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1) GENERAL
1
SUMMARY
FOREWORD .................................................................................................................................................................... 3
1 GENERAL ..................................................................................................................................................................... 4
1.1 MACHINES AND MANUFACTURERS DATA .................................................................................................................... 4
1.2 TECHNICAL SHEET ......................................................................................................................................................... 4
1.3 SPECIFICATION OF EQUIPMENT USED ............................................................................................................................. 5
1.4 CONDITIONS OF USE....................................................................................................................................................... 5
1.4.1 Environmental conditions envisaged .................................................................................................................... 6
1.4.2 Overvoltage protection ......................................................................................................................................... 6
1.5 SAFETY GLOBAL ASPECTS .............................................................................................................................................. 7
1.5.1 Note to operators .................................................................................................................................................. 7
1.5.2 Maintenance schedule........................................................................................................................................... 7
1.5.3 Personnel in charge .............................................................................................................................................. 7
1.6 RESIDUAL RISKS ............................................................................................................................................................ 9
1.7 PHONOMETRIC SURVEY ............................................................................................................................................... 10
1.8 FACTORY TEST CERTIFICATE ....................................................................................................................................... 11
1.9 SAFETY PRESCRIPTIONS ............................................................................................................................................... 12
1.10 RESPONSIBILITY ........................................................................................................................................................ 13
1.11 TECHNICAL ASSISTANCE ............................................................................................................................................ 14
1.12 HOW TO ORDER A SPARE PART ................................................................................................................................... 14
2 MACHINES DESCRIPTION ................................................................................................................................... 15
2.1 GENERAL DESCRIPTION ............................................................................................................................................... 15
3 MACHINES OVERALL DIMENSIONS ................................................................................................................ 18
3.1 REQUIRED SPACE ......................................................................................................................................................... 18
3.2 DIAGRAM OF SUPPORTING POINTS AND RELATING LOADS ............................................................................................ 19
3.3 ANCHORING ................................................................................................................................................................ 20
3.4 MACHINE FIXING ......................................................................................................................................................... 21
3.5 AIR AND ELECTRICAL CONNECTIONS ........................................................................................................................... 22
3.6 UNPACKING ROPE REFERENCE TABLE .......................................................................................................................... 23
3.6.0 Unpacking band reference table......................................................................................................................... 24
3.6.1 Hoisting notes ..................................................................................................................................................... 24
3.6.2 UNIT:26.A1 (main section hoisting)................................................................................................................... 25
3.6.3 UNIT : 26.A1(lifting sliding table)...................................................................................................................... 26
3.6.4 UNIT: 26.B2(conveyor)/ 26.B1(gripper rotation)/ 10.00(bag flattener) ............................................................ 27
3.6.5 UNIT: 13.A2 ( bend with additional conveyor ) ................................................................................................. 28
3.6.6 UNIT: 08.A19 ( belt conveyor) ........................................................................................................................... 29
3.6.7 UNIT: 08.A25 ( belt conveyor) ........................................................................................................................... 30
3.6.8 UNIT:33.00 ( arm pallet feeder )........................................................................................................................ 31
3.6.9 UNIT: 42.A4 (motorized roller conveyor) .......................................................................................................... 32
3.6.10 UNIT: 42.A3 (motorized roller conveyor) ........................................................................................................ 33
3.6.11 MAIN PANEL ................................................................................................................................................... 34
3.7 ASSEMBLY................................................................................................................................................................... 35
3.8 EQUIPMENT AND PERSONNEL FOR INSTALLATION ....................................................................................................... 35
3.9 PALLETIZERS INSTALLATION POINTS .......................................................................................................................... 36
4 PREPARATION TO SET-UP .................................................................................................................................... 37
4.1 WARNING .................................................................................................................................................................... 37
4.2 ENVIRONMENTAL CONDITIONS .................................................................................................................................... 37
4.3 OPERATING SPACE ....................................................................................................................................................... 37
5 DISMANTLING AND DISPOSAL OF DISCHARGE EQUIPMENT .................................................................. 38
2
FOREWORD
This Use and maintenance manual is an integral part of the machine.
It must be stored and kept whole throughout machines life in a safe and suitable place.
If missed or degraded, ask the manufacturer for a copy of it, at address below:
Chronos Richardson Via Edison Volta, 25/4-43100 PARMA.
Phone number 0521/940841
Fax number 0527/940827
Modem number 0521/942374
E-MAIL mmarzi@chronos-richardson.de
This manual shall be handed over to any further user or next owner of machine.
