
Light tower<br />
Alarm / Indicator, machine to automatic<br />
3.2 EXPLANATION OF BUTTONS<br />
3.2 EXPLANATION OF BUTTONS<br />
"Main switch on / off"<br />
Switch on or off all power to the machine. Remember<br />
always to switch off the power when working on<br />
the machine.<br />
"Control voltage on / off"<br />
Turn clockwise to switch on the control voltage: the<br />
lamp will come on. (Once you<br />
have turned the main switch,<br />
wait 7 seconds before the control voltage can be<br />
switched on.)<br />
"Start mode / Reset alarm"<br />
Press the lamp button to acknowledge an alarm. If<br />
alarm does not stop, the fault is still present. If you press<br />
the button when there are no alarms, the machine<br />
returns to start mode.<br />
"Automatic"<br />
Press the lamp button to switch to automatic mode.<br />
The lamp comes on. If automatic is enabled and you<br />
press this, the automatic lamp goes off and set the<br />
machine to "part-automatic".<br />
"Machine stop"<br />
Press the stop button and the film cycle comes to a<br />
soft stop. If you hold down the machine stop button<br />
for at least 2 sections, a lamp test is executed which<br />
is controlled via the CPU.<br />
"Emergency stop"<br />
Stops the machine and other connected<br />
equipment. Reset the emergency stop to<br />
restart machine operation. This is done by turning<br />
the button clockwise.<br />
"Request open door / Part-automatic"<br />
Press this button to request door opening.<br />
Automatic operation is interrupted and the machine<br />
continues to the end of the cycle. When this is<br />
complete, the lamp comes on and the door can be<br />
opened.<br />
"Display"<br />
All parameter settings<br />
and program selections are<br />
made here.<br />
"Start"<br />
If the film cycle is interrupted (e.g. because the film<br />
has run out), you can restart it after rectifying the problem<br />
(e.g. loading a film). Once the film cycle is complete,<br />
the pallet remains in place on the machine's conveyor.<br />
If you press "Automatic " at the start of the cycle,<br />
the machine returns to continuous automatic operation.<br />
"Light tower"<br />
When the red light is on, an alarm has been activated.<br />
When the green light is one, the machine is<br />
in automatic mode.<br />
11 EN
3.3 LAMP TEST<br />
A lamp test can be executed by pressing the "Automatic" button and holding it down for more than two seconds. If any of the<br />
buttons with integral lamps does not come on when this test is executed, the lamp is broken. Replace the lamp.<br />
4. Display<br />
4.1 OVERVIEW<br />
4.1.1 GENERAL<br />
<strong>GL</strong> <strong>1000</strong> settings are implemented by navigating in the<br />
pressure-sensitive display.<br />
Some buttons with a dark blue background cannot be pressed and<br />
are there only for information.<br />
Press the relevant button in the display to go to the<br />
required submenu or change a value.<br />
4.1.2 PASSWORDS<br />
Some of the pages cannot be accessed without a password. These<br />
can be accessed by service personnel only, for example.<br />
The login box on the right is displayed if the page is<br />
password-protected. Press to log in. A keypad<br />
then appears in the display. Type your password and then "ENT"; the<br />
login page is then displayed again. Then press to return to the<br />
password-protected page.<br />
4.2 HOME MENU<br />
Continue to the alarm page. When an alarm has been triggered,<br />
the button lamp is red. See section 4.8, page 15.<br />
Continue to pages showing<br />
Cyklop contact information. See section<br />
4.9, page 19.<br />
Continue to the program parameter settings<br />
menu. See section 4.10, page 17.<br />
The above menu is displayed when the machine is started. This<br />
is the top menu, which is called "home menu" from this point on<br />
in the manual.<br />
Continue to the information menu for film.<br />
See section 4.3, page 11.<br />
Continue to the manual operation menu.<br />
See section 4.5, page 12.<br />
1<br />
Displays the selected program. Continue to the program<br />
selection menu. See section 4.11, page 18.<br />
Step up or down to select a program. See section 4.11, page<br />
18.<br />
Continue to the service menu. See section 4.6, page 14.<br />
PROGRAM 1<br />
Displays the selected program.<br />
Continue to the program<br />
selection menu. See<br />
section 4.11, page 18.<br />
12 EN
4.3 INFORMATION MENU FOR FILM<br />
Switches to the previous screen/menu.<br />
Switches to the first information menu. If you are on the<br />
first page, nothing happens.<br />
Displays explanations for the menu page displayed.<br />
Switches to the home menu.<br />
Switches to the next screen/menu.<br />
The<br />
illustration<br />
on the left<br />
shows the first<br />
page below the<br />
information menu.<br />
The information menu<br />
consists of three pages<br />
in total.<br />
Shows on the right the total number of pallets with film<br />
applied.<br />
