Manual Palletizer 825pa001

BOATO INTERNATIONAL S.p.A. a s.u.
Via Chico Mendes n. 7

34074 Monfalcone (GO) Italy
Tel. +39 0481711811
Fax +39 0481482360
www.boato.com - info@boato.com
modif ied bit umen membrane plants
Automatic palletising sections for

existing production lines
and
Automatic trolley for the full pallets
transport from the palletizers to the
automatic stove mod. FT50
Customer : BITUPLAST C.A.
PROJECTS: 825.000 825.100
USE AND MAINTENANCE MANUAL

(ORIGINAL INSTRUCTIONS)
(ref. 825PA001.pdf)
Soggetta alla direzione e coordinamento di Boato Holding S.p.A.
Cap. Soc. 520.000,00 i.v. - C.F. - P.IVA - Reg. Imp. GO 00402880314
-1-

Tel. +39 0481711811
Fax +39 0481482360
General information
All the operations described or shown in this manual are to be considered as correct, however Boato
International S.p.A. a s.u. will not be held responsible for those operations carried out and not
reported in this manual.
Boato International s.p.a. a s.u. will not be held responsible for any accident or damage to persons
or things due to the non-observance of the safety rules. The safety rules described in this manual
integrate but do not replace the safety rules locally in force that the operators must comply with.
For clearness purposes, the instructions contained in this manual do not include any instruction not
connected to the reasonable use the machine and all its components have been manufactured for.
The instructions in this manual do not include those details that must be part of the average cultural
and technical knowledge of a machine operator. However particular features have been adopted to
prevent residual risks due to a reasonably foreseeable misuse.
Before an intervention as membrane passage, removing of the membrane roll not ejected, etc. on the
winding machine, it is highly recommended that the main switch on the power board if OFF or at
least the emergency push button is activated (pressed).
Before removing any mechanical and/or electrical protection make sure that the main switch on the
power board is OFF. Besides, make sure that the position OFF of the main switch is pointed out
by an apposite warning sign or key-locked.
All and any checking and/or maintenance operations that require the SAFETY PROTECTIONS TO
BE REMOVED are done under the complete responsibility of the user. It is recommended that such
operations are done by qualified and authorised personnel.
Do NOT carry out any intervention not foreseen and described in this manual. Any careless or
temporary repairs could damage to the safety and operations of the machine.

-2-

Tel. +39 0481711811
Fax +39 0481482360
The machines are not dangerous for the operator if it used according to the instructions supplied by
Boato and in condition that the safety devices be maintained constantly in function.
This sheet has the purpose to attest that at the receipt of the machine:
the safety devices are efficient
that the machine is supplied with the use and maintenance manual
that the operators get the responsibility to follow it step by step
note:
if our machine has small anomalies we kindly request to you to lay off the utilization and to
inform us tempestively, this will permit us to improve your production and our service
this manual does not contain detailed descriptions for those procedures, safety principles and
maintenance operations considered as standard procedure in your factory.
It is important to notice that this manual contains some directions that must be strictly followed
to avoid injury to persons, or damage to the machinery thus making it a non-save equipment.

-3-

Tel. +39 0481711811
Fax +39 0481482360
Premise
Kind customer premised that for this kind of machinery does not exist specific legal norms, in any
case these machines have been designed and manufactured according to the Machinery Directives
and in particular according to the following:
Machinery Directive 2006/42/EC (ex Machinery Directive 98/37/EC) and following

modifications
Directive 2006/95/CE, Low Voltage, and following modifications
Directive 2004/108/CE, Electromagnetic Compatibility
Directive 97/23/CE (PED - Pressure Equipment Directive), if applicable
besides the following harmonise/national standards have been applied:

Standard UNI EN ISO 12100: 2010
Safety of machinery. General principles for design Risk

assessment and risk reduction
Standard CEI EN60204-1
Safety of machinery. Electrical equipment of machinery.

Part 1.
Standard UNI EN ISO 13857: 2008
Safety of machinery. Safety distances to prevent hazard

zones being reached by upper and lower limbs
Standard UNI EN ISO 13732-1: 2009
Safety of machinery - Ergonomics of the thermal

environment - Methods for the assessment of human
responses to contact with surfaces - Part 1: Hot surfaces
Standard EN ISO 13849-1:2008
Safety of machinery - Safety-related parts of control

systems - Part 1: General principles for design

-4-

Tel. +39 0481711811
Fax +39 0481482360
Aim of the manual

This manual is intend as a guide for the correct and use in safety of the machine, and for its rational
maintenance. Also general instructions for the demolition and elimination are included in this
document.
It is therefore aimed for the following:
-
operators, the manual is intend as the most complete possible guide with instructions on
machine operation and how to carry out simple checks and how to operate in compliance with
accident-prevention regulations
maintenance staff, the manual provides a detailed programme and instructions of which
interventions are needed to ensure better and long-lasting working period
anyone who has to work with the machine in order to guarantee to him the best safety
conditions.
Use and preservation of the manual

This manual must be considered an integral part of the machine, and must accompany it in the event
of sale.
It must be kept in a place where it can be easily available for consultation.
In case of loss, please promptly contact the manufacturer, who will be glad to supply another copy.
The manufacturer reserves the right to carry out changes to the production and to the manual,
without any obligation to update the previous products and manuals.
No part of this publication can be re-produced without a manufacturers authorisation in writing.
Important warnings for safety

Scrupulously observe the following warning indications:
Means the possibility of injuries to persons or damage to the machinery if the

instructions given are not totally observed
CAUTION
Means high possibility of serious injury or death to persons if the instructions

given are not totally observed
DANGER
NOTE :
provides useful information
It is assumed that the supplied machine will have to be installed in an electromagnetic environment
of industrial type, complying with the emission and immunity values in accordance with the rules in
force.
-5-

Tel. +39 0481711811
Fax +39 0481482360
Reference data
Sections of machinery:
Automatic palletising sections for existing production lines
Job numbers:
825.000 825.100
Serial numbers:
Palletizers:
Automatic trolley:
Year of manufacturing:
2013
Customer:
BITUPLAST, C.A.
Venezuela
825.005 825.102
825.103
Technical assistance requests

In case you need more information, or if you have problems to realise some matters of this manual,
please contact the customer assistance office at the following address and telephone/fax number:
Boato International S.p.A. a s.u.
Via Chico Mendes, 7 - Zona Industriale Schiavetti 34074 Monfalcone (GO) - Italy
Telephone +39 0481/711811, Fax +39 0481/482360
U.R.L.:
http://www.boato.com
EMAIL:
tecnico@boato.com
info@boato.com

(Technical Department)
(General Information)
-6-

Tel. +39 0481711811
Fax +39 0481482360
Transport, lifting and storage

General instructions
In case Boato doesnt carry out the assembly of the machinery, the customer has to define with
Boato the manovering operations. The personnel performing these operations must be equipped
with helmet, gloves, and quick release footwear type complete of protection reinforced metal toe,
anti perforation and anti-slip sole, and complete overalls (individual protection equipment).
Moreover, anyone handling equipment for moving it, for example cranes, fork-lift trucks, bridge
cranes, must be qualified for this job.
All the accident-prevention and safety regulations in force in the country and place of work where
the machine works must be scrupulously observed.
The number of the persons necessary to guarantee that these operations are performed in absolute
safety, must never be less than two.
Before any handling, always make sure that the lifting devices and their accessories (cables, hooks
forks etc.) are suitable for such operation.
Keep a safe distance from suspended loads and make sure that the lifting cables and ropes are in
perfect condition and correctly inserted in their appropriate hooks.
Skilled personnel, with suitable equipment, scrupulously respecting the safety

rules must carry out the transport and lifting operations.
DANGER
Transport
In case the machine have to be transported by sea, the packing consists of a first wrapper of plastic
material containing salts against humidity, and on the outside a specially designed wooden packing
case.
When necessary the machine can be divided into parts for the transport.
In case of transport by truck, the machinery may be loaded onto the bed of the truck fixed to it by
means of tie rods and clamps.
The machine can be also loaded directly onto the truck bed, placing it on a wooden pallet, in such a
way as to allow its movement by forklift trucks.
Lifting
The machinery can be lifted by means of fork-lift, inserting the forks under the base of the machine,
in such a way as to balance the weight or by means of a crane or overhead crane pay attention to
hook the machine properly in order to balance its weight.

