Operation and Maintenance Manual-C140-18 PDF

Cut Size Wrapper
TRANSLATIOIN FROM ORIGINAL INSTRUCTIONS
Operation and maintenance manual

EN English U0G00214 Manual code:
0 - Intro
U0G00214
0.1 Customer information and machine serial number
PT Indah Kiat Pulp and

Paper TBK
Customer
WRAPMASTER C140/18
Serial number
U0G00214
Manual code
0.1.1 Previous documentation
The documentation used to draft this manual is listed in the table below.
Stampato il 23/04/2015
Codice Variazioni sulle versioni precedenti Data
U0G00214 Versione conforme a STD Bielomatik + pers. per matr. 18 23/04/2015
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0.2 Copyright
This manual is an essential part of the machine. Always ask for an additional copy if this one is ruined or no longer
legible without delay.
Carefully read all the maintenance and operating instructions as well as the warnings regarding safety.
bielomatik s.r.l. shall not be held responsible for improper use of the machine and any consequential damage, or
when operations which are not dealt with in this manual are carried out.
Use of the machine to process elements not foreseen by the manufacturer is considered improper use. In this case,
the manufacturer cannot be held liable for any damages to property and/or persons and the warranty is considered
null and void.
Any changes to the work-cycle or machine structure must be duly authorized by bielomatik s.r.l.
Only use original spare parts; bielomatik s.r.l. is not liable for personal injury or damages caused by the use of
unoriginal spare parts, voiding the warranty.
The content of this manual is of strictly technical nature and property of bielomatik s.r.l. and thus the reproduction,
distribution or full or partial modification of its content without written authorisation is prohibited. All rights reserved.
This manual was drafted as per Machine Directive 2006/42/EC (Appendix I, paragraph 1.7).
The original version of this manual was drafted in Italian and translated into other languages if necessary. Therefore,
the Italian version is the ORIGINAL INSTRUCTION MANUAL while versions in other languages are to be
considered TRANSLATIONS OF THE ORIGINAL INSTRUCTIONS.
If you believe that any part of the translation is incorrect or poor, please contact bielomatik s.r.l. who will provide
you with the necessary clarifications and correct the translation.
bielomatik s.r.l. - Via Marzabotto, 280 - 40050 Funo di Argelato (Bo) - Italy
Tel. (051) 6647444 - Fax (051) 866021
World Wide Web: http://www.bielomatik.com e-mail: bielomatik@bielomatik.it
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Contents
0.1 Customer information and machine serial number ........................................................................... 0 - 2
0.1.1 Previous documentation ........................................................................................................ 0 - 2
0.2 Copyright .......................................................................................................................................... 0 - 3
0.3 Important warnings ........................................................................................................................... 0 - 9
0.4 Document organisation ................................................................................................................... 0 - 10
0.4.1 Installation, instruction and maintenance manual ................................................................ 0 - 10
0.4.2 Spare parts and code=>unit correspondence ...................................................................... 0 - 10
0.4.3 Retail mechanical parts ....................................................................................................... 0 - 10
0.4.4 Retail electrical parts ............................................................................................................0 - 11
0.4.5 Electrical part list ..................................................................................................................0 - 11
0.4.6 Electrical part calibration tables, Motor list, Wiring diagram ..................................................0 - 11
0.4.7 Machine management program manual. ..............................................................................0 - 11
0.5 Description of the icons .................................................................................................................. 0 - 11
0.6 Qualification levels of the machine operators ................................................................................. 0 - 12
0.7 Use of the icons.............................................................................................................................. 0 - 13
0.8 How the documentation is revised .................................................................................................. 0 - 13
1 Safety ...................................................................................................... 1 - 1
1.1 General information .......................................................................................................................... 1 - 2
1.1.1 Personnel training ................................................................................................................. 1 - 2
1.1.2 Applied directives and technical reference regulations .......................................................... 1 - 3
1.1.3 Machine certification .............................................................................................................. 1 - 3
1.1.4 Intended use and operating restrictionsh ............................................................................... 1 - 7
1.1.5 Hazardous areas ................................................................................................................... 1 - 7
1.1.6 Environmental operating conditions ....................................................................................... 1 - 8
1.1.7 Vibration ................................................................................................................................ 1 - 8
1.1.8 Noise ..................................................................................................................................... 1 - 8
1.1.9 Electromagnetic emissions .................................................................................................... 1 - 9
1.2 Used material disposal ..................................................................................................................... 1 - 9
1.2.1 Instructions for special waste ................................................................................................ 1 - 9
1.2.2 Important information for the user as per directive 2012/19/EU on waste of electric and
electronic equipment (WEEE), which annuls directives 2002/96/EC and 2003/108/EC ....... 1 - 10
1.3 Safety devices installed on the machine ......................................................................................... 1 - 11
1.3.1 Emergency stop ................................................................................................................... 1 - 11
1.3.2 Fixed guards ....................................................................................................................... 1 - 12
1.3.3 Mobile guards ...................................................................................................................... 1 - 12
1.3.4 Cutting off electrical energy ................................................................................................. 1 - 14
1.3.5 Cutting off pneumatic energy ............................................................................................... 1 - 14
1.4 Personal protection devices ........................................................................................................... 1 - 15
1.5 Residual risks ................................................................................................................................. 1 - 16
1.5.1 Collision and crushing ......................................................................................................... 1 - 16
1.5.2 Shearing / cutting ................................................................................................................ 1 - 17
1.5.3 Electrocution ....................................................................................................................... 1 - 17
1.5.4 Fire ...................................................................................................................................... 1 - 17
1.5.5 Burns and scalding .............................................................................................................. 1 - 18
1.5.6 Explosive atmosphere ......................................................................................................... 1 - 18
1.5.7 Blinding ............................................................................................................................... 1 - 19
1.5.8 Falling, projecting objects .................................................................................................... 1 - 19
1.5.9 Slipping ............................................................................................................................... 1 - 19
1.5.10 Whiplash ............................................................................................................................. 1 - 19
1.5.11 Tripping ............................................................................................................................... 1 - 19
1.5.12 Circuit faults ........................................................................................................................ 1 - 20
1.5.13 Lighting ............................................................................................................................... 1 - 20
1.5.14 Noise ................................................................................................................................... 1 - 20
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1.5.15 Lightnings ............................................................................................................................ 1 - 20

1.5.16 Dusts ................................................................................................................................... 1 - 20
1.6 Hazard ........................................................................................................................................... 1 - 20
1.7 Warning .......................................................................................................................................... 1 - 21
1.8 Signal plates ................................................................................................................................... 1 - 21
1.8.1 Warning plates used on the machine .................................................................................. 1 - 22
1.8.2 Warning plate positions ....................................................................................................... 1 - 23
2 Preliminary information ......................................................................... 2 - 1

2.1 Presentation ..................................................................................................................................... 2 - 2
2.1.1 Main features ........................................................................................................................ 2 - 2
2.1.2 Optional equipment ............................................................................................................... 2 - 2
2.2 Work-cycle ....................................................................................................................................... 2 - 3
2.2.1 General process description: Wrapping sheet infeed ............................................................ 2 - 4
2.2.2 General process description: Ream infeed ............................................................................ 2 - 4
2.2.3 General process description: Ream wrapping ....................................................................... 2 - 5
2.2.4 General process description: Wrapped ream disc harge ....................................................... 2 - 5
2.3 Technical data .................................................................................................................................. 2 - 6
2.3.1 Main specifications ................................................................................................................ 2 - 6
2.3.2 Electrical system ................................................................................................................... 2 - 6
2.3.3 Pneumatic system ................................................................................................................. 2 - 6
2.3.4 Formats that can be handled ................................................................................................. 2 - 7
2.3.5 Wrapping material ................................................................................................................. 2 - 8
2.3.6 Diagram showing wrapping material unwinding ....................................................................2 - 11
2.4 Overall dimensions ......................................................................................................................... 2 - 12
2.5 Using hotmelt glue .......................................................................................................................... 2 - 13
2.5.1 Glue properties and characteristics ..................................................................................... 2 - 13
2.5.2 Processing temperature ...................................................................................................... 2 - 13
2.5.3 Open time ........................................................................................................................... 2 - 13
2.5.4 How the material influences glueing .................................................................................... 2 - 13
2.5.5 Cleaning .............................................................................................................................. 2 - 13
2.5.6 Pressing .............................................................................................................................. 2 - 14
2.5.7 Quantity applied and cost of hotmelt glue ............................................................................ 2 - 14
2.5.8 Applications ......................................................................................................................... 2 - 14
2.5.9 Specifications ...................................................................................................................... 2 - 14
2.5.10 Processing indications ........................................................................................................ 2 - 15
2.5.11 Safety precautions .............................................................................................................. 2 - 15
2.5.12 Cleaning .............................................................................................................................. 2 - 15
3 Installation .............................................................................................. 3 - 1
3.1 General information .......................................................................................................................... 3 - 2
3.2 Supply conditions ............................................................................................................................. 3 - 2
3.2.1 Packaging and transport ....................................................................................................... 3 - 2
3.3 Work site preparation ....................................................................................................................... 3 - 3
3.3.1 General information ............................................................................................................... 3 - 3
3.3.2 Site selection and installation requirement checks ................................................................ 3 - 4
3.3.3 Lifting and handling procedures ............................................................................................ 3 - 5
3.4 Assembly and positioning ................................................................................................................. 3 - 7
3.4.1 Unit assembly and positioning ............................................................................................... 3 - 7
3.5 Electrical connections ..................................................................................................................... 3 - 14
3.6 Pneumatic connections .................................................................................................................. 3 - 16
3.7 Machine part lubrication ................................................................................................................. 3 - 16
3.8 Checks and inspections before start-up ......................................................................................... 3 - 17
3.8.1 General machine unit checks .............................................................................................. 3 - 17
3.8.2 Electrical system inspection ................................................................................................ 3 - 18
3.8.3 Safety system inspection .................................................................................................... 3 - 19
3.9 Decommissioning ........................................................................................................................... 3 - 20
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4 Machine start-up and operation ............................................................ 4 - 1

4.1 Control equipment ............................................................................................................................ 4 - 2
4.1.1 Electrical control cabinet ....................................................................................................... 4 - 3
4.1.2 P1 - Main control panel ......................................................................................................... 4 - 4
4.1.3 P3 + P3.1 - Left and right jog pushbutton panel ..................................................................... 4 - 6
4.1.4 P12 - Packaging sheet feed control panel ............................................................................. 4 - 7
4.1.5 P13 - Roll carriage control panel ........................................................................................... 4 - 8
4.1.6 P13.1 - Roll change control console .................................................................................... 4 - 10
4.1.7 P14 - Emergency stop push-button ..................................................................................... 4 - 10
4.1.8 P15 - Clear Wrap unit push-button panel (optional) ..............................................................4 - 11
4.2 Warning equipment ........................................................................................................................ 4 - 12
4.2.1 Indicator pole ....................................................................................................................... 4 - 12
4.3 Description of the operating modes ................................................................................................ 4 - 13
4.3.1 Automatic mode .................................................................................................................. 4 - 13
4.3.2 Manual mode ...................................................................................................................... 4 - 14
4.3.3 Jog mode ............................................................................................................................ 4 - 15
4.4 Machine shut down ........................................................................................................................ 4 - 16
4.4.1 Stop in phase ...................................................................................................................... 4 - 16
4.4.2 Emergency shut down ......................................................................................................... 4 - 16
4.4.3 Stopping the machine when a fault is present ..................................................................... 4 - 16
4.4.4 Machine shutdown due to serious faults .............................................................................. 4 - 16
4.4.5 Stopping the machine for maintenance ............................................................................... 4 - 16
4.5 Starting the machine ...................................................................................................................... 4 - 17
4.5.1 Restart after stop in phase, immediate or due to a fault ...................................................... 4 - 18
4.5.2 Restart after an emergency stop or due to a serious fault ................................................... 4 - 18
4.5.3 Restart after a stop due to maintenance .............................................................................. 4 - 18
4.6 Wrapping material .......................................................................................................................... 4 - 19
4.6.1 Putting the roll on the expanding spindle ............................................................................. 4 - 19
4.6.2 Removing the roll from the expanding spindle ..................................................................... 4 - 19
4.6.3 Installing the roll on the Easy Splice holder ......................................................................... 4 - 20
4.7 Checking the safety devices ........................................................................................................... 4 - 26
4.8 Trial runs ........................................................................................................................................ 4 - 26
5 Machine axes .......................................................................................... 5 - 1

5.1 Datum lines ...................................................................................................................................... 5 - 2
5.2 Definition of the machine axes ....................................................................................................... 5 - 3
5.2.1 Product size parameters ....................................................................................................... 5 - 3
5.2.2 Movable axles of the machine ............................................................................................... 5 - 5
6 Machine control through operator interface ........................................ 6 - 1

6.1 Machine control through operator interface ...................................................................................... 6 - 2
6.2 Lay-out of the video-pages ............................................................................................................... 6 - 3
6.2.1 Calling up the pages in operator mode (no password required) ............................................ 6 - 3
6.2.2 Calling up the pages in maintenance worker mode (password required) ............................... 6 - 4
6.3 Description of the program pages ..................................................................................................... 6 - 5
6.3.1 General video-page description ............................................................................................. 6 - 5
6.4 Start-up: Menu page ...................................................................................................................... 6 - 7
6.5 Current order page description ...................................................................................................... 6 - 8
6.5.1 Next Order page description ............................................................................................. 6 - 10
6.5.2 Recipe sub-page description ............................................................................................ 6 - 12
6.5.3 Order change sub-page description .................................................................................. 6 - 14
6.6 Overview sub-page description .................................................................................................... 6 - 15
6.6.1 Description of the Movements parameters mask .............................................................. 6 - 16
6.6.2 Description of the Servo axles screen masks ................................................................... 6 - 17
6.6.3 Description of Variables masks ......................................................................................... 6 - 20
6.6.4 Service page description .................................................................................................. 6 - 32
6.6.5 Service Hot-melt page description .................................................................................... 6 - 34
6.6.6 Ream detector (optional) ..................................................................................................... 6 - 35
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6.6.7 Clear Wrap page description (optional) ............................................................................. 6 - 36

6.6.8 Roll holder page description .............................................................................................. 6 - 39
6.7 Signal or alarm page description .................................................................................................. 6 - 40
6.8 General settings page description ................................................................................................ 6 - 41
6.9 IO Test" sub-page description ....................................................................................................... 6 - 42
6.10 Bus-Profibus page description ..................................................................................................... 6 - 43
6.11 Syncro Overview page description ............................................................................................... 6 - 43
6.12 Report sub-page description ........................................................................................................ 6 - 44
7 Operation and format change ............................................................... 7 - 1

7.1 Introduction ...................................................................................................................................... 7 - 2
7.1.1 Size change-over .................................................................................................................. 7 - 2
7.2 General informations for the size change-over procedure ................................................................ 7 - 3
7.2.1 Size change procedure ......................................................................................................... 7 - 4
7.3 Machine layout ................................................................................................................................. 7 - 6
7.4 Wrapping sheet infeed ...................................................................................................................... 7 - 9
7.4.1 Easy Splice roll carriage unit ............................................................................................... 7 - 10
7.4.2 1st Unwinding roller assembly .............................................................................................. 7 - 13
7.4.3 De-curling unit ..................................................................................................................... 7 - 14
7.4.4 Dancing and idle rollers ....................................................................................................... 7 - 15
7.4.5 Spot detection photocell assembly ...................................................................................... 7 - 17
7.4.6 2nd Unwinding roller assembly ............................................................................................. 7 - 20
7.4.7 Cutter assembly .................................................................................................................. 7 - 21
7.4.8 Sheet conveyor belt assembly ............................................................................................ 7 - 22
7.4.9 Crosswise flap glueing assembly ........................................................................................ 7 - 25
7.5 Ream infeed section ....................................................................................................................... 7 - 27
7.5.1 Ream infeed conveyor belts ................................................................................................ 7 - 28
7.5.2 Stopping mechanism-and-synchroniser .............................................................................. 7 - 29
7.5.3 Ream squaring unit ............................................................................................................. 7 - 32
7.5.4 Stopping units and lateral pressing units ............................................................................. 7 - 35
7.6 Ream wrapping .............................................................................................................................. 7 - 37
7.6.1 Elevator and wrap tube formation ........................................................................................ 7 - 38
7.6.2 Wrapping paper stop ........................................................................................................... 7 - 40
7.6.3 Counter-elevator ................................................................................................................. 7 - 41
7.6.4 Lower hoppers .................................................................................................................... 7 - 43
7.6.5 Upper hoppers .................................................................................................................... 7 - 44
7.6.6 Lower counter-folder and folder ........................................................................................... 7 - 45
7.6.7 Folding devices for top fold .................................................................................................. 7 - 47
7.6.8 Plough folders ..................................................................................................................... 7 - 48
7.6.9 End-flap glue applicators ..................................................................................................... 7 - 50
7.6.10 Ream accelerator ................................................................................................................ 7 - 51
7.6.11 Pushers ............................................................................................................................... 7 - 51
7.7 Finished pack exit assembly ........................................................................................................... 7 - 52
7.7.1 Exit table ............................................................................................................................. 7 - 53
7.7.2 Clear Wrap unit ................................................................................................................... 7 - 55
7.7.3 Compression belts (optional) ............................................................................................... 7 - 57
7.8 Common parts ................................................................................................................................ 7 - 58
7.8.1 Electrical cabinet and electrical system components ........................................................... 7 - 59
7.8.2 Pneumatic system ............................................................................................................... 7 - 60
7.8.3 Hotmelt glue unit ................................................................................................................. 7 - 61
8 Maintenance ........................................................................................... 8 - 1
8.1 Overview .......................................................................................................................................... 8 - 2
8.2 Maintenance personnel .................................................................................................................... 8 - 3
8.2.1 Communications with customer service ................................................................................ 8 - 4
8.3 General safety precautions ............................................................................................................... 8 - 5
8.3.1 Hazard notes ......................................................................................................................... 8 - 5
8.3.2 Warning notes ....................................................................................................................... 8 - 8
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8.4 Maintenance advice ......................................................................................................................... 8 - 9

8.4.1 Operations associated with prolonged downtime .................................................................. 8 - 9
8.4.2 Screw torque ....................................................................................................................... 8 - 10
8.5 Maintenance plan description ......................................................................................................... 8 - 11
8.6 Cleaning operations........................................................................................................................ 8 - 12
8.7 Lubrication plan .............................................................................................................................. 8 - 13
8.7.1 Lubrication........................................................................................................................... 8 - 14
8.7.2 Lubrication diagrams ........................................................................................................... 8 - 15
8.8 Maintenance plan ........................................................................................................................... 8 - 17
8.8.1 Drafting criteria .................................................................................................................... 8 - 18
8.8.2 Maintenance and frequency table ....................................................................................... 8 - 20
8.8.3 Detailed specific procedures for machine parts that require detailed information ................ 8 - 21
9 Troubleshooting ...................................................................................... 9 -1
9.1 Fault messages ................................................................................................................................. 9 -2
9.1.1 Description of the Alarms and warnings ............................................................................... 9 -2
9.2 Fault indication .................................................................................................................................. 9 -3
10 Timing diagrams................................................................................... 10 - 1
10.1 Timing diagrams ............................................................................................................................. 10 - 3
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0.3 Important warnings

It is mandatory to read the manual!
Indicates a mandatory instruction for the personnel involved in the operation of
the machine/equipment or its units; according to this instruction the personnel
has to read and understand the instruction manual supplied, before performing
any operations on the machine/equipment or its units.
In order to fully safeguard the operator and prevent damaging the system, the user must read and thoroughly
understand the entire Instruction Manual before operations of any kind can be performed.
This Maintenance and Operations Manual is intended to help the user familiarize him/herself with the machine (i.e.
plant) so that it can be employed for the tasks it was expressly designed for.
The use and maintenance instructions contain information on how to use the machine properly, and describe the
safe, suitable and inexpensive use of the installation; in particular they contain the technical description of the various
functional units, describe the safety equipment and systems, the operation, the use of the instruments, any
diagnostic message and the main procedures, and give information on the routine maintenance interventions. These
instructions are to be closely followed in order to prevent hazardous situations from occurring, reduce repair costs
and downtime, as well as increase the service life of the machine.
This manual is to be considered an essential part of the machine; it must be preserved and protected for the whole
duration of the machine and delivered to any other future user or owner.
This manual must be kept in good condition and completely legible in all its parts; it must be used with great care
in order not to damage the contents or compromise the functionality. No part of this manual should be removed, torn
or rewritten. Keep this manual away from moisture and heat sources.
The instruction manual should be kept near the machine in order to facilitate the consultation. This manual is to be
kept in an easy-to-reach place that all the operators, maintenance workers or people in charge for size change or
adjustment operations know.
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0.4 Document organisation

The documents that accompany the machine are divided in various sections grouped in folders according to the
amount of material in each section. The following table lists sections:
- Installation, instruction and maintenance manual

- Spare parts and code=>unit correspondence
- Retail mechanical parts
- Retail electrical parts
- Electrical part list
- Electrical part calibration tables, Motor list, Wiring diagram
- Machine management program manual.
0.4.1 Installation, instruction and maintenance manual
This manual contains general machine information and instructions on how to safely lift and install the machine.
It contains instructions on safe machine use, operating and start-up regulations and the description of safe format
change and machine maintenance operations.
This manual also considers optional units that can be used with the machine upon customer request. Thus the
description of some parts may not correspond to your machine.
The manual is divided in chapters that group all information necessary for safe machine use by subject. Each chapter
is divided to concentrate essential points in paragraphs. Each paragraph can be divided by headings with sub-
headings and descriptions.
The beginning of a chapter is marked by a page that indicates the chapter number and title. For example, in chapter
1 you will find:
1 Chapter heading
1.1 Paragraph title
1.1.1 Sub-heading
1.1.1.1 Any additional sub-headings
Pages are numbered by chapter. Therefore, pages are numbered with a prefix indicating the chapter followed by
the progressive page number that starts from 1 at the beginning of each chapter.
0.4.2 Spare parts and code=>unit correspondence
This section contains mechanical drawings, part lists and a list of parts with reference to the groups where they are
installed.
0.4.3 Retail mechanical parts
This section contains the copies of manuals of the mechanical commercial parts installed on the machine.
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0.4.4 Retail electrical parts
This section contains the manuals for the retail electrical parts installed on the machine.
0.4.5 Electrical part list
This section contains the list of electrical parts.
0.4.6 Electrical part calibration tables, Motor list, Wiring diagram
This section contains:

- setting calibration tables for electrical parts installed on the machine;
- a list of electrical motors installed on the machine with a description, features and reference to the wiring diagram;
- a copy of the wiring diagram.
0.4.7 Machine management program manual.
This section contains a copy of the PLC program for machine control and operations.
0.5 Description of the icons

An icon is provided next to the paragraphs included in the chapters. These icons make this manual easy to consult
as the user can immediately understand what is dealt with in the text, whether it be maintenance operations,
descriptions, operation or important remarks.
This safety alert symbol identifies important information. This symbol is used to call the users attention
to items or operations that could injure him/her or cause machine damage if the instructions are not
followed.
This symbol is used to inform the reader of something that has already been mentioned which is not
dangerous. However, these recommendations should be followed to ensure top machine performance.
This symbol is usually provided with the description of the operating principles or the structural
characteristics of the machine. This description provides all the information which needs to be known in
order to properly and safely use the machine according to current safety standards.
The operations described in logical order next to this symbol let the operator know the most convenient
and safest way to carry out the change-over procedure and the adjustments required to process different
sized products.
This symbol indicates the scheduled or special maintenance operations which need to be carried out,
including the safety devices. A symbol which indicates the qualification level of the personnel required to
carry out these operations is also provided.
This represents a warning of possible deterioration or damages to the machine, equipment or other
personal user item. Pay special attention to text marked by this symbol.
Test with complementary information are introduced by this symbol. This information does not have a
direct relation with the function description or procedure. They may be references to other complementary
documents such as enclosed instruction manuals, technical documents or other sections in this manual.
This informs the reader that visual observation is required. This symbol is also found in the instructions
for use. It requires the user to read a measured value, check a signal, etc.
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0.6 Qualification levels of the machine operators

The operator responsible for servicing and controlling the machines, must be both qualified and specialized, that
is, he/she must know how to perform the required operations efficiently. The operator must be well instructed and
fully understand the jobs he/she is responsible for. The description of the various qualification levels required for the
operations to be performed is given below. The symbol shown is also used in the manual to indicate the qualification
level required to perform the operation in question.
Operator:
Personnel trained and authorized to operate the machine for production purposes to carry out the activities
it has been built for.
They must be able to perform all the operations necessary to ensure the proper operation of the machine,
ensuring the safety of themselves or of potential collaborators.
They must have a proven expertise regarding the proper use of these types of machine/equipment and
be trained and informed about it.
In case of doubt they must report any anomaly to the responsible person.
They are not authorized to carry out any maintenance operation.
Operator responsible for the use of lifting and handling equipment:

Personnel authorized to use equipment to lift and move materials and machines (keeping strictly to the
instructions of bielomatik s.r.l.), in accordance with the laws of the country where the machine is used.
Maintenance staff for mechanical system:

Qualified personnel who are able to operate the machine as the operator, and to perform the required
adjustments, maintenance, repair or replacement operations on the mechanical units.
They are able to read pneumatic and hydraulic diagrams, as well as technical drawings and spare part lists.
In extraordinary cases, they are trained to operate the machine with some safeties devices inactivated.
They are not permitted to work on live electrical parts (if present).
If necessary, they can give to the operator instructions for the proper use of the machine for production
purposes.
Maintenance staff for electrical system:

Qualified personnel who are able to operate the machine as the operator, and to perform the required
adjustments, maintenance, repair or replacement operations for the electrical system.
They are able to read wiring diagrams and to check the correct operating cycle of the machine.
They are qualified to operate inside the cabinet, junction boxes and control equipment when live (see
directive EN50110-1).
If necessary, they can give to the operator instructions for the proper use of the machine for production
purposes.
Manufacturers technician:
Engineers qualified by the manufacturer or its dealer to carry out complex operations since he/she knows
B the production cycle of the machine/equipment.
This technician operates on the basis of the agreement made with the user.
Depending on the situation, the technician has mechanical, electrical, electronic and/or software skills.
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0.7 Use of the icons

Each paragraph which deals with the various machine operations and therefore the operator, is provided with an
icon which indicates the type of operation being described.
If the operator has to work on the machine in order for the operation to be carried out, for example when maintenance
is required, the qualification level he/she must have in order to perform this operation is indicated by a symbol.
Important!
The number of persons required to run the machine as well as carry out mainte-
nance or other operations is indicated in the "Specifications", given in this
manual. If the presence of other persons is required to carry out a specific
operation it will be indicated in the description.
0.8 How the documentation is revised

If modifications are made to the machine for which the Instruction Manual as well as the other enclosed documents
need to be revised, bielomatik s.r.l. will provide a new copy of the documentation. The customer will then be held
responsible for disposing of the old documentation and using the new documentation, once provided.
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Safety
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1.1 General information