Resets the number of pallets with film applied. On the<br />
right, you can see the number of pallets with film applied<br />
since the last reset.<br />
Shows the number of metres of film used by the preceding<br />
pallet. Press the button to change film data. (Password<br />
required.)<br />
Shows the number of grams of film used by the preceding<br />
pallet. Requires the correct data to be input for the<br />
film. Press the button to change film data. (Password<br />
required.)<br />
Shows the number of turns for the preceding film application<br />
or the film application in progress.<br />
Switches to the contact information menu.<br />
Switches to the screen containing information on<br />
the degree of prestretch for different gear modes.<br />
Switches to a page with a graphic overview of sensor<br />
status. See section 4.8.2, page 16.<br />
Press to display an explanation on the digits: this will<br />
appear on the right. (See the illustration below.) Return<br />
by pressing "".<br />
Page number two.<br />
Switches to a page with a graphic overview of sensor<br />
status. See section 4.8.2, page 16.<br />
4.4 NAME PROGRAM<br />
Go into the information menu from the home menu, then scroll<br />
to the third page of information by pressing the down arrow.<br />
To edit a program name, press the required program button.<br />
A button pad will be displayed. Type the required name, then press<br />
"ENT".<br />
Page number three.<br />
13 EN
4.5 MANUAL OPERATION<br />
The machine can be operated manually using buttons<br />
in the display. The illustrations shown below may vary slightly<br />
depending on what options are installed on the<br />
machine.<br />
Sometimes manual operation is not possible; when an alarm has<br />
been activated or the film cycle is in progress, for example.<br />
If manual operation is not possible, the button<br />
with .<br />
is replaced<br />
Switches to the previous screen/menu.<br />
Switches to the first manual operation menu.<br />
If you are on the first page, nothing happens.<br />
Indicates whether manual operation is possible.<br />
If a green tick is displayed, manual opertion is possible.<br />
If a red cross is displayed, manual operation is not<br />
possible.<br />
Switches to the home menu.<br />
Switches to the next screen/menu.<br />
Press the relevant button to move the pallet on the<br />
stretch film applicator to the right or<br />
left.<br />
Page number one.<br />
Press the relevant button to move the pallet towards<br />
or away. (Only on machines with the option 90° input<br />
or output transport.) If the board is not in the correct<br />
position, the board is rotated first.<br />
Press the relevant button to rotate the board clockwise<br />
or counterclockwise.<br />
Press the relevant button to open or close the film<br />
clamp.<br />
Page number two.<br />
Press the relevant button to raise or lower the<br />
top plate. (Only on machines with the option: Top plate.)<br />
Press the relevant button to raise or lower the hoist<br />
with the stretch film unit. When moving downwards, the<br />
hoist stops in the starting position.<br />
Page number three.<br />
14 EN
Press the left arrow button to operate the left conveyor<br />
in combination with the shrink film applicator conveyor.<br />
Press the right arrow button to operate the left<br />
conveyor in combination with the shrink film applicator<br />
conveyor.<br />
Press the button with the green tick when the pallet<br />
is in position on the shrink film applicator conveyor.<br />
Page number four.<br />
Positioning has to take place manually as<br />
there is no automatic pallet sensing on the<br />
board.<br />
Manual operation of conveyor. (Optional.) Click on the relevant<br />
conveyor to activate manual operation. The shrink film applicator<br />
conveyor can also be operated manually.<br />
The conveyor is marked when it is activated by means of a green<br />
field which lights up beneath the conveyor. No more than two<br />
adjacent conveyors can be operated simultaneously.<br />
The first two conveyors are activated in the illustration. The first one<br />
also indicates that there is a pallet on the conveyor.<br />
Page number five.<br />
Press the left arrow button to start transport to the left,<br />
or the right arrow button to start transport to the right.<br />
(Requires the machine to have the option installed<br />
which permits transport forwards / back.)<br />
Remove control of top film applicators such as CTFP, TF or PLR.<br />
Applicable to the functions automatic mode and reset. (This page is<br />
included only if the top film applicator option is installed.)<br />
Sets the top film applicator to automatic mode.<br />
Resetting the top film applicator.<br />
Page number six.<br />
15 EN
4.6 SERVICE<br />
The service pages are accessible to service personnel only.<br />
Press to log in. A keypad then appears in the display. Enter your<br />
password and then press "ENT".<br />
4.7 LANGUAGE SELECTION, DATE SET<br />
P r e s s<br />