-7-

Tel. +39 0481711811
Fax +39 0481482360
Storage
If the machine remains inactive for a long period, it is advisable to proceed as follows:
- if it is packed in a wooden case or in a container with internal protection against humidity, this
will be sufficient for long period of storing;
- if the machine is not packed or has been already used for a periods, before to be stored has to be
cleaned and protected by coating before with a special protective oil and then wrapping it with
sheets of plastic containing salts against humidity.
Machine noise
The machine has been designed and built in such a way as to reduce noise at source.
However, if this machine is installed in reverberated environment or in presence of other noise
sources, and the level of daily exposure of the operator, if continuously exposed, is higher than 80
dB, than risk conditions can occur.
In this case the employer is obliged to provide the workers with individual suitable protection
devices (earmuffs, ear plugs).
Safety analysis
The customer will choose the machines operators and the personnel indicated for the maintenance
operations and for any other interventions on the machine.
The customer has to inform its personnel regarding the possibility of risks during the working
operations and which individual safety protections have to be adopted during the production.
Personnel instructions
The personnel indicated for the use of the machinery must:
- know what mentioned in the manual;
- observe the suggestions regarding the individual safety protections to be adopted.
Only this personnel can approach to the machine only after to have consulted the use and
maintenance manual in order to observe all the safety instruction described.
The manual has to be always at their disposal and has to be acquainted to the new personnel in case
of substitution of the same.

-8-

Tel. +39 0481711811
Fax +39 0481482360
Individual protection equipment

The personnel assigned has to be equipped with the following individual protection equipment:
-
quick release footwear type complete of protection metal toe,

anti perforation and slip sole
complete overalls manufactured in order to avoid that the clothes
get caught on the movable parts
helmet with glasses for head and eyes protection
protection gloves (for thermal risks)
other if necessary
adequate fire extinguishers always available
EN 20345
EN340
EN 397
EN407
The above individual protection equipment has to be supplied from the customer to the personnel
assigned for the use, maintenance or any other intervention on the machine.
IMPORTANT: in case of emergency situations, the operator presses the push-button EMERGENCY
STOP in the control board.
Pushing this push button the machine or any of its part is not in operation and all the electrical
devices on the machine are turned off.
For the start up of the machine again it is necessary to rotate the "EMERGENCY STOP" push button
in order to release it.
Before to start to carry out any operation make sure that the main switch on the power board is
OFF.
CAUTION: please pay the maximum attention to the interventions on pneumatic acted movements
due to the risk of residual energy. Before to carry out any intervention on pneumatic movements, to
disconnect the pipes of compressed air.
In case of ordinary/extraordinary maintenance ensure to switch OFF the

main switch on the electric power board.
DANGER

-9-

Tel. +39 0481711811
Fax +39 0481482360
Fire prevention
It is forbidden to work near to machine utilising welding machine or grinders or any other tools
which can produce flames or localised heating. In case it is necessary to utilise these tools for
maintenance or any other intervention, it is obligatory to follow strictly the following:
-
take off the electricity to the machinery

protect the parts of machinery from the fall of sparks and hot chips by apposite shields nonflammable
to have available a fire extinguishers
This personnel instructed and authorised from the customer have to be equipped with the above
mentioned individual protection equipment.
In any case, these jobs have to be done always in the presence of the personnel assigned for the fire
prevention equipped with fire extinguishers.
General notes for a proper utilisation of the unit

The customer will choose the personnel indicated for the management and maintenance operations
and for any other interventions on the machine.
All the fonts of danger have to be illustrated to the personnel by the customer.
Only this personnel can approach to the machine and has to be protected with the individual safety
protections.
This manual has to be always at their disposal and have to be acquainted to the new personnel in
case of substitution of the same.
All the operations for the maintenance, extraordinary intervention for reparation or modification,
cleaning operation must be carried out strictly with the machinery stopped with the electric voltage
supply taken off.
In case it is necessary to use welding machine or any other tools, which can produce flames or
localised heating, they have to know all the residual risks due to the use of these tools (see the
chapter Fire prevention).
These jobs have to be done with the presence of the personnel assigned for the fire prevention
equipped with fire extinguishers.
At the end of the shift or therefore at the end of the working day, the following components have to
be cleaned:
-
all the photocells (transmitter and receiving)

check and eventually clean all the transmissions on the machine
At the end of the week the following components have to be checked:

-
the proper functioning of the EMERGENCY STOP on the machine and its relative control board
the proper functioning of the limit switches and safety switches
- 10 -

Tel. +39 0481711811
Fax +39 0481482360
The control and power board during the normal functioning of the line has to be always closed.
Only the authorised personnel can approach to the control board with its relative key.
In order to allow reaching easily the EMERGENCY STOP, do not leave any objects close to control
boards that can cause encumbrance.
For modifications to the machine, which can modify the functioning concept of the machinery,
and/or structural modification on the same, we suggest consulting the manufacturer before.
After to have utilised the fire extinguishers take care to substitute the same immediately.
In case of ordinary/extraordinary maintenance and/or

ordinary/extraordinary intervention or reparations ensure to switch OFF the
main switch on the electric power board.
DANGER
!
ATTENTION
All the maintenance operations, reparations, or intervention for putting in

operation the machinery, cleaning operation and functioning control of the
components of the machinery have to be performed strictly by authorized
personnel instructed by the customer and must know what is mentioned in
this manual.
Pay attention when active the pneumatic manual valves. Keep your hands
away from the component pneumatically acted.
ATTENTION
DANGER
It is strictly forbidden any intervention of reparation, modification etc. on

the electric control and power boards if they are supplied by electric
current.
Any type of intervention on the electric control and power boards has to
be done by skilled personnel and authorized by the customer

- 11 -

Tel. +39 0481711811
Fax +39 0481482360
Machinery demolition instructions

For the demolition and scrapping of the machinery, please consider the following information:
- the operation of disassembling and demolition have to be carried out by qualified personnel
- disconnect all cables and wires for the current supply of the machinery before to start to
disassembly the machinery
- discharge, storage and consequently eliminate the special substances of special type or
toxic- injurious as oil on the gearboxes, compound, residue of compound in the tank,
electronic components in the control and power boards. These operations have to be done
according to the standard rules in your country.
- disassemble the machinery taking care to separate the different materials in consideration of
their chemical composition (steel, aluminium, plastic et cetera).
All of these operations have to be done in consideration of your safety standard rules of your
country
Safety norms adopted

