stretch wrapping machine l2500 auto 1 - … auto1 eng.pdf · manual and ce-instructions march 2001...

Manual andCE-instructions

MARCH 2001

STRETCH WRAPPINGMACHINE L2500 AUTO 1

STRETCH WRAPPINGMACHINE L2500 AUTO 1

Nissen L2500 Auto 1 2

Index

1 Nissen Stretch Wrapping Machines .................................31.1 Machine type: NISSEN L2500 AUTO 1..................................3

1.2 Technical specification ...........................................................4

1.3 Areas of use ...........................................................................5

1.4 Guarantee ..............................................................................5

1.5 Limits of responsibility ............................................................6

1.6 Machine plate .........................................................................6

2. Assembly instructions ......................................................72.1 Installing the machine ............................................................8

3. Dismantling ......................................................................203.1 Dismantling ..........................................................................20

3.2 Disposing of the machine .....................................................20

4. Instructions for use .........................................................214.1 General ................................................................................21

4.2 The control panel .................................................................21

4.3 Operation .............................................................................22

4.4 Adjustments on operator’s panel .........................................22

4.5 Plastic film ............................................................................24

4.6 Adjustment of stop position of turntable rotation..................25

5. Safety regulations ............................................................265.1 Area of risk...........................................................................26

5.2 Other safety instructions ......................................................27

6. Maintenance .....................................................................286.1 Cleaning of the pre-stretching unit .......................................28

6.2 Care of the drive unit ............................................................28

6.3 Care of the turntable ............................................................29

6.4 Other maintenance instructions ...........................................29


1 Nissen Stretch Wrapping Machines

It is important that you read and understand this manual beforestarting to use the wrapper.

If you have any questions, please contact your supplier and/or themanufacturer.

Manufactured by:Polynova Nissen AB, Box 42016, SE-126 12 Stockholm, SwedenPhone: +46 8 449 29 60, fax: +46 8 744 21 83

Representative/supplier:(if different from the manufacturer)

1.1 Machine type: NISSEN L2500 AUTO 1EG-certificate of compliance with regulationsManufactured in accordance with the council’s directive 98/37 EGconcerning mutual closer association of the legislation of the mem-ber states relating to machines.

The machine is manufactured in accordance with following harmon-ised standards: SS EN-60 204-1, SS EN-292-1, SS EN-292-2.

Material: Turntable in lacquered steel (also available in hot galvan-ised version). Film holder and film column in lacquered steel. Driveunit in zinc plated steel (also available in galvanised version).

Maximum load: 1 500 kg

Noise level when wrapping a load on the turntable: <70 dB (A)

Machine plate: Machine plate, stating the manufacturer’s name, ma-chine number, model number and CE-mark are fitted to every machine.

Warning signs to ensure risk-free usage are fitted to every machine(when considered necessary).


1.2 Technical specification

A. Turntable and drive unit

Turntable diameter Ø 1 500 mmMotor 0.25 kW 220/380 V 3-phaseOperating voltage 24 VTurntable height 65 mmMax. load 1 500 kgMax. diag dimension of load 2 000 mmRotation speed approx. 10 rpm

B. Stretch film column

Motor 0.12 kW 220/380 V 3-phaseOperating voltage 24 VTotal height 2 510 mm standardMax. roll diameter stretch film Ø 240 mmMax. roll width stretch film 500 mmMax. load height 2 500 mm

C. Top sheet dispenser supplementary equipment

Min. height - from floor to centre of roll 1 050 mmMax. height - from floor to centre of roll 2 200 mmMax. width 1 400 mmMin. width 300 mmAccepts bobbins from Ø 40–Ø 78


1.3 Areas of useThis machine is normally used in warehouses and/or distributioncentres for wrapping loaded pallets in stretch film in order to main-tain stability, provide protection from the elements and protect the loadduring storage or distribution.

The loaded pallet is positioned on the turntable of the machine with apallet truck or fork-lift. The stretch film is attached manually by, e.g.the film being tied to the pallet.

Wrapping is carried out by rotating the load whilst the film roll movesup and down the film column. Some machines are fitted with a topclamp plate, which holds light loads in place whilst the wrapping oper-ation takes place.