to access the service menu.<br />
P r e s s<br />
to access the login page.<br />
Then enter your password and close by pressing "ENT".<br />
The service menu screen should now have changed as shown in<br />
the illustration on the left. (The language button should have been<br />
displayed.)<br />
Press to<br />
Language<br />
continue to language selection.<br />
The language selected is shown in the top right corner. If you<br />
want to select a language different to the one selected, click<br />
on the relevant language button to switch to that language.<br />
Input password<br />
& press "ENT"<br />
Language<br />
16 EN
Press<br />
to continue and set the date and time.<br />
The date and time are used to "time-stamp" alarms, among other<br />
things.<br />
Input password<br />
& press “ENT”<br />
Language<br />
4.8 ALARM / STATUS SENSOR<br />
4.8.1 ALARM MESSAGES<br />
Continue to the alarm page. It is possible to press this<br />
button even when no alarm has been triggered. (The lamp<br />
on the button is white in this instance.)<br />
Current alarms are displayed here.<br />
Continue to alarm history.<br />
The alarm history shows the latest alarms triggered.<br />
Current alarms are also displayed as<br />
scrolling text across the bottom of<br />
the display. Displayed in all menus.<br />
17 EN
4.8.2 GRAPHIC OVERVIEW OF SENSOR STATUS<br />
This machine has a function whereby the sensor status is<br />
displayed graphically.<br />
Some sensors are normally in "on" mode, and some sensors are<br />
normally in "off" mode.<br />
Press the relevant part of the machine display to move on to a<br />
more detailed position indication.<br />
See below for a display overview.<br />
The ones with an erroneous status are framed red. Other<br />
sensors affected have a green frame.<br />
To the left, you can see an example of how an erroneous signal<br />
from a sensor might look. If an erroneous signal is displayed, try<br />
to move the machine to start mode and see whether it disappears.<br />
If the erroneous signal is still displayed, the sensor may be faulty.<br />
18 EN
4.9 CONTACT INFORMATION<br />
The contact pages contain information to allow you to contact<br />
your nearest Cyklop company to book a service or place an order for<br />
consumables or spares.<br />
4.10 SETTING PROGRAM PARAMETERS<br />
Values in brackets are max and min values that can be set.<br />
Select a program for parameter editing. (1-9)<br />
Film tension at start of film cycle. (0-90)<br />
Film tension at top of pallet. (0-90)<br />
Film tension in middle of pallet. (0-90)<br />
Page number one.<br />
Film tension at bottom of pallet. (0-90)<br />
Change film pattern. (1-6)<br />
Number of top turns. (0-15)<br />
Number of bottom turns. (1-15)<br />
Rate of film application upwards. (12-75)<br />
Rate of film application downwards. (12-75)<br />
Fig. 2<br />
The above explanations are also available in English in a<br />
submenu (Fig. 2). Press to go to this page.<br />
This explanation menu also includes a submenu with a<br />
graphic explanation (Fig. 3) for the relevant film pattern.<br />
Press or to go to this page.<br />
See section 5.7, page 21 for further information.<br />
Fig. 3<br />
19 EN
Change programs. (1-9)<br />
How high film is to be applied in relation to the top of<br />
the pallet. (0-500)<br />
Page number two.<br />
Value indicating how far down from the top<br />
edge of the pallet film is to be applied. The<br />
value is given in millimetres. Adjustable<br />
values are "0" to "999" mm. The values between "0" and<br />
998 correspond to the number of millimetres from the<br />
top edge of the pallet. If you input a value of "999", the<br />
hoist for the film unit always goes<br />
down to the lowest height for<br />
cutting. (0-999)<br />
Interim speed before rotary board reaches<br />
high speed. (0-999)<br />
Top plate. (Optional.)<br />
Top film. (Optional.)<br />
Top rotary board speed during film cycle. (25-100)<br />
Fig. 2<br />
Weld time. (0.05-2.00)<br />
The above explanations are also available in English in a<br />
submenu (Fig. 2). Press to go to this page.<br />
The next page shows an overview of the<br />
preset program parameters. There is also<br />
space there for noting your own program<br />
settings.<br />
4.11 PROGRAM SELECTION<br />
Programs can be selected in three ways. press 1 , or PROGRAM 1 .<br />
The third way is to step up and down using the arrow up and arrow<br />
down keys ( ).<br />
Step up or down to select a program.<br />
Fig. 2<br />
Displays the selected program. Press the button and a<br />
keypad is displayed. Then select the relevant number<br />
1<br />
and press "ENT".<br />
PROGRAM 1<br />
20 EN<br />
Displays the selected program.<br />
Continue to the program selection<br />
menu. See Fig. 2.<br />
Programs are selected by pressing the relevant program<br />
button. The program number selected is displayed in the bottom<br />
left corner. Programs can also be selected using an external signal<br />
when the machine is in automatic mode.