The user facilities must instruct personnel on accident risks, safety devices and the general workmans safety
regulations set by community directives and laws in the country where the machine is installed.
Operators must know the position and functions of all machine controls and features.
They must also have fully read this manual.
Maintenance must be performed by qualified personnel after having appropriately prepared the machine.
Hazard!
Tampering or the unauthorised replacement of one or more machine parts, the use
of accessories that vary machine use and the use of spare parts other than those
recommended could cause safety hazards.
1.1.1 Personnel training
Warning!
The machine is intended for professional use.
The purchaser must ensure that machine operators and maintenance technicians are suitably educated and trained.
For this reason, upon request the manufacturer provides a training course held by its qualified personnel at
commissioning.
The following subjects must be covered during the training course for machine operators and maintenance
technicians:
THEORETIC ASPECTS
PROFESSIONAL QUALIFICATIONS AND DUTIES
MACHINE TYPE TECHNOLOGY
THEORETIC ASPECTS
MACHINE COMMISSIONING AND DECOMMISSIONING
DEVICE USE AND SAFETY REGULATIONS
OPERATING CRITERIA
INSPECTION, MAINTENANCE
MANUAL CONTENT KNOWLEDGE
PRACTICAL ASPECTS
OPERATING EXERCISES
MOVEMENT EXERCISES
USE, TEST AND MAINTENANCE EXERCISES
EMERGENCY SITUATIONS
Note:
The regulations in this manual may not cover special situations that may occur
during the different work phases.
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1.1.2 Applied directives and technical reference regulations
The machine was designed, constructed and tested in accordance with the following community directives:
Machine directive 2006/42/EC to harmonise member state laws on machinery.
Electromagnetic compatibility directive 2004/108/EC.
Low voltage directive 2006/95/EC (referred to the use of compliant material).
1.1.3 Machine certification
The Declaration of Conformity with essential safety requirements as per Directive 2006/42/EC
(appendix II, point a), Low Voltage Directive 2006/95/EC and Electromagnetic Compatibility Directive 2004/
108/EC is provided with the machine.
Photocopies of the identification plate affixed to the machine and the Declaration of Conformity are enclosed.
Note:
Any modification made to the machine immediately null and voids certification.
In this case, the manufacturer cannot be held liable for any reason.
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1.1.4 Intended use and operating restrictionsh
The machine was designed for the uses described in chapter 2 Preliminary information hereto and must
be used only for the purposes intended by the manufacturer.
In particular:
do not use the machine if it has not been properly installed according to the regulations in force;
do not use the machine as support point, even if it is not in operation.
Use of unsuitable material or material not included in the machines field of application may cause serious damages
and compromise good working order.
Warning!
Use of the machine to process elements not foreseen by the manufacturer is
considered improper use. In this case, the manufacturer cannot be held liable for
any damages to property and/or persons and the warranty is considered null and
void.
The manufacturer cannot be held liable in the event of tampering with the machine
for unauthorised modifications or for maintenance conducted by personnel who
were not suitable informed, educated and trained.
Hazard!
In the event of abnormal machine operations, duly trained maintenance techni-
cians are in charge of any intervention.
1.1.5 Hazardous areas
The machine in question is intended to be used by qualified operators, duly trained on its use who are aware
of the problems concerning processing with this type of machine/material and who are well aware of the risks
in the working environment. The machine in question is characterised by units and machine parts deemed
hazardous. All areas deemed hazardous must be confined to prevent access when the machine is running.
The entire area concerned by movements is considered hazardous.
Hazard!
Mark work areas with no entrance signs.
Hazard!
To access hazardous areas, work in safety conditions and conduct all the
operations and procedures set in this chapter and in chapter 8 Maintenance.
Access to hazardous areas is reserved to specialised personnel, authorised to
conduct the interventions.
In order to limit risks in hazardous areas, adequate prevention and protection measures were taken. Follow the
procedures and instructions on Personal Safety Devices indicated hereto.
Hazard!
various risk factors in the maintenance phase were assessed during machine
design and the relevant prevention and protection measures taken.
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1.1.6 Environmental operating conditions
The work environment must be an indoor room away from the elements such as rain, hail, snow, fog,
suspended dust, etc.
The use of the machine, of the connected control systems and of the operation equipment is not allowed
under conditions different from those listed below.
In particular the environment where the machine has to be installed and used must not present:
Exposure to corrosive fumes.
Exposure to an excessive humidity (above 85 %) and to relative humidity quick ckanges (above 0.005 p.u./h).
Exposure to excessive dust.
Exposure to abrasive dust.
Exposure to oily fumes.
Exposure to explosive dust or gas mixtures.
Exposure to brackish air.
Exposure to anomalous vibrations, collisions or jolts.
Exposure to bad weather (out of the allowed limits) or to dripping.
Exposure to unusual transport or storage conditions (with respect to those described in this manual).
Exposure to high or quick temperature changes (above 5 K/h).
Nuclear radiation.
Internal pressure or vacuum.
The machine should be installed in an unclassified room equipped with all the safety devices required by current
law in the user country.
1.1.7 Vibration
If the machine is used in conformity with the prescriptions of use and according to the regulations in force,
the vibrations produced by the machine, according to use, are not harmful to operator health.
Warning!
Excessive vibrations may only be caused by a mechanical fault that must be
immediately indicated and eliminated to avoid jeopardising machine and operator
safety.
1.1.8 Noise
Noise was measured in accordance with that set by regulation ISO 3746.
Operator exposure to noise during work cycles exceeds 70 dB, remaining, in any case, under 80 dB.
The actual noise level of the machine during its working cycle at the site is different from the one measured because
the noise level is affected by different factors, such as:
type and features of the site;
other adjacent machines in operation;
type of material being processed.
We recommend personal noise protection devices are worn (headphones) by the operator working near the machine.
Warning!
The user must assess noise risks and apply consequent preventive and protective
measures in accordance with the rules in force in the country where the machine
is installed.
Hazard!
Hearing protection devices must be work during machine adjustments.
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1.1.9 Electromagnetic emissions
The machine contains electronic parts subject to Electromagnetic Compatibility regulations, conditioned by
conveyed and radiated emissions.
The emission values meet regulatory requirements thanks to the use of parts that comply with the
Electromagnetic Compatibility directive, suitable connections and the installation of filters where necessary.
The machine thus meets the Electromagnetic Compatibility Directive (EMC).
Warning!
Any non-compliant maintenance on electrical equipment or incorrect part replace-
ments may compromise the efficiency of adopted solution.
1.2 Used material disposal

During normal use, machine operations do not pollute the environment.
Residual glue may need to be discarded when glue type is changed. Please refer to the sub-manufacturers manual.
Specific environmental protection regulations are set in every country for the disposal of this material.
The Customer must know the laws in force in his country and work to meet them.
Warning!
Please observecurrent mineral oil and glue disposal regulations.
Additional information!
Additional information on hot melt glue, oil and other substance disposal proce-
dures can be found on the substance safety sheets.
Toxic waste disposal collection, transport and processing phases considered as operations necessary for recycling
as well as ground storage and disposal, are considered of public interest and must meet the following general
principles:
a) All public and private health and safety damages or hazards must be avoided.
b) Observance of hygienic-health regulations must be guaranteed an all risks of air, water, ground and substrate
pollution must be avoided.
In observance of economic and efficiency criteria, material and energy recovery and recycling systems must be
promoted.
1.2.1 Instructions for special waste
Industrial processing residue and worn and obsolete machine and equipment demolition material are
considered special waste.
Manufacturers who produce special waste, even toxic or harmful, are in charge of their disposal either directly
or through the special companies, authorised boards or public waste services with whom specific contracts were
stipulated.
Each town/municipality must provide the region with all the information in their possession on waste disposal in their
territory.
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1.2.2 Important information for the user as per directive 2012/19/EU on waste of electric
and electronic equipment (WEEE), which annuls directives 2002/96/EC and 2003/108/EC
As per directive WEEE 2012/19/EU, if purchased equipment is marked with the barred waste bin symbol, this
means that the product must be separated from other waste upon disposal at the end of its working life.
The manufacturer organises and manages the recycling and disposal of this equipment. Users who wish to dispose
of this equipment should thus contact the manufacturer and follow the system the manufacturer has adopted for the
separate disposal of this equipment at the end of its working life.
Adequate separate collection for subsequent equipment delivery to recycling, processing and environmentally
compatible disposal contributes to avoid potential negative effects on the environment and health and promotes the
reuse and/or recycling of equipment parts.
Warning!
Abusive product disposal by the holder is punishable by current law.
Important!
If the barred waste bin symbol is not found on equipment it means that the
manufacturer is not in charge of its disposal. In this case, current waste disposal
regulations apply.
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1.3 Safety devices installed on the machine

The machine is equipped with the following safety devices:
Emergency button for immediate machine stop.
Fixed guards.
Mobile guards.
Electrical supply cut-off device.
Pneumatic supply cut-off device.
1.3.1 Emergency stop
Emergency stop is triggered by pressing the buttons that interact with the safety circuit, cutting off power and
control electrical circuit supply as well as fluidic system supply. This ensures that all machine movements
are immediately stopped.
Standard machine equipment includes an emergency stop button in the operation station and a series of emergency
stop button in the various machine operating stations (see layout below - reference A).
251652
Emergency buttons are red mushroom-head buttons on yellow backgrounds. When pushed, these are locked
(inserted) in the lowered position and do not return to their initial positions. In order to reset buttons, turn them counter-
clockwise as indicated on the buttons.
Resetting the emergency button does not restart the machine.
Hazard!
Tampering with, disconnecting and bypassing safety switches is strictly prohib-
ited.
Periodically check whether emergency stop devices are in good working order as
specified below.
Warning!
The use of the mushroom-head button is only considered as an emergency
manoeuvre, not as a normal stop manoeuvre to avoid excessive machine deterio-
ration.
1.3.1.1 Test procedure
With the safety circuits on, check emergency button and relevant control circuit efficiency.
Press a mushroom-head emergency button and make sure the safety circuit turns off.
Restore the mushroom-head emergency button to its original position and restore safety circuits.
This operation must be repeated with the remaining emergency buttons. We suggest you record these activities in
the in-house safety test log.
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1.3.2 Fixed guards
Fixed guards are made up of perimeter guards whose purpose is to prevent access to the various machine
parts in motion during the operating cycle (see Lay out below - reference B).
The machine is equipped with fixed guards. These are located in the exclusive access area during
maintenance and require special tools for their removal.
Hazard!
Restarting the machine after maintenance without correctly restoring fixed guards
is strictly prohibited.
Periodically check the integrity of the fixed guards and relevant fastenings to the
structure, with special attention to the machine mechanics access door.
1.3.3 Mobile guards
Mobile guards on the tube formation area and perimeter access doors, etc. (see layout below - Reference
C) are made up of doors with safety switches that prevent access to various machine part movements
during the operating cycle.
Hazard!
Restarting the machine after maintenance without correctly restoring MOBILE
guards is strictly prohibited.
Hazard!
Tampering with, disconnecting and bypassing the safety switches installed on
inspection doors is strictly prohibited.
Periodically check mobile guard integrity and their fastenings to the structure as
well as the integrity and operations of the safety switches installed on each
inspection door as described below.
The safety circuit immediately triggers immediately stopping the machine when one of the access doors is opened.
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B A C C B C C
C C C
A C C
A
C C
B
C
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1.3.3.1 Test procedure
With the safety circuits on, check safety switch and relevant control circuit efficiency. Open an inspection door
and make sure the safety circuit triggers. Close the inspection door and reset the safety circuits. This
operation must be repeated with the remaining inspection doors. We suggest you record these activities in
the in-house safety test log.
1.3.4 Cutting off electrical energy
Before performing any type of maintenance on the machine or machine parts, cut off the electrical supply.
Connections to the factory electrical mains is controlled by a switch installed in the electrical cabinet. The switch is
2-way:
Position 1 ON position, CLOSED circuit, machine POWERED

Position 2 OFF position, OPEN circuit, machine not POWERED
Warning!
Cut-off switches can be pad locked in position 2 (open circuit). Please remember
to pad lock switches in the open position to cut off electrical energy (pad locks are
not supplied with the machine).
The user must provide maintenance staff with the electrical cabinet pad locks.
Warning!
Refer to chapter 4.1.1.1 Main shutoff switch for further information on cutting off
power.
1.3.5 Cutting off pneumatic energy
Connection to the pneumatic mains is controlled by a cut-off valve which can be pad locked.
A compressed air drain valve equipped with a silencer is installed downstream from the air supply valve to
drain the pneumatic circuit before maintenance.
Warning!
Main disconnecting switch of the air supply circuit can be padlocked in OFF
position (discharged circuit closed); when disconnecting the pneumatic circuit,
we recommend to padlock the air supply valve in OFF position (padlocks are not
supplied with the machine).
It is the responsibility of the user to provide the personnel responsible for the
maintenance operations with the padlocks to lock the air supply valve.
Periodically check connection pipe integrity between the pneumatic supply valve
and machine parts.
Also check pneumatic fitting seals on the machine.
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1.4 Personal protection devices

Operators who conduct the various activities admitted on the machine must use personal protection devices
that reduce all possible risks derived from conducting various activities such as:
helmet for head protection;
protective goggles and mask to protect against any glue sprays during the glue loading phase or when working
near glue nozzles;
safety gloves and shoes as needed;
hearing protection.
Compulsory safety helmet

It sets out that the staff has to wear the safety helmet.
PPE to be used whenever operating with the machine and/or at the work site or during maintenance
operations.
Compulsory protective shield

It sets out that the staff has to wear the protective shield.
operations.
The use of the protective shield is compulsory in case of item or material projection hazard.
Compulsory goggles
It sets out that the staff has to wear goggles.
operations.
Compulsory hearing protection

It sets out that the staff has to wear ear protection or ear protective plugs.
PPE to be used whenever operating with the machine.
Compulsory protective and insulating gloves

It sets out that the staff has to wear protective and insulating gloves.
PPE to be used whenever operating with the machine and/or at the work site or during maintenance operations
to machine parts or hot surfaces.
Compulsory safety shoes

It sets out that the staff has to wear safety shoes.
operations.
Compulsory proper protective clothes

It sets out that the staff has to wear proper protective clothes.
operations.
Compulsory safety belt and proper means for all operations on high
It sets out that the staff has to use safety belts and proper means for all operations to be carried out on high
or in positions that can not be reached directly from the ground level.
operations, or when taking positions that can not be reached directly from the ground level.
In such case make sure that any ladder or platform etc. meets the regulations in force set for these means.
Warning!
Clothing worn by machine operators or maintenance technicians must meet the
essential safety requirements set by community directives 89/656/EEC and 89/391/
EEC and the laws in force where the machine is installed.
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Hazard!
Personnel must wear suitable work clothing during control and maintenance
operations to prevent any accident.
in order to avoid mechanical risks such as dragging, catching and others, items
such as bracelets, watches, scarves, rings or necklaces should not be worn during
the work cycle and maintenance operations.
Hazard!
When conducting work that could cause shard or material projections that could
harm the operator or others in the near vicinity, the operator must prepare or
request the supervisor install screens or other adequate safety measures.
1.5 Residual risks

All areas or parts at risk were assessed in the design phase and all the precautions necessary to avoid
personal risks and damages to machine parts were taken as indicated in the previous paragraphs.
Warning!
Periodically check all safety device operations.
Do not remove fixed or mobile machine guards.
Do not introduce foreign objects or tools in the operating area and machine
operating area.
Although the machine is equipped with the abovementioned safety systems, some risks could not be eliminated but
were reduced by corrective measures implemented by the end user and correct operating procedures.
Following is a summary of residual machine risks during:

Normal operations.
Adjustments and fine tuning.
Maintenance.
Cleaning.
1.5.1 Collision and crushing
Do not access the product conveyance/movement area.

Do not access moving machine parts.
Before turning on electrical and pneumatic power supplies, make sure no maintenance is being performed
on the machine.
Residual pressure may be found in cylinders which could cause unexpected part movement during interventions.
Therefore, drain the pneumatic circuit and cut it off from the supply source using and pad locking the cut-off valve
before each intervention.
After maintenance and repairs, crushing risks persist due to unexpected movements in the direction opposite the
one required due to incorrect electrical wire or pipe connections. Therefore, run test movements in manual mode
for the parts involved, remembering to maintain safety distances from parts in motion.
In the event of a blackout, the roll pneumatic brake opens, whose pneumatic circuits are discharged causing the
roll to freely rotate for several seconds.
This situation is not hazardous to assigned personnel.
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1.5.2 Shearing / cutting
There is no shearing / cutting risk during the normal machine cycle.
Before turning on electrical and fluidic power supplies, make sure no maintenance is being performed on the
machine.
Shearing / cutting risks may exists during maintenance on the main gears inside the machine.
Warning!
Before conducting any routine or extraordinary maintenance, cut-off electrical and
pneumatic power supplies to avoid the abovementioned risk.
1.5.3 Electrocution
Risk of damaging or breaking electrical equipment parts following a short circuit with potential reduced
safety levels.
Before turning on the electrical supply, make sure no maintenance interventions are in progress and that
no one is working on the machine.
Warning!
Before performing connections, make sure the dc current in the installation point
is not over the one indicated on protection switches inside the switchboard.
Otherwise the user must install specific limiter devices.
Warning!
Any type of electrical modification is strictly prohibited to avoid additional hazards
and unforeseen consequent risks.
1.5.4 Fire
Risk due to production waste.
In the event of faults or malfunctions, the plastic material used (i.e.: sheaths, electrical wires) is self-extinguishing and
meets current regulations.
Since integrated in a production line, the machine is not equipped with its own fire extinguishing system.
The user facilities must evaluate the need for an adequate fire extinguishing system in the rooms where the
machine is installed in observance of fire safety and prevention regulations in effect in the user country and factory
regulations.
Do not use free flames or smoke near the operating machine.
Hazard!
In the event of fire, always immediately turn off the main power switch.
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1.5.5 Burns and scalding
The machine is equipped with motors/gear motors that might determine a residual risk, due to the operating
temperature they might reach, according to the work cycles.
Usually for the motors/gear motors, the surface temperature is lower than the burning temperature.
Moreover, most of the motors installed on the machine/system are located within the perimetric protections.
However some motors/gear motors might reach temperatures above 50 C depending on the functional cycle and
the working environment temperature.
Anyway during the maintenance and cleaning operations there is still a hazard resulting from the thermal inertia of
the motors/gear motors of the machine/system, therefore we recommend to wait for their cooling. It is compulsory
to use appropriate protective equipment like gloves for high temperatures, etc..
Warning!
In case of maintenance operation following a previous energy disconnection, the
motor or the gear motor might accumulate residual thermal energy.
Wait for the disposal of that energy.
For further information, please refer to the manual of the motor/gear motor
supplier. Always use appropriate PPE (gloves for high temperatures), paying
particular attention to the residual energy.
The machine includes hot glue application devices. Therefore there is a residual risk due to the working temperature
of the glue applicator/pipe/gun unit.
During the normal operating cycle, glue guns are confined inside guards. The risk remains during the glue tank
filling phase on the applicator. Suitable protection devices should be worn during this operation (Gloves, goggles,
etc.).
A risk remains during maintenance and cleaning due to the heat inertia of the glue applicator and its components.
Therefore we suggest you wait until the system cools and wear the mandatory protection devices (Gloves,
goggles, etc.).
Warning!
Hot glue application devices require high temperatures for operations. Pay special
attention not to touch these devices with unsuitably protected body parts and
always wear a mask and goggles to protect your face when filling the glue tank or
changing glue.
1.5.6 Explosive atmosphere
The machine is not suited to work in explosive or classified environments.

Machine use in explosive or partially explosive atmospheres is strictly prohibited.
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1.5.7 Blinding
This risk is mainly present in the maintenance and cleaning phases.

Personnel must wear protective goggles when cleaning the machines.
Warning!
The use of eye protection is mandatory.
Warning!
We suggest you use vacuums instead of compressed air to avoid moving any
residue without removing it, also reducing the risk of blinding the operator.
Blinding risks persists during glue filling and changing phases.
Warning!
Hot glue application devices require high temperatures for operations. Pay special
attention not to touch these devices with unsuitably protected body parts and
always wear a mask and goggles to protect your face when filling the glue tank or
changing glue.
1.5.8 Falling, projecting objects
Avoid even temporarily leaving work tools and objects on and above the machine to prevent them from
falling or being projected.
1.5.9 Slipping
Any lubricant and/or glue residue leaks in areas around the machine or on work platforms can cause machine
personnel to slip.
Access these areas wearing non-slip shoes and keep these areas clean.
Warning!
It is absolutely forbidden to use the machine or parts of it to climb on or to access
to some machine parts; otherwise disastrous fall or damages to the machine might
occur.
1.5.10 Whiplash
Broken or damaged pneumatic and lubrication system flexible tubes can cause tube twists.
Tubes and their anchors must be periodically checked and replaced if necessary.
Using rigid or flexible pneumatic and hydraulic tubes as support bases for feet is strictly prohibited.
1.5.11 Tripping
Disorderly material storage in general can be a source of tripping hazards and fully or partially obstruct
escape routes in the event of need.
Guarantee that operating and transit sites and escape routes are free of obstacles and compliant with
current regulations.
Pay attention to yellow/black signals on any steps on machine platforms.
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1.5.12 Circuit faults
Due to possible faults, safety circuits can lose part of their efficiency with the consequent lowering of safety
levels.
Periodically check safety device operations on the machine.
1.5.13 Lighting
The user must provide an adequate lighting system for machine maintenance areas in observance of current
regulations in the users country and according to Community Directives.
In the event of a black out, we recommend at least 400 lux average lighting.
Should, for special and rare maintenance operations, additional lighting be required, also tanking into account the
extremely rare nature of these operations, the user must provide portable safety flashlights (24 Vdc power, not
supplied).
1.5.14 Noise
We recommend personnel use suitable hearing protection devices when working near the machine.
1.5.15 Lightnings
The grounding systems must be checked at regular intervals as required by law.

The final user is responsible for the machine lightning protection; he has to arrange a proper power supply
for the machine/system with all protection systems installed, including the lightning protection, that should
be checked at regular intervals (at least every 5 years or according to the regulations in force in the country).
The residual current devices (thresholds and actuation times) has to be checked at least once every three years.
1.5.16 Dusts
The dusts produced during the cutting operations and the processing (depending on the type of paper used)
may be collected by means of a suction system, supplied and installed by the user.
1.6 Hazard
Hazard!
Safety shoes and goggles must be worn during machine operations and mainte-
nance.
Hazard!
Only use parts, pipes and fittings that are certified for 10 bar operating pressure.
Hazard!
Never exceed the factory set operating pressures and calibrations.
Hazard!
Never conduct any routine and extraordinary maintenance when pneumatic
circuits are pressurised nor when the power supply is connected. Always de-
energise all power circuits.
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1.7 Warning
Warning!
Make sure all personal assigned to machine operations are suitably trained
according to the correct machine safety and operating procedures.
Warning!
Do not conduct maintenance on the machine when it is running.
Warning!
Never perform maintenance on the machine when energy sources are connected
or on. When working on the machine, turn off switches and lock them in the open
position.
Warning!
Make sure all safety devices are connected and in good working order. Never
modify or bypass any alarm or stop device.
1.8 Signal plates

According to the residual risks of various nature identified for the machine, bielomatik s.r.l. has equipped
with machine with hazard, warning and mandatory signal plates as per European regulations on graphic
symbols to be used on plants (Directive 92/58/EEC).
These plates are found in highly visible positions.
Warning!
Removing signal plates from the machine is strictly prohibited.
bielomatik s.r.l. is not liable for machine safety due to failure to observe these
instructions.
Warning!
After the machine is installed in the packaging line, the final installation technician
must install the necessary signs according to the identified residual risks.
Warning!
The user must replace signal plates if illegible due to wear.
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1.8.1 Warning plates used on the machine
Following is a list of warning plates installed on the machine with their generic descriptions.
For a detailed description of relevant hazards, refer to that described in chapter 7 Operations and format change
in the relevant machine unit paragraphs.
1 Tripping or falling hazard signal (yellow and black)
2 Gear hazard signal (yellow and black)
3 Burning hazard signal (yellow and black)
4 Cutting hazard signal (yellow and black)
5 Crushing hazard signal (yellow and black)
6 No pedestrian admittance signal (red and white)
7 Do not intervene with machine running (red and white)
8 Forklift admittance only signal (blue and white)
9 Maximum load capacity signal (blue and white)
10 Crushing between rollers hazard signal (yellow and black)
11 Entrapment hazard signal (yellow and black)
12 Falling hazard signal (yellow and black)
13 Do not remove the protections (red and white)
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1.8.2 Warning plate positions
The illustration indicates where the plates are located on the machine.
Plate locations may vary from those shown according to the various machine configurations.
Consult the layout enclosed with this manual to identify your machines actual configuration.
Warning!
Removing signal plates from the machine is strictly prohibited.
bielomatik s.r.l. is not liable for machine safety due to failure to observe these
instructions.
Warning!
The user must replace signal plates if illegible due to wear.
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5 5
1 5 4 2
7 5 2
5 5
9 7 5 2
3 2
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Preliminary information
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2.1 Presentation
The WRAPMASTER C140 machine is a packing machine which wraps paper reams in wrapping material
taken from a reel.
The machine has been designed and manufactured by a market leader in the paper-making industry and
high-technology solutions have been adopted in order to meet the most demanding user requirements.
Regardless of the type of service required for the machine, the quality of the C140 ensures that the reams are
handled in the best possible way at all times without being damaged. In addition, the quality of the pack produced
is of consistent good quality and the machine guarantees total reliability even in the long-term with a minimum
amount of maintenance.
The C140 machine perfectly fits the requirements of the entire production line due to its high degree of versatility both
regarding size change-over operations and speed variation in order to meet the needs of the production process.
All structural elements, connection and control parts are designed and built with a level of safety so as to resist
abnormal stresses or stresses higher than those indicated.
Best quality materials are used: their introduction in the company, their storage and use in the shop are constantly
monitored so as to ensure the absence of damages, deteriorations or malfunctions. Although design and structural
tactics have been adopted, it is essential to carefully follow the manufacturer instructions in order to ensure a proper
use, safety, durability and reliability of the machine.
2.1.1 Main features

The main features of the C140 making it a particularly efficient machine which stands out among the
competitition include the following:
It is an automatic machine for wrapping reams of paper (refer to the specifications for the production
features).
The reams of paper are fed directly from the cutter so that operations can be perfectly timed.
The machine is provided with a power-operated system to raise the roll of wrapping material and power-assisted
unwinding.
The reams are wrapped in pre-printed paper coming from reels provided with reference marks for synchronising
the cutting operations.
The process of cutting the sheets of wrapping material, wrapping the reams, applying the glue and closing the
pack is fully automatic.
A timed central lubricating system is provided to reduce maintenance operations and downtime.
The gears and moving mechanical parts are provided with guards and safety devices guaranteeing maximum
safety and reducing noise levels.
2.1.2 Optional equipment

The machine can be supplied with a series of optional units which alter the production and packaging
characteristics of the system.
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2.2 Work-cycle
The work cycle can be divided into four basic stages. Each stage is performed by a number of mechanical
parts which carry out all the operations required to wrap the reams:
Wrapping material infeed Wrap formation

1 Reel holder 15 Elevator
2 Crosswise glue spreading (if applicable) 16 Wrapping material stop
3 De-curling unit 17 Counter-elevator
4 Dancing rolls and idle rollers 18 Fixed hopper plate
5 Unwinding rollers 19 Mobile hopper
6 Cutter 20 Ream accelerator
7 Cross glue applicator 21 Lower folders
8 Tube formation unit conveyor 22 Movable end-flap folders
23 Discharge conveyor belt
Ream infeed 24 Bottom flap folders
9 Ream feed conveyor belts 25 Glue applicator for end-flaps
10 Stopping mechanism-and-synchronizer 26 Top flap folders
11 Toothed belts
12 Frontal ream levelling Wrapped ream discharge
13 Side compactors 27a Side compression belts
14 Stop plate 27b Heated belts for polypropylene (Clear Wrap)
1 2 5 6 8 7 18 17 16 19 23 27a
26
22 25
24
22
4 21
3 21 20
9 14
13
15
12 264945
11
10 27b
WRAPMASTER 2 - 3/16
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2.2.1 General process description: Wrapping sheet infeed
The wrapping material on the roll 1 first passes through the de-curling unit 3 which straightens it out. It then
passes through a series of idle rollers and between dancing rolls 4 which keep it taut and ensure that it is
unwound in a regular manner without being torn.
A pair of unwinding rollers 5 carry the wrapping material. Cutter 6 then cuts the sheets. The length of the cut sheets
is suitable to wrap the reams.
The unwinding rollers push the sheet onto the vacuum belts 8, which receive the sheet correctly dimensioned to the
work size and move it to the tube formation area near the lift 15.
Glue 7 is applied on the cross flap when moving on the belts to close the tube. If the glue spreading system is installed
on the machine, the glue application nozzle 7 is in position 2 in front of the unwinding rollers 5. When processing
polypropylene, polythene coated or gummed paper, the glue units are inhibited.
2.2.2 General process description: Ream infeed
The cut ream is placed on the ream infeed conveyor belts 9 and is held there by the stop 10 which releases
it only when all the parts are timed.
The ream is pushed by the belts against a pair of toothed belts 11 which, moving at a lower speed than the
belts, slows it, permitting a pair of leveller teeth 12 to reach the ream and push it on the lift 15 against the front stop
14.
Once this has been done, two side compactors 13 position the ream in relation to the central machine axis.
1 2 5 6 8 7
4
3
9 14
13
15
12 264945
11
10
2 - 4/16 WRAPMASTER
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2.2.3 General process description: Ream wrapping
Elevator 15 moves up bringing the ream against the counter-elevator 17 at the same height as the tube
formation zone. If the machine is equipped with the wrapping paper stop 16, the latter also comes into
contact with the ream and sheet of wrapping material during upward movement. While moving up, the
wrapping material is bent appearing as an upside down U and placed around the ream found between the fixed
18 and mobile 19 hopper. During this stage, the top corners of the package are formed.
Next, the two lower folders 21 close the sheet to form the tube around the ream. The mobile folders 22 move
forward folding the front and rear ends. The mobile hopper 19 lifts and the ream accelerator 20 starts to push the
ream before it arrives on the outfeed conveyor 23.
The outfeed drive teeth 23 push the ream forward against the lower 24 and upper 26 head flap blades.
Glue 25 is applied to close the end-flaps before the top flap is folded down.
2.2.4 General process description: Wrapped ream disc harge
Reams discharged onto compression belts