Neither the operator nor any other person is allowed to standon the turntable. If the turntable has to be stepped on (duringservice or repairs), switch off the main power supply or pressthe emergency stop button.

1.4 GuaranteeThe guarantee is valid for one (1) year from the date of delivery, andcovers material and manufacturing faults. Maintenance must have beencarried out according to the instructions on pages 28–29 for the guar-antee to be valid.

This guarantee does not cover normal maintenance, installation or regu-lar adjustment in accordance with the instructions. Nor does the guar-antee cover labour costs involved in such work.

Damage caused by misuse or faulty usage will result in the guaranteeno longer being valid. If the machine is to be located in a damp envir-onment the turntable, film column and drive units should be galvan-ised for the guarantee to be valid.

The guarantee is valid as long as the machine is not altered or addedto without the manufacturer’s written approval.


1.5 Limits of responsibilityThe supplier accepts responsibility only for the machine and its oper-ation in accordance with the manual, on conditions that the machine isnot altered or added to without the manufacturer’s written approval.

1.6 Machine platethat is fitted to the machine (fitted under the electricity box).

Polynova Nissen ABBox 420 16, SE-126 12 Stockholm, SWEDEN

Telephone: +46-8-449 29 60www.polynova.se

ModelAuto 1

Article no.2000008

Serial no.NP xxxxx

Manufacturer: LENG Pac AB, Sweden


2. Assembly instructions

Begin by first reading through the entire assembly instructions.

Make sure that the following items are available before assembly:

1. Hammer drill2. 10 mm hammer bit3. Spanners4. Allen keys5. Socket spanners6. Screwdriver7. Cable cutters and strippers8. Vacuum cleaner (for cement dust)9. Hammer10. Cable clip pliers


2.1 Installing the machineThe machine must stand on a level floor of concrete, wood or equallyfirm material. An assembly platform must be used. (Take contact withthe supplier for advice about assembly in different types of floor).

The various parts (central bearing, drive unit, safety bar and column)must be fixed to the floor separately.

The parts are placed in order as shown in figure 1. Make sure you re-move all drill-dust before the expanding bolts are inserted in the holes.

21

4

5

6Directionof rotation

7

3Figure 1.

Positioningthe machine parts

1 Turntable

2 Central bearing

3 Position sensor

4 Drive unit

5 Stretch film column

6 Cable conduit

7 Tube


2.1.1 Assembling the various parts of the machines

• Mark out the positioning of the central bearing.

• Bolt the central bearing with three expanding bolts (enclosed in thedelivery).

• Clean the surface from cement dust and trash.

• Place the turntable on the central bearing, make sure that it turnseasily.

• Place the drive unit in position wanted along the turntable.

• Take good care to press the drive unit firmly against the turntableedge. The recess to be 180° in relation to the drive unit when thisoperation is performed.

• Bolt the drive unit with four expanding bolts (enclosed in the deliv-ery).

• Turn the table 180° by hand (NOTE: turn clock-wise) to make thetransport safety screws easily accessible in the recess.

• Loosen the transport safety screws. Figure 2.

Figure 2.

Transport safety screws

Transport safety screws

To be removed afterturnable and drive unit

have been fixed


2.1.2 Electrical installation

All electrical work must be carried out by an authorised electrician.

• Loosen the cable conduit. Figure 1.

• Insert the cables in the pre-mounted tube (mounted on the cableconduit).

• Connect the position sensor (make sure that the sensitivity distancebetween turntable and sensor is 3–5 mm). Connect according toconnection instructions in figure 3.

• Connect the rotary motor (Turntable) according to figure 4.

• Re-install the cable conduit and fix the tube with staples to the floor.

Depending on the position of the drive unit it may be neces-sary to adjust the length of the tube.Do not forget the check the direction of rotation (clock-wise).

Cable from column BlackBlue

Brown

WhiteBlueBrown

Adjust to a space of3–5mm betweensensor-turnable

TURN-TABLE

Figure 3.