5. Operate the machine<br />
5.1 STARTUP - START UP THE MACHINE AND RUN IT TO STARTING POSITION<br />
<br />
Make sure that the machine is powered up<br />
and has a compressed air feed to it.<br />
<br />
The lamp for alarms should now have gone<br />
off.<br />
<br />
Check that the emergency stop button is not<br />
depressed.<br />
<br />
The lamp button "Start mode/Alarm reset"<br />
comes on.<br />
<br />
<br />
Turn the main switch. Wait for about 7 seconds<br />
before step 4.<br />
Turn the rotary lamp button "Control voltage"<br />
clockwise.<br />
<br />
The button for semiautomatic operation<br />
in the display has lit up. The display<br />
should look as shown below, possibly<br />
with a different program selection.<br />
The machine is now in start mode and<br />
semiautomatic mode.<br />
<br />
The alarm lamp in the light tower comes on.<br />
<br />
5.2 LOAD FILM<br />
Press the alarm button "Start mode/Alarm<br />
reset". If alarms are shown in the display,<br />
acknowledge these first and then press the<br />
button again. Any parts of the machine which<br />
are not in starting position will be moved to<br />
there.<br />
NOTE: If the machine is placed in an cold environment and equipped with the<br />
-6° or -28° option, keep in mind that the film must have the same temperature<br />
as the surroundings where it will be used. Store the film in the same room as the<br />
machine for at least 24h before use.<br />
1. Check which side of the film is sticky. If the outside is sticky<br />
(most common), the roll of film must rotate counterclockwise (Fig. 1). If the<br />
inside is sticky, it must rotate clockwise (Fig. 2).<br />
2. Insert a new roll of film by pressing it down over the roller "A" (Fig. 3). Take<br />
care to make sure the roll bottoms out. NOTE: Handle the roll of film with<br />
care so as not to damage it, as this may cause the film to break.<br />
Fig. 1.<br />
3. Pull the film as shown in Fig. 1 or 2. The easiest thing to do is fold the end<br />
of the film in four and pull it between the top part of the rollers as shown in<br />
Fig. 3, B (grey area).<br />
4. Secure the end of the film in the clamp on the film retainer arm on the<br />
rotary board on the machine (Figure 4). Press and hold down the valve button "D" to<br />
open the clamp. Note that the clamp will close again as soon as the<br />
valve button is released.<br />
B<br />
Fig. 2. Fig. 4.<br />
Risk of cutting!<br />
The flanges on the<br />
roller may be sharp.<br />
Fig. 3.<br />
A<br />
Warning!<br />
The machine has a number of points where<br />
there is a risk of getting trapped or cut.<br />
Take great care when in the machine's<br />
operating range.<br />
D<br />
21 EN
5.3 SET PRESTRETCH OF FILM<br />
Use the gear control (see the figure on the left) directly above the<br />
roll of film to set different degrees of prestretch.<br />
Gear 1= 60%<br />
Gear 2= 100%<br />
Gear 3= 130%<br />
Gear 4= 160%<br />
Gear 5= 200%<br />
Gear 6= 280%<br />
Gear 7= 340%<br />
Gear 8= 400%<br />
If you select a high gear, the film will be thinner on the pallet goods.<br />
This means less film consumption per pallet, but it also requires a<br />
higher film quality than a lower gear. Start with gear 6, for example,<br />
to see whether the film holds. If it breaks, switch to a lower gear or<br />
a higher film quality.<br />
5.4 SET FILM TENSION<br />
Film tension parameters are set via the display.<br />
See section 4.10, page 19 for information on the buttons.<br />
The film tension is adjustable for every program and for different<br />
parts of the film cycle.<br />
Value set to "0" = Low film tension<br />
Value set to "90" = High film tension<br />
This value corresponds to the percentage reduction in motor torque.<br />
Example:<br />
If a value "25" is set, this is equivalent to the pallet/rotary board<br />
pulling 25% and the motor feeding 75%.<br />
5.5 START THE MACHINE<br />
<br />
IF THE MACHINE HAS A PALLET<br />
STANDING ON THE CONVEYOR<br />
Make sure that the machine is in start mode.<br />
See section 5.1, page 19.<br />
IF THE MACHINE DOES NOT HAVE A<br />
PALLET STANDING ON THE CONVEYOR<br />
<br />
Make sure that the machine is in start mode.<br />
See section 5.1, page 19.<br />
<br />
Select a program. See section 4.11, page 18.<br />
<br />
Select a program. See section 4.11, page 18.<br />
<br />
Press the "Start" button. This needs to be<br />