The product pushed by the pushers is placed between the side compression belts 27a that press the
end-flaps, closing the wrapping.
Reams discharged onto heated conveyor belts for polypropylene (Clear Wrap)
The product advanced by the pushers is placed between the heated conveyor belts 27b that exert pressure on
the reams sealing the polypropylene and closing the wrapping. When this unit is used, reams of paper can be
wrapped in pre-glued paper or polypropylene.
18 17 16 19 23 27a
26
25
24
22 22
21
20
21
15
264945
27b
WRAPMASTER 2 - 5/16
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2.3 Technical data

2.3.1 Main specifications
Model WRAPMASTER C140
Machine type Ream wrapper
Ream feed Automatic

Operation Electro-mechanical - pneumatic
Control system Electronic
No. of operators required 1 (supervisor)

Max. speed of mechanical parts strokes/min. 165
Production speed strokes/min. 150
Time required for roll change minutes approx. 2

Machine weight See chapter 3
Noise levels dB (A) 80
Dimensions See overall dimensions
2.3.2 Electrical system
Power requirements kVA 28
Phases no. 3 + earth
Neutral (not provided)

Voltage V 380
Frequency Hz 50 1%
Acceptable voltage fluctuation 5%

Electrical cabinet supply voltage: current outlets VAC 230
PLC I/O card voltage: inputs and outputs VDC 24
outputs for solenoids VDC 24

Electrical system Complies with EC standards
Logic controller (PLC) Siemens S7/400
User interface Siemens MP377
2.3.3 Pneumatic system
Minimum air supply pressure bar 6
Air requirements Nl/min 1200
2 - 6/16 WRAPMASTER
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2.3.4 Formats that can be handled
REAMS WITH END FOLDS REAMS WITH

OVERLAPPED FOLDS
RW RW
RL RL
RH
RH
261743 261744
Ream dimensions RW min mm 210

RW max mm 216
RL min mm 279
RL max mm 355
RH min mm 25
RH max mm 89
Type of folds: overlapped RH max mm 50
Minimum ream paper basic weight g/m2 70
WRAPMASTER 2 - 7/16
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2.3.5 Wrapping material
D
SL SW 261363
Wrapping paper Kraft or bonded
Wrapping paper basic weight min g/m2 80

max g/m2 120
Polypropylene 52
Roll diametre max, paper E mm 1270

Roll diametre max, polypropylene E mm 800
Min. core diametre D mm 70
Max core diametre D mm 76

Roll width SW min mm 425
SW max mm 880
Sheet cutting step SL min mm 325

SL max mm 515
2 - 8/16 WRAPMASTER
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2.3.5.1 Features of the Kraft or bonded paper
U.M. min MAX Recommended

General
Basic weight (ISO 536) g/m2 80 120 99.5
Polyethylene Inside or central Central
Thickness (ISO 534) m 110 130 121
Volume (ISO 534) g/cm3 0.822
Dry traction - Machine direction (ISO 1924/2)
Resistence kN/m >7 5.11
Stretching % >2 2.0
Operation J/m2 70.0
Tear length km 5.24
Dry traction - Crosswise direction (ISO 1924/2)
Resistence kN/m >3 2.81
Stretching % >5 2.8
2
Operation J/m 56.7
Tear length km 2.88
Resistance to tensile stress (ISO 1924/2)
Machine direction kN/m 621
Crosswise direction kN/m 327
Strength and bending L&W (15 angle) (ISO 2493)
Machine direction (length 10mm) mN 140 190 183
Machine direction (50mm long ref.) mN 7.3
Crosswise direction (10mm samples) mN 70 100 104
Crosswise direction (50mm long ref.) mN 4.2
Strength and bending HoM (75 80 angle) (ISO 5628 method)
Machine direction, 1st fold g 132
nd
Machine direction, 2 fold g 55
Crosswise direction, 1st fold g 82
nd
Crosswise direction, 2 fold g 44
Rough Bendtsen (ISO 8791/2)
Printed side ml/min >250 149
Static friction, Paper on steel surface (ENV 124448) <0.220
Coeff. of friction, printed side, machine direction 0.228
Coeff. of friction, printed side, crosswise direction 0.233
Static friction, Paper on teflon-coated surface (ENV 124448) <0.220
Dynamic friction, Paper on teflon-coated surface (ISO/FDIS 15359 method) 0.130 0.160
The values shown in the Recommended column refer to a type of paper which has excellent characteristics and
is easy to handle.
WRAPMASTER 2 - 9/16
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2.3.5.2 Polypropylene specifications
U.M. min MAX Recommended

Resistance to tensile stress
Machine direction N/mm2 155
Crosswise direction N/mm2 265
Modulus of elasticity
Machine direction N/mm2 2200
Crosswise direction N/mm2 3500
Breakage after stretching
Machine direction % 175
Crosswise direction % 65
Other
Coefficient of friction 0.25
Sealing temperature C 120-180
Specific weight g/m2 45.5
Thickness m 52 65 60
The specifications given here in refer to Bicor 52/MB666 polypropylene, produced by Mobil plastics Europe, or
Rayopp T710/52 produced by UCB films Gmbh Germany.
Note:
The polypropylene used in the machine may not show any signs of electrostatic
charges.
Note:
The polypropylene must not have any imprints on the areas affected by the
bonding.
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2.3.6 Diagram showing wrapping material unwinding
The following diagram illustrates how to calculate the dimensions of the sheet of wrapping paper in order
to choose which roll of paper should be used.
=
SL RW
RL
SW RW
= 2 /2 +
RW R
+2 H + 1
RH
RH
5
+3
0
261760
RW Ream width
RL Ream length
RH Ream height
SL Sheet unwinding
SW Sheet width
WITH OVERLAPPED FOLDS WITH END FOLDS
261746 261745
SL = RL + 2RH + 60 SL = RL + 2 (9/10RH)
SW = 2RW + 2RH + 30 SW = 2RW + 2RH + 30
2.3.6.1 Wrapping sheet calculation
The CD supplied with the paper documentation contains a spreadsheet, C140-Sheet-calculation, with
which the correct dimension of the wrapping sheet can be calculated, by inserting the data of the ream to
be packaged (input data).
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2.4 Overall dimensions
265715
265526
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2.5 Using hotmelt glue

2.5.1 Glue properties and characteristics
Hotmelt substances are basically thermoplastic glues. They are liquified for processing by melting at high
temperatures between 120 C and 200 C, depending on the quality of the glue. Adhesion takes place when
the hotmelt cools down below the melting temperature and solidifies. Their special advantage is the
extremely short setting time of only a few seconds. Hotmelt glues stand up to water, in some cases freezing
(according to type of hotmelt) or extreme temperatures. When hotmelt is applied on just one side it can be brought
back to the correct temperature to reacquire its adhesive properties and heat sealed at a later time. Various types
of units are currently available on the market, from simple manually-operated units to sophisticated electronically
controlled equipment with automatic adjustment that can be easily installed in already existing production lines and
manufacturing plants.
Careful attention must be paid to the processing temperature and open time for the type of hotmelt being used.
2.5.2 Processing temperature
The hotmelt must be processed at the temperature stated on the technical data sheets at the moment and
in the area in which the glue is applied on the support. Viscosity and fluidity can be widely varied by changing
the processing temperature. The higher the processing temperature the less viscous the hotmelt will be
but this will make the open time longer. The lower the temperature the more viscous will be the hotmelt making
the open time shorter. When temperatures below the indicated values are used the hotmelt will be less fluid and
will not adhere 100% to the support when sprayed on. A 10 - 20 % decrease in temperature will increase viscosity
20 - 50%.
2.5.3 Open time
Open time signifies the time during which adhesion to the glue takes place. It is influenced by the hotmelt
temperature, thickness applied, room temperature, the support and the heat conduction of the latter (e.g.
the open time is shorter with aluminium). If the time span between application and pressing is longer than
the open time the hotmelt will already be partly or completely hardened and the parts will not be well glued.
The open time can be extended by increasing the processing temperature and amount of glue (e.g. when the
temperature is increased 10 C, the open time is 1 - 2 sec. longer) or reduced by decreasing the amount of glue and
processing temperature.
2.5.4 How the material influences glueing
Good quality glueing of composite material (thermoplastics such as polyethylenes, pvc, Pvdc) is obtained
only if the processing temperature is high enough to melt the thermoplastics. Polyethylene coated carton
is to be glued at a temperature of approximately 180 C. If possible, the hotmelt should be applied on the
surface hardest to glue.
When wax paper is used, the processing temperature and amount of glue applied should be increased.
2.5.5 Cleaning
Build ups may form on the bottom and sides of the tank that can clog the spray nozzles due to dust particles
or over-heating. If the manufacturer has not recommended a specific cleaning agent, clean the tank by
quickly melting the Termomelt 301 specially formulated detergent. As it liquifies very quickly it can be
removed easily with the dirt with a hard-bristle brush. If charring has occurred, turn off the unit and soak the parts
in question, once cooled down, in solvents such as trichloroethylene, toluol, etc for a good amount of time.
Warning!
Follow all the safety rules and precautions given in the Users Manual that deals
with the glue applicator.
U0G00214
2.5.6 Pressing
The two parts in question must be glued and pressed together immediately or simultaneously. During
pressing, the two parts must never be moved to prevent the glue stitches from shifting while hardening. The
two parts to be glued must be brought together within the maximum open time. The pressure must not be
decreased when the parts are initially pressed to prevent the film of hotmelt from breaking.
2.5.7 Quantity applied and cost of hotmelt glue
Even if good hotmelt is about double the price of vinyl based glue, it does not necessarily signify an increase
in glueing cost as hotmelt contains 100% glueing substances while vinyl glue contains 50% water.
The stitch of hotmelt applied expands from 2 to 3 times during pressing (e.g. a 1 mm stitch of hotmelt
expands 2 - 3 mm on the surface to be glued).
The quantity of glue needed per linear meter of hotmelt in relation to the thickness of the stitch applied is given below:
stitch thickness 1 mm. Usage approx. 0.5 g/linear m
2 mm. approx. 1.5
3 mm. approx. 3
The specific weight of the hotmelt for glueing is approximately 0.92 g/cm3.
2.5.8 Applications
Seals polyethylenes, bonded paper-aluminium.

Suitable for varnishes or hard-to-glue paints.
2.5.9 Specifications
Type of adhesive: hotmelt

Form: granular
Colour: white or beige
Melting point: C 90 110

Open time: seconds 24
Viscosity: at 150 C strokes per second > 3000
160 C strokes per second 2094

Stability: excellent
Resistence to tensile stress: kg/cm2 26
Stretching: % 545
Odour: odourless
Filtration: micron 100
Setting time: sec. <1
Food safe; complies with Law 21/3/73 for packaging food products.
U0G00214
2.5.10 Processing indications
Processing temperature: 160 - 180 C.
Use the indicated temperature ranges. At lower temperatures the amount of glue used notably increases
and the parts may not be well glued.
2.5.11 Safety precautions
Do not overheat above 200 C. The hotmelt will decompose at higher temperatures.
2.5.12 Cleaning
Clean the tanks and hoses, removing any residue of other glues handled before using the product.
Clean with the cleaning agents recommended by the glue manufacturer.
Clean the tanks with detergents or solvents recommended by the machine manufacturer.
The information given above is based on our experience in the field and result obtained. However, this does not imply
responsibility for the results obtained when using the glue. The users must make sure the indications given are
suitable for their individual production requirements and perform all the necessary tests.
bielomatik s.r.l. recommends glues whose manufacturers have offices world-wide:
HENKEL TECHNOMELT Q 3183
LEUENBERGER TERMOMELT C783
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3 - Installation
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Installation
WRAPMASTER 3 - 1/20
3 - Installation
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3.1 General information

Warning!
Considering that the installation operations (including assembly and commission-
ing) may involve risks for unskilled personnel since they require specific machine
knowledge, the manufacturer is in charge of these operations.
The machine must thus only be handled and installed at the user customers
premises by bielomatic specialised and trained personnel.
3.2 Supply conditions

3.2.1 Packaging and transport
The machine is shipped by bielomatik s.r.l., from the production facilities c/o the user customer,
dismantled and divided in boxes.
According to the transport distance, specific customer requests and amount of time the machine remains packaged,
the machine may be shipped in one of the following ways:
normal protective packaging for short and medium distances;

special protective packaging for long distances.
Goods must always be shipped in covered or canvassed vehicles.
264752
Lifting points are indicated on the boxes.

Furthermore, all instructions for content identification and safe handling are listed on the packaging exterior:
shipping address and senders address
dimensions (length, width, height)
gross and net weight, tare
barycentre
notes and pictograms (i.e.: fragile, top, etc.).
Packing list.
Warning!
Observe the following precautions and warnings to guarantee stability and avoid
risks associated with machine handling:
Do not improvise any manoeuvre that is not officially approved by skilled
personnel.
Important! cables or chains must be suited to machine load.
We suggest a crane or bridge crane is used to lift and position the machine.
Do not stand under suspended loads.
Only assign these operations to trained personnel (slingers, crane operators, etc.). If load volume does not permit
sufficient visibility, assign personnel to signal the handler to supervise all handling phases.
3 - 2/20 WRAPMASTER
3 - Installation
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3.3 Work site preparation

3.3.1 General information
With the due exceptions made in the contract, the machine user customer must prepare:
appropriate lifting means for parts in accordance with the loads to be handled;
machine power supplies, including a GROUNDING wire according to the required specifications and
tolerance specified in this manual;
pneumatic machine supply adjusted as specified in this manual.
The data listed above is described in the subsequent paragraphs.
Note:
bielomatik s.r.l. cannot be held liable for operating faults if the power supplies do
not meet the specifications provided with the machine.
Installation is provided by the manufacturers specialised personnel. The manufacturer provides the customer with
all the documentation required to prepare the necessary infrastructures before installation (see layout).
Warning!
All external power must be connected to the machine by the manufacturers
personnel during installation.
Connecting the machine to external power sources or using it before the
manufacturers personnel arrives is strictly prohibited.
Warning!
The customer must ensure that the floor supports the machines static/dynamic
load.
WRAPMASTER 3 - 3/20
3 - Installation
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3.3.2 Site selection and installation requirement checks
The machine installation area must be sufficiently ample to meet:

work spaces;
B
transit routes (trolleys, etc.);
escape routes.
The floor of the site selected for installation must be even, level and meet the application specifications. It must also
be able to support specific machine weights such as the supplied static and dynamic loads.
The room must be equipped with the electrical and pneumatic supply connections required to operate the machine.
The room must be equipped according to current safety regulations in force in the user country and guarantee correct
ventilation and equipment grounding.
The minimum clearances indicated in the following layout are required to install and use the machine. The minimum
safety distances from walls and the ceiling must be considered in order to conduct machine inspections and/or
maintenance.
Note:
The machine installation position is indicated in the previously delivered drawing
and enclosed with this manual.
2000
2000
263891
3 - 4/20 WRAPMASTER
3 - Installation
U0G00214
3.3.3 Lifting and handling procedures
Follow the instructions below to lift and handle boxes and machine components.
B
Lifting vehicle capacities must at least meet machine weight (see technical specifications table) increased
according to safety regulations.
Note:
Only bielomatic specialised and trained personnel can lift and handle boxes.
Follow the instructions and pictograms marked on boxes and use suitable tools
and equipment to handle boxes.
Additional information
For information on lifting and handling machine parts supplied by sub-suppliers
and retail parts including in the overall system, see the relevant instruction
manuals.
Hazard!
Before use, check the status and correct installation of lifting devices and means.
Use suitable slings and equipment.
Safety gloves Protective Always check cables Transit under

must be worn. shoes must be worn. and chains before use suspended loads is
and, in any case, prohibited.
periodically.
Where possible, the work are must be free of materials that could hinder or limit visibility, create impediments
or obstacles.
Machine boxes must be handled with an adequate lifting system such as a forklift, crane and bridge crane and
hooking slings/cables and lifting accessories that are approved and of suitable capacity, superior to the weight
to be lifted.
Warning!
Adequate lifting means are required to lift boxes taking into account the safety
margins set by current laws and safety regulations.
Before lifting, make sure no mobile parts or tools are on boxes.
Make sure the load is correctly balanced: slightly lift the load off the ground and make sure it is level before
continuing. Otherwise, lower the load, reposition the slings and repeat the operation until satisfactorily balanced.
WRAPMASTER 3 - 5/20
3 - Installation
U0G00214
Warning!
In the event obstacles and/or operating situations do not allow the handler clear
visibility, personnel should be positioned outside the lifting means range of action
to signal the handler.
Hazard!
Never pass under suspended loads.
Never move the load over people working in the factory.
Hazard!
When operating on lifted machine parts, operators must pay the utmost attention
and use adequate lifting devices and personal protection systems to avoid the risk
of falling.
3 - 6/20 WRAPMASTER
3 - Installation
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3.4 Assembly and positioning

The machine should be positioned in accordance with that set in the supplied layout drawings.
B
Before beginning machine installation, the following must be completed:

remove covers and protective packaging.
Warning!
Dispose of packaging material according to current regulations in the country of
installation. The user is in charge of packaging disposal.
remove any fastening restrictions used for transport;

make sure the floor of the room selected for installation is even, level and supports the machine weight
specifications listed in paragraph 3.4.1.
Note:
The machine must only be installed c/o the user customer by bielomatik s.r.l.
specialised and trained personnel who have the experience, technical know-how,
documentation and tools required for installation (except for lifting means).
For correct machine assembly, follow the design specific technical documents
made up of:
Factory layout
General machine drawings with machine part list
Mechanical units with relevant part lists
Wiring and pneumatic diagrams
Retail part instruction manuals.
During assembly, make sure the measured quotas correspond to that indicated in drawings. In the event of faults,
problems or difficulties of any kind, contact the design engineering office.
Note:
For machine and part positioning and relevant minimum distances to be observed,
refer to the layout in paragraph 3.3.2. In any case, leave work space between and
around parts to permit easy access for maintenance operations.
3.4.1 Unit assembly and positioning
The machine is made up of a packing unit, made up of a frame, the heated belt unit (Clear Wrap), the roll
B holder unit and electrical cabinet.
Machine configuration at deliver ex-works.
WRAPMASTER 3 - 7/20
3 - Installation
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3.4.1.1 General notes on unit positioning
The machine must be positioned on a stable and flat surface with capacity suited to the weight to be
B supported.
Any offsets must be within building construction regulations.
The machine is not subject to particular vibrations, thus it does not require special platforms or supports;
however, adding a shock-absorbent bottom helps to reduce noise pressure.
Make sure any adjustable support feet are well secured to and evenly rest on the floor.
(In any case, avoid using shims or spacers to compensate uneven floors).
Use a spirit (or laser) level and check single unit planarity both longitudinally and crosswise within a maximum
tolerance of +/- 3 mm.
Position the level both longitudinally and crosswise on the processing surface.
Use the screws on the support feet to level and tighten the counter nut under the surface.
264441
260050
260039
3 - 8/20 WRAPMASTER
3 - Installation
U0G00214
Warning!
If the machine is not levelled to meet the indicated tolerance, guides and movement
axes may emit noise or be subject to unusual wear that can compromise the life
cycle as well as correct operations.
Warning!
Levelling must be periodically checked.
After the various units are correctly positioned, release the hooks from the lifting rings and remove the lifting rings.
Once all the above described operations are completed and any mechanical brackets removed, make sure all
guards are installed and connect the main and single unit control panels to the main switchboard.
Next connect the machine with the utilities required for operations in accordance with the supplied power
specifications (for air and electricity).
3.4.1.2 Packing unit
It is positioned first using the 4 specific slings/cables whose end hooks should be attached to the 4 lifting
rings on the 4 corners of the frame. Before lifting the packing unit, secure and tighten supplied cables A to
B guarantee correct ream feed balance and support.
Next hook the 4 previously positioned slings/chains to the bridge crane chain hooks as indicated in the
following illustration.
2500 mm long slings/chains with 2000 kg capacity each, suited for this purpose and readily available on
the market, are required to position the pallet unloader.
Before lifting the unit, make sure the slings/chains are correctly tightened and positioned without being able to slip
or slid when taut.
Warning!
The angle (a) created by the 2 machine lifting slings/chains must not exceed 60.
Once the above described activities are completed,

lift the unit to position it, making sure the packing unit 4000 kg
remains levelled and does not swing or tip.
When perfectly balanced, lift and move the load.
The packing unit should be positioned on the support
surface which must be suited to support its static and
dynamic load. Level the unit at this point.
Once the unit is stably and correctly positioned, the

next units can be positioned. a
A max 60
264948
WRAPMASTER 3 - 9/20
3 - Installation
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3.4.1.3 Heated belt unit (Clear Wrap)
After positioning the packing unit, the Clear Wrap unit is positioned using the 4 specific slings/cables whose
B end hooks should be attached to the 4 lifting rings on the 4 corners of the frame.
the market, are required to position the frame.
Before lifting the unit, make sure the slings/chains are correctly tightened and positioned without being able to slip
or slid when taut.
Warning!
1000 kg
a
max 60
264949
Once the above described activities are completed, lift the unit to position it, making sure the frame remains levelled
and does not swing or tip.
The unit should be positioned on the support surface which must be suited to support its static and dynamic load.
Level the unit at this point.
Once the unit is stably and correctly positioned, the next units can be positioned.
3 - Installation
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3.4.1.4 Roll holder
After positioning the previous units, this roll holder is positioned using the 4 specific slings/cables whose
B end hooks should be attached to the 4 lifting rings on the 4 corners of the frame.
the market, are required to position the roll holder.
Before lifting the frame, make sure the slings/chains are correctly tightened and positioned without being able to slip
or slid when taut.
Warning!
800 kg
251141
Once the above described activities are completed, lift the unit to position it, making sure the frame remains levelled
and does not swing or tip.
The unit should be positioned on the support surface which must be suited to support its static and dynamic load.
Level the unit at this point.
Once the unit is stably and correctly positioned, the next units can be positioned.
3 - Installation
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3.4.1.5 Pallet guards and platforms
Pallet guards and platforms should be lifted with a forklift, as indicated in the following illustration, that must
B be suited for this purpose with at least 1000 kg capacity.
Before lifting, make sure the unit is well-balanced on the forklift.
600 kg
264779
Once the above described activities are completed, lift the pallets to position them, making sure they remain levelled
and do not swing or tip when the lift platform is lifted.
All guards and platforms should be installed by attaching them with the specific brackets, on the machine frame or
on the ground using suitable fasteners as per the machine layout.
Check the stability and correct installation of all platforms, guard rails and perimeter guards.
Once platforms, rails and perimeter guards are stably and correctly positioned, the next units can be positioned.
3 - Installation
U0G00214
3.4.1.7 Electrical cabinet
After positioning the previous units, this electrical cabinet is positioned using the 4 specific slings/cables
B whose end hooks should be attached to the 4 lifting rings on the 4 corners of the frame.
2000 mm long slings/chains with 500 kg capacity each, suited for this purpose and readily available on the
market, are required to position the electrical cabinet.
Before lifting the electrical cabinet, make sure the slings/chains are correctly tightened and positioned without being
able to slip or slid when taut.
Warning!
500 kg
a 0
x6
ma
264852
Once the above described activities are completed, lift the electrical cabinet to position it, making sure it remains
levelled and does not swing or tip.
The electrical cabinet should be positioned on the support surface which must be suited to support its static and
dynamic load. Level the unit at this point.
3 - Installation
U0G00214
3.5 Electrical connections

Electrical connections are performed by the manufacturers specialised personnel in accordance with
B applicable regulations in the country where the machine is installed. In any case, connection instructions
are provided:
machine-electrical cabinet wires must be connected according to the manufacturers wiring diagram;
a copy of the wiring diagram is enclosed. An additional copy is located in the electrical cabinet. The position
of the electrical cabinet(s) is set by the manufacturer and indicated in the previously delivered foundation
drawing;
minimum wire section for transformation cabin-electrical cabinet connections must be selected according to
voltage, installed power and distance between source and use.
Warning!
Before performing electrical connections, make sure the machine power circuit
breaker is locked in the open position.
Hazard!
Power connections must only be performed by specialised personnel and
subject to the use of individual protection devices.
Make sure the power mains are dimensioned according to machine load.
Connect the grounding system before any other mains connections.
Make sure the voltage listed on the machine wiring diagram and type of
connection on the switchboard are correct.
The user must install an automatic circuit breaker for all power lines (with cut-off
capacity suited to the switch in switchboards) at the start of the line to facilitate
maintenance.
In any case, the user must protect the machine switchboard connection cable.
All machine parts (transformers, drivers, etc.) are connected to the general
grounding terminal in the switchboard.
Note:
For adequate safety, we suggest you install an indirect contact protection system
coordinated with the grounding system where the machine is installed (for
example, using a circuit breaker).
3 - Installation
U0G00214
Power sires must be directly connected to the terminals on the main switch in the switchboard.
The grounding wire must be directly connected to the grounding terminal in the switchboard.
When connected, cover main switch terminals.
R
S
L1
L2 T
L3
261443
260589
All system connections were suitable marked to avoid incorrect connections upon assembly or for future
dismantling, inspections or maintenance.
All connection points are specifically marked.
There are no reference where connections are not restrictive.
Warning!
The customers grounding system must be efficient and meet current regulations.
The machine must be connected to the grounding circuit which must be free of
interferences, dispersion or harmonic currents, etc. And meet current regulations.
3 - Installation
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3.6 Pneumatic connections

Machine supply pressure P=6 bar
B Air conditioning unit connection tube dimensions (with minimum pressure gauge) 3/8.
Pneumatic connections are performed by the manufacturers specialised personnel in accordance with
applicable regulations in the country where the machine is installed. In any case, connection instructions
are provided:
Your pneumatic connection should be directly connected to the air conditioning unit on the machine.
The machine is equipped with an air conditioning unit with filter unit with 40 micron filtering capacity.
The purchaser must guarantee that supplied compressed air is clean and dry without water or oil and that is has
the following specifications:
- Minimum input pressure = 6 bar (85 psi)
- Maximum input pressure not over 8 bar (115 psi)
- Temperature range = 5 C to +45 C
- Filtration level upstream from the machine at least 50 micron
- Air purity grade 2.7.3 as per DIN ISO 8573-1
- No oil in the pneumatic circuit.
Warning!
Failure to meet the above pneumatic supply conditions may compromise machine
operations and reduce average pneumatic part working life thus voiding the
warranty for these parts.
Pneumatics must not be lubricated. Oil must not be found in the pneumatic circuit.
Air consumption required by the machine during normal work cycle is 1200 Nl/minute
The customer must provide a pneumatic supply system that constantly guaran-
tees this capacity.
3.7 Machine part lubrication

After connecting supply mains and before operating the machine, check whether machine parts require
lubrication.
For instructions on these operations, see the paragraph on the Lubrication schedule in chapter 8
Maintenance.
3 - Installation
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3.8 Checks and inspections before start-up

