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<strong>Stretch</strong> <strong>wrapper</strong> <strong>model</strong> <strong>GL</strong> <strong>1000</strong><br />

Manual<br />

Ver. 2.1<br />

EN<strong>GL</strong>ISH


Model: <strong>GL</strong> <strong>1000</strong> Serial number:........................ Delivery date:...............................<br />

YY-MM-DD<br />

This machine is equipped with the following options on delivery:<br />

6<strong>1000</strong>1 CONVEYOR FOR BIG LOADS<br />

6<strong>1000</strong>2 CUSTOM COLOR<br />

6<strong>1000</strong>3 MAST MOVED BACK<br />

6<strong>1000</strong>4 CABINET MOVED BACK<br />

6<strong>1000</strong>5 FORMAT CONTROL<br />

6<strong>1000</strong>6 HALF PALLET<br />

6<strong>1000</strong>7 CABINET EXCLUDED<br />

6<strong>1000</strong>8 SEPARATE CABINET<br />

6<strong>1000</strong>9 ALLEN BRADLEY CONTROL<br />

610012 LIGHTBEAM, 1 PC<br />

610013 LIGHTBEAMS, 2 PCS<br />

610014 LIGHTBEAMS, 3 PCS<br />

610148 TOP PLATE, RECTANGULAR<br />

610149 TOP PLATE, ROUND<br />

610150 FREQ. CONTROL OF TOP PLATE<br />

610159 ALARM, ”FILM ALMOST AT AN END”<br />

610179 GALVANIZATION OF BOTTOM CHASSIS<br />

610184 CUSTOM MAST HEIGHT<br />

610188 CHAIN CONVEYOR, 3 CHAINS<br />

610189 CHAIN CONVEYOR, 2 CHAINS<br />

610191 INFILL CONVEYOR FOR LARGE CONVEYOR<br />

610192 INFILL CONVEYOR FOR STD CONVEYOR<br />

610194 LARGER FILM ROLL DIAMETER<br />

610198 POWERED OUTER ROLLERS<br />

610206 INCREASED TRANSP. HEIGHT, 575-700 mm<br />

610207 INCREASED TRANSP. HEIGHT, 625-750 mm<br />

610208 INCREASED TRANSP. HEIGHT, 750-875 mm<br />

610209 CUSTOM CONVEYOR HEIGHT<br />

610254 WELDING UNIT<br />

610261 90 DEGREE IN OR OUT TRANSPORTATION<br />

610324 STRING ROLLER<br />

610325 PNEUMATIC STRING ROLLER<br />

610481 PALLET GUIDING DISCS<br />

610210 AIR CONDITIONED ELECTRICAL CABINET<br />

610010 INTEGRATION CI 1110<br />

610011 CONTROL OF 1 CONVEYOR<br />

610012 CONTROL OF 2 CONVEYORS<br />

610013 CONTROL OF 3 CONVEYORS<br />

610014 CONTROL OF 4 CONVEYORS<br />

610015 CONTROL OF 5 CONVEYORS<br />

610016 FREQ. CONTROL OF CONVEYOR<br />

610199 SEPARATE START BOX<br />

610663 PASSIVE ANTISTATIC<br />

610664 ACTIVE ANTISTATIC<br />

Throughout the entire manual, the following symbols will be used to indicate particularly important information.<br />

Particularly important<br />

information<br />

Must be executed by<br />

an operator<br />

Must only be executed by a<br />

Cyklop service engineer<br />

Hazard<br />

"Fast return" to a page. To access this menu/page,<br />

press the buttons in order in the grey field. (This is an example.)<br />

Rights to make any technical modifications are reserved. This manual must not be copied or otherwise duplicated.<br />

Nor may its content be amended or passed on without our written permission. All rights reserved.<br />