On the engineering and manufacturing of the machinery the following norms have been considered:
-
for the platform, parapet and staircase

for the control/power boards
for the safety distance
prEN547-3
CENELEC file EN60204-1
UNI EN 294
The platforms, protection guards, parapets have been

painted with the colour:
yellow RAL 1007
The mobile parts of machinery which may cause risks,

have been painted with the colour:
orange RAL 2010

- 12 -

Tel. +39 0481711811
Fax +39 0481482360
Risks residual - prevention

The personnel indicated for the use of the plant, for the maintenance operations and for any other
interventions must:
- know what mentioned in the above paragraphs
- observe the suggestions regarding the individual safety protections to be adopted
Only this personnel instructed and authorised from the customer can approach to the working area.
In any case all the working operations such maintenance operations, reparations or other can be
done with the machinery stopped and without electricity.
In case it is necessary to use welding machine or any other tools, which can produce flames or
localised heating, they have to know all the residual risks due to the use of these tools.
These jobs have to be done with the presence of the personnel assigned for the fire prevention
equipped with fire extinguishers.
!
CAUTION
In case of maintenance or any other intervention on the machinery (less

than those of normal operation of the machine during production), we
recommend to take off the electricity to the machinery.
These jobs have to be done with the presence of the personnel assigned for
the fire prevention equipped with fire extinguishers
For any cleaning or maintenance operations advise the operators that work
in the area where the machine is installed at the beginning and at the end
of these kind of works
CAUTION
Risks residual - localisation

Even if the personnel utilised for operating on the machinery (and for any other intervention like
maintenance etc.) is qualified, instructed and equipped with the individual protection equipment
notice that even if on the machinery are installed safety protections there are risks residual due to
the following factors:
Parts in motion
Closed the area where are installed the movable parts of the Automatic palletising unit with
fixed protections (protection nets) to avoid the access of the operator into the dangerous area of
this section when the machine is in production.
The access in the are closed by the protection nets is allowed through safety doors. If one of the
doors is opened, all the operations of the area are stopped. To restore the operation it is necessary
to act on the apposite reset push-button.
Installed safety ropes in correspondence of the connection benches of the existent machinery. If
one of the safety barriers is activated, all the operations which involve dangerous movements of
the components in the related areas are stopped, as in emergency condition.
- 13 -

Tel. +39 0481711811
Fax +39 0481482360
Installed a safety barrier with muting system in correspondence of the outlet of the automatic
palletising unit in order to avoid the access of the operator in the area where the dangerous parts
of the palletiser are moving.
Automatic trolley for full pallets transport equipped with safety laser scanner to stop the
translation movement in case of detection of obstacles in the way of the trolley.
Cylinders/rollers in motion
The cylinders during the production turn and have to be observable from the operators during the
membrane production.
Even if during the production it is not necessary to approach these cylinders, during the design and
manufacturing of them we have
applied the following safety standards:
reduction of the cylinders/rollers revolutions as much as possible
elimination of rotating projecting parts
installation of protections, guards on the cylinders/rollers transmissions
Do not remove the safety devices.
DANGER
Do not work on moving members
DANGER
It is compulsory that only qualified personnel approaches and controls
the machinery

- 14 -

Tel. +39 0481711811
Fax +39 0481482360
Pay attention to the hands
DANGER
DANGER
In case of malfunctioning of the machinery or emergency situations

push the button Emergency stop installed in the control board of the
section.
After having solved the problem, in order to start the machine again,
push-button has to be rotated to be released.
This push-button stops any operation of the machine.

- 15 -

Tel. +39 0481711811
Fax +39 0481482360
EC Declaration of Conformity of the Machinery

(within the meaning of Machinery Directive 2006/42/EC)
(see the separated documents)

- 16 -

Tel. +39 0481711811
Fax +39 0481482360
Identification label on the machine

The identification plates shown here below are fixed on the machinery frames:
via Chico Mendes, 7 - Z.I. Schiavetti - 34074 Monfalcone (Italy)

tel. +39 0481 711811 - fax. +39 0481 482360 - www.boato.com
Plant and
model type:
S.L. 825
Automatic palletising unit complete of empty
pallets feeding unit and connection benches
Job number:
825.100
Serial number:
825.102
2013
by Boato International S.p.a. a s.u.

Plant and
model type:
S.L. 825
Automatic palletising unit complete of empty
pallets feeding unit and connection benches
Job number:
825.000
Serial number:
825.005
2013

Plant and
model type:
S.L. 825
Automatic trolley for the full pallets transport
Job number:
825.100
Serial number:
825.103
2013

- 17 -

Tel. +39 0481711811
Fax +39 0481482360
Working area and Overall dimensions

Refer to the drawing 825.PF.002_01, extracted hereinafter:
1.1
Enrrolladora-1
Center shaft
1410 mm. from
the floor
2.1
Enrrolladora-2
Center shaft
1410 mm. from
the floor
Plataforma
de
Enrrollador
1.2
AUTOMATIC
PALLETIZER P2
Plataforma
de
Enrrollador
2.2
AUTOMATIC
PALLETIZER P1
2.3
1.3
AUTOMATIC
TROLLEY
A
3.1
4.1
- Automatic palletising unit with Empty pallets loading system and connection benches: refer
to this manual
- Automatic trolley for the full pallets transport from the palletizers to the automatic stove
mod. FT 50: refer to this manual
- Automatic stove mod. FT 50 operating by thermoretractable film (with manual application
of the plastic hood): refer to the Operating and Maintenance Manual from Company Bocedi
- 18 -

Tel. +39 0481711811
Fax +39 0481482360
Technical description of the equipment and functioning description

Two connections benches are provided for each of the two Automatic palletising unit sections:
- the first connection bench consists of a frame completely welded supporting a motorized
belt conveyor for transferring the roll coming from the existent winder to the next rollers
connection bench. In case of change of production with finished membrane rolls with
different diameter, to avoid the jump of the membrane rolls ejected from the winder to this
bench, two idle rollers vertically adjustable are provided;
- the second connection bench consists of frames supporting a set of motorized transporting
rollers to move the roll of finished product to the next inclined belt transport conveyor. This
bench is provided with a pivoting movement pneumatically acted in order to allow the
discharge of the roll onto the mentioned inclined belt transport conveyor.
The roll of membrane is transported by the inclined belt transport conveyor and then is released
with a lifting system onto the palletiser turning table.
The lifting system is moved by a pneumatic cylinder acting softly with a mechanical leverage to
permit the correct positioning of the roll onto the turning table as well as its compactness with
respect to the other rolls already on the turning table.
When a prefixed number (complete row) of rolls are set on the turning table, it rotates automatically
by 90, thanks to an inverter controlled AC motor, and releases the row of rolls in a vertical position
on the pallet.
The number of rows as well as the number of rolls per row can be set into the touch panel HMI
located on the control board of the machine, described further on in this manual. The software of the
HMI shows graphically the pallet pattern so as to give an immediate sight of the recipe to the
machine operator.
The pallet is situated on a motorized trolley, which is able to move from its loading position
(creation of the pallet) to its unloading position (full pallet unload and empty pallet loading).
During the loading phase, the trolley is moved progressively until it is completely loaded.
Automatically, from the empty pallet section (10 pallet capacity), an empty pallet is loaded onto the
trolley during the unloading (full pallet) phase.