Before conducting the machine start-up operations described in Chapter 4 Machine start-up and
B operation, conduct a series of general checks and inspections on mechanical units and the electrical and
pneumatic systems to avoid operating risks and problems during this phase.
Hazard!
These checks and preparations for first start-up must be conducted by a special-
ised bielomatik s.r.l. technician.
Hazard!
Considering that sensors and actuators may have suffered alterations during
transport, handling, repairs, etc., we recommend the utmost caution in running
manual movements.
The following checks and inspections are considered normal maintenance and described in chapter 8 Mainte-
nance.
3.8.1 General machine unit checks
Generally inspect the mechanical part and specifically:

visually inspect machine units, making sure there are no anomalies on mechanical parts or foreign
B objects in work areas and that all parts (electro-mechanical actuators, proximity switches, etc.) are
correctly installed and positioned as per the construction drawings;
make sure mechanical units are correctly installed and aligned to their work axes, connected and
secured to their frame;
check that all main machine part screws and nuts are tight;
make sure moving parts are lubricated and can freely move;
make sure the machine installation area is clean and free or oil or grease stains, scraps, tools, cloths or parts
that could impede moving parts.
Hazard!
The checks and inspections on mechanical units must be conducted with the
machine stopped with the electrical and pneumatic supplies cut-off.
Warning!
Pay the utmost attention when inspecting the machine, making sure the machine
operating area is free of various tools and foreign objects and that all residual
energy (pneumatic) is drained.
3 - Installation
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3.8.2 Electrical system inspection
After inspecting mechanical parts, generally inspect the electrical system and, specifically:
B make sure all shunt boxes and ducts on the machine were closed and that all conductors were
connected.
SWITCHBOARDS
For the main switch:
test main switch operations and make sure distribution upstream from auxiliary circuit breakers is correct;
check power distribution and voltage in auxiliary circuits;
also check control unit part integrity.
For motor controls:

test motor drive direction. Check using the relevant remote controls testing their correct connection and drive
direction. If incorrect motor rotation is found, do not invert motor connection but invert the conductors on the main
switch (for all asynchronous motors);
for servo motors, make sure correct movements can be run from the control panel using the Jog functions
(described in chapter 6).
For interconnections:
check correct interconnection connections.
ON BOARD MACHINE:
For limit switches:
test inputs and limit switch adjustments, limit switch triggering with correct on-board led operations and
consequent input activated on the control unit board.
For keyboards:
test inputs by pressing control buttons/selectors to see whether the input on the relevant control unit board is
activated.
For safety circuits:

check correct ground continuity control system operations, emergency stop circuit operations, etc.
Warning!
Before conducting any movement, make sure no faults are found to prevent
machine damages.
Before resetting any fault, check the cause and eliminate it.
3 - Installation
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3.8.3 Safety system inspection
Before operating the machine, make sure fixed guards and safety devices are correctly installed and in
B good working order.
Safety devices and inspection procedures are described in Chapter 1 Safety.
Note:
This procedure must be adopted as a normal maintenance procedure.
Warning!
Machine safety is not guaranteed when safety devices are tampered with or
removed.
Warning!
The machine and all its structural units are equipped with safety devices integrated
in the machine main safety/emergency circuit. Any connections or parts before or
after the machine, that are not included in the delivery, are not part of this manual;
in the event they have to be carried out, the operator should follow the laws in force.
3 - Installation
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3.9 Decommissioning
The following paragraph provides recommendations and instructions for decommissioning, dismantling
and removing the machine at the end of its working life.
The following operations are strictly reserved to authorised personnel:
create enough space around the machine to perform all the movements without operator risks.
turn off all machine power circuit breakers and lock them in the open position;
disconnect the power cable from the circuit breaker, first disconnecting the power conductors and then
the grounding conductors;
disconnect the pneumatic supply tube from the air conditioning unit, first checking whether pneumatic
power is cut-off (closed) and then releasing residual air from pneumatic actuators;
dismantle the machine from the top to the bottom, paying special attention to machine units/parts that could fall
due to gravity.
Hazard!
Pay the utmost attention since falling parts or components during the removal
phase could be seriously dangerous to operators.
remove mobile parts and separate the various components by material as much as possible. Parts must be
separated by material (plastic, metal, etc.) for recycling purposes. Hire special companies to dispose of
demolition materials;
removing and handling various machine parts from the work area adopting all the necessary precautions before
lifting large-sized parts;
make sure lifting devices are correctly secured and only use adequate slings and equipment as described in
previous paragraphs.
Note:
Specific environmental protection regulations are set in every country for the
disposal of this material.
The Customer must know the laws in force in his country and work to meet them.
Note:
In the event of difficulties when removing, demolishing and dismantling machine
parts, consult the bielomatik s.r.l. engineering design department for operating
methods that meet safety and environmental protection standards.
Warning!
Keep in mind that some large-sized and heavy parts can only be handled with
adequate lifting means.
4 - Machine start-up and operation
U0G00214
4
Machine start-up and operation
WRAPMASTER 4 - 1/26
U0G00214
4.1 Control equipment

A Electrical control cabinet
B Indicator pole
P1 Main control panel
P3 Left jog pushbutton panel
P3.1 Right jog pushbutton panel
P12 Packaging sheet feed control panel
P13 Roll carriage control panel
P13.1 Roll change control console
P14 Emergency stop push-button (*)
P15 Clear Wrap unit push-button panel (*)
(*) Thispush-button panel is not shown in the drawing.
P13.1 P13 A
P12
P1 P3
265525
P3.1 B
4 - 2/26 WRAPMASTER
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4.1.1 Electrical control cabinet
Main shutoff switch Q1 is installed on the electrical control cabinet.
4.1.1.1 Main shutoff switch
The main shutoff switchQ1 found on the electrical control cabinet cuts off power needed to run the machine.
As it is located before the electrical components the operator can isolate the machine from the power supply
to carry out maintenance in complete safety. Put a padlock (not supplied with the machine) in the eyelets
to lock the main shutoff switch in position OFF.
STD0044
Q1
265772
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WRAPMASTER 4 - 3/26
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4.1.2 P1 - Main control panel
1 Control panel MP 377

Instrument used to control machine operation.
2 Start (10N1-S3H)
There is only one lighted button and, when pressed, it starts the first emergency reset cycle to then start the
machine in the operating mode selected with selector 5.
3 Stop (10N1-S4)
Machine stop button. When this button is pressed in AUTO mode, the machine stops in phase. When presses
twice in a row, the machine immediately stops; in manual mode, the machine immediately stops when this
button is pressed.
Warning!
When this button is pressed the Clear Wrap unit (optional) remains on to prevent
sealing belt deterioration.
4 Machine running (10N1-H2)

This light comes on to signal the machine is running.
5 Automatic/manual selector (10N1-S11)

Manual/jog or automatic operating mode selector.
0 Automatic mode.
1 Manual mode or left jog enabled.
2 Manual mode or right jog enabled.
69 Available
10 Emergency (10N1-S1)
When this self-latching button is pressed the machine immediately shuts down and the pressure in the
pneumatic system drops.
Any emergency buttons are only reset when the start button is pressed.
2 3 4 5 6 7 8 9 10
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4 - 4/26 WRAPMASTER
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4.1.2.1 Control panel
The control panel allows the user to control machine operation and more precisely:
read out machine status;
read fault messages which help the user clear malfunctions;
set size-related parameters;
set machine operating data.
The panel comes with a 10" backlit liquid crystal touch-screen. Touch the buttons shown on the pages with your
finger to execute the set functions.
The control panel also has a numeric and alphanumeric keypad via software to enter data and arrow keys to scroll
the lists provided.
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WRAPMASTER 4 - 5/26
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4.1.3 P3 + P3.1 - Left and right jog pushbutton panel
Use this plug-in button to jog the machine.
1 Emergency (10N1-S2) (10N1-S2.1)

Whenever this red mushroom head button is pressed, all the machine units immediately stop, the power
supply to the motors is cut off and the pressure in the pneumatic circuit drops. The emergency stop circuits
can be reset only by pressing the lighted start button on the main push-button panel.
2 Jog (10N1-S6) (10N1-S6.1)

Plug-in button used to jog the machine.
The machine will jog until the button is released.
STD0104
4 - 6/26 WRAPMASTER
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4.1.4 P12 - Packaging sheet feed control panel
1 Dancing roller ON/OFF (12N1-S12)

Press the button to open or close the dancing roller, only in MANUAL mode and with the auxiliary circuits on.
The dancing roller opens or closes the first time the button is pressed according to the initial dancing roller
conditions. The opposite is obtained the next time the button is pressed.
N.B. Before pressing the button, assigned personnel must always check physical dancing roller conditions
(open or closed) to avoid movements other than those required.
2 Simulation cycle (12N1-S2H)

Button that simulates ream presence between the phasing unit photocells at infeed in AUTOMATIC mode.
The machine starts the automatic cycle as if packaging the foreseen size reams (machine operation, paper
cut and unwound, etc...). The cycle continues until the button is pressed again. The light inside the button
comes on and the machine carries out two more cycles and then stops in phase.
In manual mode, press and hold down the button for a few seconds to enable button 3 which, during roll
change, can unwind, cut and position the new packaging sheet.
3 Roller jog (12N1-S5)

Press this button to only drive the roll carriage unit unwinding rollers and only in manual mode. The rollers
move for as long as the button is held down. When the button 2 is pressed (light on), only in manual mode,
the packaging sheet can be unwound, cut and positioned.
After the button is pressed, the cycle continues until the button is released.
4 Unwinding roller (12N1-S9)

Press this button to lift or lower the unwinding roller in MANUAL mode only.
5 Spot detection for timing (12N1-S11)

Button that runs the rollers and roll of wrapping material until the photocell detects the spot on the wrapping
paper in relation to the machine motor. The button is only enabled in MANUAL mode.
6
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WRAPMASTER 4 - 7/26
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4.1.5 P13 - Roll carriage control panel
1 Available
2 Reset light barriers button (13N1-S8H)

Illuminated pushbutton to restore operation of assembly after a foreign body has been caught between the
photocells.
35 Available
6 Opening the unwind rolls (13N1-S10)

Pushbutton to open or close the unwind rolls.
The button is only enabled in MANUAL mode.
7 Stop button (13N1-S7)

Stop pushbutton for assembly. Pressing this key stops the assembly.
Warning!
When this button is pressed the Clear Wrap unit (optional) remains on to prevent
sealing belt deterioration.
8 Roll axle upward movement pushbutton (13N1-S1)
This pushbutton is used to activate the upward movement of the support arms in order to lift the roll.
The button is only enabled when the photoelectric barriers are on (button 2).
9 Retract support arms of almost empty roll pushbutton (13N1-S5)

This pushbutton is used to activate the retraction of the support arms, which connect with the almost empty roll.
10 Upper brake exclusion pushbutton (13N1-S12)

Pushbutton to exclude the upper brake of the almost empty roll.
1 2 3 4 5
6 7 8 9 10
11 12 13 14
15
16 17 18 19
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4 - 8/26 WRAPMASTER
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11 Dancing roller lock (13N1-S3)

This selector turns the dancing roller unit brake and paper lock buffers on and off.
The button is enabled in any operating mode.
Warning!
Pressing the button when the machine is in AUTOMATIC mode immediately stops
the machine and turns on the dancing roller brake.
12 Roll axle downward movement pushbutton (13N1-S2)

This pushbutton is used to activate the downward movement of the support arms in order to lower the roll.
Il pulsante operativo solo a barriere fotoelettriche inserite (pulsante 2).
13 Depleting roll arms out button (13N1-S6)

Push this button to move the arms out to grasp the depleting roll.
14 Lower brake exclusion pushbutton (13N1-S11)

Pushbutton to exclude the lower brake of the roll being processed.
Press this red mushroom head retained button to immediately stop the entire machine, cutting off power to
motors and depressurising the pneumatic circuit.
Emergency buttons are only reset by pressing the start button on the main control panel.
1619 Available
1 2 3 4 5
6 7 8 9 10
11 12 13 14
15
16 17 18 19
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4.1.6 P13.1 - Roll change control console
1 Roll change pushbutton (13N1-S19H)

Illuminated pushbutton to change the roll.
263895
4.1.7 P14 - Emergency stop push-button
260398
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4.1.8 P15 - Clear Wrap unit push-button panel (optional)
1 Start (15N1-S3H)
Lighted button that starts the Clear Wrap unit.
2 Stop (15N1-S4)
Push and hold down this button to stop the Clear Wrap unit.
The Clear Wrap unit restarts when this button is released.
3 Available
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4.2 Warning equipment

4.2.1 Indicator pole
The machine is equipped with a pole that has colored lights that signal different machine states.
The lights signal the following conditions:

A Red Flashing means the machine is stopped in emergency conditions or stopped with auxiliary
circuits off, or in alarm conditions.
B Orange Machine in manual mode.
C Green Machine in automatic mode.
D Siren Machine signal at the start up phase for automatic cycle start purposes.
First CPU start signal after power returns or when the switchboard is first turned on.
Emptying reel.
Hotmelt unit ready.
STD0025
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4.3 Description of the operating modes

The machine can operate in three modes:
Automatic
Manual
Jog mode
These three modes of operation differ in the way the operator has to interact with the machine.
4.3.1 Automatic mode
When set to this mode, the machine carries out all the operations included in the work-cycle. The operator
simply has to start the machine and make sure the work cycle is correctly executed.
Turn the manual/automatic selector 5 to 0 (pushbutton panel P1).

Press the start button 2 (pushbutton panel P1). Light 4 turns on (the machine resets general alarms).
Wait until the siren mutes.
Start button2 starts to blink and must be pressed again within 6 seconds to start the machine (the machine starts
and the start button light 2 and machine running light 4 on pushbutton panel P1 turn on and the green light C
on the lighted column turns on).
Important!
You must repeat the procedure from the start if you wait more than 6 seconds
before pressing start button 2 again.
Make sure the machine runs properly.
P1
2 4 5
STD0025
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4.3.2 Manual mode
In this mode, the operator runs the single operations using the pushbutton panels located on the machine.
Turn the manual/automatic selector 5 to 1 or 2 (pushbutton panel P1).

Press the start button 2 (pushbutton panel P1). Light 4 turns on (the machine resets general alarms).
Start button2 begins to blink and must be pressed again within 6 seconds to start the machine in manual
mode (the machine starts and the start button light 2 and machine running light 4 on pushbutton panel P1 turn on
and the green light B on the lighted column turns on).
Important!
P1
2 4 5
STD0025
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4.3.3 Jog mode
In this mode, the operator runs the single operations using the jog button located on the mobile pushbutton
panel.
Turn the manual/automatic selector 5 to 1 or 2 (pushbutton panel P1).
Press the jog button 11 (pushbutton panel P3/P3.1). Light 4 (pushbutton panel P1) turns on (the
machine resets general alarms).
Press jog button 11 within 6 seconds to start the machine in jog mode.
Important!
Important!
The machine moves for as long as button 11 is held down.
P1
4 5
265527
P3/P3.1
11
STD0104
U0G00214
4.4 Machine shut down

4.4.1 Stop in phase
When the MACHINE STOP buttons are pressed with the machine running in automatic mode. The
machine finishes wrapping the reams still in the machine and stops once the cycle has been completed
(the indicator pole emergency light flashes slowly).
Thanks to this feature the operator can interrupt the production run without affecting packaging of the ream
in the various work stations.
4.4.2 Emergency shut down
Red self-latching mushroom buttons are located on the various control panels around the machine. These
buttons are used to stop the machine in the event of emergency. When these buttons are pressed the
machine immediately stops running and the pressure in the pneumatic system drops.
Warning!
Sole exception to pneumatic de-energising are the following circuits:
- Clear Wrap cooling jet supply circuit.
- Roll brake supply circuit.
- Outfeed surface jet supply circuit.
The machine should be stopped in this way only when there is an actual emergency as it may cause the reams to
be poorly packaged. The machine is also stopped in this way when one of the access doors is opened while the
machine is running.
4.4.3 Stopping the machine when a fault is present
If a fault which in no way affects the packaging process is present, the machine carries out all the operations
and then stops once the cycle has been completed. A fault message is displayed.
4.4.4 Machine shutdown due to serious faults
If a fault occurs during the work-cycle that affects how the reams are wrapped, the machine will shutdown
immediately and wait until the trouble has been cleared. A fault message is displayed.
4.4.5 Stopping the machine for maintenance
The main switch is located on the electrical cabinet and can be locked in the 0 position using a padlock
(not supplied).
Whenever servicing the machine turn the selector switch to "0" to prevent the moving parts from running
as well as the machine from being accidentally started up while the maintenance man is in dangerous
zones.
To stop the machine proceed as directed below:
Time stop the machine by pressing the MACHINE STOP button.
Turn the maintenance selector switches to "0".
U0G00214
4.5 Starting the machine

Proceed as directed below to turn on the machine and carry out operations either in automatic or manual
mode:
Turn the main switch Q on the electrical control cabinet to ON.
Make sure the hotmelt unit or heaters for polypropylene wrapping (if installed) have reached the
required temperature.
Make sure no objects/things or people are inside the machine.
Press start button 2 on control panel P1.
Wait until the audible alert signal stops ringing.
Press start button 2 again.
A message is shown on the operator panel display asking the operator to perform the homing procedure for the
drive motor.
Turn selector 5 to MANUAL.
Press JOG button 11 on control panel P3/P3.1. Hold it down until the cam integral with the main motor reaches
the 0 sensor (the machine stops running and the message is cleared). If the machine is equipped with a sheet
magazine, the magazine is simultaneously reset by another cam with sensor, found on the magazine motor, while
the machine is being reset. The magazine is timed with the front stop down and the unwinding rollers closed.
Turn selector switch 5 to the desired position according to whether the machine is to be run in MANUAL or
AUTOMATIC mode.
Press start button 2 (control panel P1) to work in AUTOMATIC mode or JOG button 11 (control panel P3/P3.1)
for operation in MANUAL mode.
Wait for the buzzer to stop ringing.
Press the button again.
Important!
If AUTOMATICmode has been selected the machine is ready to start the production
cycle.
The packaging cycle starts as soon as a ream reaches the stopping mechanism-and-synchronization assembly
photocell at the machine inlet.
P1 Q
2 5
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P3/P3.1 11
STD0104
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4.5.1 Restart after stop in phase, immediate or due to a fault
In this case, the unit is ready to operate with the safety circuit enabled and on, and with the power and
pneumatic supplies on.
Check and eventually remove the cause of the stop due to fault.
To put the unit in operating conditions, you must run the procedure described in paragraph 4.5.
4.5.2 Restart after an emergency stop or due to a serious fault
In this case, not only the unit but the entire machine/system is in emergency conditions with the power and
pneumatic supplies cut off.
To put the unit in operating conditions, you must run the following procedure:
Remove the cause of the emergency stop (return the emergency button to off).
Make sure no objects or things are inside the concerned area.
Acknowledge any alarms or signals on the main operator panel.
To put the machine in operating conditions, run the procedure described in paragraph 4.5 on the main pushbutton
panel.
4.5.3 Restart after a stop due to maintenance
In this case the machine is off with the electrical and pneumatic supplies off.
Proceed as follows to put the machine in work conditions:
Make sure there are no objects or things inside the area concerned by maintenance work.
Remove the padlock from the main switch and turn the switch to 1.
Acknowledge any alarms or signals on the main operator panel.
Press the start button once to restore the safety circuit and power and pneumatic supplies.
Follow the procedure described in paragraph 4.5 to put the machine in work conditions.
U0G00214
4.6 Wrapping material

The machine wraps the reams of paper with wrapping material drawn from a roll installed on a reel
assembly.
The following kinds of wrapping material can be used:
Paper or bonded material: with these materials glue needs to be applied in order to close the flaps and finish
the pack.
Clear Wrap: polypropylene or materials which can be heat-sealed. Glue does not need to be applied to this
kind of material but the wrapping material is heat-sealed instead.
Warning!
During the reel replacement, please use lifting and handling means suited to the
load (reel) to be lifted.
4.6.1 Putting the roll on the expanding spindle
Put the spindle A through the hole in the roll, positioning it according to the product size being handled.
To ease installation of the rolls in the future, we recommend using the side reference ring F.
Insert the wrench B and turn clockwise until the expanding sectors C are blocked on the roll shank D.
4.6.2 Removing the roll from the expanding spindle
In order to remove the roll from the expanding spindle, position it horizontally and block it so that it cannot
roll round.
Insert key B in the seat and turn anti-clockwise until the expanding sectorsC on roll shank D are unblocked.
Remove spindle A.
F
A
B
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4.6.3 Installing the roll on the Easy Splice holder
In order to load a new roll which is already inserted on the expanding spindle on the roll holder assembly
proceed as follows:
Make sure arms D of roll holder assembly are fully down.
Use a fork lift truck to position the ends of the expanding spindle A on bearings B. Seat C for the spindle
must be aligned with bearing E.
Turn on the machine.
By these controls on P13 push button panel, lift the reel from the floor in order to allow its free rotation.
251343
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4.6.3.1 Paper insertion
After loading the roll with the machine running and the safety guards closed, move the dancing roller 1 fully
up with the handwheel 2 and secure it in place with the lock 3 provided. When the two guards for the roll
holder are opened, the dancing roller is automatically locked in place. Run the paper 5 (see figure) until
beneath the unwinding rollers. Use button P12 to open and close the rollers.
As soon as the paper as been secured between the unwinding rollers, close the safety guards, release the dancing
roller and start the machine. The dancing roller will request paper from the roll with the brake 4 provided until enough
paper has been accumulated.
P12
2
251150
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1
251346
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4.6.3.2 Feeding packing material into the infeed rolls
To be able to draw in the belt with packing material A between the rolls that tension the belt for unwinding
and cutting, turn the crank handle on the side of the Unwind unit assembly to bring the dancer B into the
up position. Guide the packing material through the rolls, into the first Unwind unit assembly as shown
in the figure below and under the rolls below the footboards as shown in the layout below. Afterwards, guide the
packing material over the roll of the second Unwind unit assembly and fix between infeed rolls C by pressing button
3 on the control console P12. Turning the crank handle returns the dancers to their starting position and tensions
the packing material as required.
P12
263897
262690
C B
U0G00214
4.6.3.3 Raising the roll that is almost finished
While the machine is running, move the roll lift fully up (this can be done only if the roll completed photocell
is not darkened) and press the button for moving out the arms of the roll nearly finished 13 on control panel
P13 to pull out the arms of the roll that is almost finished.
Once out, press the button to move the lift down 12 so that the roll can move by (light on control panel P13.1 flashes
slowly). Move the roll lift fully down.
P13
12
13
263894
4.6.3.4 Installing the new roll
Install the new roll and raise it to the height at which the roll is changed.
4.6.3.5 Splicing a new roll
Before changing the completed roll with a new one, make sure the machine is running at most at 40-45 cpm.
Press the roll change button 10 once (light on control panel P13.1 flashes quickly) and wait until the paper
has been blocked in place. This is done by the retainers 1 usually when the dancing roller is down (light
on control panel P13.1 steady).
If button P13.1 is pressed before the operation is completed, the splicing operation is reset (light on control panel
P13.1 flashes slowly).
Cut the paper of the roll nearly finished and attach it to the new roll making sure it is perfectly aligned.
Once this has been done, press the roll change button 10 again to release the retainers 1. The roll will be unwound
in a normal manner again (light on control panel P13.1 off).
P13.1
10
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4.6.3.6 Removing the completed roll
Take out the completed roll, go out of the protected zone and press the reset button 2 on control panel
P13 to reset the safety barrier. Press the button to move in the arms of the roll almost finished 9 and
press button 12 to lower the roll being used to the desired height.
2
P13
263894
12
4.6.3.7 Changing the roll being used with a roll that has different material
With the machine shutdown, using the control panel P13 use selector 11 to secure the paper with the
retainers and block the dancing roller; cutting the paper, replacing the roll, splicing and centering the paper.
Turn the selector to position OFF to enable the dancing roller and open the retainers.
P13
263894
11
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4.6.3.8 Operations to be followed when installing a roll for the same product size
Follow the instructions below when a new roll containing the same kind of wrapping material as that
previously being used is to be installed.
When the roll being used is about to run out it should be changed for a new one before it has completely
run out. This is to avoid repeating the operations when a sheet is inserted between the belts of the unwinding
assembly.
This operation is divided into five different stages:

Lifting the roll that is almost finished
Hooking the finished roll with upper arms
Installing the new roll on the mobile roll holder assembly
Splicing and centering the wrapping material
Removing the finished roll
Before performing the operations described below the new rolls need to be installed on the roll holder spindle.
Follow the instructions indicated previously.
U0G00214
4.7 Checking the safety devices

Before starting the production run, make sure the safety devices work properly.
First check:
With the machine running in automatic mode at reduced speed, press the emergency stop buttons and
make sure the machine shuts down immediately.
Second check:
With the machine running in automatic mode at reduced speed, open the access doors and make sure the
machine shuts down immediately.
4.8 Trial runs

After operations have been performed with the machine shut off, i.e. maintenance, size change-over or an
emergency shutdown caused by jamming or other reasons, restart the machine in manual mode and carry
out some trial runs with the plug-in jog button.
5 - Machine axes
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Machine axes
WRAPMASTER 5 - 1/22
5 - Machine axes
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5.1 Datum lines

The machine has three fixed reference axes that the user must know about in order to understand how
the machine functions and to be able to change machine part mountings and settings.
F.F.1 Machine axis of symmetry i.e the axis the reams move along.
F.F.2 Fixed hopper datum line which is also the point in which the positioners stop.
F.F.3 This axis is in line with the edge of the outfeed table for the ream.
F.F.2
F.F.3
F.F.2
F.F.2
F.F.1 F.F.1
F.F.2
263919
5 - 2/22 WRAPMASTER
5 - Machine axes
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5.2 Definition of the machine axes

Machine axes refers to mechanical axes driven by brushless electric motors that areresolver-controlled.
The exact position of the motor is known each and every minute as is the position of the driven mechanical
part. The formulas given below must be used to determine the machine axes. The following aspects are
taken into consideration:
Product size parameters: these determine the size of the reams to be handled.
Machine drive axes: these are electrically controlled mechanical parts used to position the units according to
the ream size being handled.
5.2.1 Product size parameters
The ream size parameters are entered on the Order data page on the operator interface panel. These
data items are used to obtain the values employed to position the machine drive axes.
RH Ream height
RL Ream length
RW Ream width
SL Sheet length (unwinding length)
SW Sheet width (roll width)
REAM WITH REAM WITH

END FOLDS OVERLAP FOLDS
RW RW
RL RL
RH
RH
261743 261744
WRAPMASTER 5 - 3/22
5 - Machine axes
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5.2.1.1 Determining the length of the sheet of wrapping material
The wrapping sheet length parameter is to be determined according to the ream dimensions and how the
reams are to be wrapped.
The type of packages that can be obtained and relative formulas for calculating the length of the sheet are given
below:
Ream with end folds
SL = RL + 2 (9/10RH)
Ream with overlap folds
SL = RL + 2RH + 60
=
SL RW
RL
SW RW/
=2 2+
RW RH
+2 +
RH
RH 15
+3
0
261760
RH Ream height
RL Ream length
RW Ream width
REAM WITH END REAM WITH OVERLAP

FOLDS FOLDS
261746 261745
5 - 4/22 WRAPMASTER
5 - Machine axes
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5.2.2 Movable axles of the machine
The movable axles of the machine are the position values of some movable components based on format
size, machine parameters and the type of wrapping.
The servo axles consist of a servomotor with resolver and a sensor for 0 position.
The following axles are present on the machine:
Axle A11 Elevator 1 lateral

Axle A12 Elevator 2 central
Axle A13 Counter plate
Axle A14 Lower folder
Axle A15 Lower counterfolder
Axle A16 Left aligner
Axle A36 Right aligner
Axle A17 Folding device for top fold
Axle A18 Movable hopper
Axle A19 End damper
Axle A20 Ream accelerator
Axle A37 Phaser stop in the feeding area (gate)
Axle A21 Ream feed
Axle A22 Transport finger, outfeed
Axle A23 Knife
Axle A24 Sheet conveyor belts
Axle A25 Unwinding rollers
Axle A26 Infeed rolls on unwind unit
The values determined from the individual measurements of distances of the mechanical components after
positioning the axles are target dimensions that result when possible offsets are added to the required parameters
required for the calculation.
5.2.2.1 Referencing the axles
Referencing the servo axles is performed automatically when the automatic cycle is activated.
Important!
If mechanical parts have been replaced in an axle (pull rod), be sure to check that
the mechanical installation complies with the description in Chapter 10 of this
manual with regard to the specified pull rod lengths of the axles. After replacing
electrical components (sensor original setting), reference the axles. This setting is
to be performed with empty machine and in manual mode.
Proceed as follows to reference a servo axle (for a detailed description of each axle, see the following paragraphs):
In JOG mode check the machine direction (see chapter 6 Machine control through operator interface):
Reference the axle by using the sensor for 0 position (see chapter 6 Machine control through operator
interface). If referencing does not occur, set the 0 position sensor.
Determine the value Home_position of the axle and enter in the axle parameter mask.
Reset again.
WRAPMASTER 5 - 5/22
5 - Machine axes
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5.2.2.2 Axle A11 - Elevator 1 lateral
Defines the position of the lateral elevator A in relation to F.F.3.