© Copyright by Cyklop Teknik AB – Burseryd 2010 /mka<br />

2 EN


Contents<br />

Chapter Page<br />

Machine configuration 2<br />

Positioning of safety decals 4<br />

EC declaration 5<br />

General safety instructions 1 6<br />

Main machine parts 2 10<br />

Control cabinet 3 11<br />

• Overview 3.1 11<br />

• Explanation of buttons 3.2 11<br />

• Lamp test 3.3 12<br />

Display 4 12<br />

• Overview 4.1 12<br />

• Home menu 4.2 12<br />

• Information menu for film 4.3 13<br />

• Name program 4.4 13<br />

• Manual operation 4.5 14<br />

• Service 4.6 15<br />

• Language selection, date set 4.7 15<br />

• Alarm / Status sensor 4.8 17<br />

• Contact information 4.9 19<br />

• Setting program parameters 4.10 19<br />

• Program selection 4.11 20<br />

Operate the machine 5 21<br />

• Activation 5.1 21<br />

• Load film 5.2 21<br />

• Set prestretching of film 5.3 22<br />

• Set film tension 5.4 22<br />

• Start the machine 5.5 22<br />

• Pause automatic mode 5.6 23<br />

• Description of film patterns 5.7 23<br />

Care and daily maintenance 6 24<br />

• Cleaning 6.1 24<br />

• Service & maintanence 6.2 24<br />

Resetting 7 26<br />

• Film breakage / End of film 7.1 26<br />

• Machine stop activated 7.2 26<br />

• Emergency stop activated 7.3 26<br />

• Light beam which has tripped (optional) 7.4 27<br />

Troubleshooting 8 27<br />

Transport 9 29<br />

Technical specifications 10 30<br />

Table of set values, program parameters 11 31<br />

3 EN


EN<strong>GL</strong>ISH<br />

This user guide describes the operation, safe use,<br />

maintenance and adjustment of the machine. ATTENTION!<br />

Connection to the power grid is not included.<br />

Machine design and construction allows for safe<br />

use and maintenance. This is true provided that<br />

the installation is done as is described in this guide.<br />

The warning labels that have been applied to the machine should<br />

be kept in such condition that the content is easy to read. If not,<br />

the label must be replaced. Explanations and positioning below.<br />

Design may differ slightly on label affixed to the machine, but the<br />

meaning is the same.<br />

Part No: 400777<br />

7. HAZARD!<br />

The turn table rotates in the direction of the<br />

arrrow.<br />

18. HAZARD!<br />

Aggregate travels in the directions of the arrows.<br />

Crush hazard.<br />

2. HAZARD!<br />

Topplattans släde rör sig i pilarnas riktning. Crush<br />

hazard. (For option: Top plate)<br />

MANDATORY<br />

Outtakes for forks. Lift the machine here.<br />

9. HAZARD!<br />

Rotating rollers. Crush hazard.<br />

12. HAZARD!<br />

Sharp egdes. Risk of cutting.<br />

3. VARNING!<br />

Rotating rollers. Crush hazard.<br />

5. HAZARD!<br />

Crush hazard.<br />

8. HAZARD!<br />

Crush hazard.<br />

17. HAZARD!<br />

Dangerous electrical voltage.<br />

13. HAZARD!<br />

Hot surface.<br />

(For option: Weld)<br />

4. INFORMATION<br />

1. Tread the stretch film according to the picture.<br />

2. Gear ratio.<br />

15.<br />

10.<br />

1.<br />

14.<br />

16.<br />

4 EN


The declaration of incorporation of the partly completed machinery under the EC’s Machinery<br />

Directive 2006/42/EC, Annex 2B.<br />

We:<br />

Cyklop Teknik AB<br />

Villstadsvägen 1<br />

330 26 BURSERYD<br />

Org. Nr. 556224-0001<br />

declare under our sole responsibility that the partly completed product:<br />

Model: <strong>Stretch</strong> <strong>wrapper</strong> <strong>GL</strong> <strong>1000</strong><br />

Type designation: <strong>1000</strong>50-<strong>1000</strong>50/99<br />

Machine Number:<br />

________________________<br />

• is designed to be incorporated in a larger machinery or assembled with another machine, which<br />

together will constitute machinery covered by Directive 2006/42/EC ”Machinery Directive”<br />

and which shall be made in accordance with Directive 2006 / 42/EC.<br />

• conforms to the applicable sections of annex 1 regarding essential health and safety in the design<br />

of machines have been performed and that the relevant technical documentation is compiled in<br />

accordance with Annex 7, Section B.<br />

• Remaining items in Annex 1: 1.1.3, 1.3.1, 1.3.2, 1.3.3, 1.3.7 samt 1.5.2. At the substantiated<br />

request of national authorities relevant documents on the partly completed machinery<br />

will be presented.<br />

• and declares, moreover, that the machinery should not be put into any use until the machinery<br />

it must be incorporated in, or forming part of, has been found and declared in accordance with<br />

Directive 2006/42/EC and national legislation, namely the overall including the machine,<br />