- 19 -

Tel. +39 0481711811
Fax +39 0481482360
The HMI (human-machine-interface), located on the electrical control board of the machine, is of
the touch screen type has a graphic display LCD colours and where all the parameters and cycle
values are viewed and controlled. All these parameters are recordable.
With the HMI it is possible to set the graphic layout of the pallet, named Pallet Recipe (PR). The
PR consists of the following parameters:
- Number of rows on the pallet.
- Number of rolls for each row.
- Disposition (rectangular or staggered arrangement) of the rows in the pallet:
RECTANGULAR
STAGGERED
During the setting of the recipe the display shows in real time the layout of the pallet while being
created, so that the operator can appreciate what is the result of the setting.
In this phase there is also an automatic control of the numbers of rolls per row being input by the
operator so as to avoid impossible configurations and human mistakes.
The PR can be saved in order to be easily recalled at any time according to the membrane being
manufactured and the rolls geometry for them.
During the loading of the rolls in the palletiser, in the home page of the display there is a drawing of
the pallet with circles that represent the rolls. A circle in white colour indicates that the roll is not
placed in the pallet. As soon as the rolls are positioned in the pallet, the colour of the circles
becomes green, and when a row of rolls is completed on the pallet, all the circles of that row
become black. When the pallet is completed, all the circles are black in the display.
In case of manual positioning or removing of rolls

in the pallet by your personnel, those physical
operations must be reported in the HMI by the
operator, in order to have in the display the
correct situation of the pallet in the machine.

40,2
15
405
- 20 -

Tel. +39 0481711811
Fax +39 0481482360
The display can also show:

- The weight of the rolls (if rolls weighing unit is installed in the machinery).
- The partial counting of the finished rolls fabricated.
- The total counting of the finished pallets fabricated.
Protection for every operation (motor) is given by thermal magnetic relays. On the instrument
board there are all the control buttons and warning lights to control each phase of the palletising
cycle. The electrical components are SIEMENS.
The electrical power board is contained in a RITTAL cabinet and is built according to
CENELEC standards.
All the functions are controlled by a PLC (programmable logics controller).
The safety protections are the following:
- Set of security light barriers with emitter and receiver at the entrance and exit of the
machine operating area.
- Set of net fence guard to install all around the line
- Set of key limit switches for fence guard openings for operators access (maintenance).
The Automatic trolley is composed of a tubular frame completely welded supporting a belt of
metallic tubular motorised by a gearmotor assembled on a trolley driven by a second gear motor,
foreseen for running on runways.
It is used for transferring the full pallets coming from the two new palletizing sections to the
automatic stove. Runways, supports for the festoon cable are provided for the control of the
machine. The length of the runways is 8mt approx. designed for running with high speed for
servicing the two production lines (according to this runways length).

- 21 -

Tel. +39 0481711811
Fax +39 0481482360
Mechanical features:
Standard pallets EUR and EUR2: 1)
1200x800mm - 1200x1000mm
Pallet minimum height: 1)
120mm
Pallet maximum height: 1)
160mm
Pallet maximum height with rolls:
1500 mm
Maximum weight of the pallet:
1200 kg
Compressed air:
6 bar
Electric voltage:
440 V, 3 phases 60 Hz
Auxiliaries voltage:
24 VDC
1)
In case different Customized pallet sizes are required, the approval from Boato
International technical department is necessary.

- 22 -

Tel. +39 0481711811
Fax +39 0481482360
Adjustments and preparatory operations
Before any preparatory operation is carried out in the machine

switch OFF the main switch on the power board.
DANGER
!
ATTENTION
DANGER
All the maintenance operations, reparations, or intervention for

putting in operation the machinery, cleaning operation and
functioning control of the components of the machinery have to
be performed strictly by authorized personnel instructed by the
customer and must know what is mentioned in this manual.
Before of any intervention for putting in operation the
machinery after a production stop, cleaning operation or
functioning control of the components of the machinery to be
sure that the main switch on the power board is OFF
Before of any ordinary/extraordinary intervention or
reparations on the machinery the machinery must be stopped
and without electricity
DANGER
Pay attention when active the pneumatic manual valves. Keep

your hands away from the cylinders.
ATTENTION
DANGER
It is strictly forbidden any intervention of reparation,

modification etc. on the electric control and power boards if they
are supplied by electric current.
Any type of intervention on the electric control and power boards
has to be done by skilled personnel and authorized by the
customer

- 23 -

Tel. +39 0481711811
Fax +39 0481482360
Palletizing unit preparatory operations

Before running the palletizing unit for the first time, carry out the following operations:
-
Trolley brake adjustment

The trolley brake have to be adjusted acting to the knurled knob pos. A2 (fig.2) in order to
increase or decrease the braking effect considering the requirement.
A2
fig.2

- 24 -

Tel. +39 0481711811
Fax +39 0481482360
Sensors adjustment of the roll lifting arms

The roll lifting arms are foreseen with 2 sensors pos. A3 and B3 (fig.3 typical picture).
One of these reads the lifting arms position when they are placed in lower position, the other
one reads the lifting arms when they are positioned in the higher position.
B3
A3
fig.3 typical picture

-
Sensors adjustment of the roll pusher

Two sensors are assembled on the pusher (one limit switch for the return pos. A4 (fig.4) and one
limit switch for the exit pos. B4 (fig.4).
After to have adjusted them the first time it is not necessary to adjust them again.
B4
A4

- 25 -

Tel. +39 0481711811
Fax +39 0481482360
Adjustment of the flow regulators of the pneumatic cylinder and membrane roll lifting
arms.
Two flow regulators are assembled on the pneumatic cylinder of the membrane roll lifting arms
pos. D5 (fig.5), one for the rise and one for the descent of the arms.
The flow regulators are necessary in order to adjust the lifting and lowering speed of the roll
lifting arms.
D5
D5

-
Adjustment of the turning table width

The turning table width is modified
by the opening and closing of the
turning table side.
This movement is performed by
means of a gear-motor.
The sensor pos. A6 fig. 6 are fixed
and the distance from them is set in
the operator panel. When the set
distance is reached, the mentioned
motor is stopped.
In order to move the sensor, the
following operations are necessary:
- loose the relative handles
- move the sensors in the desired
position
- lock the handles

A6
A6
- 26 -

Tel. +39 0481711811
Fax +39 0481482360
Adjustment of mechanical stop

The adjustment of the mechanical stops pos. A8 (fig.8) occurs acting on hand-wheel pos B8
(fig.8). This mechanical stop is for the regulation of the displacement of the first row of rolls
from the edge of the pallet.
A8
B8
A8

- 27 -

Tel. +39 0481711811
Fax +39 0481482360
Adjustment of the lower mechanical stops on the trolley

The lower stop of the pallet on the trolley can be moved vertically and toward the palletizer.
For the vertical adjustment:

- loose the two screws pos. C8 (fig.8A)
- move vertically the stop pos. A8 (fig.8A)
- lock the two screws pos. C8 (fig.8A)
For moving the stop toward the palletizer:
- loose the two screws pos. B8 (fig.8A)
- move the stop A8 (fig.8A) toward the palletizer
- lock the two screws pos. B8 (fig.8A)
A8
B8
B8
C8
C8
fig.8A - typical

- 28 -

Tel. +39 0481711811
Fax +39 0481482360
Adjustment of the pallet stops under the palletizing unit

Under the palletizing are assembled two stops pos. A9 (fig.9) in order to align and center the
pallet.
It is necessary to adjust these stops every time the pallet dimension are changed.
The transversal adjustment is performed by means of a mechanical block, the longitudinal
adjustment by means of pneumatic cylinders.
In order to adjust the stops, the following operations are necessary:
-
switch OFF the main switch on the electric power board;

loose the fixing screws (to permit the transversal position adjustment) of both stops;
exclude the trolley exit positioning "EXIT TROLLEY" in "0" position;
put a empty pallet on the trolley;
switch ON the main switch on the power board and push the "START-UP MACHINE" (the
ray of action of the machine have to be free from the operators);
return the trolley manually acting on the "RETURN TROLLEY" selector till the trolley is
completely gone back;
switch OFF the main switch on the power board;
move the stops pos.A9 (fig.9) close to the pallet (attached);
exclude the trolley return positioning "RETURN TROLLEY" in "0" position;
move out the trolley manually acting on the selector "EXIT TROLLEY" till the trolley is
completely gone out;
switch OFF the main switch on the power board;
lock the relative screws;
in order to adjust the damper action of pneumatic cylinders for the longitudinal stop, adjust
the air pressure by means of the related pressure regulators (shown in fig. 9A).
Also flow regulators are provided to avoid rough movement of the cylinders when these
ones opened or closed, during the damper action;
let return the trolley manually;

- 29 -

Tel. +39 0481711811
Fax +39 0481482360
A9
A9
A9
A9
fig.9A typical picture

At this point the machine is ready to start to work normally.