done only if the machine has a pallet on the<br />
conveyor.<br />
<br />
Press the "Automatic" button to switch to automatic<br />
mode.<br />
<br />
Press the "Automatic" button to switch to automatic<br />
mode.<br />
The machine is now ready for operation and in<br />
automatic mode.<br />
The machine is now ready for operation and in<br />
automatic mode.<br />
22 EN
5.6 PAUSE IN AUTOMATIC MODE<br />
<br />
<br />
Pause in automatic mode can be used if the<br />
operation needs to enter the machine's operating<br />
area.<br />
Press the button "Request open door". This<br />
button then starts to flash.<br />
The machine stops and the lamp for the button<br />
"Request open door" is on continuously.<br />
<br />
<br />
<br />
Check that nobody is present within the safety<br />
fencing before closing the gate.<br />
Acknowledge with the button "Start mode /<br />
Reset alarm".<br />
The lamp for alarms on the light tower should<br />
now have gone off and the button "Start<br />
mode / Reset alarm" comes on.<br />
<br />
Open the gate and do what has to be done.<br />
The alarm lamp comes on at the light tower.<br />
<br />
Press the "Automatic" button to return to automatic<br />
mode.<br />
Warning!<br />
The machine has a number of points where<br />
there is a risk of getting trapped or cut.<br />
Take great care when in the machine's<br />
operating range.<br />
The machine will now continue in<br />
automatic mode from the position<br />
in the sequence<br />
where it was interrupted.<br />
5.7 DESCRIPTION OF FILM PATTERN<br />
Pattern 1 - Dust-protected /<br />
Secure<br />
This film program starts at the bottom<br />
and ends at the top. With the parameter<br />
"Down before cutting" and the<br />
value set to "999", the hoist moves<br />
down to the lowest height for cutting.<br />
(Gives one to two layers of film.)<br />
The number of bottom and top turns, film<br />
tension, film overlap, etc. can be selected<br />
via film parameters.<br />
TS<br />
Topsheet<br />
Pattern 4 - Water-protected (Requires<br />
optional top film equipment)<br />
This film program starts at the bottom,<br />
then pauses at the top where top<br />
film is applied. The film sequence<br />
then continues and can be<br />
terminated at either the top<br />
or the bottom of the pallet.<br />
The number of bottom and top turns, film<br />
tension, film overlap, etc. can be<br />
selected via film parameters.<br />
Pattern 2 - Secure<br />
This film program starts at the bottom,<br />
applies film up to the top and then<br />
applies film down to the bottom and<br />
up to the lowest height for cutting.<br />
(Gives two-and-a-half layers of film.)<br />
The number of bottom and top turns, film<br />
tension, film overlap, etc. can be selected<br />
via film parameters.<br />
Pattern 5 - Custom (Optional)<br />
Pattern 3 - Extra secure<br />
This film program starts at the bottom,<br />
applies film up to the top and then<br />
applies film down to the bottom and ends<br />
at the top. With the parameter<br />
"Down before cutting" and the value<br />
set to "999", the hoist moves<br />
down to the lowest height for<br />
cutting. (Gives three to four layers of<br />
film.)<br />
The number of bottom and top turns,<br />
film tension, film overlap, etc. can be<br />
selected via film parameters.<br />
Pattern 6 - Through-transport<br />
The pallet is transported through the<br />
machine without film being applied.<br />
23 EN
6.1 CLEANING<br />
6. Care and daily maintenance<br />
(Trained personnel only)<br />
Always keep the area inside and around the machine clean and tidy. Get into the habit of checking over the machine at least once a<br />
week, and clean if so required. Use a damp cloth with water and washing-up liquid.<br />
ATTENTION !<br />
The installation should be turned off before<br />
cleaning. Lock the master switch located<br />
on the mast so that the installation<br />
can’t be turned on while cleaning is in<br />
progress.<br />
WARNING !<br />
Ensure that electrical components are<br />
not in contact with water or other liquids.<br />
When the machine is cleaned by<br />
staff other than the operator, eg a cleaner,<br />
he or she must be given instructions<br />
regarding cleaning of the machine<br />
6.2 SERVICE & MAINTENENCE<br />
Within the warranty period, repairs may only<br />
be performed under the supervision of a<br />
technichian of the supplier.<br />