Important for referencing axle A11:
The value Home_position corresponds to the dimension X between F.F.3 and of the level of
elevator A.
Proceed as follows to reference axle A11:

Determine rotation direction: If you press the - button (see chapter 6 Machine control through operator
interface) while in JOG mode, the axle must move downward.
Reference the axle and check that the axle reaches the position specified in the Home_position value.
If the position is not reached, determine dimension X and enter in Home_position in the axle parameters.
Reset again.
F.F.2
F.F.3 F.F.3
X
263906
F.F.2
5 - 6/22 WRAPMASTER
5 - Machine axes
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5.2.2.3 Axle A12 - Elevator 2 central
Defines the position of the central elevator B in relation to F.F.3.

The value Home_position corresponds to the dimension X between F.F.3 and elevator level B.

interface) while in JOG mode, the axle must move downward.
Reset again.
F.F.2
F.F.3 F.F.3
X
263907
F.F.2
WRAPMASTER 5 - 7/22
5 - Machine axes
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5.2.2.4 Axle A13 - Counter plate
Defines the position of the counter plate C in relation to F.F.3.

The value Home_position corresponds to the dimension X between F.F.3 and the lower elevator of
the counter plate C.

Determine rotation direction: If you press the + button (see chapter 6 Machine control through operator
interface) while in JOG mode, the axle must move upward.
Reset again.
C
F.F.2
F.F.3 F.F.3
X
263908
F.F.2
5 - 8/22 WRAPMASTER
5 - Machine axes
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5.2.2.5 Axle A14 - Lower folder
Defines the position of the lower folder D in relation to F.F.2.

The value Home_position corresponds to the dimension X between F.F.2 and the tip of the lower
folder D.

interface) while in JOG mode, the axle must move toward the ream outfeed.
Reset again.
F.F.2
F.F.3 F.F.3
263909
F.F.2
WRAPMASTER 5 - 9/22
5 - Machine axes
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5.2.2.6 Axle A15 - Lower counterfolde
Defines the position of the lower counterfolder E in relation to Z, which is the mobile hopper position.
The value Home_position corresponds to the dimension X between Z and the tip of the lower
counterfolder E.

Reset again.
Z
F.F.2
F.F.3 F.F.3
E
F.F.2
265529
5 - Machine axes
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5.2.2.7 Axle A16/A36 - Right and left aligners
Defines the position of finger F of the aligner in relation to F.F.2

Important for referencing axle A16/A36:
The value Home_position corresponds to the dimension X between F.F.2 and fingerF of the aligner.
Proceed as follows to reference axle A16/A36:

interface) while in JOG mode, the axle must move toward the elevator.
Reset again.
F.F.2
X
F
F.F.1 F.F.1
F.F.2
263911
5 - Machine axes
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5.2.2.8 Axle A17 - Folding device for top folder
Defines the position of the folding devices for top fold G and G1 in relation to F.F.2.
The information on the plate refers to the rear folding device for top fold G.
The value Home_position corresponds to the dimension X between F.F.2 and the tip of the rear
folding device for top fold G.

Reset again.
Note:
The value of measurement between F.F.2 and the head folder is only reliable if the
machine is mechanically in A4 format.
G G1
F.F.2
F.F.3 F.F.3
263912
F.F.2
5 - Machine axes
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5.2.2.9 Axle A18 - Movable hopper
Defines the position of the movable hopper H in relation to F.F.3.

The value Home_position corresponds to the dimension X between F.F.3 and the lower tip of the
movable hopper H.

interface) while in JOG mode, the axle must move upward.
Reset again.
H
F.F.2
F.F.3 F.F.3
X
263913
F.F.2
5 - Machine axes
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5.2.2.10 Axle A19 - End damper
Defines the position of damping plates I in relation to the end plate on elevators L.
The value Home_position corresponds to the dimension X between end plate L and damper plates
I when the pneumatic cylinder is fully open.

Reset again.
F.F.2
F.F.3 F.F.3
X
263914
F.F.2
I L
5 - Machine axes
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5.2.2.11 Axle A20 - Ream accelerator
Defines the position of ream accelerator M in relation to F.F.2.

The value Home_position corresponds to the dimension X between F.F.2 and the plate of ream
accelerator M.

Reset again.
M
F.F.2
F.F.3 F.F.3
263915
F.F.2
5 - Machine axes
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5.2.2.12 Axis A37 - Phaser stop in the feeding area (gate)
This axis controls the movement of the motor of the phaser belt (feeding area), which is continuously moved
depending on the speed set by the operator on the control panel, or according to the speed of the cutter
positioned before this machine.
5.2.2.13 Axle A21 - Ream feed
Defines the position of the reference teeth (coloured black) N on the ream feed belt compared to F.F.2.
Determine rotation direction: If you press the + button (see chapter 6 Machine control through
operator interface) while in JOG mode, the axle must move toward the elevators.
Reset the axis and make sure that the belt reference tooth is xxx mm from F.F.2 at 0 axis when A4
format is set or at xxx mm when A3 format is set. If this is not the case, read the X distance between the
tooth and notch in the Home Offset value in axis parameters.
Reset again.
Note:
When reference teeth N are in line with the notch, both sensors (for A4 and A3
formats) should be obscured.
F.F.2
F.F.3 F.F.3
N
F.F.2
263914
5 - Machine axes
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5.2.2.14 Axle A22 - Transport finger, outfeed
Defines the position of the first finger O to the outfeed of the transport finger in relation to F.F.2.
The value Home_position corresponds to the dimension X between F.F.2 and the first finger O
of the transport finger to the outfeed.

Reset again.
X
F.F.2
F.F.3 F.F.3
263915
F.F.2
5 - Machine axes
U0G00214
5.2.2.15 Axle A23 - Knife
Defines the position of the circular knife.

Determine rotation direction: If you press the + button (see chapter 6 Machine control through
operator interface) while in JOG mode, the axle must rotate in the direction of the speed advance of the
wrapping sheet.
Reference the axle and check that axles with the setting on 0 agree with the reference indices; if this is not the
case, add the difference between the tooth and notch to the value entered in axis parameter Home Offset.
Reset again.
251833
5 - Machine axes
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5.2.2.16 Axle A24 - Sheet conveyor belts
Axle 24 defines the stop position of the conveyor belts for positioning the wrapping sheet above the elevator.
This movement is based on the length of the wrapping sheet:
Axle A24 = Y - SL/2
Y is the distance between knife and centre axle of the machine (F.F.1). This distance is determined when the machine
is approved. Enter the measured value on the control panel in the Cross cutter - machine centre distance field in
the General parameters mask.
SL
= =
Axle A24
Y
F.F.1
263805
5 - Machine axes
U0G00214
5.2.2.17 Axle A25 - Unwinding rollers
Axis A25 determines the length of the sheet unwound by the rollers.
To calculate the value use the Wrapping sheet length parameter given in the present order data.
Ream with end folds
Axle A25 = SL = RL + 2 (9/10RH)
Ream with overlap fold
Axle A25 = SL = RL + 2RH + 60
=
SL RW
RL
SW RW
= 2 /2 +
RW R
+2 H +
RH 15 RH
+3
0
261760
RW Ream width
RL Ream length
RH Ream height

FOLDS FOLDS
261746 261745
5 - Machine axes
U0G00214
5.2.2.18 Axle A26 - Infeed rolls on unwind unit
Axle A26 defines the sheet length unwound from the infeed rolls on the unwind unit.
The parameter for calculating the formula is based on the Length of the wrapping sheet parameter, which
is defined for the working size in the current job.
The axle unwinds the wrapping paper continuously with varying speed depending on the length of the
wrapping sheet and the state of the dancer on the Sheet feed assembly (full or empty).
Ream with end folds
Axle A26 = SL = RL + 2 (9/10RH)
Ream with overlap fold
Axle A26 = SL = RL + 2RH + 60
=
SL RW
RL
SW RW
= 2 /2 +
RW RH
+2 +
RH 15
+3 RH
0
261760
RW Ream width
RL Ream length
RH Ream height

FOLDS FOLDS
261746 261745
5 - Machine axes
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6 - Machine control through operator interface
U0G00214
Machine control through

operator interface
WRAPMASTER 6 - 1/44
U0G00214
6.1 Machine control through operator interface

The WRAPMASTER C140 machine is equipped with an operator panel that manages the main functions,
specifically:
Manual operations and various settings;

format programming (display only if the machine is included in another order management system).
A touch screen is provided that allows the user to interact with the operator panel by touching an area on its screen.
The machine performs the processings of the packaging process in automatic cycle following the selection of a work
order.
With the automatic cycle and in synchronism with the system located before the machine/equipment, all the
parameters regarding the work order are set in the order database (those values are subject to a confirmation); the
operator responsible for the production can not modify the parameters (such as speed, acceleration etc.) of the
various actuators on the machine/equipment but can only implement a work according to the required format.
Any change of the machine/equipment speed can be carried out only in manual cycle and for maintenance purposes
(always under safety conditions and with all protections enabled) so as to test the machine/equipment idling
operation or during the machine test phase or adjustment.
266056
6 - 2/44 WRAPMASTER
U0G00214
6.2 Lay-out of the video-pages

The video-pages shown on the display screen are linked together as illustrated on the following pages.
Three different modes have been established to access the pages, entering different passwords, so that
various operations can be carried out.
The three modes are:

OPERATOR
MAINTENANCE WORKER
MANUFACTURER (bielomatik s.r.l.)
Warning!
Password access should be used only by qualified technical staff in case of mainte-
nance operations or in special cases such as encoder, drive replacement etc...
The misuse of this section (access with password) regards the entry of data that
do not meet the actual physical characteristics of the process, which may cause
damages or injuries to things or people; this is prohibited and falls under the direct
responsibility of the technical staff responsible.
6.2.1 Calling up the pages in OPERATOR mode (no password required)
266055
WRAPMASTER 6 - 3/44
U0G00214
6.2.2 Calling up the pages in MAINTENANCE WORKER mode (password required)
266054
6 - 4/44 WRAPMASTER
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6.3 Description of the program pages

6.3.1 General video-page description
The users interface control program used to control and monitor the machine operations includes a number
of video-pages which can be accessed by using specific keys. Each video page is divided into zones where
data, illustrations and various buttons are displayed.
The following zones are provided:

1 Heading: shows the manufacturers trade name, the Machine ID Name, the name of the page and the date
and time.
2 Body: this zone contains lists, buttons and different controls for each page depending on the function of that
page.
3 List of buttons: the control buttons are located in this zone so as to access other pages or to enable other
functions.
3A HELP: on-line help.
3B ALARM: button used to display the faults.
3C MACHINE SPEED-: button used to decrease the machine speed.
3D MACHINE SPEED: graph bar to illustrate the machine speed in graphic form.
3E MACHINE SPEED+: button used to increase the machine speed.
3G LANGUAGES: repeatedly press this key to change the operator interface language; the last language
selected is used on all pages.
3H SYNC: button used to synchronise the cutter.
3L PREVIOUS: press this button to go back to the previous video-page.
3M MENU: press this button to go back to the main item menu.
3X STAND-BY: key that loosens packaging paper between the 1st and 2nd unwinding rollers to eliminate
packaging paper tension if the machine remains idle for a certain amount of time. The function is only
enabled when the machine is not synchronised with the cutter.
4 Error messages: this area displays a message about the last error or warning message.
3M
265534
4
3B 3A 3X 3C 3D 3E 3H 3L 3G
WRAPMASTER 6 - 5/44
U0G00214
6.3.1.1 Editing the data items
Some parameters on the program pages are set to numeric values. To enter the values, click the data item
to be modified and use the keyboard displayed to type the required characters.
263306 263305
264985
6 - 6/44 WRAPMASTER
U0G00214
6.4 Start-up: Menu page

When the machine is turned on, the MENU page appears where you can open other pages.
In this page, a series of keys used to open other pages is found in area A. Press these keys to open
dropdown menus with additional choices:
1 Order: this opens the format data management and order production page.
2 Overview: this opens the page where production order data is displayed.
3 Messages and diagnostics: this opens a window where service or alarm messages are displayed.
4 Report: this opens the page where production data logs are displayed (optional).
5 General settings: this opens the operator interface settings management page (password required - level 8).
6 Clear screen: clear screen of any electrostatic discharges.
X Simulation cycle: key that simulates a ream between the infeed phasing unit photocells. When the key is
pressed, the machine starts the automatic cycle as if the set format was to be packaged (sheet cut and
unwinding). The key lights up. The cycle continues until the key is pressed again.
Furthermore, a series of keys are included with the following functions:
B Press this key to open the Servo Axes page.

C Press this key to open the Service page.
D Press this key to open the Roll carriage page (optional).
E Press this key to open the Glue parameters page.
F Press this key to open the Clear Wrap page (optional).
G Push button to enables/disables the exchange signals with the Pre-stacker. In addition it is possible to display
the operation status of the Pre-stacker.
X G A
B 1
C 2
3
D
4
E
5
F
6
266056
WRAPMASTER 6 - 7/44
U0G00214
6.5 Current order page description

This page displays parameters on the current production order. Only data displayed in the list on a yellow
background can be edited.
If a parameter is changed, press key E to save changes.
Data displayed on the current order are calculated by the machine during production.
Data on the current order includes:

1 Order number.
2 Ream length.
3 Ream width.
4 Ream height.
5 Wrapping sheet length.
6 Distance between spot and cutting point on wrapping paper.
7 Number that identifies the type of packaging to be processed:
1 Standard longitudinal glue.
2 Longitudinally spread glue.
3 No glue (polypropylene).
8 Spot (YES= spot on, NO= Spot off).
1
2
3
4
5
6
7
8
266057
6 - 8/44 WRAPMASTER
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11 Left Clear Wrap side reference temperature.

12 Right Clear Wrap side reference temperature.
13 Clear Wrap surface reference temperature.
14 Minimum Clear Wrap speed.

A (HOST COMPUTER) Key that lets the operator check and change connections with the host computer
OPTIONAL (green connected, red disconnected).
B (FLYING ORDER) Key that enables Flying Order. The key is only enabled the Host computer is
OPTIONAL disconnected and if the operation is compatible with the current order. If the machine
is connected to the Host computer, the key is only displayed if Flying order is enabled.
C (PACKAGING SHEET) Key that turns on splice at the end of the current order. The key is only enabled if the
OPTIONAL Host computer is disconnected and thus the operator must decide whether to change
the reel for the next order (red key) and splice or not to change the reel (green key). If
the machine is connected to the Host Computer, the key is only displayed if the reel is
changed (red key) or not (green key) when the order is completed.
D (REPORT) OPTIONAL Key that opens the page where production data logs are displayed.
F (ORDERS) Press this key to open a drop down menu where the operator can open the next order
page by pressing key G1.
H (RECIPES) Press this key to open the page where current orders can be managed.
G1
11 F
12 H
13
14
264998
A B C D
WRAPMASTER 6 - 9/44
U0G00214
6.5.1 Next Order page description
These pages display parameters on the next production order. Only data displayed in the list on a yellow
background can be edited.
If a parameter is changed, press key E to save changes.
Data on the next order includes:
1 Order number.
2 Ream length.
3 Ream width.
4 Ream height.
1
2
3
4
5
6
7
8
266058
U0G00214
11 Left Clear Wrap side reference temperature.

12 Right Clear Wrap side reference temperature.
13 Clear Wrap surface reference temperature.
14 Minimum Clear Wrap speed.

A (HOST COMPUTER) Key that lets the operator check and change connections with the host computer
OPTIONAL (green connected, red disconnected).
B (FLYING ORDER) Key that enables Flying Order. The key is only enabled the Host computer is
disconnected and if the operation is compatible with the current order.
If the machine is connected to the Host computer, the key is only displayed if Flying
order is enabled.
C (PACKAGING SHEET) Key that turns on splice at the end of the current order. The key is only enabled if the Host
OPTIONAL computer is disconnected and thus the operator must decide whether to change the
reel for the next order (red key) and splice or not to change the reel (green key).
If the machine is connected to the Host Computer, the key is only displayed if the reel
is changed (red key) or not (green key) when the order is completed.
D (REPORT) OPTIONAL Key that opens the page where production data logs are displayed.
F (ORDERS) Press this key to open a drop down menu where the operator can open the next order
page by pressing key G2.
H (RECIPES) Press this key to open the page where current orders can be managed.
I (ORDER CHANGE) Press this key to control format change to load the next order settings.
G2
11 F
12 H
13
14 I
264996
A B C D
U0G00214
6.5.2 Recipe sub-page description
From the Order page, press key H to open the page where you can manage, edit and create new recipes.
Data to be entered in the recipe are:

1 Order number.
2 Ream length.
3 Ream width.
4 Ream height.
1
2
3 H
4
5
6
7
8
266057
U0G00214
New recipe creation

Press key 1 and enter the new name.
Select the created order from dropdown menu 2.
Edit fields in area 3.
Save changes by pressing key 4.
Creating a recipe from a similar one

Select the order from dropdown menu 2.
Save with a new name by pressing key 5.
Edit fields in area 3.
Save changes by pressing key 4.
Deleting a recipe
Select the order from dropdown menu 2.
Press key 6.
Press key Z, only enabled in Hand mode, to set the next order.
2 3
264995
1 4 5 6 Z
U0G00214
6.5.3 Order change sub-page description
From the Order page, press key I to change the order.

When the key is pressed, the next order data are loaded in the current order and axes start positioning (this
operation can be performed only with the Host Computer disconnected).
266058
U0G00214
6.6 Overview sub-page description

From the Menu page, press the Overview key to open the page that displays the machine layout.
Displayed keys can be used to open sub-pages:
1 Movement parameters: this opens the sub-pages where machine parameters are managed.
2 Service: this opens the maintenance management page.
3 Ream control: this opens the page where ream controls are managed (optional).
4 Report: this opens the page where production data logs are displayed.
5 Clear Wrap: this opens the page where Clear Wrap parameters are managed (optional).
6 Roll holder: this opens the page where roll holder parameters are managed.
7 I/O Test: access to the sub-page where the PLC inputs and outputs can be checked.
8 Profibus: access to the sub-page where the Bus-Profibus can be checked.
9 Hot-melt Service: service: this opens the Hot-melt maintenance management page.
10 Syncro Overview: this opens the page where the synchronization data of the Wrapper/Cutter are displayed.
Some working machine data can be displayed from the OVERVIEW page:
A Cutter speed
B Machine phase.
C Machine speed.
D Ream acceptance phase on gate.
E Blade synchronism error value.
F Mark reading error value.
Use the buttons X to change the ream count between the gate and the elevator, following the intervention of the
operator for the removal and/or arrangement of the reams.
The buttons turn white if the ream is present, otherwise they are coloured in blue.
If other reams are placed again, press the corresponding button to delete them.
This operation can be performed only if the machine is stopped.
6 7 8
A
1
B
2
C
3
D
E 4
F
10
5
266059
X 9
U0G00214
6.6.1 Description of the Movements parameters mask
Pressing the Movements parameters touch button in the Overview mask causes a pull-down menu to
appear for the axle and machine parameters.
1 Servo axle movement: displays the parameters of the servo axles.

2 Axle movement ON/OFF: displays the parameters of the axle ON/OFF (if present).
3 Variables: displays the masks of variables (with password prompt level 8).
4 Setup: accessible only to the manufacturer.
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6.6.2 Description of the Servo axles screen masks
This mask contains a list of the machine axles as well as the parameters for the chosen axle.
Axle A11 Elevator 1: touch button for activating the parameters for the axle of the first elevator.
Axle A12 Elevator 2: touch button for activating the parameters for the axle of the second elevator.
Axle A13 Counter plate: touch button for activating the parameters for the axle of the counter plate.
Axle A14 Lower folder: touch button for activating the parameters for the axle of the lower folder.
Axle A15 Lower counterfolder: touch button for activating the parameters for the axle of the lower counterfolder.
Axle A16 Left aligner: touch button for activating the parameters for the left aligner axle.
Axle A36 Right aligner: touch button for activating the parameters for the right aligner axle.
Axle A17 Folder for top fold: touch button for activating the parameters for the axle of the folding devices for
the top fold.
Axle A18 Movable hopper: touch button for activating the parameters for the axle of the movable hopper.
Axle A19 End damper: touch button for activating the parameters for the axle of the end dampers.
Axle A20 Ream accelerator: touch button for activating the parameters for the axle of the ream accelerator.
Axle A37 Gate: touch button for activating the parameters for the axle of the Gate.
Axle A21 Ream feed: touch button for activating the parameters for the axle of the ream feed.
Axle A22 Transport finger, outfeed: touch button for activating the parameters for the axle of the outfeed
transport finger.
Axle A23 Knife: touch button for activating the parameters for the knife axle.
Axle A24 Wrapping paper belt: touch button for activating the parameters for the axle of the wrapping paper belt.
Axle A25 Second infeed roll: touch button for activating the parameters for the axle of the second infeed roll.
Axle A26 First infeed roll: touch button for activating the parameters for the axle of the first infeed roll.
On each side of the axle are two fields. The first contains the value of the actual position, the second any pending
error codes. The error code appears in the field only if the axle stops due to a fault. To clear this code, the operator
must look it up in the warning list supplied by the motor manufacturer.
Pressing the Axle parameter 2 touch button accesses the parameters for the selected axle (required: password,
level 8). The selected axle is indicated by a flashing yellow marker next to the axle name.
The table for checking the axles has the following columns:
Blue Axle moving.

Yellow Axle is incorrectly positioned based on the setting in the size data.
Violet Axle is not referenced; axle position values not reliable because no correct referencing has taken place.
Red Axle with warning.
Green Axle corrected by referencing or positioning; no pending warnings and the axle is correctly positioned.
Orange Axle not enabled.
265722 266061
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6.6.2.1 Description of the commands for axle movements
Pressing the touch button for the axle to be selected displays all parameters.
The available fields contain the following:
1 MDI position: shows the angle position which defines the zero point of the axle in manual mode.
2 MDI speed: shows the speed of the axle during manual mode.
The commands are carried out using the following touch buttons:
3 Start MDI: starts manual mode.
4 Stop MDI: stops manual mode.
5 Homing: carries out the axle reference run.
6 Jog +: enables inching mode and increases the angle.
7 Jog -: enables inching mode and decreases the angle.
8 Brake: controls actuation and release of the brake of the selected axle. This function is activated if the
machine is at a standstill as a result of an Emergency Stop.
9 Sim: accessible only to the manufacturer.
Note:
Some touch buttons may be deactivated for some axles or deactivated due to the
state of the axles (white lettering).
3 1
4
7
6
5
8
9
264992
U0G00214
6.6.2.2 Description of the Servo axles parameters masks
This screen displays all parameters pertaining to the selected axle:
1 Feed constant: this value (in millimetres) shows the linear development for each rotation of the movement
(value present only for some axles).
To change the value, switch the machine off and then on again.
2 Home position: this dimension (in millimetres) specifies the value for referencing the selected axle (see
chapter 5 Machine axes).
3 Home offset: this value (in millimetres) specifies the distance between the proximity switch of the starting
position and the actual starting position.
4 Home velocity: this value (in millimetres/second) specifies the speed of the axle during referencing.
5 Not used
6 Overload limit: this value (in Nm) specifies the value of the electronic overload protection.
7 Software position limit +: this shows the largest value which the movement can reach (software limit switch).
8 Software position limit -: this shows the smallest value which the movement can reach (software limit
switch).
9 Jog/MDI maximum velocity +: this value specifies the highest possible speed of the axle of the movements
in manual mode.
The boxes A allow to display the activation status of the selected axis (green = OK, red = error); for further details,
please refer to the manufacturers manual.
1
2
3
4
5
A
6
7
8
9
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6.6.3 Description of Variables masks
This screen mask contains the touch buttons that call up the masks containing the parameters for
controlling the machine movements.
Warning!
Changing these parameters may compromise the proper functioning of the
machine; therefore, changes should be performed only after a thorough analysis
and when the movement is adequately known. Our Customer Service will be glad
to provide you with further information if required.
The touch buttons in the screen mask have the following functions:
1 General parameters: opens the mask where you can manage the parameters for machine movements.
2 Switchcam parameters: opens the mask for managing the parameters for actuating the solenoids,
photocells etc.
3 Glue parameters: opens the mask for the control system responsible for glue application assemblies.
4 Switch system parameters:opens the mask where you can manage the parameters for actuating the axles.
5 Syncron parameters: opens the mask for managing the general parameters for synchronisation with the
cross cutter.
6 Syncro displacement parameters:opens the mask for managing the parameters for synchronising with the
cross cutter based on size.
7 Print mark control parameters: opens the mask for controlling the reference mark (print mark) on the
packaging material.
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6.6.3.1 General machine parameters sub-pages
This page contains a series of fields that list an angular value, a numeric value or time, necessary to adjust
machine movement start and stop.
Only data displayed in the list on a yellow background can be edited.
Parameters in the page include:

1 This value sets the machine stop in phase position
2 This value identifies minimum admitted machine speed
3 This value identifies minimum ream width accepted by the machine
4 This value identifies maximum ream width accepted by the machine
5 This value identifies the distance between the blade and machine centre (F.F.1)
6 This value identifies the distance between the blade and standard glue gun
7 Not used
8 This value identifies the output air pressure exiting the proportional valve at minimum machine speed
9 This value identifies the output air pressure exiting the proportional valve at maximum machine speed
10 This value identifies lubrication frequency
11 Not used
12 Not used
13 Not used
14 Not used
15 Not used
16 This value identifies a set Clear Wrap conveyor temperature
1
2
3
4
5
6
7
8
9
10
11
265723
12
13
14
15
16
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6.6.3.2 Swirchcam Parameters sub-pages
These pages contain a series of fields that display an angle or value in millimetres, absolute or relative,
necessary to regulate start (X), stop (Y), start delay (V) and stop delay (Z) concerning machine
movements.
The purpose of the delay is to obtain real movement start/stop moments according to machine speed, and according
to movement delays due to their reaction times.
A This value identifies the machine phase.
B This value identifies the gate closing phase for minimum ream.
C This value identifies the gate closing phase for maximum ream.
1 This value sets the gate acceptance range.
2 This value sets the gate acceptance range for the A3-format.
3 This value sets the air jet phase on the lower folder.
4 This value sets the air jet phase on the upper part of the lower folder.
5 This value sets the air jet phase on the lift.
6 This value sets the base dampener action phase.
7 This value sets the air jet phase on the lower hopper.
8 This value sets the packaging paper shape up/down phase.
9 This value defines the air jet phase on the blade according to blade position.
10 This value defines the air jet phase on the blade according to unwinding roller position.
A X Y V Z
1
2
3
4
5
B
C
265724
6 7 8 9
264985 265539
10
U0G00214
6.6.3.3 Description of the Glue Parameters sub-pages
This video-page shows a number of fields that indicate a numeric value required to control the opening or
closure of the glue application nozzles while the reams are passing by.
Use the on-line help functions to access the video-page that indicates the formula required for the
theoretical calculation of the length of glue applied according to the ream size and the packing material.
The following parameters are given on these pages:
A Offset glue ON: indicates the value in millimetres that is added to the Start glue parameter set in size data.
B Offset glue OFF: indicates the value in millimetres that is added to the Stop glue parameter set in size data.
C Glue spray delay ON: indicates the glue spray start delay to proportionally compensate for the change in
machine speed.
D Glue spray delay OFF: indicates the glue spray stop delay to proportionally compensate for the change in
machine speed.
1 F.F.2 and left glue gun distance: indicates the distance measured on the machine in the inspection phase
between the F.F.2 and nozzle that applies glue on the left head flap.
2 F.F.2 and right glue gun distance: indicates the distance measured on the machine in the inspection phase
between the F.F.2 and nozzle that applies glue on the right head flap.
3 Hot melt longitudinal glue gun blade distance: indicates the distance between the blade and the hot melt
application nozzle.
4 Longitudinally spread glue gun blade distance: indicates the distance between the blade and the glue
spreading nozzle.
A B C D
1
2
3
4
264983
264982
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Calculates parameters to apply longitudinally spread glue
HP
B
A
HP SC
262647
PC
START SIDE GLUE APPLICATION = FS
A Ream width
B Ream length
SC Packing paper length
HP= (SC-B):2 Flap height
PC Distance between the Machine zero-point and the glue gun
ON Side glue offset ON
TOn Side glue application delay On
FS=PC+HP-A-ON-TOn
SIDE GLUE APPLICATION STOP =FT
A Ream width
B Ream length
HP= (SC-B):2 Flap height
PC Distance between the Machine zero-point and the glue gun
OF Side glue offset OFF
TOff Side glue application delay OFF
FT=PC-HP+OF-TOff
If the parameter is varied or fields FS or FT are set to zero, the PLC calculates the equations (for each program step)
and, as a result, will update the fields.
U0G00214
Determining the lengthwise hot glue application parameters
HP
PC
B
SC
262648
LENGTHWISE GLUE APPL. START= FS
B Ream length
HP = (SC-B):2 Flap height
ON Lengthwise glue application offset ON
TOn Lengthwise glue application delay On
FS=PC-SC+HP-ON-TOn
LENGTHWISE GLUE APPL. STOP = FT
B Ream length
PC Distance between blade and glue gun
OF Lengthwise glue application offset OFF
TOff Side glue application delay off
FT=PC-HP+OF-TOff
If the parameter is varied of fields FS or FT are set to zero, the PLC calculates the equations (for each program step)
U0G00214
Determining the lengthwise glue application parameters - spiral shape or smeared (optional)
HP
B
SC
PC
HP
B
SC
262649
LENGTHWISE GLUE APPL. START = FS
B Ream length
ON Lengthwise glue application offset ON
TOn Lengthwise glue application delay On
FS=HP-ON-TOn
LENGTHWISE GLUE APPL. STOP = FT
B Ream length
PC Distance between blade and glue gun
OF Lengthwise glue application offset OFF
TOff Side glue application delay off
FT=SC-HP+OF-TOff
If the parameter is varied of fields FS or FT are set to zero, the PLC calculates the equations (for each program step)
U0G00214
6.6.3.4 Movement Parameters sub-page description
This page contains a series of fields that list an angular value or a numeric value necessary to adjust
machine movement positioning.