Connectingposition sensor

• Connect sensor according to colour marking

• Switch on power (main switch) and check that the built-inluminous diode (sensor) shines during all the rotation –however not at the recess for the fork lift.

NOTE! Be careful so that the sensor does not scrapeagainst the turntable during rotation.


Figure 4. Connecting the rotary motor


Figure 5.

Diagram electricity box

Terminalbox

PL

C

R01

T1 N1

Q1

Q2

F1

K0 K1 K2

P1

E100

S0

S02H02

S01HB

Terminalbox


HB Main switch

Q1 Motor protector switch

Q2 Motor protector switch

K01–K03 Contactor

R01 Auxiliary relay

F1 Automatic fuse

T1 Transformer

N1 Control card

P1 Potentiometer

S0 Push-button

S01 Lamp push-button

PLC Control system

E100 Operator´s terminal

E100 Cable to display

B1 Inductive sensor

B2 Inductive sensor

B3 Inductive sensor

B4 Photocell

Abbreviations

Figure 6. Diagrams for Stretch Wrapping Machine Auto 1

Figure 6a Circuit diagram “Power” Page 14

Figure 6b Circuit diagram “Operation” Page 15

Figure 6c PLC input X0 – X7 Page 16

Figure 6d PLC output Y0 – Y3 Page 17

Figure 6e Layout N1, control card Page 18

Figure 6f Terminal box diagram Page 19


Figure 6a. Circuit diagram “Power”

HB

L1L2

3 X

400

V A

C

+ N

+ P

EM

AX

10

AM

P

L3N

PE

PE

N

M 3~

Q2

1 2

3 4

5 6

K1

4 U

5 V

FIL

M C

AR

RIE

R0.

12 K

W0.

40 A

6 W1K2

2 BR

AK

E

34

5

A/4

.0

N/4

.0

13

5

24

6

13

5

24

6

M 3~

1 2

3 4

5 6

K0

1 U

2 V

TU

RN

TA

BLE

0.25

KW

0.78

A

3 W1

2 BR

AK

E

34

5

13

5

24

6

01

02

03

0.40

AQ

10.

78 A

24

5

13

6

01

02

03


Figure 6b. Circuit diagram “Operation”3.

8/A

4 AF1

08

0809

230/

24V

T1

05 019

018

6.5 D 6.5

D0

24 V

dc

supp

ly to

brak

e ca

rdfil

m b

rake

010

MA

CH

INE

ST

OP

S01

11 12 011

OP

ER

AT

ION

TOS

0213 14 -

013

OP

ER

AT

ION

TO

H02

X1

X2 07

011

R01

11 1214 012 012

1112

7.7

14 7

.7

OP

ER

AT

ION

C0N

TA

CT

OR

R01

A1

A2

0506

3.8/

N

04E A

E

N/4

.8

B/6

.0

A/4

.8


Figure 6c. PLC input X0–X7

06

07

N

09

010

L PLC

CP

U

E 1

00

TE

XT

DIS

PLA

Y

+S

S

S0

017 X 0

ST

AR

TIM

PU

LSE

+

B1

21

X 1

TU

RN

-T

AB

LE0-

PO

SIT

ION-

+

B2

22

X 2

FIL

M C

AR

RIE

RD

OW

N

-+

B3

23

X 3

FIL

M

CA

RR

IER

U

P

-+

B4

24

X 4

FIL

M C

AR

RIE

RT

OP

OF

PA

LLE

T

-

X 5

RE

SE

RV

E

7.0/

A

6.0/

N

PE

0V

++

++

--

--


Figure 6d. PLC output Y0–Y3

CO

M 0

Y 0

014

K 0

A1

A2

TU

RN

TA

BLE

RO

TA

TIO

N

CO

M 1

Y 1

015

K2 3

22 21

K 1

A1

A2

FIL

MC

AR

RIE

R U

P

CO

M 2 013

Y 2

016

K1 3

22 21

K 2

A1

A2 04

FIL

M C

AR

RIE

RD

OW

N

4.3 D 4.3

D0

CO

M 3 019

018

Y 3

020

CO

NT

RO

LF

ILM

BR

AK

E

021

11

5 KP1

022

12

FIL

M B

RA

KE

4.8/

B

5.0/

N

1 3 5 21

2 4.