The quality of any replacement part must at least<br />
correspond to the one of the original part (compare specifications).<br />
All parts can be ordered from the manufacturer.<br />
As a precaution, it may be advisable to stock some spare<br />
parts to minimize downtime. Consult the manufacturer. See<br />
”Recommended spare parts list” last in the spare parts section.<br />
The installation consists mainly of standard parts (which<br />
can be purchased on the open market), but also of original<br />
parts (which are available from the manufacturer).<br />
Standard parts:<br />
• Use preferably the same make as the original. If in doubt,<br />
consult the supplier.<br />
Original parts:<br />
• Replacement parts must be ordered from the supplier.<br />
WARNING !<br />
Deviations from the above rules can<br />
have consequences that endanger the<br />
safe operation of the installation and<br />
the warranty period will be forfeited.<br />
The manufacturer is not responsible for<br />
events resulting from such deviations.<br />
SERVICE AND MAINTENANCE<br />
The power should be broken with the<br />
power main switch during service or<br />
maintenance. Also the main switch must<br />
be locked to prevent unplanned actuation.<br />
ELECTRICAL WORKS<br />
Although the power switch is turned off<br />
some electricity may remain in the<br />
installation, eg in capacitors or in the<br />
form of potential energy differences.<br />
Therefore wait a few minutes before<br />
work with electrical wiring can begin.<br />
24 EN
Air and power must be switched off before work may commence on the machine. Make sure that there are no goods on the machine.<br />
To be checked Adjustment and/or lubrication Range<br />
General<br />
Cleaning should be carried out around the rotary board and<br />
unit in order to<br />
minimise the risk of problems<br />
Weekly<br />
To be checked Adjustment and/or lubrication Range<br />
Knife, Catcher<br />
Check that the knife blade (A) is not blunt or cracked.<br />
Replace where necessary.<br />
Check that the blade steels (B) are<br />
not cracked or bent. Replace where<br />
necessary.<br />
As necessary<br />
As necessary<br />
Risk of cutting!<br />
The knife and blade steels are sharp.<br />
Discard any worn-out knives/blade<br />
steels in a container for sharp waste.<br />
Do not discard among ordinary waste.<br />
B<br />
A<br />
To be checked Adjustment and/or lubrication Range<br />
Roll of film<br />
- Brake<br />
A<br />
B<br />
Check the friction brake by pulling on the film at<br />
normal film speed and then suddenly releasing the film.<br />
The roll of film should then stop after approx. 1/5 of a turn.<br />
3 mths<br />
Basic setting: Screw down the nut (A) until the spring washer<br />
(B) is fully compressed.<br />
Then unscrew the nut by (A) ¾ turn.<br />
Lubrication!<br />
Apply a lubricant spray with a<br />
pipe. Avoid applying lubrication in<br />
locations not specified.<br />
25 EN
7. Resetting<br />
7.1 FILM BREAKAGE / END OF FILM<br />
If the film has run out or broken, the machine<br />
goes automatically to its starting position.<br />
The alarm lamp comes on at the light tower.<br />
<br />
The lamp for alarms on the light tower should<br />
now have gone off and the button "Start<br />
mode / Reset alarm" comes on.<br />
<br />
<br />
<br />
<br />
Press the button "Start mode / Reset" to<br />
acknowledge the alarm. The button lights up.<br />
Press the button "Request open door" and<br />
the button will light up.<br />
Open the gate and go in and - if the film has<br />
run out - switch to a new roll of film. If the<br />
film has broken, secure the end of the film in<br />
the film retainer. See section 5.2, page 19 for<br />
further information.<br />
Check that nobody is present within the safety<br />
fencing before closing the gate.<br />
Once the gate is closed, the contactor<br />
automatically applies the gate switch.<br />
Acknowledge by pressing either "Request<br />
open door" or "Start mode / Reset alarm".<br />
<br />
<br />
The button for semiautomatic operation in<br />
the display has lit up. The machine is now in<br />
start mode and semiautomatic mode.<br />
If there is a pallet in the machine which needs<br />
to have film applied again, press the button<br />
"Cycle start" to start the film cycle.<br />
Press the "Automatic" button once the cycle<br />
has started.<br />