This manual can be easily and promptly referred to by maintenance man and machine
operator. It must be placed, therefore, near the palletizer.
Please keep this manual constantly updated, integrating it with all addition or change
made during operation.
Chronos decline all responsibility for any intervention or operation carried out to the
machine using procedures other than those described in this manual.
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1 GENERAL
Installed power Kw 17
Absorbed average power Kw 10
Supply voltage 380 v 50 Hz
Consumed air 100 Nl/mn (dry and filtered)
Air pressure 6 Kg/cm2
Motor protection IP 55
Electrical protection IP 55
Pallet type wood
Bag type Polypropylene
Palletization pattern 5/3 bags per layer
Actual output 1400 b/h
Full pallet height (incl. pallet) 1850 mm
4
1.3 Specification of equipment used
Bag size shall be adequate to size and weight of content. It must be agreed upon with
the manufacturer in case of production change.
5
1.4.1 Environmental conditions envisaged
6
1.5 Safety global aspects
User is responsible for spreading information in this Manual to all operators. User is
also to see that proper training is provided to personnel in charge of machine running
and maintenance, checking suitability to envisaged tasks.
For a proper operation of palletizer, all prescriptions for use, cleaning and regular
maintenance, in addition to indications relating to correct, predictive and preventive
maintenance in this Manual, must be adhered to.
Operator entrusted with palletizer running shall undergo theoretical and practical
training according to following training schedule:
- machine running and all manual operations, machine push-button panel and control
panel
- machine running in conjunction with no. 1 suppliers technician or expert operator
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MECHANIC:
Fitter who, under executive autonomy conditions, is capable of carrying out overhaul of
automatic equipment intervening on basic elements of same (including pneumatic
system), identifying trouble and relating cause, see, via technical drawings, to
disassembling of sections and units and their remounting, performing the required
calibration and check work
ELECTRICIAN:
A technician who, in executive autonomy conditions, is capable of carrying out
maintenance, troubleshooting and repairing work with setting up and replacement of
defective parts on plants and complex equipment, being familiar with their operation
and interpreting functional and complex diagrams (basic knowledge of PLC-
INVERTER required).
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1.6 Residual risks
9
1.7 Phonometric survey
NOTES: Test conditions: machine was factory started, simulating, for each survey point, 6-layer
pallet load, with 5 bags (25 kg each) on each layer, at the max. speed of 40 e/i. Survey
points 1, 2, 3 and 5 are at ground level, 1 m from machine. Microphone was held at
~1500 mm from supporting platform. Background noise was < 15 dBA.
10
1.8 Factory test certificate
CERTIFICATO DI COLLAUDO
FACTORY TEST CERTIFICATE
ORD. INT. N.I3595 MACCH. MOD.PL1200H CLIENTE UNO FOOD DATA 04/11/1998
ORDER N. _I0598____ M/C. MOD. CLIENT____________________________ DATE _____________
__________________
POS. CONTROLLI DA ESEGUIRE O.K. CLIENT
CHEK TEST
1 LETTURA NOTE TECNICHE CON CONTROLLO AI RIFERIMENTI PARTICOLARI 9 9
READ TECNICAL DATA TO SPOT SPECIFIC REQUIREMENT
2 CONTROLLO DIMENSIONALE CAMPIONATURA E CARATTERISTICHE 9
CHECK OF DIMENSIONS AND FEATURES OF SAMPLES
3 CONTROLLO DIMENSIONI MACCHINA E LAYOUT E CONTROLLO ALTEZZE 9 9
CHECK OF MACHINE DIMENSIONS ACCORDING TO LAYOUT
4 COMPONENTISTICA SECONDO SPECIFICA 9 9
COMPONENTS AS PER SPECIFICATION
5 CABLAGGI SECONDO SPECIFICA 9 9
CABLING ACCORDING TO SPECIFICATION
6 CONTROLLO ASSORBIMENTO MOTORI E TARATURA DELLE PROTEZIONI 9 9
CHECK MOTOR LOAD AND OVERLOAD SETTINGS
7 TARGETTE E INDICAZIONI GENERALI DI MOVIMENTO O REGOLAZIONE 9 9
LABELS AND MAIN INSTRUCTION FOR THE ADJUSTMENT MOTION OF COMPONENTS
8 CONTROLLO DISPOSITIVI DI SICUREZZA E PROTEZIONI SECONDO SPECIFICHE 9 9
CHECK OF SAFETY DEVICE AND GUARDS ACCORDING TO SPECIFICATION
9 VELOCITA TRASPORTI DI COLLEGAMENTO IN ENTRATA E USCITA 9 9
SPEED OF INFEED/OUTFEED CONNECTION CONVEYOR
10 CONTROLLO QUALITA E PRECISIONE 9 9
QUALITY AND ACCURACY CHECK
11 SEGNALI DA E PER MACCHINE A MONTE E A VALLE 9 9
SIGNAL FROM/TO UPSTREAM AND DOWNSTREAM MACHINE
12 CONTROLLO PRODUZIONE 9
PERFORMANCE TEST
13 CONTROLLO RUMOROSITA COME DA SPECIFICA 9 9
NOISE LEVEL CHECK AS PER SPECIFICATION
14 CONTROLLO VERNICIATURA 9
CHECK OF PAINT FINISH
OGNI ANOMALIA VA SEGNALATA SULLE SCHEDE E AL RESPONSABILE DEL SERVIZIO. SE UN CONTROLLO
NON E STATO ESEGUITO PRECISARLO CHIARAMENTE CON LE RAGIONI RELATIVE SULLA SCHEDA.