1 This value sets the high lift positions.
2 This value sets the lift safety position to allow other movement positioning and reset.
3 This value sets the low lift positions.
4 This value sets the central lift position after first descent.
5 This value sets the central lift restart phase after first movement.
6 This value sets an offset on the counter-lift position at start according to ream height.
7 This value sets the distance between the lower folder and the counterfolder, when they are completely closed.
8 This value sets an offset on the distance between the counter-lift and the lift during the ream lifting phase.
22 This value sets a percent speed variation on the 1st unwinding roller according to the position of the dancer
roller on sheet feed.
1
2
3
4
5
6
7
8
265725
22
264980
U0G00214
6.6.3.5 Synchronism Parameters sub-page description
These pages contain a series of fields that list an angular value, a numeric value or time, necessary to adjust
wrapper/blade synchronism.
1 This parameter sets linear belt movement at wrapper infeed for each encoder revolution.
2 This value sets the acceleration degree of the axis that allows the synchronism correction.
3 This value sets the maximum acceptable speed that allows gate operations.
4 This value sets the wrapper speed increase to correct ream synchronism.
5 This value sets minimum admitted machine speed to correct synchronism, according to the minimum format.
6 This value sets maximum admitted machine speed to correct synchronism, according to the maximum format.
7 This value sets the maximum speed, calculated according to values 5 and 6.
8 This value sets minimum admitted machine speed to correct synchronism.
9 This value sets minimum machine acceleration to correct synchronism.
10 This value sets how many machine degrees are needed to correct synchronism.
1
2
3
4
5
6
7
8
9
10
266064
U0G00214
11 This value sets the distance between the cutter synchronous photocells and the wrapper synchronous photocell.
12 This value sets the maximum distance required after the synchronism photocell to correct synchronism.
13 This value sets minimum correction error.
14 This value sets the maximum distance with reference to optimal correction.
15 This value sets the distance between the wrapper synchronous photocells and the gate synchronous
photocell.
16 This value permits correct ream transit to be calculated from the cutter conveyor to the wrapper conveyor,
compensating the step difference between the two conveyors.
50 This data sets encoder rotation direction.
51 This value sets the reading direction of the wrapper synchronous photocell on the ream.
52 This value sets the reading direction of the cutter synchronous photocell on the ream.
A These values indicate the linear blade speed.
11
12
13
14
15
16
50
51
52
266065
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6.6.3.6 Synchronism Correction Parameters sub-page descriptions
These pages contain a series of fields that list an angular value, a numeric value or time, necessary to adjust
wrapper/blade synchronism correction.
1 Ream width.
2 Offset value for the synchronous reference phase of the cutter photocell.
3 Distance of the reams on the cutter belt, according to the ream width.
4 Distance of the reams on the gate belts, according to the ream width.
5 Offset value for the synchronous reference phase of the wrapper photocell.
9 Synchronous reference phase of the cutter photocell, according to the ream width.
10 Synchronous reference phase of the wrapper photocell, according to the ream width.
1
2
3
4
5
9
10
266066
U0G00214
6.6.3.7 Spot Control Parameters sub-pages
This video page contains a number of fields that indicate a numeric value required to control the movement
of the cutter in relation to the spot photocell as soon as the unwind rollers start operating.
1 This value identifies the distance between the blade and the spot reader photocell.
2 This value identifies the spot reading area.
3 This value identifies the maximum admitted spot reading error.
4 This value sets the maximum correction on the single packaging sheet to correct the spot read error during
the production cycle.
5 This value sets the maximum correction on the single packaging sheet to correct the spot read error during
empty machine operations.
1
2
3
4
5
264975
U0G00214
6.6.4 Service page description
Press the Service key in the Overview page to open the page where some maintenance functions can be
managed:
1 Manual lubrication: press this key to run an addition lubrication cycle.

2 Lubrication: this value identifies the number of machine cycles since the last lubrication cycle.
3 Lubrication: this value identifies the number of machine cycles left until the next lubrication cycle.
4 Suction adjustment on conveyor belts: edit the entered value to change suction on the packaging sheet
conveyor belts.
5 Press this button to access the parameters of the suction pump on the conveyor belts.
6 Counter-folder suction: key that enables/disables counter-folder suction according to whether or not glue
is used.
7 Press this button to access the parameters of the counter-folder suction pump.
8 Use the drop-down menu to select the position of the spot check photocell and splice check photocell.
9 Key to enable/disable the splice presence check.
10 This value sets the minimum speed above which the cooling air blows on the outfeed belts are activated.
1 2 3 4 5 6 7
8
9
265726
10
U0G00214
6.6.4.1 Parameters of the suction pump on the conveyor belts page description
1 Motor constant: this value refers to the ratio between the frequency and the axis current speed.
2 Reference speed: this value corresponds to the reference speed.
50 Direction: use this key to reverse the axis direction.
1
2
50
266068
6.6.4.2 Parameters of the counter-folder suction pump page description
1 Motor constant: this value refers to the ratio between the frequency and the axis current speed.
2 Reference speed: this value corresponds to the reference speed.
7-9 Reference speed 1-2: min. and max. machine speed range, within which the pump increases its speed
proportionally.
8 Reference freq. 1: pump minimum speed, with reference to parameter 7.
10 Reference freq. 2: pump maximum speed, with reference to parameter 9.
50 Direction: use this key to reverse the axis direction.
1
2
7
8
9
10
50
266069
U0G00214
6.6.5 Service Hot-melt page description
From the page Overview press button Service Hot-melt to access the page that allows to manage some
functions regarding the Hot-melt unit maintenance:
1 Key to turn on or off the Hotmelt unit.

2 Key for stand-by of the Hotmelt unit.
3 Key to by-pass possible warnings from the Hotmelt unit.
4 Icon warning that Hotmelt unit is ready (coloured icon).
5 Icon warning that glue level of the Hotmelt unit is low (coloured icon).
6 Icon warning that the Hotmelt unit is in alarm (coloured icon).
4
5
6
266070
1 2 3
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6.6.6 Ream detector (optional)
Press the Ream control key in the Overview page to open the page to manage and view defective reams
found by the ream control unit:
1 Maximum number of consecutively rejected ream settings.

2 Rejected ream counter.
3 Disable/Enable barcode scanner (green button)
4 Disable/Enable exchange signals between labeller and detector (green button).
A-B-C Disable/Enable lateral (A), front (B) and under surface (C) closing flap control (green button).
B 1
C 2
4
A
264973
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6.6.7 Clear Wrap page description (optional)
Press the Clear Wrap key in the Overview page to open the page to manage and view Clear Wrap unit
parameters and temperatures.
The page includes keys or values that can be used to:
A This key opens the sub-page where some Clear Wrap motor variables can be managed.
B This value sets minimum Clear Wrap operating speed.
C This key enables/disable all Clear Wrap resistances.
D This key loosens the lower Clear Wrap conveyor to facilitate replacement (key only enabled when the machine
is stopped).
E Press the resistance keys to open the single temperature regulators.
Each temperature adjustment key changes colour according to status:

Green: the set temperature was reached.
Yellow: the temperature is under that set (heating).
Red: thermoregulator alarm (thermocouple may be damaged).
Grey: disabled.
264969
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6.6.7.1 Temperature regulators sub-page description
Press any resistance key in the Clear Wrap page to open the selected resistance temperature manage-
ment page.
1 Resistance on selector.
2 Current temperature.
3 Set temperature.
4 Set temperature tolerance.
5 Range settings keys.
6 Working temperature settings keys.
Directly touch the set temperature or range field to open the number pad you can use to enter the required data.
2 1
264968
4 5 6 3
For numeric field
263306
U0G00214
6.6.7.2 Clear Wrap settings page description
Press the motor key in the Clear Wrap page to open the page where some Clear Wrap motor settings can
be edited and viewed:
A This value displays the Clear Wrap conveyor speed.

B This value displays motor inverter frequency.
1 This value, measured during inspection, sets the Clear Wrap conveyor speed according to motor inverter
output frequency.
2 This value sets the maximum inverter frequency.
50 This value sets motor direction.
A
B
1
2
50
264967
U0G00214
6.6.8 Roll holder page description
Press the Roll holder key in the Overview page to open the page to manage and view roll holder unit
parameters:
1 This value refers to the number of sheets cut, following the photocell reading.
2 This value refers to the unwounded length, following the photocell reading.
3 This value determines the number of sheets cut after which, following the photocell reading, the alarm appears
on the operator panel.
4 This value determines the number of sheets cut after which, following the photocell reading, the machine is
decelerated and the corresponding message appears on the operator panel.
5 This value determines the number of sheets cut after which, following the photocell reading, the synchronism
is disabled.
6 This value determines the number of sheets cut after which, following the photocell reading, the machine is
stopped.
7 This value identifies the deactivation time of the upper brake on the almost empty reel during the splice phase
at low and high speed.
8 This value identifies the actuation time of the upper brake on the almost empty reel during the splice phase.
9 This value identifies the cutter speed during the splice phase.
1
2
3
4
5
6
7
8
9
266071
U0G00214
6.7 Signal or alarm page description

All service signals or machine alarms can be managed from the Menu page.
The dropdown menu includes the keys needed to perform operations on service signals or alarms:
1 Online messages: a page opens listing current machine service signals and alarms.
2 Message log: a page opens listing all machine service signals and alarms in the buffer.
3 Print service: prints service signals and alarms if the machine is connected to a printer.
4 Delete messages: deletes all messages accumulated in the service signal and alarm buffer.
Alarm messages that stop machine operations are displayed in a popup window on the operator panel that displays
the alarm message and a key:
A HELP: displays online help for the message displayed in the window.
264972
264971
U0G00214
6.8 General settings page description

In the Overview page, press the General settings to open the page where general machine control
settings are listed. Passwords can also be created and managed to log onto the program and manage
operator panel system functions.
1 Date and time: lists the current date and time.

2 Acoustic signal: use to select one of the programmed acoustic signals.
3 Tactile calibration: use to adjust touch-screen sensitivity.
4 Clear screen: clear screen of any electrostatic discharges.
5 Windows: close the application and return to the operating system.
Use this page to create and manage program login passwords.

Enter the correct password and relevant level number to create new passwords or edit existent ones.
Note:
The password is set to 1234 by default.
1
2
264970
U0G00214
6.9 IO Test" sub-page description

In the Overview page, press the "IO TEST" button to open the page where PLC inputs and outputs can
be checked.
265089
U0G00214
6.10Bus-Profibus page description

From the page Overview press button Bus-Profibus to access the page that allows checking the status
of the Bus-Profibus nodes.
The grid is used to identify the node number, which can be coloured as follows:
Grey: the node does not exist

Green: the node does not work
Red: the node is in fault
266074
6.11 Syncro Overview page description

From the page Overview press button Syncro Overview to access the page that allows displaying the
synchronization data between the cutter and the wrapper.
The following values of the synchronization photocells (cutter/wrapper/gate) refer to:
1 Reference value
2 Average value of the last data detected
3 Value of the last reading
4 Values of the readings preceding the last reading.
1
2
3
266075
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6.12 Report sub-page description

In the Menu page press the Report key to open the machine production data dropdown menu.
1 Actual data: Actual production data.

2 Last data: Previous production data.
3 Time frame data: Annual production data.
4 Shift Setup: Production data for team shifts.
1
2
265728
266072 266073
265731 265732
7 - Operation and format change
U0G00214
Operation and format change
WRAPMASTER 7 - 1/62
U0G00214
7.1 Introduction
This chapter provides all the information needed to understand machine operations, instructions for format
changes and adjustments.
All information that concern the same machine unit or section are grouped and only marked by the icons
indicated the operation they run.
Warning!
Before performing any type of operation on the machine, the user must first read
and fully understand the entire Instruction Manual.
7.1.1 Size change-over
The machine is adjusted in all its parts by our engineers before it is delivered. However, the user should
know how to carry out these adjustments or replace the parts to optimize the quality of the product according
to its variables. In addition, after maintenance has been performed the machine can be brought back to
its initial state by simply following the directions given.
7 - 2/62 WRAPMASTER
U0G00214
7.2 General informations for the size change-over procedure

The operations of size group change are necessary to arrange the machine ream wrapping with different
dimensions in comparison with the previous one.
To obtain a very good packing it is suggested to observe the instructions reported on the following pages.
Some parts shall have to be replaced, other need a displacement in order to position themselves to the
correct required size group dimension.
The parts can be adjusted by using handwheels, dials and metric scales.
260527
hRH
Ra
W b
RL
260010
WRAPMASTER 7 - 3/62
U0G00214
7.2.1 Size change procedure
To change format/order, some operations must be run from the control panel and/or pushbutton panel and
format parts replaced or adjusted.
The following operations are required for format change:
1 Make sure no reams are still in the machine.
2 Replace the roll (see paragraph 7.4.1).
3 Position the new packing sheet using the buttons on pushbutton panel P12.
A Start the machine in manual mode.

B Press and hold down button 2 for a few seconds (the button light turns on and enables button 3 for paper
unwinding and cutting.
C Press and hold down button 3 until the old packaging sheet has fully exited, stopping the packaging
paper junction point immediately before the blade.
D Press button 2 again (the light with flash), the machine will unwind the packaging paper and start cutting
(the light turns off when the operation has completed).
7 - 4/62 WRAPMASTER
U0G00214
4 Replace and/or adjust format parts.
The following list of operations refers to a format change from small to large format (i.e.: from A4 to A3):
A Adjust the lateral Clear Wrap unit belts (optional unit) according to ream width (see paragraph 7.7.2.1).
B Adjust the upper Clear Wrap unit belt (optional unit) according to ream height (see paragraph 7.7.2.1).
C Adjust the glue guns according to flap length (see paragraph 7.6.9), which depends on ream height and
the type of package to be created (heat or underneath folds).
D Adjust and/or replace the rear head folders according to ream height (see paragraph 7.6.7.1).
E Adjust and/or replace the front fixed head folders according to ream height (see paragraph 7.6.7.1).
This operation must be performed at the same time as step F.
F Adjust and/or replace the helical folders according to ream height (see paragraph 7.6.8.1). This
operation must be performed at the same time as step E.
G Adjust sheet feed guides according to packaging sheet dimensions (see paragraph 7.4.8.1).
H Adjust front head folders according to ream width (see paragraph 7.6.7.2).
I Adjust side pressing units according to ream length (see paragraph 7.5.4.2).
L Adjust the outfeed conveyor according to ream length (see paragraph 7.6.11).
M Adjust the bottom stop and lower hopper according to ream width (see paragraph 7.5.4.1).
N Adjust the width of the aligner chains and teeth according to the ream length (see paragraph 7.5.3.1).
O Adjust the phasing stop unit belts according to ream length (see paragraph 7.5.2.1).
P Replace the ream support slats in the phasing unit stop area (see paragraph 7.5.2.2).
Q Replace squaring unit teeth (see paragraph 7.5.3.2).
R Replace lateral slats on the ream infeed conveyor in the squaring unit area according to ream length
(see paragraph 7.5.3.3).
S Replace lift plates (see paragraph 7.6.1.1).
T Replace the upper mobile hopper according to ream length, correctly positioning it according to ream
width (see paragraph 7.6.5.1).
U Replace the counter-lift according to ream width and length (see paragraph 7.6.3.1).
V Insert the ream support slats in the outfeed surface area (see paragraph 7.7.1.1).
5 Launch the new format using the operator panel (see paragraph 6).
To switch from large to small format, steps 1 through 5 remain the same while the sequence in point 4 changes. Thus
format part replacement and/or adjustments must be performed in reverse order.
Important:
This operation must be performed with the machine in manual mode.
The above format change operations refer to a complete format change meaning
all ream dimensions change (width - height - length).
One only one ream dimension changes, only some of the above operations are
required.
WRAPMASTER 7 - 5/62
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7.3 Machine layout

To better comprehend the layout and operating principle the machine is divided into 5 sections each of
which includes a number of mechanical units that interact to obtain the final product.
1 Wrapping sheet infeed assembly

1.1 Roll holder assembly
1.2 1st Unwinding roller assembly
1.3 De-curling unit
1.4 Dancing and idle rollers
1.5 Spot detection photocell assembly
1.6 2nd Unwinding roller assembly
1.7 Cutter assembly
1.8 Sheet conveyor belt assembly
1.9 Crosswise flap glueing assembly
1.1
1.2
1.3 1.6
1.5 1.4
1.8 1.7
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1.9
7 - 6/62 WRAPMASTER
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2 Ream infeed assembly

2.1 Ream infeed conveyor belts
2.2 Synchronising and stopping mechanism at entry end
2.3 Ream evener
2.4 Stopping unit and lateral pressing units
3 Ream wrapper
3.1 Elevator
3.2 Paper stop
3.3 Counter-elevator
3.4 Upper hoppers
3.6 Lower folder and counter-folder assembly
3.7 Mobile and fixed end folder assembly
3.8 Plough folders
3.9 End flap glue applicator
3.10 Ream accelerator
3.11 Pushers
2.2 2.1 3.7 3.10 3.2 3.3 3.4 3.11 3.9
3.6 2.4 3.1 3.8
2.2 2.1 3.8
263892
2.3 3.2 3.8

WRAPMASTER 7 - 7/62
U0G00214
4 Finished pack exit assembly

4.1 Exit table
4.2a Clear Wrap assembly
4.2b Lateral pressing unit (*1)
5 Common parts
5.1 Electrical cabinet
5.2 Pneumatic system
5.3 Hotmelt unit
(*1)
This part is not shown in the drawing.
4.1 4.2a
5.1
5.3
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5.2 4.1 4.2a
7 - 8/62 WRAPMASTER
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7.4 Wrapping sheet infeed

The units which make up this part of the machine are used to feed the sheet of wrapping material cut to
size. The material is either unwound from a roll. Glue is applied (if required for the reams being wrapped)
to the cut sheet in order to close the cross flap as it is carried forward. The sheet is then stopped near the
ream wrapping zone and is kept taut.
The unit works together with the ream wrapping section which receives the wrapping sheet required for the
subsequent operations.
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WRAPMASTER 7 - 9/62
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7.4.1 Easy Splice roll carriage unit
The wrapping material is provided in rolls of various diameters. The roll is installed on an expanding spindle
which rests on two arms A used to raise the roll to the work height.
A manual adjustment system is used to centre the roll in the correct position in relation to the elevator in
the tube forming zone (the operations to move the roll holders and centre the roll are described in Chapter 4 at
paragraph 4.6 Wrapping material).
Warning!
When replacing the roll, using lifting and handling vehicles suited to the load (roll)
to be lifted.
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7.4.1.1 Roll holder pressure regulation
The pressure at cylinders A, which dampen the lowering of the dancer, is set via pressure regulator B.
Check the value here at the corresponding pressure gauge.
Calibration pressure: 5 bar
The pressure for the unwinding of the roll is set via pressure regulators C and D. Check the value here on the
corresponding pressure gauges.
The regulators actuate the brake F and act dependent on the diameter of the unwinding roll.
Regulator C works with a roll diameter over 300 mm, while regulator D works with a roll diameter less than 300 mm.
The change between the two regulators is activated via light scanner E, which determines when the roll diameter
is less than 300 mm.
Calibration pressure for D >300: 2.5 bar
Calibration pressure for D <300: 1 bar
The pressure for unwinding the almost empty roll is set via control knob G. This setting influences brake L for the
unwinding of the almost empty roll.
251460 L
C G B D
F
E
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Warning!
Before attempting to carry out any operations on the machine, make certain the
main shutoff switch on the electrical control cabinet is turned to position 0 and
that the machine is disconnected from the pneumatic system.
7.4.1.2 Changing the roll
Change the roll before it is completely finished to avoid having to insert the sheet between the unwinding
unit belts a second time.
The operations for changing the roll are described in chapter 4 at paragraph 4.6 "Wrapping material".
7.4.1.3 Moving the new roll into the work position
As soon as the new roll has been installed it must be moved into the work position.
The operations for moving the roll holder with the new roll are described in chapter 4 at paragraph 4.6
"Wrapping material".
7.4.1.4 Paper splicing and centering
When the new roll reaches the work position it needs to be spliced to the paper already in use on the machine
and centered properly. The operations to splice and centre the wrapping material are described in chapter
4 at paragraph 4.6 "Wrapping material".
7.4.1.5 Paper splicing and centering
When the new roll reaches the work position it needs to be spliced to the paper already in use on the machine
and centered properly.
The operations to splice and centre the wrapping material are described in chapter 4 at paragraph 4.6
"Wrapping material".
7.4.1.6 Removing the finished roll
As soon as the machine has started to operate with the new roll the finished one can be removed.
The operations for removing the finished roll are described in chapter 4 at paragraph 4.6 "Wrapping
material".
U0G00214
7.4.2 1st Unwinding roller assembly
This assembly consists of a pair of infeed rolls 1 controlled by a servomotor, unwinds the wrapping paper
from the rolls and supports the paper unwinder of the 2nd assembly, which is located upstream of the cutting
group, by reducing the inertia produced by the rolls.
The pressure of the unwind rolls can be regulated by pressure regulators I and H and a correct and linear
unwinding of the wrapping paper can be guaranteed without slippage.
Danger!
Hand crushing hazard due to the unwinding rollers opening and closing during the
packaging paper insertion phase.
251378
251460
H I
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7.4.3 De-curling unit
A decurling unit L allows to tighten the wrapping material soon before its insertion between the unwinding
rolls. This device has the task to eliminate the paper bending due to the storing in reel, allowing a better
sheet moving.
Note:
This device does not provide to eliminate the cross curling
7.4.3.1 Adjusting the de-curling unit
De-curling unit L should be adjusted according to the type of wrapping material handled and roll diameter.
To adjust, proceed as follows:
loosen handle O;
manually adjust the device by working on lever N;
re-tighten handle O.
Danger!
Cutting hazard during the yield adjustment phase, wear protective gloves.
251689
N O L
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7.4.4 Dancing and idle rollers
The wrapping material coming from the reel passes through a set of idle rollers E keeping it aligned for a
correct unwinding. A couple of dandy rollers in addition to the idle rollers E, keeping the film tensioning
create a store necessary for the unwinding roller action.
The speed difference between the two unwinding roll couples is compensated by the return movement of the dandy
rollers that, according to the paper requirement approach the idle rollers changing the store dimension from time
to time.
The dandy rollers are controlled by a pneumatic cylinder G and controlled by a couple of sensors, relieving the
position of Dandy roller on and Dandy roller off.
Should the sensor relieving these positions, they will control the 1 unwinding group to modify its speed in order to
balance again the unwinding process.
Danger!
Hand crushing hazard during the wrapping paper feed phase.
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7.4.4.1 Setting the dancer cylinders
The pressure setting received by the cylinder responsible for actuating the dancer cylinders in order to
change the paper tension is performed using regulator M. The pressure here can be checked at the
corresponding pressure gauge.
Calibration pressure: 1-4 bar
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7.4.5 Spot detection photocell assembly
In order to time the printed sheet (using silk-screen printing), the film must be provided with a reference
mark (spot). The position of this mark is detected by photocell B which is connected to the machine's
logic control system and therefore adjusts unwinding according to the required measurement in
relation to the spot.
Use handwheel C to move the photocell crosswise in relation to the film, so that the reference mark can be read
perfectly.
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7.4.5.1 Centering the print on the roll by using references spots
When reference spots are employed to center the print on the wrapping paper, the dimensions of the spot
detection area must be observed, as indicated below:
DIAGRAM FOR MACHINE LEFT VERSION
WRAPPING MATERIAL
AREA WHERE
PAPER IS CUT
BLACK MARK PRINT
AREA WITH NO PRINTS