When the film cycle is complete, the pallet<br />
will be transported out of the machine and<br />
the machine will continue to operate in<br />
automatic mode.<br />
7.2 MACHINE STOP ACTIVATED<br />
<br />
<br />
If the button "Machine stop" has been<br />
depressed during any sequence, the<br />
sequence in progress will be terminated. The<br />
alarm lamp comes on at the light tower.<br />
Press the button "Start mode / Reset".<br />
Press the button "Start mode / Reset" again.<br />
Any parts of the machine which are not in<br />
starting position will be moved to there.<br />
<br />
<br />
<br />
If there is a pallet in the machine which<br />
needs to have film applied again, press the<br />
button "Cycle start" to start the film cycle.<br />
Press the "Automatic" button once the cycle<br />
has started.<br />
When the film cycle is complete, the pallet<br />
will be transported out of the machine and<br />
the machine will continue to operate in<br />
automatic mode.<br />
7.3 EMERGENCY STOP ACTIVATED<br />
<br />
<br />
<br />
<br />
If the button "Emergency stop" has been<br />
depressed during any sequence, the<br />
sequence in progress will be<br />
stopped immediately and the alarm<br />
lamp will come on at the light tower.<br />
Release the emergency stop button.<br />
Rotate the button "Control voltage" clockwise<br />
to on position. The lamp comes on.<br />
Press the button "Start mode / Reset" to acknowledge<br />
the alarm.<br />
Press the button "Start mode / Reset" again.<br />
Any parts of the machine which are not in<br />
starting position will be moved to there.<br />
<br />
<br />
<br />
<br />
The lamp for alarms on the light tower should<br />
now have gone off.<br />
If there is a pallet in the machine which needs<br />
to have film applied again, press the button<br />
"Cycle start" to start the film cycle.<br />
Press the "Automatic" button once the cycle<br />
has started.<br />
When the film cycle is complete, the pallet<br />
will be transported out of the machine and<br />
the machine will continue to operate in automatic<br />
mode.<br />
26 EN
7.4 LIGHT BEAM WHICH HAS TRIPPED (OPTIONAL)<br />
<br />
<br />
In some cases, a reset can be executed<br />
without going into the machine's operating<br />
range. The following description is applicable<br />
if the operator needs to go in to reset light<br />
boom.<br />
Open the gate. The alarm lamp comes on at<br />
the light tower. Go in and reset light boom.<br />
When the gate is closed, acknowledge with<br />
the button "Start mode / Reset alarm".<br />
<br />
<br />
The lamp for alarms on the light tower should<br />
now have gone off and the button "Start<br />
mode / Reset alarm" comes on.<br />
If the machine was in automatic mode before<br />
the pause in automatic mode, press the<br />
button "Automatic".<br />
The machine will now continue at the point<br />
where it left off in the automatic sequence.<br />
The machine will continue working in automatic<br />
mode.<br />
27 EN
8. General troubleshooting<br />
8.1 TROUBLESHOOTING<br />
Problem<br />
If nothing works<br />
Action<br />
Check that the machine is powered up and that the main switch and the rotary knob for control<br />
voltage are set to position "1". Try holding down "Machine stop" for 3 s.<br />
Then press "Reset". Run to starting position.<br />
Error message "A2", main contactor not on, check that the emergency stop is not depressed. If it is,<br />
turn the button clockwise to release it.<br />
If the film breaks Check that the roll of film has sustained no damage. Replace the roll of film if it has. See section 7.1,<br />
page 23 for resetting.<br />
If the rotary board stops<br />
in the wrong position<br />
If the film is not applied<br />
right up to<br />
the top of the goods<br />
The display is not working.<br />
The hoist does not operate<br />
and gives error message<br />
"A15", "A16" or "A4"<br />
Press the button "Start mode / Reset alarm" to return the rotary table to home position.<br />
Check the goods height sensor. Check the film application settings: read "Display - Pallet parameters"<br />
(password required).<br />
The machine can be run, but only with the latest cycle setting (program selection) run. Contact<br />
Cyklop.<br />
The obstruction protection under the hoist or cutting unit may be activated. Check that there is nothing<br />
under the hoist or cutting unit. With error message "A4", check the hoist pulse sensor.<br />