74

4.7

6 4.

722

.3

2 4.

64

4.6

6 4.

622

.4

1 3 5 21

1 3 5

2 4.

24

4.2

6 4.

3


Figure 6e. Layout N1, Control card

BRAKE0V

+24V

BRAKE CARD

NL–EL001

P 1

SUPPLY 24Vac


Figure 6f. Terminal box diagram

L1 L2 L3 N PE 1 2

TERMINAL BOXIN CABINET BOTTOM

3 PE + - 21 + - 22 4 5 6 PE 11 12 PE

TERMINAL BOXIN CABINET TOP

+ - 23 24+ -

INC

OM

ING

SU

PP

LY3

x 40

0Vac

+N

+P

E M

AX

10

A

MO

TO

R R

OT

AT

ION

B 1

SE

NS

OR

TU

RN

TA

BLE

PO

SIT

ION

B 2

FIL

M C

AR

RIE

R D

OW

N

MO

TO

R F

ILM

CA

RR

IER

FIL

M B

RA

KE

B 3

FIL

M C

AR

RIE

R U

P

B 4

FIL

M C

AR

RIE

R A

T T

OP

OF

PA

LLE

T


3. Dismantling

3.1 DismantlingIn order to dismantle the machine follow the instructions under point2.1, but in the reverse order.

3.2 Disposing of the machineWhen, after many years service, your machine is finally ready for dis-posal it should be done in a way that is not detrimental to the environ-ment.

NISSEN STRETCH WRAPPING MACHINES are manufactured fromrecyclable and, therefore, environmentally friendly materials.


4. Instructions for use

4.1 GeneralThe management responsible for the machine shall make sure that theoperator checks to see that there is nobody close to the machine whocould be injured before the machine is started.

A safety area of at least 800 mm from the edge of the turntable mustalways be kept free of people, goods etc.

4.2 The control panel

Figure 7. Control panel

1 Start: Impulse button for start of wrapping

2 Operation: Switch PLC etc.

3 Stop: Stop of movements by cuttingvoltage on outputs on PLC etc.

4 Operator’s panel: For adjustment ofwrapping program etc.

5 Film brake: Adjusts the film brake force

6 Main switch: Switch electricity box

1

2

3

4

5

6

Operator’s panel E100


4.3 Operation1. Position the pallet on the turntable

2. Attach the film to the pallet

3. Choose wrapping program on the operator’s panel. This adjust-ment will be stored and need not be repeated

4. Push start button and follow possible instructions shown on theoperator’s panel

5. When wrapping is completed, cut the film and remove the pallet.

4.4 Adjustments on operator’s panel

PUSH START P:Down1=Pr 2=Adj 3=M 4=?

4.4.1 Main menu (MENU)

PUSH START Shows action to be taken or stateof operation

P: Down Shows wrapping programchosen (F1)

Choice of function by meansof F1–4

F1 (Pr) Programming of program choiceregarding type of wrapping cycle

F2 (Adj) Adjustment of wrapping program(type, number of turns etc.)

F3 (M) Manual operation of the machine

F4 (?) Information


4.4.2 Wrapping program (F1=Pr)

P:Stop Down (Stop Up) Choice between wrapping com-pleted at top or bottom of pallet

P:Normal (Top sheet) Choice between wrapping be-tween with or without top sheet

Change of program choice

Move the twinkling marker on the text to be changed by means of thearrow keys, then push enter

F4 (MENU) Return to main menu

P:Step DownP:Normal F4=MENU

4.4.3

Wrapping program (F2=Adj)

Following adjustments can bemade:

N:2 Number of turns on lower part ofthe pallet

U:2 Number of turns on upper part ofthe pallet

St:2.0 Overlap between turns upwards

Fc:2.0 Overlap on top of pallet

Change of adjustment

Move the twinkling marker to the value to be changed by means ofthe arrow keys.

Then push NUM-button at the same time as new value is chosen viathe number keys. To write decimal numbers the key with an 0 must beactivated by double push.