- 30 -

Tel. +39 0481711811
Fax +39 0481482360
Adjustment on the empty pallet loading system

This unit has a capacity of housing 10 empty pallets.
Optional feature: the machine is complete of a movable wall (side) capable of reducing and
enlarging the empty pallet housing area manually. The machine operator can
modify the housing area acting on the locking devices A9B (fig.9B), if
installed, and moves the movable side and then fixes again the locking devices.
The lift arms pneumatically drive can be moved vertically according to the
height of the pallets to be loaded. For such purpose loose the fixing bolts B9B
(fig.9B) and move up/down the lifting arms.
A9B
B9B
B9B
fig.9B

- 31 -

Tel. +39 0481711811
Fax +39 0481482360
Adjustment of the belt tension on the trolley

In order to adjust the belt tension on the trolley, the following operations are necessary:
- loose the relative nut pos. B10 (fig.10)
- adjust the screw pos. A10 (fig.10) till the belts are loosed
- lock the relative nut pos. B10 (fig.10).
Replacement of the belts on the trolley

In order to replace the belts on the trolley, the following operations are necessary:
- loose the relative nut pos. B10 (fig.10)
- adjust the screw pos. A10 (fig.10) till the belts are loosed
- replace the old belts with new belts
- adjust the screw pos. A10 (fig.10) till the belts are stretched
- lock the relative nut pos. B10 (fig.10).
A10
B10

- 32 -

Tel. +39 0481711811
Fax +39 0481482360
Palletizers Controls on Control Board Functions Description

Here below are described the controls installed in the control board of the Automatic palletising unit
with automatic empty pallets feeding unit.
02
03
04
09
10
11
16
17
20
21
01
05
06
07
12
13
14
18
08
15
19
22
fig.11

- 33 -

Tel. +39 0481711811
Fax +39 0481482360
Here follows the description of the controls installed in the control board.
OPERATOR PANEL
HMI-TOUCH PANEL TYPE
POS. 01 FIG.11
OVERVIEW
In this page a top view representation of current pallet configuration is available, as well as actual
alarms, rolls and pallet data.
Each circle is a roll. Rolls color code is the following:
BLACK Rolls already on pallet;
GREEN Rolls on pallettizer;
WHITE Rolls not yet on pallettizer/pallet;
A
B
C
D
By clicking on a circle, the operator is able to change rolls count to match real value if, i.e., a
manual load/unload has been made:
A PREVIOUS ROW: Change previous row rolls count. This operation has no consequences on
the machine.
B - ACTUAL ROW: Decrease actual rolls count on pallettizer by 1. After this operation, the green
circle will become white.
- 34 -

Tel. +39 0481711811
Fax +39 0481482360
C ACTUAL ROW: Increase actual rolls count on pallettizer by 1. After this operation, the white
circle will become green.
D NEXT ROW: This row can not be modified.
ROLL WEIGHT: Roll weight of last roll. Can be clicked to open the WEIGHT RESET page.
PALLETS COUNT: Partial pallets count. Can be edited.
TOTAL PALLETS: Total pallets count. Can not be edited.
RECIPES: This button opens the RECIPES page.
USER: This is a BOATO staff button only.
ALARMS SUMMARY: See alarms section for details.
ROW-1: This button allows the operator to reduce the actual row number (B).
: This flag allows the operator to change the current language.
RECIPES
In this page the operator is able to TRANSFER/EDIT/DELETE recipes.
TRANSFER: This button allows the operator to download the selected recipe to the PLC.
EDIT: Open the EDIT RECIPES page.
DELETE: The operator can delete the selected recipe using this button.
MENU: Go back to overview page.

- 35 -

Tel. +39 0481711811
Fax +39 0481482360
EDIT RECIPE
In this page the operator can CREATE/EDIT recipes.
A RECIPE PREVIEW: This is a on the fly preview of actual recipe. By editing number of rolls
and/or shift, the circles will appear/disappear or shift to reflect the final pallet output.
RECIPE CODE : This is a unique number for actual recipe. It cannot be edited.
RECIPE DESCRIPTION: The description of actual recipe can be edited in this field.
N ROW: Number of the row.
N ROLLS : Number of rolls in the row. If there is an error in the configuration of the pallet, this
field becomes red.
SHIFT: Select YES if a shift for this row is required. The corresponding circles in the preview will
be shifted as well.
SHIFT (mm) : Set the turning table width by means of the values of the distances of the membrane
roll edge from the beginning of the turning table, respectively with the turning table (SHIFT) in
open and closed configuration.
FLAP: Select YES if the flap is required for this row. This value does not affect the preview.
SAVE: Save the actual recipe. A description must be entered in order to perform this operation
successfully. If there is an error in the configuration of the pallet, this button is not available.
LOAD: Load a recipe.
BACK: Go to previous page.
- 36 -

Tel. +39 0481711811
Fax +39 0481482360
ALARMS
When an alarm occurs, his description will appear in the overview alarms summary table.
The alarm is still active and has not been acknowledged yet.
The alarm is still active and has already been acknowledged.
The alarm is returned but has not been acknowledged yet.
When an acknowledged alarm returns, it disappears from the overview alarms summary table.
ACK: The operator must use this button to acknowledge an alarm.
HIST ALARMS: This button opens the historical alarms page.

- 37 -

Tel. +39 0481711811
Fax +39 0481482360
SAFETY BARRIER
MUTING BUTTON AND RESET PUSH-BUTTON
POS. 02-03 FIG.11
In the full-pallet unloading area a safety device is installed. This type of safety device is provided
with photocells and safety barrier and detects if it is a pallet to pass through the device or an
operator, on the basis of the covered areas and of the sequence and time of interruption of the
photocells and barrier (called muting sequence). In case of intervention of the barrier, the light of
the push button (pos.03) turns ON and the moving parts of this working area stop. To restore the
safety barrier is needed to push the reset button (pos.03). During the normal passage of the pallet, a
yellow blinking light is switched ON at one side of the safety barrier, on the top.
In case it is necessary to manually move away from the palletizer the full pallet, in order to pass
through the barrier, it is necessary to push the OVERRIDE button (pos.02) and hold it, then push
the reset button and move the pallet with manual controls (described further on). In case the
photocells are not covered, it is necessary to cover them manually.
THERMAL INTERVENTION
WARNING LIGHT
POS. 04 FIG.11
This warning light flashes in case a motor of the machinery is in overload condition.
Check and solve the problem that caused the overload and restore the relative magnetic thermal
relay.
FIRST CONNECTION BENCH
SELECTOR MAN-0-AUT
POS. 05 FIG.11
Positioning this selector in position MAN the operator activates the motor of the belt conveyor
which transfers the finished rolls from the existing automatic winding machine of the production
line to the second connection bench. When the selector is released it goes back automatically to its
centre 0 position. Positioning this selector in position AUT the motor is activated automatically
according to the production cycle.