EVERY FAULT TO BE MENTIONED IN THE FORM AND TO THE TEST MANAGER. IF A CHECK WAS NOT
POSSIBLE STATE IT IN THE FORM EXPLAINING THE REASON.
DOCUMENTAZIONE FORNITA LASCIARE UNA COPIA DEL LAYOUT PER CHI SMONTERA LA MACCHINA
DOCUMENTATION AVAIABLE ONE COPY OF LAYOUT TO BE LEFT FOR PEOPLE IN CHARGE OF DISMANTLING
SCHEMI ELETTRICI 9
ELECTRICAL DIAGRAM
NOTES
SCHEMA PNEUMATICO 9
PNEUMATIC DIAGRAM
COLLAUDATORE
TEST ENGINEERING
RESPONSABILE COLLAUDI FERRARI
TEST MANAGER
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1.9 Safety prescriptions
General precautions:
)Before palletizers installation, use and maintenance, read carefully this Manual.
)Check operating space around machine, which must be unhampered, clean and
adequately lighted.
)Each operation on machine must be carried out solely by expressly authorized
personnel.
)Check that all protections and guards be properly placed, that all safety devices be
present and effective and not having been tampered.
)Do not carry out productive running with disabled safeties or fixed guards
uninstalled.
)Do not leave machine with guards dismounted.
)Do not use machine if faulty.
)Machine must be run by authorized personnel only.
)Look after personal safety equipment of personnel operating the machine: use sturdy
work footwear, keep sleeves tight around wrists and however do not wear garments
with hanging parts such as ties, scarves, unbuttoned jacket or torn garments, to avoid
the risk of being caught in palletizer loading and/or unloading area.
)Remove all safety jeopardizing condition before using machine and always inform
maintenance head of all possible operating anomalies.
)Panel must always be kept shut.
)All operations must be carried out with machine stopped, disconnected from
pneumatic and power supply.
)After all adjustments or maintenance operations, ensure that no tools or foreign
matter remain between palletizers moving elements, so as to avoid damage to
machine and/or accidents to personnel.
)Should machine be intended to handle products noxious to maintenance mans
health, he is to wear individual protections (mask, glasses, gloves, etc.); refer to
information from user who knows how to handle and store such products.
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)For overhead-area operation, maintenance man must use all due precautions to
prevent being exposed to risk or danger of fall:
-Safety helmet use is compulsory
-Use of safety belt with tight-piece braces fixed to stable parts is compulsory
-Proper scaffolding use is obligatory.
)Never insert your body into machines opening without guards.
)Never use gasoline or flammable solvents as detergent, but always use non toxic, non
flammable authorized commercial solvents
)Do not lubricate palletizer mechanical parts when palletizer is moving.
)Keep area for maintenance operation always clean and dry, removing oil stains, if
any.
)If compressed air is used for part clean when other systems cannot be used, protect
yourself with side-guard glasses and keep pressure to 2 bar maximum.
1.10 Responsibility
13
1.11 Technical assistance
Special and routine maintenance must be carried out according to instructions in this
Manual. Please keep to said instructions and, when in doubt, consult the manufacturer
referring to the data on machines plate.