referred to in this declaration.<br />

Covered by this declaration in conformity are the following directives:<br />

2006/42/EG Machinery Directive, Basic safety regulations<br />

2006/95/EG Low Voltage Directive (LVD)<br />

2004/108/EG Electromagnetic Compatibility (EMC)<br />

The following harmonized standards apply:<br />

EN ISO 14121 Machine safety - Principles for risk assessment<br />

EN ISO 12100-1 Machine safety - Basic terminology, methodology<br />

EN ISO 12100-2 Machine safety - Technical principles<br />

SS-EN 60204-1 Machine safety - Electrical equipment of machines<br />

SS-EN 954-1 Machine safety - Control systems<br />

SS-EN 415-6 Packaging machines safety<br />

Burseryd<br />

Place and date (YY-MM-DD)<br />

Bo Eriksson<br />

Managing director<br />

Position<br />

Burseryd<br />

Place and date (YY-MM-DD)<br />

Lars Karlsson<br />

Responsible for Technical file<br />

Position<br />

Cyklop Teknik AB<br />

Villstadsvägen 1<br />

SE-330 26 BURSERYD<br />

Ph: +46 (0)371 50800<br />

Fax: +46 (0)371 50775<br />

info@cyklopteknik.se<br />

www.cyklopteknik.se<br />

5 EN


1. General safety instructions<br />

GENERAL<br />

Machine design and construction allows for safe use and<br />

maintenance. This is true provided that the installation is done<br />

as described in this guide. The guide should be read and the instructions<br />

followed by anyone working with the machinery. It is<br />

the customer’s responsibility to ensure that the instructions are<br />

complied with by staff.<br />

In some countries or some companies more safety regulations are<br />

to be observed, mainly related to personnel. This documentation<br />

does not take account of such company-specific or national<br />

guidelines. The technical specifications in the manual shall be<br />

sufficient to base for decisions on any local safety regulations.<br />

Consult with the appropriate the authorities or with company<br />

safety representatives.<br />

This documentation distinguishes between ”normal operation”<br />

(see Chapter 3-4 Running the machine) and ”other management”<br />

(see Chapter 5 Care and daily maintenance). The reason is that<br />

they place different demands on operators and service personnel,<br />

specially in regards to security.<br />

Easier maintenance, as described in Chapter 4, may also be<br />

performed by operators. Maintenance only described in Chapter 5,<br />

only carried out by skilled service personnel.<br />

SAFETY<br />

Here are the rules to be observed: Ensure that no children or<br />

animals in the vicinity of the installation.<br />

Only people who have read and understand this manual may work<br />

with this machinery. Do not tamper with the machine while it is<br />

working or is on. Warning! Even if the machine is not working,<br />

it may be switched on. Safety devices shall not be removed or<br />

eliminated. All the protection of electrical and mechanical compo<br />

nents must be correctly installed when the installation is in<br />

operation. The safety devices are essential for safety in the work<br />

environment. Thus, it is strictly forbidden in any way ignore or<br />

circumvent them. Keep the work area clean and free of foreign<br />

objects. Make sure the lighting in the work area is adequate.<br />

UNAUTHORIZED USE<br />

Some use may lead to unnecessary security risks because they are<br />

not in conformity with the machine’s specifications and therefore<br />

unlawful. You may not:<br />

• wrap pallets that do not meet specifications<br />

• wrap pallet goods exceeding the maximum allowable weight<br />

• wrap pallet goods which have not been stacked properly.<br />

Keep in mind that even if the goods look like it is stacked<br />

properly, packages can still fall due to other causes<br />

• wrap pallets that are in poor condition<br />

• wrap pallets that extends outside the periphery of the turn<br />

table<br />

• negligering of installation specifications<br />

• wrap unpackaged foods<br />

USERS<br />

Operators<br />

The machine may be operated by any adult person who has read<br />

and understood the contents of Chapters 1-4. It is not necessary<br />

that the operators have any special knowledge. Machine operators<br />

are trained by personnel from Cyklop or by Cyklop designated<br />

dealers.<br />

• daily standard maintenance This means for example cleaning<br />

of photocells - no major tasks may be performed.<br />

• ensure that dangerous situations can not arise.<br />

• keep the work area clean and free from foreign objects.<br />

Service<br />

Specific skills, experience and / or training is required. Service<br />

personnel should also master the entire contents of this<br />

documentation. Service typically have the following types of tasks:<br />

• maintenance of the installation<br />

• repair of defects<br />

• give support to operators<br />

Service personnel shall after rectifying an error restore the<br />

machine to original state. With security in mind, this means for<br />

example, re-installation of protective caps and also return safety<br />

switch to its original position. When a service person take their<br />

own initiatives to implement changes in the installation, the<br />

customer forfeits the moment of their warranty claims in the case<br />

of any problems as a consequence of the change.<br />

PERSONAL PROTECTION<br />

Some personal protection measures are not to be taken by<br />

operators of the machine. However, a number of measures<br />

are recommended. For example shoes with steel caps, hearing<br />

protection, etc.. Some products used, however, may require<br />

protective measures - advice the documentation of those devices.<br />

When handling sheet metal take certain precautions to prevent<br />

injuries such as hand injuries and the likes. When performing<br />

service local safety regulations must be folowed. Discuss personal<br />

safety with company safety representatives.<br />

The whole installation was designed and tested to work with the<br />

specified substances. Unforeseen dangers may arise from the use<br />

of substances other than those specified. The manufacturer can<br />

not accept responsibility for the complications arising from the use<br />

of substances other than those specified.<br />