- 38 -

Tel. +39 0481711811
Fax +39 0481482360
SECOND CONNECTION BENCH

SELECTOR MAN-0-AUT
POS. 06 FIG.11
Positioning this selector in position MAN the operator activates the motor of the rollers conveyor
which transfers the finished rolls from the first connection bench to the following inclined belt
transport conveyor. When the selector is released it goes back automatically to its centre 0
position. Positioning this selector in position AUT the motor is activated automatically according
to the production cycle.
SECOND CONNECTION BENCH PIVOTING
MOVEMENT
SELECTOR MAN-0-AUT
POS. 07 FIG.11
Positioning this selector in position "MAN", the pivoting movement (pneumatically acted) of the
second connection bench which discharges the roll onto the inclined belt transport conveyor is
activated even if the roll is not present in the bench.
When the selector is released it goes back automatically to its centre "0" position.
Positioning this selector in position "0", the pivoting movement is excluded.
Positioning this selector in position "AUT", the pivoting system discharges the roll automatically
onto the inclined belt conveyor according to the production cycle.
INCLINED BELT CONVEYOR

SELECTOR MAN-0-AUT
POS. 08 FIG.11
Positioning this selector in MAN position the inclined belt conveyor advances of one step. When
the selector is released it goes back automatically to its centre "0" position.
Positioning this selector in position "0", the inclined belt conveyor is excluded.
Positioning this selector in AUT position the inclined belt conveyor moves automatically
according to the production cycle.

- 39 -

Tel. +39 0481711811
Fax +39 0481482360
MEMBRANE ROLL LIFTING ARMS

SELECTOR MAN-0-AUT
POS. 09 FIG.11
Positioning this selector in position "MAN", the two-arms system move even if the roll is not
present on the holding frame that holds the membrane roll discharged from the inclined transport
conveyor.
The row counter roll is increased by 1 unit every time the arms make the lifting operation. When the
selector is released it goes back automatically to its centre "0" position.
Positioning this selector in position "0", the rolls lifting arms are excluded.
Positioning this selector in position "AUT", as soon as the photocell reads the presence of the
membrane roll on the holding frame at the end of the inclined conveyor, the two-arms system
withdraws the roll and put it on the turning table of the palletizer.
The row counter roll is increased by 1 unit every time the arms make the lifting operation.
The arms do not lift the roll neither in manual neither in automatic mode when the turning table of
the palletizer is not in horizontal position and when the quantity of the rolls on the turning table is
not lower than the number of rolls selected for that row.
TURNING TABLE-DESCENT
SELECTOR MAN-0-AUT
POS. 10 FIG.11
Positioning this selector in position "MAN", the turning table of the palletizer will perform the
turning operation only if the lifting arms are in lower position and the trolley is gone back. When
the selector is released it goes back automatically to its centre "0" position.
The turning table stops when the it finds the pallet (an electronic barrier stops gradually the rotation
movement) or when the turning table goes down till to reach the limit switch.
When the turning table turns completely and the selector "TURNING TABLE RISE" is in "AUT"
position , the turning table goes back in its horizontal position automatically.
Positioning this selector in position "0", the turning table descent is excluded.
Positioning this selector in position "AUT", the turning table turns every time the pre-set value is
shown on the display (turning table full).
If the trolley does not go back, the turning table does not work.
If the turning table does not find any pallet on the trolley, it goes back automatically in its
horizontal position if the selector "TURNING TABLE RISE" is in "AUT" position.
In order to release the turning table it is necessary to perform a manual turning operation taking care
to place a pallet before.

- 40 -

Tel. +39 0481711811
Fax +39 0481482360
TURNING TABLE - RISE

SELECTOR MAN-0-AUT
POS. 11 FIG.11
Positioning this selector in position "MAN", the turning table will rise only if the lifting arms are in
lower position. When the selector is released it goes back automatically to its centre "0" position.
Positioning this selector in position "0", the turning table rise is excluded.
Positioning this selector in position "AUT", the turning table rise will be performed when the roll
pusher has carried out its function or when the turning table does not find any pallet on the trolley.
ROLL PUSHER
SELECTOR MAN-0-AUT
POS. 12 FIG.11
Positioning this selector in position "MAN", the roll pusher will push the rolls on the pallet, only if
the turning table is in vertical position. When the selector is released it goes back automatically to
its centre "0" position.
Reached the limit switch the roll pusher goes back.
If the selector is in position "0" the roll pusher is excluded, the turning table does not rise if the
selector "TURNING TABLE RISE" is in position "AUT".
Positioning the selector "ROLL PUSHER" in position "AUT", the pusher will push the rolls on the
pallets when the turning table will be in vertical position. After this it goes back automatically.
Every time the roll pusher start to go back, the counter rows is increased by 1 unit.
The turning table start to rise if the selector "TURNING TABLE RISE" pos. 8 fig. 11 is in "AUT"
position.
EXIT TROLLEY
SELECTOR MAN-0-AUT
POS. 13 FIG.11
Positioning this selector in position "MAN" with the turning table in horizontal position, the trolley
start going out till to reach the limit switch. When the selector is released it goes back automatically
to its centre "0" position.
Positioning this selector in position "0" exit trolley is excluded.
Positioning this selector in position "AUT" with the turning table in horizontal position, the trolley
start going out according to the pre-set value of the rows, shown on the display pos.1 fig. 11 (pallet
full).

- 41 -

Tel. +39 0481711811
Fax +39 0481482360
RETURN TROLLEY
SELECTOR MAN-0-AUT
POS. 14 FIG.11
Positioning this selector in position "MAN" with the turning table in horizontal position, the trolley
start going back till to reach the loading position and stops after that you must put the selector to
0 and again in MAN to reach the internal proximity switch. When the selector is released it
goes back automatically to its centre "0" position.
Positioning this selector in position "0" the return trolley is excluded.
Positioning the selector "RETURN TROLLEY" in position "AUT", the trolley goes back till to
reach the loading position after loading new pallet goes to the internal proximity switch.
The turning table can turn when the trolley goes back completely till to reach the loading limit
switch.
TROLLEY BELT (OF THE PALLETIZER)
SELECTOR MAN-0-AUT
POS. 15 FIG.11
Positioning this selector in position "MAN", the trolley metallic belts turns FORWARD when the
trolley is stopped on unloading position and BACKWARD when the trolley is stopped on loading
position.
Positioning this selector in position "0" the trolley belts is stopped.
Positioning this selector in position "AUT" the metallic trolley belt turns when the trolley is on
unloading and loading position.
The belt turns for a max. time of 15 seconds or till the discharged pallet does not reaches the
photocell placed at the end of the final belts.
METALLIC BELT TRANSPORT CONVEYOR
FOR FULL PALLETS (OF THE PALLETIZER)
SELECTOR MAN-0-AUT
POS. 16 FIG.11
Positioning this selector in position "MAN", the metallic belt of the conveyor installed at the outlet
of the palletizing unit turns even if the full pallet is not present on it.
Positioning this selector in position "0" the metallic belt is stopped.
Positioning this selector in position "AUT" , when requested from the automatic production cycle,
the metallic belts turns transferring the full pallets to the following sections of machinery.
EMPTY PALLET FEEDER ROLLERS
SELECTOR MAN-0-AUT
POS. 17 FIG.11
Positioning the selector EMPTY PALLET FEEDER in pos. MAN, with this pushbutton the
operator can manually move the feeding rollers.
- 42 -