Should machines maintenance be carried out in a way not consistent with the
instructions provided, using non original spare parts or spare parts without written
authorization from the manufacturer, or however such as to jeopardize the integrity or to
alter the specifications of the machine, CHRONOS RICHARDSON will deem
themselves free from any and all responsibilities as to personnel safety and machine
faulty operation. Also, all unauthorized change operations will invalidate contractually
established warranty.
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2 MACHINE DESCRIPTION
Bag palletizer type CR1200H consists of a modular basic structure equipped with a
series of units.
Bag flattener.
Made up of two belt conveyors (lower and upper ones), where the function of the upper
one is to compact bags in transit (for adjustment, see notes in use and maintenance
chapter).
Rotation conveyor:
Bag rotation is done on this conveyor, which consists of 1 belt and 1 motor.
15
Loading area motorized roller platform:
Motorization by tangential chain. Provided with control device for pallet onto the
conveyor.
16
Pallet lifting with inverter-controlled self-braking three-phase motorization:
Pallet lifting device consists of:
- Two motorizations placed in the upper part of machine
structure.
- A connection shaft for side catenaries
- Two 3-inch catenaries to support the lifting forks
- Two balancing counterweights placed inside the uprights
Main features of adopted drive are as follows:
- Low power of motors, being balanced by two adequate
counterweights
- Regulability, through operator panel, of up/down speed and
pressing force
Sliding guides of lifting forks are made from wear-proof drawn steel. Sliding occurs on
four tight bearings.
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3 MACHINE OVERALL DIMENSIONS
18
3.2 Diagram of supporting points and relating loads
19
3.3 Anchoring
Machine must be anchored to floor which must be level, free from bumps and solid to
avoid sagging.
20
3.4 Machine fixing
21
3.5 Air and electrical connections
T= Earth connection
A= Air connection 1/2 60 nL /min
22
3.6 Unpacking rope reference table
If using steel cables, always apply end eye to lifting hook, as shown in figure.
23
3.6.0 Unpacking band reference table
Band diameter Capacity with Capacity with Capacity with 120 Band identifier
mm 45 angle Kg 90 angle Kg angle Kg
50 1800 1400 1000 1
75 3600 2800 2000 2
100 5400 4200 3000 3
150 9000 7000 4000 4
Above table refers to the use of U bands. Angle given is that band forms in grip angles.
Ex:
24
3.6.2 UNIT:26.A1 (main section hoisting)
25
3.6.3 UNIT : 26.A1(lifting sliding table)
26
3.6.4 UNIT: 26.B2(conveyor)/ 26.B1(gripper rotation)/ 10.00(bag flattener)
27
3.6.5 UNIT: 13.A2 ( bend with additional conveyor )
28
3.6.6 UNIT: 08.A19 ( belt conveyor)
29
3.6.7 UNIT: 08.A25 ( belt conveyor)
30
3.6.8 UNIT:33.00 ( arm pallet feeder )
31
3.6.9 UNIT: 42.A4 (motorized roller conveyor)
32
3.6.10 UNIT: 42.A3 (motorized roller conveyor)
33
3.6.11 MAIN PANEL
34
3.7 Assembly
BEFORE SWITCHING POWER ON, REMOVE THE MECHANICAL LOCKS (RED PART)
INDICATED BY THE ARROW
Assembly instructions.
Palletizer was broken down for haulage reason, into:
1) Palletizer infeed belt
2) Palletizer main section
3) Pallet feeding conveyor
4) Pallet feeder
5) Pallet outfeed conveyor
6) Gangway - Handrail - Stairs
7) Main panel
35
3.9 Palletizer installation points
36
4 PREPARATION TO SET-UP
4.1 Warning
LIGHTING
Environment in which palletizer is placed must be sufficiently lighted, so that the
operator may carry out visual checks of machine and signs - marks on palletizer.
Do not place light sources likely to cause glare to operator.
See that operators areas allow sufficient space for running, maintenance and
dismantling operations.
Operation and environmental conditions must be such as not to hamper access to
machine controls, especially the emergency stop.
Machine operativity must be ensured, considering the maintenance work, too.
In particular, pay special attention to:
) Easy opening of all panels and unhampered access to all areas for palletizer
cleaning and maintenance.
37
5 DISMANTLING AND DISPOSAL OF DISCHARGE EQUIPMENT
According to EEC directives or to the laws in force in his own country, the user shall
have to take care of dismantling the machine parts, paying special attention to the
disposal of environmentally significant materials such as:
- polyzene profiles
- lubricant oils and greases
- gaskets.
In all case, before dismantling the machine, the User shall inform the Manufacturer of
all data on identification plate.
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