TRANSPORTATION<br />

When transporting the installation on a public road, there may<br />

be local regulations to follow. Consult with national and local<br />

authorities on these kinds of regulations and if application for a<br />

permit is needed.<br />

ENVIRONMENTAL CONCERNS<br />

Potential environmental risks are in the form of, for example, oil,<br />

grease and detergent. This type of substances are to be disposed<br />

of in accordance with national environmental regulations.<br />

DISPOSAL OF THE MACHINE / INSTALLATION<br />

If and when the machine is disposed local environmental<br />

regulations must be observed. The machine contains only material<br />

that can be considered public knowledge. All the materials in the<br />

machine was at the time of manufacture of such a nature that<br />

they could be disposed of in an environmentally sound manner<br />

and without risk of personal injury.<br />

DISASTERS<br />

Disasters include fire, flood, and the like. There are no specific<br />

rules for the conduct of disaster relief.<br />

Fire fighting can be done under the usual standards.<br />

The operator is normally involved in the following tasks:<br />

• operation of the machine<br />

6 EN


Basic operation<br />

Before use, please read the handbook and safety instructions<br />

carefully. The operator handbook is to be stored ready<br />

for use in direct machine proximity. Maintenance and inspection<br />

intervals are to be adhered to.<br />

The machine/plant must only be used in technically perfect<br />

condition in accordance with its designated use and the<br />

instructions set out in the operating manual, and only by<br />

safety–conscious persons who are fully aware of the risks<br />

involved in operating the machine/plant. Any functional disorders,<br />

especially those affecting the safety of the machine/<br />

plant, should therefore be rectified immediately.<br />

The machine/plant may be operated only for its designated<br />

use.<br />

Organizational measures<br />

In addition to the operating instructions, observe and instruct<br />

the user in all other generally applicable legal and<br />

other mandatory regulations relevant to accident prevention<br />

and environmental protection. These compulsory regulations<br />

may also deal with the handling of hazardous<br />

substances, issuing and/or wearing of personal protective<br />

equipment, or traffic regulations.<br />

For reasons of security, long hair must be tied back or otherwise<br />

secured, garments must be close–fitting and no jewellery<br />

– such as rings – may be worn. Injury may result<br />

from being caught up in the machinery or from rings catching<br />

on moving parts.<br />

Use protective equipment wherever required by the circumstances<br />

or by law.<br />

Observe all safety instructions and warnings attached to the<br />

machine/plant.<br />

See to it that safety instructions and warnings attached to<br />

the machine are always complete and perfectly legible.<br />

In the event of safety relevant modifications or changes in<br />

the behaviour of the machine/plant during operation stop<br />

the machine/plant immediately and report the malfunction<br />

to the competent authority/person.<br />

Never make any modifications, additions or conversions,<br />

which might affect safety without the supplier’s approval.<br />

This also applies to the installation and adjustment of safety<br />

devices and valves as well as to welding work on load–bearing<br />

elements.<br />

Spare parts must comply with the technical requirements<br />

specified by the manufacturer. Spare parts from original<br />

equipment manufacturers can be relied to do so.<br />

Never modify the software of programmable control systems.<br />

Replace hydraulic hoses within stipulated and appropriate<br />

intervals even if no safety relevant defects have been detected.<br />

For the execution of maintenance work, tools and workshop<br />

equipment adapted to the task on hand are absolutely indispensable.<br />

The personnel must be familiar with the location and operation<br />

of fire extinguishers.<br />

Observe all fire–warning and fire–fighting procedures.<br />

Accident preventing devices, which are not included in the<br />

scope of supply, such as protective guarding, are to be provided<br />

by the customer in accordance with the local safety<br />

regulations.<br />

Selection and qualification of personnel<br />

Any work on and with the machine/plant must be executed<br />

by reliable personnel only. Statutory minimum age limits<br />

must be observed.<br />

Employ only trained or instructed staff and set out clearly<br />

the individual responsibilities of the personnel for operation,<br />

set–up, maintenance and repair.<br />

Make sure that only authorized personnel works on or with<br />

the machine.<br />

Define the machine operator’s responsibilities – also with<br />

regard to observing traffic regulations – giving the operator<br />

the authority to refuse instructions by third parties that are<br />

contrary to safety.<br />

Do not allow persons to be trained or instructed or persons<br />

taking part in a general training course to work on or with<br />

the machine/plant without being permanently supervised<br />

by an experienced person.<br />

Work on the electrical system and equipment of the machine/plant<br />

must be carried out only by a skilled electrician or<br />

by instructed persons under the supervisions and guidance<br />

of a skilled electrician and in accordance with electrical engineering<br />

rules and regulations.<br />

Work on gas–fuelled equipment (gas consumers) may be<br />

carried out by specially trained personnel only.<br />

Work on the hydraulic system must be carried out only by<br />

personnel with special knowledge and experience of hydraulic<br />

equipment.<br />

7 EN


Safety instructions governing specific operational<br />

phases<br />

Avoid any operational mode that might be prejudicial to<br />

safety.<br />

Take the necessary precautions to ensure that the machine<br />

is used only when in a safe and reliable state. Operate the<br />

machine only if all protective and safety– oriented devices,<br />