Tel. +39 0481711811
Fax +39 0481482360

MOTORIZED FLAP FOR THE TURNING
TABLE WIDTH
SELECTOR ALWAYS OPEN - AUT ALWAYS
CLOSED
POS. 18 FIG.11
Positioning this selector in position "ALWAYS OPEN" , the motorised flap of the turning table is
always completely opened without consider the programmed data.
Positioning this selector in position "AUTOMATIC" , the motorised flap of the turning table is
opened or closed, it depends by the programmed data.
Positioning this selector in position "ALWAYS CLOSE" , the motorised flap of the turning table is
always closed without considering the programmed data.
PNEUMATIC FLAP OF THE TURNING TABLE
SELECTOR ON-OFF
POS. 19 FIG.11
Positioning this selector in position "ON" with the turning table opened, the pneumatic flap of the
turning table closes when start the turning operation in order to compact the row of rolls during the
unloading.
Positioning this selector in position "OFF" the pneumatic flap is excluded. Note that the pneumatic
flap must be enabled in the recipe in order to work in automatic mode.
FALLEN ROLL RESET
PUSH BUTTON
POS. 20 FIG.11
In case that a membrane roll falls down during the phase of creation of the finished pallet, the
palletising automatic cycle stops. The operator puts the membrane roll straight (vertically) by hands
and then pushes this push-button to restore the palletising automatic cycle (before pushing this reset
it is obviously necessary to operate the reset push-button pos.03, since the barrier is interrupted
when the operator enters the area).
START
PUSH-BUTTON
POS. 21 FIG.11
After you have pushed the button "EMERGENCY STOP":

- release the push-button "emergency stop"
- push the button "start" to start again the machine.

- 43 -

Tel. +39 0481711811
Fax +39 0481482360
EMERGENCY STOP
PUSH-BUTTON
POS. 22 FIG.11
Pushing this button the machine or any of its part is not in operation and turn-off all the electrical
devices on the machine.
In order to start-up the machine again it is necessary to rotate the "EMERGENCY STOP" button for
releasing it, and then push the "START" button placed on the palletizing unit control board.
Before to start to perform any operation make sure that the main switch on the power board is
switched OFF.

- 44 -

Tel. +39 0481711811
Fax +39 0481482360
Automatic Trolley Controls

The controls of the Automatic trolley for the full pallets transport are installed in the Electric Power
Board of the Automatic palletising unit on duty to Production Line 2 (in line with the Automatic
stove).
01
02
03
fig.12
MANUAL/AUTOMATIC MODE
SELECTOR MAN-AUT
POS. 01 FIG.12
MANUAL MOVEMENT
JOISTICK
POS. 02 FIG.12
In AUTOMATIC mode the automatic trolley is stationed on duty to Production Line P2. When a
finished full pallet is ready in the final position of the transporting belt at the end of the palletizing
section of Production Line P1, automatically the trolley is receiving the request, moves to the
Production Line P1, loads the full pallet, moves again to Production Line P2 and as soon as possible
discharges the full pallet to the Automatic Stove.
In MANUAL mode, by using the joystick, it is possible to move the trolley as follows:
- LEFT/RIGHT: translational movement of the trolley
- UP/DOWN: trolley belt movement forward/reverse

- 45 -

Tel. +39 0481711811
Fax +39 0481482360
EMERGENCY STOP
PUSH-BUTTON
POS. 03 FIG.12
Pushing this button the machine or any of its part is not in operation and turn-off all the electrical
devices on the machine.
In order to start-up the machine again it is necessary to rotate the EMERGENCY STOP button for
releasing it, and then push the START button placed on the palletizing unit control board.
Before to start to perform any operation make sure that the main switch on the power board is
switched OFF.

- 46 -

Tel. +39 0481711811
Fax +39 0481482360
Electric control and power boards

Its strictly forbidden to work internally to the control and power board if
supplied by current
DANGER
Before making any maintenance operations on the machine, switch

OFF the main switch on the power board
DANGER
In case of extraordinary/ordinary maintenance or in case of anomaly

situations take care that the electric voltage supply must be taken off.
DANGER
DANGER
The electric control and power boards can be opened only by an

authorised electrician. Remember to remove tension to the board in case
the door must be opened by turning the main switch to OFF (0) position.
The board door will not open if this main switch is not at its OFF (0)
position. Never switch to ON (1) the main switch with the door opened.
At the end of the week the have to be checked the proper functioning of
the Emergency stops on the control board
CAUTION
In order to allow to reach easily the Emergency stop, do not leave any
objects close to control boards
CAUTION

- 47 -

Tel. +39 0481711811
Fax +39 0481482360
Description of the fences/protections installed in the working area

ID
1
Type
Fixed protection net type
Safety barrier with muting

system
Emergency safety ropes
Safety doors
Safety laser scanner
Function
It doesnt allow the operator to enter in the area without the
removal of the protection (to be carried out with the machine in
safety conditions)
With its intervention the operations of the whole Automatic
palletising unit are stopped.
To restore the barrier, refer to the description of the controls
installed in the control board in the previous pages.
If one of the safety rope is activating the safety switch, all the
operations which involve dangerous movements of the
components in the related areas are stopped, as in emergency
condition
If one of the doors which is part of the fence made by fixed
protection net is opened, all the operations of the area are
stopped. To restore the operation it is necessary to act on the
apposite reset push-button
The Automatic trolley for full pallets transport is equipped with
safety laser scanner to stop the translation movement in case of
detection of obstacles in the way of the trolley

- 48 -

Tel. +39 0481711811
Fax +39 0481482360
GENERAL
After the first starting of the machine, to check at least once a week for the first two working
months the tightening of all the bolts.
After the mentioned period of time, the mentioned check can be performed less frequently, but it is
always necessary.
Make sure that there is no any unexpected behavior of the machine due to the loosening of fixing
elements.
Pay attention to check that the guide bearings of the fulcrum of the turning table of the palletiser are
properly tightened.
MAINTENANCE CARD: SUPPORTS WITH SELF-ALIGNING BEARINGS

All the bearing units are prelubricated, that means they are completed with the normal grease
charge. Such grease charge is sufficient to guarantee a perfect lubrication for about 300 hours
running.
- Relubrication
All the bearing units have a lubricator which gives the possibility of periodical relubrications.
For such operation use the following greases:
ALVANIA R3
ALVANIA RA
ENERGREASE LS3
BEACON 3
MULTIS SPECIAL 3
CUPUS A3
MOBILUX 3
SHELL
SHELL
B.P.
ESSO
TOTAL
CENTURY OILS
MOBIL OIL CO.
General rules: introduce gently the grease, possibly during running. Too much lubrication is
deleterious, therefore it is better to lubricate often with small quantities of grease.
Never lubricate with oil but only with grease.