Then push enter

F4 (MENU) Return to main menu

Turns:N2 U2 F1=StoreSt 2.0 Fc 2.0 F4=MENU


4.4.4 Manual operation (F3=M)

F1 Turntable rotation

F2 Film carrier up

F3 Film carrier down

F4 Return to main menu

MANUAL OPERATIONTurntable Up Down Menu

4.4.5 Information (F4=?)

Information about type of machine

F4=MENU Return to main menu

Machine type: 2500L A1F4=Menu

4.5 Plastic filmWidth: 500 mm

Max diameter: 240 mm

Inner core: 76 mm

Thickness: 15–35 micron

Quality: Contact your supplier for right choice of film

Figure 8. Thread the film, Auto 1

NOTE: When film with sticky out-side is used


4.6 Adjustment of stop position of turntable rotationAdjustment is made by a timer that starts the rotation sensor and runsthe time that has been set and finally stops the turntable.

Control for this function is placed on the PLC of the machine in theelectricity box.

Figure 9. Timer for turntable rotation

timer


Under no circumstance may anyone stand within the area ofrisk whilst the machine is in operation. The area of risk mustbe clearly marked on the floor.

(Warning tape is supplied.)

5. Safety regulationsNISSEN STRETCH WRAPPING MACHINE

These safety regulations must be read by everyone who willuse the machine.

5.1 Area of risk

Min 0.8 m

Min 0.8 m

Min 0.8 m


5.2 Other safety instructionsGreat care must be taken to see that nobody comes between the loadedpallet and the turntable when the pallet is driven onto the turntable.

• The operator must not stand near the film carrier when it travelsup the film column. The risk area including the film carrier ismarked with warning tape to avoid risk of the operator putting afoot under the film carrier. Warning tape is supplied.

• Great care should be taken to ensure that no hand or arm gets caughtbetween the top clamp and the load when a top clamp is used.

• The machine must be shut off if it is not used during an extendedperiod or when the operator is not present.

• All electrical installation and repair work must be carried out by anauthorised electrician.

• After servicing or repairs, check that the safety bar, lift wire and allswitches, including the emergency stop switch, are fully operatio-nal.

• IN CASE OF EMERGENCY: PRESS THE EMERGENCY STOPBUTTON.

IMPORTANT!

The maximum load is 1 500 kg

The turntable must not be stepped on by any person.

Ensure that the fully loaded pallet is positioned in the centre ofthe turntable for the best possible stability.


6. MaintenanceTo ensure that your stretch wrapper works efficiently it is important thatyou regularly carry out maintenance in accordance with the instructionsbelow.

Service and repairs may only be carried out when the machineis totally disconnected from the power supply.

6.1 Cleaning of the pre-stretching unitBoth rollers of the pre-stretching unit must be kept clean to enable thefilm to run freely. Clean with spirit.

6.2 Care of the drive unitThe drive station is equipped with automatic chain tension. However,it may be necessary, after some time of operation, to exchange the chain(see separate instructions delivered together with the spare chain).

Besides, the drive station is equipped with two drive wheels whichmay have to be exchanged after some time of operation (see separateinstructions delivered together with the spare chain).

Check yearly both chain and drive wheels.

The chain is to be oiled regularly, 2–4 times yearly depending on oper-ation conditions.

NOTE! Lubrication is to be made with care to avoid oil stainson the drive wheels

NOTE! When the covering plate on the drive unit is beingremoved, be careful as the drive station contains chain tension-er which can cause damages if carelessly handled.


6.3 Care of the turntableKeep the turntable free of dust. Do not use cleaning fluid, since this cancause the drive wheel to slip if cleaning fluid is left on the periphery ofthe turntable.

6.4 Other maintenance instructionsElectrical connections: Check all connections and repair any damage orwear found. Replace with new parts when necessary.

Nuts and screws: Check that all nuts and screws are tightened thoroughly.

Notice plates: Check that all warning plates are firmly fixed and clearlylegible. They are there for your safety.

stretch wrapping machine l2500 auto 1 - … auto1 eng.pdf · manual and ce-instructions march 2001...

Documents