such as removable safety devices, emergency shut–off<br />

equipment, sound–proofing elements and exhausters, are<br />

in place and fully functional.<br />

Check the machine/plant at least once per working shift<br />

for obvious damage and defects. Report any changes (incl.<br />

changes in the machine’s working behaviour) to the competent<br />

organization/person immediately. If necessary, stop<br />

the machine immediately and lock it.<br />

In the event of malfunctions, stop the machine/plant immediately<br />

and lock it. Have any defects rectified immediately.<br />

Before starting up or setting the machine/plant in motion,<br />

make sure that nobody is at risk.<br />

Never switch off or remove suction and ventilation devices<br />

when the machine is in operation.<br />

Brief operating personnel before beginning special operations<br />

and maintenance work, and appoint a person to supervise<br />

the activities.<br />

Ensure that the maintenance area is adequately secured!<br />

Lift units must be secured by mechanical fall–safety units<br />

(clamps), before entering the machine!<br />

If the machine/plant is completely shut down for maintenance<br />

and repair work, it must be secured against inadvertent<br />

starting by:– locking the principal control elements and<br />

removing the ignition key and/or– attaching a warning sign<br />

to the main switch.<br />

Carry out maintenance and repair work only if the machine<br />

is positioned on stable and level ground and has been secured<br />

against inadvertent movement and buckling!<br />

To avoid the risk of accidents, individual parts and large assemblies<br />

being moved for replacement purposes should be<br />

care-fully attached to lifting tackle and secured. Use only<br />

suitable and technically perfect lifting gear and suspension<br />

systems with adequate lifting capacity. Never work or stand<br />

under suspended loads!<br />

For carrying out overhead assembly work always use specially<br />

designed or otherwise safety–oriented ladders and working<br />

platforms. Never use machine parts as a climbing aid.<br />

Wear a safety harness when carrying out maintenance work<br />

at greater heights. Keep all handles, steps, handrails, platforms,<br />

landings and ladders free from dirt, snow and ice.<br />

Clean the machine, especially connections and threaded<br />

unions, of any traces of oil, fuel or preservatives before<br />

carrying out maintenance/repair. Never use aggressive detergents.<br />

Use lint–free cleaning rags.<br />

Before cleaning the machine with water, steam jet (high–<br />

pressure cleaning) or detergents, cover up or tape shut all<br />

openings which – for safety and functional reasons – must<br />

be protected against water, steam or detergent penetration.<br />

Special care must be taken with electric motors and<br />

switchgear cabinets.<br />

Ensure during cleaning of the machine that the temperature<br />

sensors of the fire– warning and fire–fighting systems<br />

do not come into contact with hot cleaning agents as this<br />

might activate the fire–fighting system.<br />

After cleaning, remove all covers and tapes applied for that<br />

purpose.<br />

After cleaning, examine all fuel, lubricant, and hydraulic<br />

fluid lines for leaks, loose connections, chafe marks and<br />

damage. Any defects found must be rectified without delay.<br />

Always tighten any screwed connections that have been<br />

loosened during maintenance and repair.<br />

Any safety devices removed for set–up, maintenance or repair<br />

purposes must be refitted and checked immediately<br />

upon completion of the maintenance and repair work.<br />

Ensure that all consumables and replaced parts are disposed<br />

of safely and with minimum environmental impact.<br />

Before setting the machine in motion always check that the<br />

accessories have been safely stowed away.<br />

Avoid any operation that might be a risk to machine stability.<br />

Do not step on conveying equipment.<br />

The fastening of loads and the instructing of crane operators<br />

should be entrusted to experienced persons only. The<br />

mars-holler giving the instructions must be within sight or<br />

sound of the operator.<br />

8 EN


Warning of special dangers<br />

Electric energy<br />

Use only original fuses with the specified current rating.<br />

Switch off the machine/plant immediately if trouble occurs<br />

in the electrical system.<br />

Work on the electrical system or equipment may only be<br />

carried out by a skilled electrician himself or by specially<br />

instructed personnel under the control and supervision of<br />

such electrician and in accordance with the applicable electrical<br />

engineering rules.<br />

If provided for in the regulations, the power supply to parts<br />

of machines and plants, on which inspection, maintenance<br />

and repair work is to be carried out must be cut off.<br />

Before starting any work, check the de–energized parts for<br />

the presence of power and ground or short–circuit them in<br />

addition to insulating adjacent live parts and elements.<br />

The electrical equipment of machines/plants is to be inspected<br />

and checked at regular intervals. Defects such as loose<br />

connections or scorched cables must be rectified immediately.<br />

Necessary work on live parts and elements must be carried<br />

out only in the presence of a second person that can cut<br />

off the power supply in case of danger by actuating the<br />

emergency shut–off or main power switch. Secure the working<br />

area with a red– and–white safety chain and a warning<br />

sign. Use insulated tools only.<br />

Before starting work on high–voltage assemblies and after<br />

cutting out the power supply, the feeder cable must<br />

be grounded and components, such as capacitors, short–<br />

circuited with a grounding rod.<br />

EMERGENCY OFF equipment must not be bridged nor set<br />

out of function.<br />

Close area by means of a red and white chain and a warning<br />

panel. Use voltage insulated tools only.<br />

Actuation of the sensors can trigger hazardous machine<br />

functions. Use covers, protective fence or safety light barriers<br />

to prevent access. Set up warning signs.<br />