- 49 -

Tel. +39 0481711811
Fax +39 0481482360
MAINTENANCE CARD: LUBRICATION POINTS

In various points of the machine lubricators are provided to allow a periodic relubrication.
Such operation should be repeated every 300 working hours using only the following greases:
ALVANIA R3
ALVANIA RA
ENERGREASE LS3
BEACON 3
MULTIS SPECIAL 3
CUPUS A3
MOBILUX 3
SHELL
SHELL
B.P.
ESSO
TOTAL
CENTURY OILS
MOBIL OIL CO.
GENERAL RULES: introduce gently the grease, possibly during running. Too much lubrication is

- 50 -

Tel. +39 0481711811
Fax +39 0481482360
MAINTENANCE CARD: TRANSMISSION BY PINION-RACK SYSTEM

For the transformation of the rotary motion into linear motion, in the machine are used pinion-rack
groups module 3. Such groups due to their low rotation speed, need only a lubrication every now
and then with a type of grease as follows:
ALVANIA R3
ALVANIA RA
ENERGREASE LS3
BEACON 3
MULTIS SPECIAL 3
CUPUS A3
MOBILUX 3
SHELL
SHELL
B.P.
ESSO
TOTAL
CENTURY OILS
MOBIL OIL CO.
GENERAL RULES: introduce gently the grease, possibly during running. Too much lubrication is
The groups are provided with regulation screws for the adjustment of the right pinion-rack distance,
after an eventual disassembling operation. In case there are no regulation screws, loosen the bearing
screws of the pinion shafts axis and fix the right distance.
Example: Coupling pinion Z19 m3 with racket m3 section 30X30.
Calculation of the assembly distance (d):
p= pinion primitive diameter Z19 m3 = 19X3 = 57 mm.
For a rack m3 section 30X30 ... m=3
The assembly distance (d) is: d = (57/2) + 9 X 3 = 55,5
See sketch:

- 51 -

Tel. +39 0481711811
Fax +39 0481482360
MAINTENANCE CARD: CHAIN TRANSMISSION

All transmission and driving chains should be periodically checked and lubricated according to the
work load, and in any case, at least once a week.
Oil has to be applied by brush in the inside sections of the chain, near a pinion, in this way the
centrifugal movement will spread the lubricant on the pin-bush and roll-bush surfaces.
TEMPERATURE (C)
-5 5
5 40
40 50
50 60
OIL TYPE
SAE 20
SAE 30
SAE 40
SAE 50
REGULATION OF THE CHAIN TENSION

To regulate the chain tension, adjustable tighteners are provided. The right tension insures a longer
life of the chain and less noise.
Remove the chain once a year and wash it with fuel-oil in order to remove any eventual material
(bitumen, talc, etc.). Wash the sprockets and the chain tighteners in the same way. After
reassembling of the parts, lubricate them in the usual way.

- 52 -

Tel. +39 0481711811
Fax +39 0481482360
MAINTENANCE CARD: PNEUMATIC SYSTEM

The compressed air is connected to a group "F.R.L." filter, reducer, lubricator. The group filters the
air, reduces the pressure and forces the nebulized oil into circuit.
The oil lubricates the boxes of the electro-valves and the jackets of the pneumatic cylinders, thus
allowing a constant functioning.
The quantity of oil that passes is controlled by the knob located on top of the oil container. Adjust
the consumption so that the oil lasts for 810 working hours. To refill, unscrew the container and
fill it up to the level mark, exclusively with hydraulic oil.
Before the "F.R.L." group there is a container for the condensed water and for the impurities
contained in the compressed air. remove the container and clean it every 2030 working hours
according to the impurities contained in it.
The central knob is used to reduce the pressure of the air. The working pressure is 6 atm. The
maximum input pressure cannot exceed 10 atm, to avoid the explosion of the containers.
All the pneumatic connections are made of Rilsan pipes and brass junctions. Check periodically if
there are any drippings or pipe occlusions.
The valves are electrically operated by means of a coil and do not need any special care. An
eventual jamming is due either to the electric coils or to an excess of condensed water or by the
filter. In the second case it will be sufficient to disassemble the valve and wash it with petrol.
The pneumatic cylinders, having an alternate movement, wear out in a standard period of time.
Such wear is greater in the pistons seals of the long stroke cylinders.
Never work with a pressure that is above 6 atm.
CAUTION
(see the attached document from the Camozzis supplier brochure)

- 53 -

Tel. +39 0481711811
Fax +39 0481482360
MAINTENANCE CARD: WORMGEARS SERIES W WR - VF

(see the attached document from the Bonfigliolis supplier brochure)

- 54 -

Tel. +39 0481711811
Fax +39 0481482360
MAINTENANCE CARD (TECHNICAL DATA): LAFERT MOTOR

(see the attached document from the LAFERTs supplier brochure)

- 55 -

Tel. +39 0481711811
Fax +39 0481482360
MAINTENANCE CARD (TECHNICAL DATA):ELECTRO MAGNETIC CLUTCH

(see the attached document from the LENZEs supplier brochure)

- 56 -

Tel. +39 0481711811
Fax +39 0481482360
OPERATING INSTRUCTIONS: SAFETY LASER SCANNER

(see the attached manual from the REER supplier brochure)

- 57 -

Tel. +39 0481711811
Fax +39 0481482360
Pictures and drawings showing the main spare parts of the palletizer
Find here enclosed pictures and drawings showing the main parts subjected of wearing.
In case of spare parts order, mark the component that you need on the picture/ drawing and send to
us by fax the same.

- 58 -

Manual Palletizer 825pa001

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Palletizer 825pa001

Uploaded by

Copyright:

Available Formats

BOATO INTERNATIONAL S.p.A. a s.u.

Via Chico Mendes n. 7

modif ied bit umen membrane plants

Automatic palletising sections for

USE AND MAINTENANCE MANUAL

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

Soggetta alla direzione e coordinamento di Boato Holding S.p.A.

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

Soggetta alla direzione e coordinamento di Boato Holding S.p.A.

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

Machinery Directive 2006/42/EC (ex Machinery Directive 98/37/EC) and following

besides the following harmonise/national standards have been applied:

Safety of machinery. General principles for design Risk

Standard CEI EN60204-1

Safety of machinery. Electrical equipment of machinery.

Standard UNI EN ISO 13857: 2008

Safety of machinery. Safety distances to prevent hazard

Standard UNI EN ISO 13732-1: 2009

Safety of machinery - Ergonomics of the thermal

Standard EN ISO 13849-1:2008

Safety of machinery - Safety-related parts of control

Soggetta alla direzione e coordinamento di Boato Holding S.p.A.

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

Aim of the manual

Use and preservation of the manual

Important warnings for safety

Means the possibility of injuries to persons or damage to the machinery if the

Means high possibility of serious injury or death to persons if the instructions

provides useful information

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

Automatic palletising sections for existing production lines

Technical assistance requests

Soggetta alla direzione e coordinamento di Boato Holding S.p.A.

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

Transport, lifting and storage

Skilled personnel, with suitable equipment, scrupulously respecting the safety

Soggetta alla direzione e coordinamento di Boato Holding S.p.A.

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

Soggetta alla direzione e coordinamento di Boato Holding S.p.A.

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

Individual protection equipment

quick release footwear type complete of protection metal toe,

In case of ordinary/extraordinary maintenance ensure to switch OFF the

Soggetta alla direzione e coordinamento di Boato Holding S.p.A.

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

take off the electricity to the machinery

General notes for a proper utilisation of the unit

all the photocells (transmitter and receiving)

At the end of the week the following components have to be checked:

BOATO INTERNATIONAL S.p.A. a s.u.

modif ied bit umen membrane plants

In case of ordinary/extraordinary maintenance and/or

All the maintenance operations, reparations, or intervention for putting in

It is strictly forbidden any intervention of reparation, modification etc. on

Soggetta alla direzione e coordinamento di Boato Holding S.p.A.