265718
DIAGRAM FOR MACHINE RIGHT VERSION
WRAPPING MATERIAL
AREA WHERE
PAPER IS CUT
265719
BLACK MARK PRINT
AREA WITH NO PRINTS
U0G00214
7.4.5.2 Splice reading photocell
The purpose of the Splice reading photocell A is to identify the point of Splice on the wrapping sheet, in order
to determine which ream will be packaged with the Splice sheet and to reject it by means of the ream
rejection unit positioned after the machine.
With handwheel B, the photocell can be moved crosswise with respect to the film, so as to allow a perfect
reading of the reference mark.
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7.4.6 2nd Unwinding roller assembly
The Infeed rolls assembly S consists of one pair of facing rolls that take the sheet and draw it in between
the Cross cutter assembly and the conveyor belt.
The top roll is rubber-coated in order to increase gripping ability and prevent slipping; it has two spirals that
tension the sheet.
The infeed rolls are driven by a three-phase servomotor controlled by the machine control system; the servomotor
unwinds the amount of material required for the size to be processed. The action of the servomotor is defined as
electrical axle; its characteristics are detailed in Chapter 5.
A system of levers controlled by two pneumatic cylinders keeps the two infeed rolls in contact with each other; by
means of button 4 on control console P12 the upper infeed roll is moved away from the lower infeed roll to release
the wrapping material.
The pressure of the unwind rolls can be regulated by pressure regulators N and P and an unwinding of the wrapping
paper can be guaranteed without slippage.
P12
251380
264166
251690 251462
U0G00214
7.4.7 Cutter assembly
It is composed by a blade F installed on a roll A, and a fix blade C allowing the sheet cutting. The knife
rotation is controlled by a servomotor changing the speed according to the cutting length function.
In case of ream lack, the knife stop rotating suspending the wrapping paper sheet feeding
The motor action is defined as electric axis and its features are explained in chap. 5.
Danger!
Cutting hazard during the wrapping paper feed phase and during operations in
manual or jog mode due to the accessible cutting blade. Wear protective gloves.
263899
A F C
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7.4.8 Sheet conveyor belt assembly
The transport belts C receive the sheet from the unwinding rolls A and take it into the machine. The group
is made of a couple of suction belts C with the task to take the cut sheet and bring it in the ream wrapping
section timed with the machine cycle.
The belts have holes and are connected to a suction pumpB creating a depression between belt and wrapping sheet
in order to allow the transport of the sheet without sliding.
The tubes supporting the holed belts are connected to the suction pump by means of two collectors.
251380
C A C
251381
U0G00214
The conveyor belts are operated by brushless motor which is controlled by the machines logic system. This ensures
accurate positioning according to the size of the sheet. The sheet is placed centrally along axis F.F.1. Motor is
referred to as electric drive and its operating principle is described in chapter 5.
Photocell G assures the sheet is present on the conveyor belts.
251835
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7.4.8.1 Adjusting the conveyor belts
The conveyor belts with suction B should be positioned so that they are both in contact with the cut sheet.
To position the belts, insert the wrench in the pins of the position indicators C and D. Set the numeric
indicator to the value obtained from formula XC (indicator C) and XD (indicator D). Position the conveyor
belts with suction as shown in the drawing below.
Make sure there are approximately 15 20 mm between the edge of the sheet and the belt wall.
251380 251693 251694
B B C D
XC = RH + 1/2RW - 35
XD = RH + 3/2RW - 35
XC XD
1520 1520
35 35
RH
262126
30
RW
B B
RH
262161
RW RL
262119
U0G00214
7.4.9 Crosswise flap glueing assembly
The hot-melt glue nozzle A is installed in a position suitable for applying glue on the edge of the sheet while
the latter passes through the machine.
These nozzles apply the required amount of glue on the part of the sheet that will be overlapped to form
the tube.
Danger!
Hot glue application devices require high temperatures for operations. Pay careful
attention to avoid hitting or touching these devices with unprotected body parts.
Wear protective gloves, goggles and masks for protection when working near glue
nozzles.
Important!
Glue does not need to be applied if polyethylene wrapping material is used. In fact,
the wrapping will be sealed by the molten polyethylene.
251463
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7.4.9.1 Glue spreading system (optional)
This system allows a line of glue to be applied on the packaging paper, flattened and dried by a jet of air
to prevent machine parts from being dirtied by glue. Applied glue is heated and adhered later.
The unit is made up of a glue gun A and air jet nozzle supported by a specific support rod system.
Danger!
nozzles.
7.4.9.2 Glue applicator position adjustments
The spread glue applicator can be positioned crosswise along rods C to adjust to packaging sheet width:
Loosens the fastening screw B.
Move the unit long the rods C and read the position on the linear scale D.
Tighten the fastening screw B.
B
C
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7.5 Ream infeed section

The units found in this section feed the reams into the machine properly aligned and timed with the
subsequent operations.
These units are placed before the ream wrapping station. The wrapping operations are performed only after
the reams have been fed into the machine.
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7.5.1 Ream infeed conveyor belts
The ream is fed to the machine by infeed assembly A which is made up of a set of belts, operated by
servomotors C.
Toothed belt B ensures that ream feed is timed with the jogger which evens the ream.
Warning!
Keep hands away from belts during normal operations to avoid dragging hazards.
251913
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7.5.2 Stopping mechanism-and-synchroniser
If the incoming reams are not timed with machine operation, they must be synchronised.
Stopping mechanism-and-synchroniser B stops ream infeed and then starts it again once the system has
been properly timed.
Photocells C detect the ream positioned on conveyor belts A and send a signal to the machines logic system to stop
phaser D.
The encoder located on the main motor controls the machine timing and the data are processed by the logic system.
According to an appropriate programming, the machine logic system allows a timed release of the ream.
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251914
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7.5.2.1 Adjusting the side bands
Position side bands A according to the length of the ream RL and check on the counter is at the correct
position for the product size to be handled.
In order to check the position measure the distance between the two bands and increase the measurement
by approx. 2 - 5 mm beyond the ream.
Release handles C.
Turn crank B and position the conveyor belts at the required distance by checking on the counter.
Lock handles C again.
The measurement indicated on the counter corresponds to the size of the ream. In reality the actual distance
between the guides is increased by the clearance required for the reams to pass through without getting stuck or
slowing down due to obstructions or friction in the slide zone.
C B
251913
hRH
Ra
W Rb
L
260010
U0G00214
7.5.2.2 Support slat replacement on phasing stop unit
Lateral ream support slats A must be replaced according to ream length RL.
Unscrew screws B fastening slat A.
Replace the slats.
Tighten the screws to secure the slats.
251915
A B
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7.5.3 Ream squaring unit
The ream, which is timed with the machine, is carried by the feeding belts up to thesquaring unit which is made
up of two chain sprockets which, together with teeth A, move the ream forwards.
The teeth move more quickly than the belts in order to push the ream up to the stop plate on elevator B. The
squaring unit is driven by two servomotors controlled by the machine logic able to position the ream on the elevators,
according to the worked size. The motor action is defined as electric axis and its features are explained in chap. 5.
7.5.3.1 Adjusting the width of the eveners
The two squaring units, on the right and left, can be moved together or apart according to the length of the
ream RL. This can be done by inserting the crank in pin C and moving counter E to the measurement
required for the product size in question.
251873
C E A
hRH
Ra
W Rb
L
260010
U0G00214
7.5.3.2 Equipping the squaring unit with two or three teeth (only for machine with A3-format)
To equip the squaring unit with two or three teeth, identify the fixed tooth, marked by paint, that should not
be replaced.
Once the fixed tooth has been identified, follow the specific procedure below:
Two-teeth (for A3- Format and similar) or three-teeth (for A4-formats or similar) installation
Remove teeth F to be replaced, by unscrewing screws G and remove the internal fastening slat.
Install teeth F: for the two-teeth installation, teeth will have an opposite position with respect to the fixed tooth
on belt H, for the three-teeth installation, the teeth will be installed in the other two assembling positions, by
screwing screws G on the belt by means of the internal fastening slat.
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7.5.3.3 Support slat replacement on squaring unit
Lateral ream support slats L must be replaced according to ream length RL.
Loosening slat L fastening screws.
Replace the slats.
Tighten the screws to secure the slats.
251873
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7.5.4 Stopping units and lateral pressing units
The group is composed of a front stopping system and two lateral jogging plates.
The stopping unit is composed by a fix plate A, determining the final position of the ream on elevators and
two movable plates with the function of ream deceleration.
The movable plates move according to the squaring group movement. Behind the movable plates a pneumatic
cylinder C is installed which function is to compensate possible differences in speed between the squaring unit and
the stopping movable plates. The movable plates take the motion from a servomotor D controlled by the machine
logic able to perform the ream positioning on the elevators according to the worked size.
The motor drives also the jogging plates B to which it is connected, making the ream lateral jogging.
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7.5.4.1 Ream stop and adjustable lower hopper adjustment
Position the ream stopping plate A according to the ream width RW:
Release terminals B loosening screws C.
Adjust the ream stop position using the key clamp D and checking the quota on the linear scale E.
Lock the terminals B, tightening the screws C, being sure the terminals are well-fit to the plate F, to
guarantee the ream stop position is maintained during machine operations.
Adjusting the ream stop plate also adjust the adjustable lower hopper M, sustained by the same support.
F
D
B
M
251840
E
7.5.4.2 Lateral pressing unit adjustment
Adjust the lateral pressing units G accordino to the ream length RL:
Release the screws H.
Move the pressing units until they reach the required position, checking the quota on the linear scale I.
Fix again the screws H.
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7.6 Ream wrapping

This section is used to wrap the ream and close the pack in time with subsequent operations. The ream
and sheet of wrapping material are received from the infeed systems. All sections work together in a
synchronised manner.
The wrapping station is placed before the wrapped ream discharge section. Once the reams have been closed, they
are discharged.
263902
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7.6.1 Elevator and wrap tube formation
The squared ream against the stopping plate A is taken by the elevator made by three plates changing
according to the size making the ream the vertical movement.
The elevators take the motion from a servomotor controlled by the machine logic able to make the correct
timing according to the worked size.
During the lifting the wrapping sheet, supported by the transport belts E is bending around the ream taking the
reversed U shape, guided by the hoppers F and G. During the lifting phase the ream goes In touch with the
counterelevator H avoiding the elevator stop and the ream misplacing.
G
F
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F G E
263903
E
A
U0G00214
External plates C - E move down so that the lower folder and lower counter-folder can take their place
holding up the ream and folding the wrapping paper under it in the mean time. The middle plate D moves
down to complete this operation.
In addition, the elevator is equipped with an air blower that creates a cushion between the table and ream
to ease movement.
The air blower can be adjusted according to the characteristics of the reams being handled. Use pressure
regulator to make any required adjustments. The blower is activated when solenoid valve found in the
battery valve pack opens.
Calibration pressure: 2.5 bar
7.6.1.1 Replacing the elevator plates
The plate is made up of three plates C-D-E which have to be changed according to the size of the reams
being handled.
Loosen the screws F and replace the plates with the ones required for the reams being handled.
E D C
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7.6.2 Wrapping paper stop
The wrapping paper stopper has the function to lean on the wrapping sheet as it goes in touch with the ream,
to avoid that this its misplacing may jeopardize the well done packing. The wrapping paper stopper is a plug
A connected to a pneumatic cylinder B and the whole is installed on the counter elevator support C.
In ream starting phase due to the intervention of the outfeed section fingers, one solenoid valve controls the plug
A detaching avoiding the ream misplacing.
A pressure regulator adjusts the working pressure.
B A C
263903
U0G00214
7.6.3 Counter-elevator
The counter elevator A has the function to carry the ream during the elevator B lifting to avoid its
misplacing during the lifting jeopardizing the well done packing.
The counter elevator is a plate A to be replaced according to the size, connected to the support E,
vertically moving by means of guide C, a spring system grant the right pressure e on the ream by lifting,
compensating possible speed differences between elevator and counter elevator.
The counter elevator takes the motion from a servomotor controlled by the machine logic able to make the
correct timing according to the worked size.
A E
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263903
U0G00214
7.6.3.1 Counter-lift equipment
When the RW and/or RL ream quota changes, counter-lift A must be replaced.

Loosen the screws in holes D.
Replace the counter-lift A.
Tighten the screws.
A D
251842
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7.6.4 Lower hoppers
The lower hopper includes a fixed part A and an adjustable part B so that it can adapt itself to the
dimensions of the reams being handled. Its function is to act as a contrast when the ream and sheet move
up so that the sheet can be given an upside down U shape to form the wrapping tube.
The adjustable lower hopper is always aligned with ream stop C, since installed on the same support. Therefore,
the hopper position is adjusted when the ream stop is adjusted according to ream width RW.
Both the adjustable B and fixed A parts of the lower hopper are equipped with a series of holes through which the
suction system hold the wrapping sheet in a certain phase of the wrapping cycle. The level of depression applicable
on the hoppers can be adjusted using taps D and E.
B C A
251873 251841
D E
hRH
Ra
W Rb
L
260010
U0G00214
7.6.5 Upper hoppers
The upper hopper is composed by a fix part A and a movable part B.

Its function is to contain the ream both during the elevator lifting and during the insertion of the lower folders
coinciding with the elevator lowering.
The back part B is movable, to allow the ream passage when it is pushed by the outfeed dragging fingers.
The front part A is aligned to the lower fix hopper D, while the back part B, when in low position, must be aligned
to the adjustable lower hopper F.
The movable hopper takes the motion from a servomotor controlled by the machine logic able to cary out the correct
timing according to the worked size.
7.6.5.1 Setting up the top hoppers (mobile and fixed)
Change the size-related plate of fixed hopper A if necessary.

Remove screws G.
Replace plate A.
Put back screws G.
Mobile hopper B must be replaced when ream quota RL changes.

Take away the screws H.
Replace hopper B, positioning it in the corresponding holes according to the ream RW quota.
Reinstall the screws H.
A
G
hRH
263903
Ra
W Rb
L
260010
D F
H
251843
U0G00214
7.6.6 Lower counter-folder and folder
The lower folder A and counter-folder B fold the packaging sheet and close the tube around the ream. This
occurs during lift descent.
The lower folder and counter-folder are driven by 2 independent servo motors controlled by machine logic,
able to correctly complete phases according to the work format.
Motor power is defined as electric axis and its specifications are described in chapter 5.
A B
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7.6.6.1 Adjusting the suction for the lower counter-folder
The counter-folder is provided with a series of holes connected to suction device, which are used to keep
the sheet in contact with the folder while the fold is made.
The vacuum created by device can be adjusted by using cocks M which allows air to be taken in from
outside the system, this reducing the intensity of the vacuum in the counter-folder.
The air taken in by the counter-folder passes through filters N.
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U0G00214
7.6.7 Folding devices for top fold
The top flaps are folded before conveying the product to the Ream outfeed assembly.
Movable folding devices A and B extend before the product can be pushed further by the transport fingers
and they fold the front and rear flaps.
The movable folding devices for the top fold are moved by a servomotor that is controlled by the machine control
system; this guarantees that the phases are correctly carried out based on the working size.
The action of the servomotor is defined as electrical axle; its characteristics are detailed in Chapter 5.
7.6.7.1 Head folder height adjustment
The height of the folding devices for the top fold can be adapted to the RH dimension of the ream.
The upper folding devices A and B are fastened to their supports by means of screw C.
Move these supports in the slots to achieve various dimensions, checking the position on the linear scale.
The sizes that can be processed are divided into two size ranges: with the first folding device reams that
are 25-40 mm in height can be processed; with the second, reams that are 40-89 mm.
7.6.7.2 Front head folder adjustment
Position the front head folders B according to ream width RW.

Loosen screws D.
Adjust mobile head folder support E, checking the position on the linear scale.
Tighten screws D.
D B A C
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h
RH
Ra
W Rb
L
260010
U0G00214
7.6.8 Plough folders
The top and bottom flaps are folded as the product moves towards the exit assembly.
The product is pushed forward by the pusher teeth and the bottom flaps are folded by folders A. Glue is
then applied to these flaps by the applicators positioned between the first and second plough.
The product continues to move along until reaching second folders B which fold the top flaps.
B
A
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U0G00214
7.6.8.1 Setting the plough folder
Upper plough folders A-B should be adjusted according to the height RH of the ream.
Turn hand-wheel E until pointer C is positioned at the required measurement shown on graduated
scale D.
As for the mobile head folders the dimensions of the fixed folders are designed to fit all the different product
sizes which can be handled.
There are two set-ups: the first set-up is used to handle reams which are 25-40 mm high, the second one
reams which are 40-89 mm hig.
251844
hRH
Ra
W Rb
L
260010
U0G00214
7.6.9 End-flap glue applicators
Glue is applied to the end-flaps by two adjustable spray-guns A which are located near the plough folders.
As the ream passes by with the end-flaps and the bottom flaps already folded, photocellB checks the length
of the flap where glue is to be applied. The photocell then sends a signal to operate the spray-gun for
applying the glue on the upper end-flap.
Danger!
nozzles.
Adjust the position of spray-gun A to apply the glue on the top flap of the ream.
Place the wrench supplied on the hexagonal pin C and then turn it according to the height of flap P until
the pointer is positioned on the measurement shown on plate D.
Make the same adjustment for the spray-gun on the other side of the machine.
B
C
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7.6.10 Ream accelerator
The group is composed of two pushers starting the ream movement towards the outfeed, before the
intervention of the outfeed dragging fingers, reducing the impact effect.
The ream accelerator A takes the motion by a servomotor controlled by the machine logic able to make
the correct timing according to the worked size.
7.6.11 Pushers
The formed tube is moved by a set of rods connected to a chain named conveyor fingers B.
This group will withdraw the product from the elevator and bring it up to the outlet.
The outfeed drawing unit takes the motion from a servomotor controlled by the machine logic able to make
correct timing, according to the worked size.
The unit is adjusted according to ream length RL using the key clamp C that adjusts all movements at the same
time thus adjust according to RL (head and helical folders, pressure belts) and reading the quota on the specific
numerator D.
B A
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7.7 Finished pack exit assembly

The machine units included in this section are used to complete ream wrapping and discharge the pack
from the machine. The ream is received from the wrapping assembly which works in synchrony with this
section.
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7.7.1 Exit table
The reams advanced by the conveyor pushers are placed on the exit table A. The latter may have different
configurations and functions depending on the machine layout.
In any case, it is basically designed to hold up the finished products while they are being transferred. The
exit table A is equipped with an air blower that creates a cushion between the surfaces and reams, so that they are
able to flow freely.
The air blower is activated when lever E, located before the pneumatic unit, is opened.
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7.7.1.1 Inserting ream support slats on the outfeed surface
Lateral ream support slats A must be inserted according to ream length RL for large formats (example
A3).
Insert slats A securing them with screws B.
B B
251851
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7.7.2 Clear Wrap unit
This optional unit is placed after the discharge unit and can be used to:
seal polypropylene;
heat up the glue applied on the sheets of paper beforehand to close the wrapping;
heat up the glue applied by theby the spreading glue unit.
The unit consists of:

a heated lower conveyor belt A;
an upper belt C that pushes the ream down on the lower conveyor belt A;
two heated side belts B;
The heated belts are Teflon coated to stand up to the heat produced by the elements on plates D. These heating
elements can be set to the temperature required for the operation to be performed: to seal polypropylene or bring
the pre-applied glue back to the correct temperature to reacquire its adhesive properties.
The upper belt C is not equipped with heated plates as it simply pushes the reams down on the lower conveyor belt.
As a result, the overlapped flap is sealed cross-wise. The side belts seal the front end-flaps.
The group is complete with a set of air blowing in order to accelerate the cooling of the belts and of the plates, in
case of replacements.
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7.7.2.1 Belts adjustement
The unit can be adjusted according to the dimensions of the reams being handled, more precisely:
Use the wrench provided on pin E to adjust the upper belt position:
- place a ream that is the required size between belts B;
- turn the handwheel E to bring the upper belt C into contact with the ream;
- press the ream 2 3 mm further down, depending on the wrapping material being used (paper or
polypropylene of various thicknesses);
Place the wrench provided on pin G to adjust the side belts:
- the belts have to be set to the RL measurement of the ream; refer to the numeric indicator H.
The group speed is managed directly by the machine.
251400
hRH
263986
Ra
W Rb
L
260010
U0G00214
7.7.3 Compression belts (optional)
The compression belts A exert pressure on the sides of the ream so that the flaps adhere perfectly to the
glue. The discharge conveyor pushers push the reams through the belts A. The belts driven by the
discharge drive system, receive the ream and carry it out of the wrapping machine.
The compression belts are used when hotmelt glue is used to wrap the reams.
On the compression belts is installed a cooling system, whose purpose is to cool the belts in order to ensure the
correct cooling of the hot-melt glue on the reams, avoiding any re-opening of reams.
The cooling system is made up of cooling guns B and nozzles C.
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7.8 Common parts

The units dealt with in this section interact with all the other parts previously described.
263905
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7.8.1 Electrical cabinet and electrical system components
The electrical cabinet houses all the electric and electronic equipment not installed on-board the machine,
but which are required to control and operate the mechanical units.
The electrical control cabinet comes with a main shutoff switch Q1 which turns on or cuts off power to the
electric system, depending on the position the operator turns the switch to.
Q1
263984
The wiring diagram is provided along with this documentation to aid in better understanding the functions of the
components.
U0G00214
7.8.2 Pneumatic system
The pneumatic system contains a number of air-operated parts fed from the factory air mains. Use inlet
A to connect the machine to the air mains.
The air is filtered by a filtering element B. The latter is able to hold back any humidity present capturing it
in a bowl from where it flows back outside.
The proportional solenoid valve C gradually increases the pressure in the pneumatic system, reaching the required
value. This system avoids sudden pressure changes which may damage the pneumatic components.
The air-operated parts are installed on the machine near the mechanical units which they interact with and drive.
A
C
251845
A pneumatic diagram is supplied with this documentation to help the user understand how the various parts work.
U0G00214
7.8.3 Hotmelt glue unit
Various types of hotmelt glue units may be installed in the machine, depending on the customers requests
made at the time of purchase.
For more detailed information and instructions on how to adjust and operate the unit, refer to the manual
supplied with the unit itself.
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8 - Maintenance
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Maintenance
WRAPMASTER 8 - 1/34
8 - Maintenance
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8.1 Overview
This chapter, intended for the customers maintenance technicians, describes the maintenance operations
to be performed on the machine.
The purpose of the maintenance operations described below is to keep the machine efficient and in good working
order and prevent any faults or breakdowns.
Maintenance includes the following activities:
Preventive maintenance
The group of interventions conducted at set intervals or in accordance with set criteria and aimed to reduce the
possibility of faults or deteriorated machine operations; preventive maintenance includes inspection, control,
adjustment, cleaning and lubrication activities.
Special maintenance
Special maintenance is the group of activities conducted at set intervals or following faults or breakdowns to
restore machine operations. Special maintenance includes overhaul, repairs, the restoration of nominal
operating conditions or replacement of faulty, defective or worn units.
Note:
Preventive and special maintenance activities can be conducted by the user
customer of bielomatik s.r.l. technicians according to the instructions listed in the
sheets.
Due to their complexity, some particular special maintenance operations were
intentionally omitted from the manual and can only be conducted by bielomatik
s.r.l. technicians who have the technical know-how, documentation and tools
required to conduct these activities.
Machine Directive 2006/42/EC defines the operator as the Person qualified to install, run, adjust, clean and
maintain the machine (Appendix I, point 1.1.1).
Note:
Repair frequency must be:
A) According to wear: Repairs are conducted after analysing the results of a
preliminary revision in order to avoid damaging the unit in question.
B) Following a fault or deterioration: A revision, during which the fault or deterio-
ration is identified, precedes repairs.
Repairs must be conducted after analysing the revision results.
Please remember that correct maintenance can reduce downtime after faults to a minimum.
Prompt repairs avoid additional deterioration.
Use original spare parts and accurately repair faulty parts to restore them to nominal status.
Use original spare parts and accurately perform the indicated maintenance activities.
Note:
The manufacturer cannot be held liable for faults or malfunctions during the
machine warranty period in the event of poor maintenance, lack or lubrication,
machine parts replaced with non original or unauthorised parts and machine use
other than that indicated in this instruction manual.
8 - 2/34 WRAPMASTER
8 - Maintenance
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8.2 Maintenance personnel

Specifically, maintenance personnel must:
Know the directives in force in the users country concerning workmans safety during machine work,
and be able to apply them.
Have fully read and understood this instruction manual.
Know how to correctly use and consult the design technical documentation, including the machine diagrams,
mechanical units with part lists, mechanical drawings and wiring and fluidic diagrams.
Perform the authorised operations (Mechanical, Electrical, Fluidic).
Be able to use the most appropriate and adequate troubleshooting instruments and know which equipment is
best suited for the maintenance operations.
Warning!
Only trained and authorised personnel can conduct maintenance, adjustment and
tuning operations.
Warning!
The need to place the machine in operating conditions with the guards bypassed
requires adequate skills and knowledge and the maintenance technicians utmost
care.
Warning!
If unit, equipment or system malfunctions or defects are found during the normal
operating cycle, stop the machine and immediately inform the customer service
centre.
WRAPMASTER 8 - 3/34
8 - Maintenance
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8.2.1 Communications with customer service
The machine type, machine number and year of construction are the means of identifying the machine and
must be quoted in all dealings with the customer service centre.
Our customer service centre locations:
Leuze Group
Neuffen Bologna
Bielomatik Leuze GmbH + Co. KG
Bielomatik S.r.l.
Bielomatik Jagenberg GmbH + Co. KG
Via Marzabotto, 280
Daimlerstrasse 6-10
I - 40050 Funo di Argelato (Bo)
DE-72639 Neuffen Germany
Tel. +390518650711
Phone:+49(0) 7025/12-0
Fax +39051866021
Fax:+49(0) 7025/12-200
bielomatik@bielomatik.it
info@bielomatik.de
www.bielomatik.com
www.bielomatik.com
8 - 4/34 WRAPMASTER
8 - Maintenance
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8.3 General safety precautions