Plug or unplug quick disconnects only when mains off.<br />

Hydraulic and pneumatic equipment<br />

Work on hydraulic equipment may be carried out only by<br />

persons having special knowledge and experience in hydraulic<br />

systems.<br />

Check all lines, hoses and screwed connections regularly<br />

for leaks and obvious damage. Repair damage immediately.<br />

Splashed oil may cause injury and fire.<br />

Depressurize all system sections and pressure pipes (hydraulic<br />

system, compressed–air system) to be removed in<br />

accordance with the specific instructions for the unit concerned<br />

before carrying out any repair work.<br />

Hydraulic and compressed air lines must be laid and fitted<br />

properly. Ensure that no connections are interchanged. The<br />

fittings, lengths and quality of the hoses must comply with<br />

the technical requirements.<br />

Noise<br />

During operation, all sound baffles must be closed. Always<br />

wear the prescribed ear protectors.<br />

Hazardous substances for humans and the<br />

environment<br />

When handling oil, grease and other chemical substances,<br />

observe the product related safety regulations. Be careful<br />

when handling hot consumables (risk of burning or scalding)!<br />

Mobile Machine<br />

For loading only use lifting gear and tackle of sufficient<br />

capacity. Appoint a competent marshaller to assist in the<br />

lifting operations. Lift machinery and equipment properly<br />

with suitable lifting gear and only in accordance with the<br />

operating instructions (fixing points for lifting tackle, etc.).<br />

Only use suitable means of transport of adequate carrying<br />

capacity. Do not stay or work below suspended loads. Fasten<br />

the loads safely using the suitable fixing points.<br />

Before or immediately after completion of the loading operations<br />

the machine/plant must be secured by means of<br />

recommended/supplied devices against unintentional changes<br />

of position and a corresponding warning sign attached<br />

to the ma-chine/plant.<br />

Before re-commissioning the machine/plant these devices<br />

must be properly removed. Carefully refit and fasten all<br />

parts to be removed for transport purposes before re-commissioning<br />

the machine/plant.<br />

Cut off the external power supply of the machine or plant<br />

even if only minor changes of place are envisaged. Properly<br />

re-connect the machine to the supply mains before<br />

re-commissioning.<br />

9 EN


CYKLOP TEKNIK AB<br />

CYKLOP TEKNIK AB<br />

2. Main machine parts<br />

<br />

<br />

<br />

<br />

<br />

<br />

<br />

<br />

<br />

Machine<br />

plate<br />

Mast<br />

Top plate (optional)<br />

Control cabinet<br />

Prestretch unit<br />

Weld (optional)<br />

Cutter unit<br />

Film retainer arm<br />

Conveyor<br />

(roller conveyor is shown in<br />

the illustration)<br />

Chassis<br />

10 EN


3. Control cabinet<br />

3.1 OVERVIEW<br />

<br />

Pos Type<br />

Rotary switch<br />

Function<br />

Main switch, lockable<br />

<br />

Rotary lamp button<br />

Control voltage<br />

<br />

Lamp pushbutton<br />

Start mode / Alarm reset<br />

<br />

Lamp pushbutton<br />

Automatic<br />

<br />

Pushbutton<br />

Start<br />

<br />

<br />

<br />

Pushbutton<br />

Pushbutton<br />

Machine stop<br />

Emergency stop<br />

<br />

<br />

<br />

<br />

Lamp pushbutton<br />

Control system / Display<br />

Request open door / Part-automatic<br />

Program selection/ Parameter setting<br />

<br />

Light tower<br />

Alarm / Indicator, machine to automatic<br />

3.2 EXPLANATION OF BUTTONS<br />

3.2 EXPLANATION OF BUTTONS<br />

"Main switch on / off"<br />

Switch on or off all power to the machine. Remember<br />

always to switch off the power when working on<br />

the machine.<br />

"Control voltage on / off"<br />

Turn clockwise to switch on the control voltage: the<br />

lamp will come on. (Once you<br />

have turned the main switch,<br />

wait 7 seconds before the control voltage can be<br />

switched on.)<br />

"Start mode / Reset alarm"<br />

Press the lamp button to acknowledge an alarm. If<br />

alarm does not stop, the fault is still present. If you press<br />

the button when there are no alarms, the machine<br />

returns to start mode.<br />

"Automatic"<br />

Press the lamp button to switch to automatic mode.<br />

The lamp comes on. If automatic is enabled and you<br />

press this, the automatic lamp goes off and set the<br />

machine to "part-automatic".<br />

"Machine stop"<br />

Press the stop button and the film cycle comes to a<br />

soft stop. If you hold down the machine stop button<br />

for at least 2 sections, a lamp test is executed which<br />

is controlled via the CPU.<br />

"Emergency stop"<br />

Stops the machine and other connected<br />

equipment. Reset the emergency stop to<br />

restart machine operation. This is done by turning<br />

the button clockwise.<br />

"Request open door / Part-automatic"<br />

Press this button to request door opening.<br />

Automatic operation is interrupted and the machine<br />

continues to the end of the cycle. When this is<br />

complete, the lamp comes on and the door can be<br />

opened.<br />

"Display"<br />

All parameter settings<br />

and program selections are<br />

made here.<br />

"Start"<br />

If the film cycle is interrupted (e.g. because the film<br />

has run out), you can restart it after rectifying the problem<br />

(e.g. loading a film). Once the film cycle is complete,<br />

the pallet remains in place on the machine's conveyor.<br />

If you press "Automatic " at the start of the cycle,<br />

the machine returns to continuous automatic operation.<br />

"Light tower"<br />

When the red light is on, an alarm has been activated.<br />

When the green light is one, the machine is<br />

in automatic mode.<br />

11 EN


3.3 LAMP TEST<br />

A lamp test can be executed by pressing the "Automatic" button and holding it down for more than two seconds. If any of the<br />

buttons with integral lamps does not come on when this test is executed, the lamp is broken. Replace the lamp.<br />

4. Display<br />

4.1 OVERVIEW<br />

4.1.1 GENERAL<br />

<strong>GL</strong> <strong>1000</strong> settings are implemented by navigating in the<br />