28 EN
9. Transport<br />
9.1 TRANSPORT<br />
The machine must be transported by truck. The machine can be<br />
lifted from the long sides or from the front. Do not lift from the side<br />
with the electrical cabinet. See illustrations.<br />
If the machine is lifted from the side, the truck must have forks<br />
which reach through the entire machine chassis.<br />
If the machine is lifted from the front, the truck must have forks<br />
long enough to reach the centre beam (A).<br />
Lift the machine carefully and transport it slowly.<br />
Risk to life!<br />
Remaining under any type of<br />
suspended load, or working<br />
there, may risk your life!<br />
A<br />
Service area: Minimum of 1 m around the machine is needed for service.<br />
The service places of the machine must be reachable by approved<br />
person lift or similar, alternatively, the customer takes responsibility<br />
that the machine’s service can be performed. NOTE! This will then<br />
be determined at the time of procurement.<br />
Transport<br />
National rules and regulations must be observed when transporting<br />
Cyklop film stretch machines and accessories.<br />
Individual parts and large components are carefully fixed during<br />
delivery. When the machine is assembled or moved, great care<br />
must be taken. Check that the lifting device is designed to take the<br />
weight and does not pose a safety risk.<br />
Only approved lifting devices with a lifting capacity greater than<br />
the total weight of the machine, plus packaging, may be used.<br />
Dimensions and weight<br />
The delivery note with the goods includes details on the weight and<br />
dimensions of the goods.<br />
General rules<br />
Unless stated otherwise, all parts must be transported in their original<br />
packaging to the installation site. When unpacked, all parts<br />
must be examined so that any transport damage can be found. If<br />
the goods have been damaged in transit, the shipping agent must<br />
be contacted immediately and unpacking must be stopped.<br />
Transport damage<br />
Any damage to the goods must<br />
be noted on the delivery note<br />
when the goods are received.<br />
No exceptions!<br />
Risk of damage!<br />
The centre of gravity of the machine may be high,<br />
which increases the risk of the machine tipping<br />
over. Check carefully where the centre of gravity<br />
is so as to eliminate the risk of tipping.<br />
29 EN
10. Technical specifications<br />
Machine<br />
Capacity<br />
Rotary board speed<br />
Hoist speed<br />
Temperature range<br />
Safety class<br />
Max 80 pallet/h (depending on goods type)<br />
Max 23 r/min<br />
Max. 0.6 m/s<br />
+5 to +35°C, for use in a dry, tempered area<br />
2<br />
Electricity<br />
Connection<br />
Output<br />
Safety norm<br />
EX-classification<br />
3x400 V + N + PE, 50 Hz<br />
t.b.a. kW<br />
IP54<br />
Not approved for ATEX classified areas<br />
Pallet goods<br />
Min size (length x width)<br />
Max size (length x width)<br />
Lowest inc. pallet<br />
Height inc. pallet<br />
Weight<br />
0.4 x 0.6 m<br />
1.2 x 1.2 m or 1.4 x 1.0 m<br />
>500 mm (depending on goods type)<br />
Std. height 2500 mm<br />
Max 1500 Kg<br />
<strong>Stretch</strong> film<br />
Diameter, core<br />
Outer diameter, max<br />
Film width, max<br />
Film thickness<br />
76.4 mm +-<br />
250 mm<br />
500 mm<br />
12-25 my, 20 my recommended<br />
The above values apply to standard machines. These values may differ if the machine is<br />
fitted with additional options.<br />
30 EN
11. Table of set values, program parameters<br />
Film parameters<br />
Prog 1 Prog 2 Prog 3 Prog 4 Prog 5 Prog 6 Prog 7 Prog 8 Prog 9<br />
1 1 1 6<br />
10 10 10<br />
15 15 15<br />
15 15 15<br />
15 15 15<br />
2 2 2<br />
3 3 3<br />
35 35 35<br />
35 35 35<br />
75 75 75<br />
100 999 999<br />
75 75 75<br />
60 60 60<br />
1,00 1,00 1,00<br />
No No No<br />
No No No<br />
31 EN
Version log<br />
1.0 Initial release<br />
1.1 Version log added.<br />
EC declaration updated according to new machine directive.<br />
2.0 EG-declaration updated with SS-EN 415-6, Packaging machines<br />
safety.<br />
General safety instructions uppdated with unauthorized use.<br />
Installation updated with service area.<br />
2.1 Temperature information for stretch film handling added.<br />
32 EN
33 EN
Ver. 1.0<br />
English<br />
Deutsch<br />
Svenska<br />
Art.no: 961010EN