Machine maintenance personnel must be well-trained an have in-depth knowledge of workmans safety
regulations. Unauthorised personnel must remain outside the work area during operations. The safety
precautions described in this paragraph must always be strictly observed during machine maintenance to
avoid personal injury and machine damages.
8.3.1 Hazard notes
Following are a series of notes on hazards to be taken into account during maintenance.
They indicate the risk of personal injury, even fatal.
Hazard!
Protections and safety devices must be turned off and guards opened to perform
certain maintenance operations.
In this case, operating personnel are in hazardous conditions and, therefore, the
following rules must be strictly observed: Personnel assigned to perform mainte-
nance must be authorised and specifically trained on the safety and operating
procedures to be conducted, on the hazardous situations that may occur and on
the correct methods to avoid them.
During these operations, personnel must work with the utmost care and extreme
caution.
Place specific warning signs such as: MAINTENANCE IN PROGRESS DO NOT TURN ON, WORK IN
PROGRESS DO NOT RUN or DO NOT TURN ON (see illustration) near the main switch and machine access
areas.
Examples of signs indicating maintenance operations
Hazard!
Before starting maintenance operations, place signs indicating machine mainte-
nance status.
WRAPMASTER 8 - 5/34
8 - Maintenance
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Touching live wires may be fatal. Always work with the utmost caution and according to applicable workmans
safety regulations.
When the machine is running, parts are in motion that could cause serious personal injury. For this reason,
maintenance and relevant checks, part dismantling and replacement on the machine or control unit must
be conducted with the system off. Therefore, main switches must be in the OFF position (OPEN) and
locked with a safety pad lock that prevents them from being switched ON. The shutter must be on.
Even if the control unit is not powered (main switch off), interconnected voltage may still be present.
In case of maintenance operations and/or access to internal parts of the machine, following a previous
disconnection of the electric and pneumatic power, motors/ gearmotors, glue applicator and relative pipings and
spray guns might accumulate residual thermal energy.
Warning!
Avoid contact with the hot metal surfaces of the guns, of the pipes, of some
components of the melting unit and of the motors/gearmotors.
If contact is unavoidable, wear gloves, protective equipment for high temperature
and face shield when working near the heated equipment.
Unprotected contact with hot metal surfaces can cause injuries.
Before performing maintenance, make sure the pneumatic system is not pressurised. Before beginning
work, maintenance personnel must make sure that the pneumatic supply is turned off and that pressurised
systems are drained. For this reason, before working on pressurised parts, reduce pressure in the system
concerned by work to room pressure.
Hazard!
Before starting maintenance or removing jammed machine parts or units, cut-off
and pad lock all energy sources and drain fluidic systems.
Keep away from drain holes and taps when releasing system pressure.
Keep away from any part that could be moved by pneumatic pressure when the system is not fully drained.
Make sure all fittings and joints are correctly tightened before pressurising systems after repairs.
Make sure units with vertical movements are lowered to idle positions or, in alternative, supported with adequate
lifting system to prevent accidental movements or falls, especially when actuators or drives require replacement.
Before performing maintenance on moving parts, make sure shutters are correctly inserted.
Hazard!
Before starting maintenance, place vertical units with moving or fall risks in safety
conditions.
Never exclude safety and protection devices installed on the machine. If this is necessary, signal this conditions
with suitable warning signs and work with the utmost caution. Restore all safety and protection devices as soon
as possible.
Failure to ground equipment may cause serious personal injury. Always make sure grounding
connections are complete and compliant with regulations.
Before starting the machine after maintenance, make sure that maintenance personnel are at safety distance
and that tools or materials were moved away from devices.
8 - 6/34 WRAPMASTER
8 - Maintenance
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Equipment must always be installed in accordance with workmans safety regulations. All parts in motion and
transmission devices must be protected against accidental contacts. Always make sure that all protections are
installed, correctly positioned and closed before starting equipment.
Prolonged overloads or faults may cause electrical equipment to overheat generating toxic fumes. Immediately
cut-off the power supply and stay clear of equipment until these fumes are removed by adequate ventilation.
Avoid inhaling fumes that remained inside equipment during repairs.
Do not spray water to extinguish fires, especially on electrical equipment: immediately cut-off all power supplies
and use CO2 extinguishers. Warn the factor fire fighting service or the fire department.
Wear appropriate personal protection devices during maintenance (safety shoes, goggles and gloves, etc.)
according to the work to be performed. When working on suspended parts, use fall-safe devices.
Wearing clothing or personal items such as necklaces, bracelets, etc. is strictly prohibited since they can catch
in tools and equipment and react to conductors.
Hazard!
Personnel must wear all the personal safety devices required to avoid accidents.
Make sure electrical equipment is in good working order and equipped with insulated grips. Make sure that test
equipment wiring and conductor insulation is not minimally broken or damaged.
Any temporary access platforms or supporting equipment for the maintenance of parts (such as motors and
other machine parts), that can not be easily reached by the user, that are not installed on the machine, must be
provided by the user, who has to supply any equipment (ladders, shims, belts, ropes, etc.) necessary to carry
out such maintenance operations.
Tighten all screws and nuts with correct torque. Incorrect torque could cause malfunctions or hazardous
situations.
Where possible, troubleshooting must be conducted outside protected areas. If necessary when troubleshoot-
ing, perform work with the control unit and machine powered. All the precautions required by safety regulations
when working on live parts and powered drive axles must be taken.
All excluded safety devices (panels, guards, safety limit switches, interlocks, etc.) must be restored when
maintenance and troubleshooting is completed.
Maintenance, repairs and troubleshooting must be concluded by testing correct machine and safety device
operations.
Hazard!
Before restarting the machine, pay the utmost attention and make sure no one is
still working in the machine work area marked by hazard signs.
Hazard!
Before restarting the machine, re-check the entire system according to the start-
up procedures. After maintenance, run a few test cycles in manual mode to check
for correct movements.
WRAPMASTER 8 - 7/34
8 - Maintenance
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8.3.2 Warning notes
Following are a series of notes on general warnings to be taken into account during maintenance.
They represent a warning of possible deterioration or damages to the machine, equipment or other
personal user item.
Maximum machine reliability and minimum maintenance costs are the result of a planned and meticulously
performed maintenance and inspection program during the entire machine working life. Strictly observe the set
maintenance intervals.
Make sure machine parts are correctly lubricated. Insufficient or defective lubrication can cause damages and
malfunctions.
Before beginning checks and maintenance, remove dust, processing residue and dirt in general from the
machine with a vacuum and clean with appropriate liquid detergents.
Always use perfectly dry air during cleaning at pressures not superior to 0.2 MPa (2 bar). The use of a vacuum
is preferable and recommended.
When dismantling parts, mark single parts with ID plates to ensure the subsequent correct assembly. After
maintenance that requires wiring and/or fixed or mobile parts to be removed, check number/plate consistency
with the fixed or mobile part.
When using a mega ohm meter to check electrical device insulation, make sure all electronic control devices
are disconnected to avoid damaging components.
Always use tools in good working order and specifically designed for the work to be completed. The use of
unsuitable or inefficient tools may cause serious damages.
Conduct repairs in clean rooms and, where possible, free of dust. Protect all connection lights with plastic caps
and accurately cover all dismantled part work surfaces until they are assembled on the machine.
Replace machine parts with original spare parts.
8 - 8/34 WRAPMASTER
8 - Maintenance
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8.4 Maintenance advice

8.4.1 Operations associated with prolonged downtime
If machine operations need to be stopped for a prolonged period of time, the maintenance technician must
prepare the machine according to the following procedure:
Clean the machine removing processing material residue or dirt.
Fully clean the machine, especially sliding guides, fluidic cylinder rods and sliding parts with rags and
specific products.
Spread specific oil on processed surfaces, sliding guides, fluidic cylinder rods and parts in motion.
Clean and dry the remaining painted machine parts.
Periodically run the machine for short periods of time and, before turning it on, make sure there are no traces
of rust on sliding guides and fluidic cylinder rods.
The machine must be stored indoors. In the event of prolonged storage, cover all movement parts to protect them
from dust.
WRAPMASTER 8 - 9/34
8 - Maintenance
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8.4.2 Screw torque
During maintenance, different types and differently sized steel screws may require tightening with a
dynamometric wrench.
The following table lists the maximum torque to be used according to material resistance and screw
dimensions.
TORQUE FOR STEEL SCREWS WITH LARGE ISO THREAD
',$0(752
DIAMETER 020(1720$;0DNJP
MAX TORQUE Ma (kgm)
120,1$/(
NOMINAL
9,7(
M 4 x 0.7 0.17 0.31 0.43 0.52
M 5 x 0.8 0.33 0.60 0.84 1.01
M6x1 0.58 1.03 1.46 1.75
M7x1 0.94 1.69 2.36 2.83
M8 x 1.25 1.39 2.48 3.49 4.19
M 9 x 1.25 2.05 2.67 5.18 6.17
M10 x 1.5 2.83 4.97 7.0 8.37
M 12 x 1.75 4.74 8.46 11.9 14.30
M 14 x 2 7.54 13.46 18.92 22.70
M 16 x 2 11.50 20.40 28.80 34.60
M 18 x 2.5 16.0 28.40 40.0 48.0
M 20 x 2.5 22.2 39.6 55.60 66.60
M 22 x 2.5 30.0 53 74.5 90
M 24 x 3 39 70 98 117
M 27 x 3 56 101 142 170
M 30 x 3 77 138 193 232
TORQUE FOR STEEL SCREWS WITH FINE ISO THREAD
',$0(752
DIAMETER 020(1720$;0DNJP
MAX TORQUE Ma (kgm)
120,1$/(
NOMINAL
9,7(
M8x1 1.48 2.60 3.70 4.40
M 10 x 1.25 2.90 5.20 7.30 8.70
M 12 x 1.25 5.30 9.10 12.80 15.40
M 12 x 1.5 5 8.9 12.50 15
M 14 x 1.5 8 14.30 20 24
M 16 x 1.5 12 21.50 30 36
M 18 x 1.5 17.40 31 43 52
M 20 x 1.5 24.40 43 61 73
M 22 x 1.5 32 57.5 80.5 97
M 24 x 2 41 76.5 103 124
M 27 x 2 60 107 150 180
M 30 X 2 83 147 208 250
8 - Maintenance
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8.5 Maintenance plan description

The following maintenance plan is made up of a collection of all maintenance operating descriptions
organised as follows:
CLEANING OPERATIONS indicated in paragraph 8.6 consisting of a series of advice and general instructions
to keep the area concerned by machine activities clean and orderly.
LUBRICATION PLAN indicated in paragraph 8.7 consists of a series of advice and general instructions to keep
mobile machine element efficient.
MAINTENANCE PLAN indicated in paragraph 8.8 consists of a series of preventive maintenance and
dismantling instructions sheets that list the maintenance operations to be performed on the various machine
units and systems.
Note:
For maintenance operations to be conducted on retail machine parts, see the
relevant enclosed instruction manuals.
Note:
For cleaning operations on the sheet feeder unit and on the glue application
unit, see the relevant instruction manual provided with the machine and part of this
documentation.
SPARE PARTS CATALOGUE

The maintenance plan is completed by the SPARE PARTS CATALOGUE, enclosed hereto. We recommend
the Customer always purchase original spare parts. Always specify the model and serial number of the machine
to which the spare part refers and the complete spare part references indicated in the SPARE PARTS
CATALOGUE when ordering.
8 - Maintenance
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8.6 Cleaning operations

The machine must be cleaned at regular intervals following the frequency indicated in the maintenance
plan. Following are a series of notes and general warnings to be taken into account during cleaning.
If caked on dirt that is hard to remove with dry cloths or brushes is found when cleaning, use a suitable
cleaning liquid that does not have harmful effects on gaskets, rubber parts and paint, non-toxic, non-
flammable and whose use is admitted.
Do not spray cleaning liquid using pressurised tanks since its volatility does not allow it to clean and can generate
vapours in the work area. Instead, use soft damp cloths for the best results and/or manual domestic type spray
bottles.
Avoid prolonged contact with cleaning liquids and avoid inhaling their vapours. Avoid use near free flames or
heat sources. Ensure adequate ventilation in the room where used.
When cleaning, in addition to the usual caution the operator must use suitable personal protection devices such
as work overalls, goggles, gloves and shoes according to the work to be performed.
The machine and system must be cleaned with care, especially unpainted guides and sliding parts. When
finished cleaning unpainted parts, spread a thin layer of rustproof oil on them.
Note:
The machine must be cleaned at regular intervals according to use and the work
environment.
Hazard!
Before cleaning the machine, cut-off and pad lock all energy sources and safely
lock its mobile units. Place machine in maintenance - do not turn on signs near
the main switch. Removing machine guards and safety devices by cleaning
personnel is strictly prohibited.
Warning!
Machine parts must be carefully cleaned of dust or other substances. We suggest
you use cleaning liquids that have good grease solvent properties that are not
harmful to rubber seal gaskets.
During these activities, personnel must be equipped with suitable protective
clothing (gloves and goggles) and use non-fray cloths.
Warning!
Only use dry and soft cloths that do not leave frays or flexible silk brushes to clean
delicate mechanisms, references and lubricating mechanisms.
Note:
Use the types of cleaning liquids and observe the restrictions set by current
regulations in the country of use.
Hazard!
The use of cleaning liquids not permitted in the country of use and compressed air
with pressure over 0.2 MPa to clean is strictly prohibited.
Avoid prolonged personnel exposure to cleaning liquid vapours ensuring good
room ventilation.
Failure to observe these precautions may cause personal injuries.
8 - Maintenance
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8.7 Lubrication plan

It is easy to understand the extreme importance of adequate machine lubrication. The correct use of
appropriate lubricants considerably contributes to achieving the best machine performance and reducing
faults.
If the machine is question is equipped with a centralised lubrication system, no manual controls or
lubrication are required except for the points indicated in the following chapter.
When handling lubricant, observe the following preventive measures for health reasons:
only use the amount of lubricant necessary to lubricate the concerned mechanism. Dry excess oil, grease or
graphite with a non-fray cloth;
excess lubricant, like insufficient lubricant, may, at times, compromise good machine operations;
only the recommended lubricants or greases or lubricants and greases with equivalent characteristics of known
and proven quality can be used for lubrication;
avoid prolonged, excessive or repeated skin contact with lubrication products and avoid inhaling their vapours;
protect skin by wearing appropriate protective clothing and devices (for example, overalls, goggles and
protective gloves) or by applying a protection product;
in the event of skin contact, wash with soap or specific products and rinse under running water.
Hazard!
Lubricants are inflammable products. Follow the instructions on the container
labels.
When disposing used lubricants, follow the environmental protection regulations listed below:
lubricants can pollute water and the ground. Therefore, never pour lubricant products on the ground, in water
or in sewers. Failure to follow these instructions is punishable by law. When using lubricants, keep oil binders
on hand;
carefully collect used lubricants separating mineral-based products from synthetic-based ones. Observe
current used oil disposal regulations.
Lubricants used must have good emulsion stability and resistant to aging. They should not damage the material with
which oil scrapers, joints, rubber/plastic parts and machine paint are made.
Continue using the same lubricants used for the first time to fill the machine. If this is not possible, only use the
compliant products indicated in the reciprocity tables provided by the various manufacturers.
Only the use of suitable quality lubricants guarantees safe machine operations.
Warning!
Mixing lubricants of different qualities is strictly prohibited since their composition
and additives do not have the same specifications. This rule especially applies to
mixing synthetic and mineral lubricants.
If lubricants other than those indicated must be used, check whether the two
products are compatible. In the event of doubt, the lubricant used until that time
must be fully eliminated by cleaning the entire circuit.
Warning!
To avoid the risk of contamination, careful attention must be paid to cleanliness
during lubrication procedures.
Warning!
For further information on lubrication points and procedures for retail units and
parts installed on the machine, see the relevant maintenance sheets.
8 - Maintenance
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8.7.1 Lubrication
The machine is equipped with a central lubrication system which keeps the lubricated parts in top working
order. During its cycle the pump sends the required amount of lubricant to the lubricating circuit. The
frequency at which this operation is performed is determined by the operator according to the state of the
machine.
The operator can run a non-programmed lubricating cycle by pressing button on the control panel (optional).
Regularly check the level of lubricant in tank C and, if necessary, top up by opening filler plug B.
SHELL:
"OSSAGOL V"
TAMOIL:
BP: TAMLITH
BECHEM:
"ENERGREASE ZS 00" GREASE 000 EP RHUS LIC-000
251698
8 - Maintenance
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8.7.2 Lubrication diagrams
SOSTITUIRE QUESTA PAGINA CON GLI SCHEMI DI

LUBRIFICAZIONE IN ORIGINALE O IN COPIA
8 - Maintenance
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8.8 Maintenance plan

Machine part maintenance was organised in technical maintenance sheets.
These are based on traditional machine maintenance activities and on system analysis results and specific
databases.
This allows information to be included in a single document that takes into account the specific machine differences
derived from its critical points.
Note:
Preventive and special maintenance activities can be conducted by the user
customer of bielomatik s.r.l. technicians according to the instructions listed in the
sheets.
Due to their complexity, some particular special maintenance operations were
intentionally omitted from the manual and can only be conducted by bielomatik
s.r.l. technicians who have the technical know-how, documentation and tools
required to conduct these activities.
Hazard!
The following maintenance activities are to be conducted with the machine
stopped and power sources cut-off.
Controls that need to be conducted with power on are specifically marked with a
hazard symbol and highlighted text. In this case, pay the utmost attention.
8 - Maintenance
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8.8.1 Drafting criteria
The maintenance sheets were drafted as illustrated below.
0DLQWHQDQFHVKHHW 1U 'DWH
6\VWHP ,QWHUYHQWLRQ
5HIHUHQFHGUDZLQJ 1XPEHU
,QWHUYHQWLRQIUHTXHQF\ ,QWHUYHQWLRQ
OHQJWK
Intervention description
Required spare parts
Required tools
Detailed description of the
operations to be
conducted in chronological
order.
Comments
Specifically, it is essential that the sheet illustrated above is filled out for all maintenance activities and filed by the
maintenance supervisor in a specific folder.
8 - Maintenance
U0G00214
Data that must be included in the sheet:
1. Type of maintenance (preventive, dismantling instructions, etc.).

2. Maintenance sheet number.
3. Date of maintenance.
4. System/machine name.
5. Type of intervention.
6. Reference drawing (if applicable).
7. Reference drawing number (if applicable).
8. Frequency: minimum recommended intervention frequency.
9. Estimated intervention length.
10. Description event supported by drawings (if applicable) of the type of intervention with indications of
intervention points.
11. Indication of the spare parts required to conduct/complete the intervention.
12. Tools required to conduct the intervention: wrenches, compressed air, gloves, etc.
13. Detailed description of the operations to be conducted (in chronological order) for correct intervention.
Suggestions, warnings, hazards (if applicable) for this maintenance activity are listed here.
8 - Maintenance
U0G00214
8.8.2 Maintenance and frequency table
The following table lists machine maintenance activities, with relevant frequency.
Please periodically conduct the interventions described below to keep the machine in excellent working and
safety conditions. The estimated length of each intervention is also listed in the table.
The indicated frequency is expressed in machine operating hours (h).
Nr. OPERATION DESCRIPTION 800 h 1200 h 1600 h 2400 h

1 Check chain wear and tensioning 0.50 0.50
2 Check conveyor belt wear 0.50 0.50 0.50
3 Check toothed chain wear and tensioning 1.00 1.00 1.00
4 Check toothed pulley and return roller wear 1.00 1.00 1.00
5 Check bearing and linear guide wear 0.50 0.50 0.50
6 Check shaft and grooved bushing wear 0.25
7 Check sliding guide and folder wear 0.25 0.25
8 Check gear integrity 0.50 0.50 0.50
9 Check ties (tight and correct measure) 0.25 0.25 0.25
10 Check lubrication pipes and the correct lubrication of 0.50 0.50
the points reached
11 Check pneumatic pipes 1.00
12 Check pneumatic system condensation drainage 0.25 0.25 0.25
13 Check pneumatic part operations (cylinders, solenoid 1.00 1.00
valves, etc.)
14 Replace electrical cabinet filters 0.50
15 Check and test safety devices (emergency buttons, 0.50
switches, etc.)
16 Check and test indicator lights 0.25
17 Suction filter cleaning 0.50 0.50 0.50
Note:
In the event of prolonged machine disuse, conduct the all the checks listed in the
table above before resuming production.
8 - Maintenance
U0G00214
8.8.3 Detailed specific procedures for machine parts that require detailed information
8.8.3.1 Replacing and tensioning the side bands
To replace the side bands proceed as follows:

Release handles A.
Move the bands as far apart as possible by using crank B.
Slacken the side bands by loosening screws C and sliding roller D along the slot.
Loosen driving belt E and free pulleys F.
Uncrew screws G and remove the drive roller of belts H.
Pull out bands H from the bottom.
Replace the bands by inserting them from the bottom.
Reinstall the drive roller of the belts and tighten screws G.
Insert belt E on pulleys F and tension the belt.
Tension the band by moving roller D along the slot. Use your finger to press on the band at point I. The band
should deflect by approx. 5 mm.
Fully tighten screws C.
Bring the side bands close together and adjust as explained in the Adjusting the side bands paragraph.
Fully tighten handles A.
251912
A D C H I
8 - Maintenance
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8.8.3.2 Replacing the ream feeding belts
To replace the horizontal belts A for the ream feeding, the equipment (not supplied with the machine) to
solder the belts is required; then proceed as follows:
Loosen the belt tensioner.

Cut the worn belt and remove it, then insert the new belt opened by following the path on the rollers and
the tensioners.
Solder the belt using the proper equipment and follow the instructions described in the equipments manual.
Tension the belt.
251913
8 - Maintenance
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8.8.3.3 Replacing the toothed belts on the ream feeding unit
To replace the toothed belts, proceed as follows:
Remove side slats of the ream feeding unit A.

Loosen toothed belt B by unlocking screws C; then let tensioner D slide along the loop.
Remove the toothed belt.
Install the new toothed belt
Tension the toothed belt and let tensioner D slide along the slot, then lock screws C.
Install side slats A.
251919
D C
8 - Maintenance
U0G00214
8.8.3.4 Cutting pressure
Perform the operations given below after the blade has been changed or when adjusting the cutting
pressure:
shut off the machine and close the air supply;

slightly loosen screws B in the area in which the pressure has to be increased or decreased;
turn screw G in the area in which the pressure has to be increased or decreased;
fully tighten screws B that secure blade C.
263899
8 - Maintenance
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8.8.3.5 Knife replacement
The knife blades can be used on the two sides H.

If on both sides the cutting is not perfect, regrind the blade.
Proceed as described below:
Rotating knife
machine and compressed air switched off;
bring the knife in an accessible position for the blade removal;
lift the upper unwinding roll A; to lift the roll, unhook the tie-rods lifting the roll, which are positioned inside the
side guards;
remove the sliding plate D;
unscrew the screws E and remove the blade F.
Fixed knife
remove blocks L;
loosen screws M;
remove the counter-knife unit I;
unscrew the screws B and remove the blade C;
regrind the blades following the instruction of the drawing (see subsequent chapter);
re-install all the components, following the reversed procedure.
Of course after repeated grindings, it will be necessary to replace the blades.
M I L D
263899
E F B
8 - Maintenance
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8.8.3.6 Regrinding the cutting blades
Two edges H of the cutting blades are normally used.

If the cuts produced by both edges are inaccurate, the blade needs to be re-ground.
Proceed as described below:
Perform a horizontal and vertical precision grinding operation by using plenty of coolant.
The coolant must be directed to the point where the grinding wheel and the piece come into contact.
Bakelite-based and soft abrasive material is to be used, typically 46H6 or 46G6/8.
If a vertical grinder is available, it is preferable to use a sectional grinding wheel instead of cup grinders.
The cutting edge along with the two respective faces of the blade is to be reground. The amount of material to
be removed from the blade is 2 mm until a fairly consistent cutting edge is obtained.
In general, in order to perform the procedure in the proper way, always straighten the piece before grinding.
The blades obviously are to be replaced after repeated regrinding procedures.
Hardening HRc 63
32 0,1
6 0,1 H 24 50
263900
8 - Maintenance
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8.8.3.7 Replacing the discharge pushers
Triple links C are used to attach the discharge pushers A to the chains B.
To replace the pushers, take off the counter-link D and remove the link. Hold up the pusher with your hand
as it will otherwise fall down.
Pull it off the chains and remove it from the bush E.
Install the new pusher by carrying out the operations given for removing it in reverse order.
B
B
C D
260024
8 - Maintenance
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8.8.3.8 Tensioning the discharge conveyor chains
Proceed as directed below to tighten the upper conveyor chains:

Unscrew the lock nut A.
Turn screw B clockwise.
Make certain the chain deflects no more than 10 mm.
Fully tighten the lock nut.
A B
251399
8 - Maintenance
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8.8.3.9 Tensioning the squaring unit belts
To tension the squaring unit belts, do as follows:

Loosen fastening screws of slide A (which supports the pulley), positioned under plate B.
Remove block C (usually positioned as shown in Picture 1), unscrewing screws D completely.
Install block C (see Picture 2), and rotate it with the fastening holes upwards, then screw screws D
thoroughly.
Insert tensioning screw E and tension the belt.
Lock the fastening screws of slide A.
Remove and rotate block C, by fixing it to its original position, i.e. with the fastening holes downwards (Picture 1).
Picture 1
251876
B A C
Picture 2
251877
B A C
8 - Maintenance
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8.8.3.10 Toothed belt tensioning
The toothed belts must be tensioned using the turnbuckles D, loosening the lock screws C and the acting
on turnbuckle movement screw B.
251699
8 - Maintenance
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8.8.3.11 Clear Wrap unit belt replacement
To replace the lateral belts proceed as follows:

Completely enlarge the lateral belts B, out of dimensions of the lower plate.
De-tensioning the belts.
Withdrawal of the belts and insertion of the new belts.
Put again the belt in tension.
Newly adjust the belts to the size dimension of the worked size.
To replace the lower belt:

De-tension the belt A pressing the corresponding push-button on the operator panel, which controls tensioning
cylinder N.
Remove supports M of the sliding surface.
Remove the belt to be replaced and position the new belt.
Reassemble supports M of the sliding surface.
Tension the belt again, by pressing the corresponding push-button on the operator panel.
263985
M N A B M
251402
8 - Maintenance
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8.8.3.12 Pressure unit belt replacement
To replace the lateral belts proceed as follows:

Loosen screws E.
Completely enlarge the lateral belts A, out of dimensions of the lower plate B.
Loosen belts by loosening the nut C and screw D.
Withdrawal of the belts and insertion of the new belts.
Put again the belt in tension.
Newly adjust the belts to the size dimension of the worked size.
251918
A B E
D C
251917
8 - Maintenance
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8.8.3.13 Suction filter cleaning
As indicated in the maintenance table, periodically clean filters F connected to the suction vents on the
machine.
To clean the filters do as follows:

Remove the container.
Clean it carefully with a dry cloth to remove all the dust which has built up on the walls.
If necessary, remove the filter element by pulling it downwards.
Use a jet of compressed air to remove any dust or residue left on the filter element.
After the filters have been cleaned many times or if the filter is not restored to top condition after cleaning it needs
to be replaced with a new one.
Install the filtering device by performing the operations described above in reverse order.
251841
8 - Maintenance
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9 - Troubleshooting
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Troubleshooting
WRAPMASTER 9 - 1/4
9 - Troubleshooting
U0G00214
9.1 Fault messages

The following messages may be displayed. The machine may react in different ways depending on the type of
message displayed:
Faults: messages displayed as faults are present, the machine shuts down.
Service messages: messages for the operator, machine operation is not affected in any way.
9.1.1 Description of the Alarms and warnings
All the fault and service messages can be accessed from page Menu.
The mask contains men with touch buttons which can be used to perform actions relating to the fault or
warning messages:
Clear messages: deletes all messages stored in the memory for warning messages.
View current messages: opens the screen mask with the list of operating messages currently active on the
machine.
View messages memory: opens the screen mask with the list of messages which have occurred on the machine
and are stored in the memory.
Print messages: prints the warning messages if the machine is connected to a printer.
The fault messages that stop the machine from operating are displayed in a window that is overlaid on top of the
window displayed on the operator panel and contains the text of the fault message and three touch buttons:
A HELP: The online help for the fault message indicated in the window is displayed.
264823 264824
9 - 2/4 WRAPMASTER
9 - Troubleshooting
U0G00214
9.2 Fault indication

To determine which faults occur most frequently, a chart is provided below. This is to be filled in to provide
useful information in order to solve the problem as soon as possible.
Fault Day Action taken Shut down Additional

code or occurred time notes
description time
WRAPMASTER 9 - 3/4
9 - Troubleshooting
U0G00214
Fault Day Action taken Shut down Additional

code or occurred time notes
description time
9 - 4/4 WRAPMASTER
10 - Timing diagrams
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10
Timing diagrams
WRAPMASTER 10 - 1/...
10 - Timing diagrams
U0G00214
10 - 2/... WRAPMASTER

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TRANSLATIOIN FROM ORIGINAL INSTRUCTIONS

Operation and maintenance manual

0.1 Customer information and machine serial number

PT Indah Kiat Pulp and

0.1.1 Previous documentation

Codice Variazioni sulle versioni precedenti Data

U0G00214 Versione conforme a STD Bielomatik + pers. per matr. 18 23/04/2015

1.5.15 Lightnings ............................................................................................................................ 1 - 20

2 Preliminary information ......................................................................... 2 - 1

4 Machine start-up and operation ............................................................ 4 - 1

5 Machine axes .......................................................................................... 5 - 1

6 Machine control through operator interface ........................................ 6 - 1

6.6.7 Clear Wrap page description (optional) ............................................................................. 6 - 36

7 Operation and format change ............................................................... 7 - 1

8.4 Maintenance advice ......................................................................................................................... 8 - 9

0.3 Important warnings

0.4 Document organisation

- Installation, instruction and maintenance manual

0.4.1 Installation, instruction and maintenance manual

0.4.2 Spare parts and code=>unit correspondence

0.4.3 Retail mechanical parts

0.4.4 Retail electrical parts

0.4.5 Electrical part list

This section contains the list of electrical parts.

0.4.6 Electrical part calibration tables, Motor list, Wiring diagram

This section contains:

0.4.7 Machine management program manual.

0.5 Description of the icons

0.6 Qualification levels of the machine operators

Operator responsible for the use of lifting and handling equipment:

Maintenance staff for mechanical system:

Maintenance staff for electrical system:

0.7 Use of the icons

0.8 How the documentation is revised

THIS PAGE INTENTIONALLY LEFT BLANK

1.1 General information

1.1.1 Personnel training

1.1.2 Applied directives and technical reference regulations

1.1.3 Machine certification

THIS PAGE INTENTIONALLY LEFT BLANK

THIS PAGE INTENTIONALLY LEFT BLANK

1.1.4 Intended use and operating restrictionsh

1.1.5 Hazardous areas

1.1.6 Environmental operating conditions

1.1.9 Electromagnetic emissions

1.2 Used material disposal

1.2.1 Instructions for special waste

1.3 Safety devices installed on the machine

1.3.1 Emergency stop

Resetting the emergency button does not restart the machine.

1.3.1.1 Test procedure

1.3.2 Fixed guards

1.3.3 Mobile guards

1.3.3.1 Test procedure

1.3.4 Cutting off electrical energy

Position 1 ON position, CLOSED circuit, machine POWERED

1.3.5 Cutting off pneumatic energy

1.4 Personal protection devices

Compulsory safety helmet

Compulsory protective shield

Compulsory hearing protection

Compulsory protective and insulating gloves