pressure-sensitive display.<br />

Some buttons with a dark blue background cannot be pressed and<br />

are there only for information.<br />

Press the relevant button in the display to go to the<br />

required submenu or change a value.<br />

4.1.2 PASSWORDS<br />

Some of the pages cannot be accessed without a password. These<br />

can be accessed by service personnel only, for example.<br />

The login box on the right is displayed if the page is<br />

password-protected. Press to log in. A keypad<br />

then appears in the display. Type your password and then "ENT"; the<br />

login page is then displayed again. Then press to return to the<br />

password-protected page.<br />

4.2 HOME MENU<br />

Continue to the alarm page. When an alarm has been triggered,<br />

the button lamp is red. See section 4.8, page 15.<br />

Continue to pages showing<br />

Cyklop contact information. See section<br />

4.9, page 19.<br />

Continue to the program parameter settings<br />

menu. See section 4.10, page 17.<br />

The above menu is displayed when the machine is started. This<br />

is the top menu, which is called "home menu" from this point on<br />

in the manual.<br />

Continue to the information menu for film.<br />

See section 4.3, page 11.<br />

Continue to the manual operation menu.<br />

See section 4.5, page 12.<br />

1<br />

Displays the selected program. Continue to the program<br />

selection menu. See section 4.11, page 18.<br />

Step up or down to select a program. See section 4.11, page<br />

18.<br />

Continue to the service menu. See section 4.6, page 14.<br />

PROGRAM 1<br />

Displays the selected program.<br />

Continue to the program<br />

selection menu. See<br />

section 4.11, page 18.<br />

12 EN


4.3 INFORMATION MENU FOR FILM<br />

Switches to the previous screen/menu.<br />

Switches to the first information menu. If you are on the<br />

first page, nothing happens.<br />

Displays explanations for the menu page displayed.<br />

Switches to the home menu.<br />

Switches to the next screen/menu.<br />

The<br />

illustration<br />

on the left<br />

shows the first<br />

page below the<br />

information menu.<br />

The information menu<br />

consists of three pages<br />

in total.<br />

Shows on the right the total number of pallets with film<br />

applied.<br />

Resets the number of pallets with film applied. On the<br />

right, you can see the number of pallets with film applied<br />

since the last reset.<br />

Shows the number of metres of film used by the preceding<br />

pallet. Press the button to change film data. (Password<br />

required.)<br />

Shows the number of grams of film used by the preceding<br />

pallet. Requires the correct data to be input for the<br />

film. Press the button to change film data. (Password<br />

required.)<br />

Shows the number of turns for the preceding film application<br />

or the film application in progress.<br />

Switches to the contact information menu.<br />

Switches to the screen containing information on<br />

the degree of prestretch for different gear modes.<br />

Switches to a page with a graphic overview of sensor<br />

status. See section 4.8.2, page 16.<br />

Press to display an explanation on the digits: this will<br />

appear on the right. (See the illustration below.) Return<br />

by pressing "".<br />

Page number two.<br />

Switches to a page with a graphic overview of sensor<br />

status. See section 4.8.2, page 16.<br />

4.4 NAME PROGRAM<br />

Go into the information menu from the home menu, then scroll<br />

to the third page of information by pressing the down arrow.<br />

To edit a program name, press the required program button.<br />

A button pad will be displayed. Type the required name, then press<br />

"ENT".<br />

Page number three.<br />

13 EN


4.5 MANUAL OPERATION<br />

The machine can be operated manually using buttons<br />

in the display. The illustrations shown below may vary slightly<br />

depending on what options are installed on the<br />

machine.<br />

Sometimes manual operation is not possible; when an alarm has<br />

been activated or the film cycle is in progress, for example.<br />

If manual operation is not possible, the button<br />

with .<br />

is replaced<br />

Switches to the previous screen/menu.<br />

Switches to the first manual operation menu.<br />

If you are on the first page, nothing happens.<br />

Indicates whether manual operation is possible.<br />

If a green tick is displayed, manual opertion is possible.<br />

If a red cross is displayed, manual operation is not<br />

possible.<br />

Switches to the home menu.<br />

Switches to the next screen/menu.<br />

Press the relevant button to move the pallet on the<br />

stretch film applicator to the right or<br />

left.<br />

Page number one.<br />

Press the relevant button to move the pallet towards<br />

or away. (Only on machines with the option 90° input<br />

or output transport.) If the board is not in the correct<br />

position, the board is rotated first.<br />

Press the relevant button to rotate the board clockwise<br />

or counterclockwise.<br />

Press the relevant button to open or close the film<br />

clamp.<br />

Page number two.<br />

Press the relevant button to raise or lower the<br />

top plate. (Only on machines with the option: Top plate.)<br />

Press the relevant button to raise or lower the hoist<br />

with the stretch film unit. When moving downwards, the<br />

hoist stops in the starting position.<br />

Page number three.<br />

14 EN


Press the left arrow button to operate the left conveyor<br />

in combination with the shrink film applicator conveyor.<br />

Press the right arrow button to operate the left<br />

conveyor in combination with the shrink film applicator<br />

conveyor.<br />

Press the button with the green tick when the pallet<br />

is in position on the shrink film applicator conveyor.<br />

Page number four.<br />

Positioning has to take place manually as<br />

there is no automatic pallet sensing on the<br />

board.<br />

Manual operation of conveyor. (Optional.) Click on the relevant<br />

conveyor to activate manual operation. The shrink film applicator<br />

conveyor can also be operated manually.<br />

The conveyor is marked when it is activated by means of a green<br />

field which lights up beneath the conveyor. No more than two<br />

adjacent conveyors can be operated simultaneously.<br />

The first two conveyors are activated in the illustration. The first one<br />

also indicates that there is a pallet on the conveyor.<br />

Page number five.<br />

Press the left arrow button to start transport to the left,<br />

or the right arrow button to start transport to the right.<br />

(Requires the machine to have the option installed<br />

which permits transport forwards / back.)<br />

Remove control of top film applicators such as CTFP, TF or PLR.<br />

Applicable to the functions automatic mode and reset. (This page is<br />

included only if the top film applicator option is installed.)<br />

Sets the top film applicator to automatic mode.<br />

Resetting the top film applicator.<br />

Page number six.<br />

15 EN


4.6 SERVICE<br />

The service pages are accessible to service personnel only.<br />

Press to log in. A keypad then appears in the display. Enter your<br />

password and then press "ENT".<br />

4.7 LANGUAGE SELECTION, DATE SET<br />

P r e s s<br />

to access the service menu.<br />

P r e s s<br />

to access the login page.<br />

Then enter your password and close by pressing "ENT".<br />

The service menu screen should now have changed as shown in<br />

the illustration on the left. (The language button should have been<br />

displayed.)<br />

Press to<br />

Language<br />

continue to language selection.<br />

The language selected is shown in the top right corner. If you<br />

want to select a language different to the one selected, click<br />

on the relevant language button to switch to that language.<br />

Input password<br />

& press "ENT"<br />

Language<br />

16 EN


Press<br />

to continue and set the date and time.<br />

The date and time are used to "time-stamp" alarms, among other<br />

things.<br />

Input password<br />

& press “ENT”<br />

Language<br />

4.8 ALARM / STATUS SENSOR<br />

4.8.1 ALARM MESSAGES<br />

Continue to the alarm page. It is possible to press this<br />

button even when no alarm has been triggered. (The lamp<br />

on the button is white in this instance.)<br />

Current alarms are displayed here.<br />

Continue to alarm history.<br />

The alarm history shows the latest alarms triggered.<br />

Current alarms are also displayed as<br />

scrolling text across the bottom of<br />

the display. Displayed in all menus.<br />

17 EN


4.8.2 GRAPHIC OVERVIEW OF SENSOR STATUS<br />

This machine has a function whereby the sensor status is<br />

displayed graphically.<br />

Some sensors are normally in "on" mode, and some sensors are<br />

normally in "off" mode.<br />

Press the relevant part of the machine display to move on to a<br />

more detailed position indication.<br />

See below for a display overview.<br />

The ones with an erroneous status are framed red. Other<br />

sensors affected have a green frame.<br />

To the left, you can see an example of how an erroneous signal<br />

from a sensor might look. If an erroneous signal is displayed, try<br />

to move the machine to start mode and see whether it disappears.<br />

If the erroneous signal is still displayed, the sensor may be faulty.<br />

18 EN


4.9 CONTACT INFORMATION<br />

The contact pages contain information to allow you to contact<br />

your nearest Cyklop company to book a service or place an order for<br />

consumables or spares.<br />

4.10 SETTING PROGRAM PARAMETERS<br />

Values in brackets are max and min values that can be set.<br />

Select a program for parameter editing. (1-9)<br />

Film tension at start of film cycle. (0-90)<br />

Film tension at top of pallet. (0-90)<br />

Film tension in middle of pallet. (0-90)<br />

Page number one.<br />

Film tension at bottom of pallet. (0-90)<br />

Change film pattern. (1-6)<br />

Number of top turns. (0-15)<br />

Number of bottom turns. (1-15)<br />

Rate of film application upwards. (12-75)<br />

Rate of film application downwards. (12-75)<br />

Fig. 2<br />

The above explanations are also available in English in a<br />

submenu (Fig. 2). Press to go to this page.<br />

This explanation menu also includes a submenu with a<br />

graphic explanation (Fig. 3) for the relevant film pattern.<br />

Press or to go to this page.<br />

See section 5.7, page 21 for further information.<br />

Fig. 3<br />

19 EN


Change programs. (1-9)<br />

How high film is to be applied in relation to the top of<br />

the pallet. (0-500)<br />

Page number two.<br />

Value indicating how far down from the top<br />

edge of the pallet film is to be applied. The<br />

value is given in millimetres. Adjustable<br />

values are "0" to "999" mm. The values between "0" and<br />

998 correspond to the number of millimetres from the<br />

top edge of the pallet. If you input a value of "999", the<br />

hoist for the film unit always goes<br />

down to the lowest height for<br />

cutting. (0-999)<br />

Interim speed before rotary board reaches<br />

high speed. (0-999)<br />

Top plate. (Optional.)<br />

Top film. (Optional.)<br />

Top rotary board speed during film cycle. (25-100)<br />

Fig. 2<br />

Weld time. (0.05-2.00)<br />

The above explanations are also available in English in a<br />

submenu (Fig. 2). Press to go to this page.<br />

The next page shows an overview of the<br />

preset program parameters. There is also<br />

space there for noting your own program<br />

settings.<br />

4.11 PROGRAM SELECTION<br />

Programs can be selected in three ways. press 1 , or PROGRAM 1 .<br />

The third way is to step up and down using the arrow up and arrow<br />

down keys ( ).<br />

Step up or down to select a program.<br />

Fig. 2<br />

Displays the selected program. Press the button and a<br />

keypad is displayed. Then select the relevant number<br />

1<br />

and press "ENT".<br />

PROGRAM 1<br />

20 EN<br />

Displays the selected program.<br />

Continue to the program selection<br />

menu. See Fig. 2.<br />

Programs are selected by pressing the relevant program<br />

button. The program number selected is displayed in the bottom<br />

left corner. Programs can also be selected using an external signal<br />

when the machine is in automatic mode.


5. Operate the machine<br />

5.1 STARTUP - START UP THE MACHINE AND RUN IT TO STARTING POSITION<br />

<br />

Make sure that the machine is powered up<br />

and has a compressed air feed to it.<br />

<br />

The lamp for alarms should now have gone<br />

off.<br />

<br />

Check that the emergency stop button is not<br />

depressed.<br />

<br />

The lamp button "Start mode/Alarm reset"<br />

comes on.<br />

<br />

<br />

Turn the main switch. Wait for about 7 seconds<br />

before step 4.<br />

Turn the rotary lamp button "Control voltage"<br />

clockwise.<br />

<br />

The button for semiautomatic operation<br />

in the display has lit up. The display<br />

should look as shown below, possibly<br />

with a different program selection.<br />

The machine is now in start mode and<br />

semiautomatic mode.<br />

<br />

The alarm lamp in the light tower comes on.<br />

<br />

5.2 LOAD FILM<br />

Press the alarm button "Start mode/Alarm<br />

reset". If alarms are shown in the display,<br />

acknowledge these first and then press the<br />

button again. Any parts of the machine which<br />

are not in starting position will be moved to<br />

there.<br />

NOTE: If the machine is placed in an cold environment and equipped with the<br />

-6° or -28° option, keep in mind that the film must have the same temperature<br />

as the surroundings where it will be used. Store the film in the same room as the<br />

machine for at least 24h before use.<br />

1. Check which side of the film is sticky. If the outside is sticky<br />

(most common), the roll of film must rotate counterclockwise (Fig. 1). If the<br />

inside is sticky, it must rotate clockwise (Fig. 2).<br />

2. Insert a new roll of film by pressing it down over the roller "A" (Fig. 3). Take<br />

care to make sure the roll bottoms out. NOTE: Handle the roll of film with<br />

care so as not to damage it, as this may cause the film to break.<br />

Fig. 1.<br />

3. Pull the film as shown in Fig. 1 or 2. The easiest thing to do is fold the end<br />

of the film in four and pull it between the top part of the rollers as shown in<br />

Fig. 3, B (grey area).<br />

4. Secure the end of the film in the clamp on the film retainer arm on the<br />

rotary board on the machine (Figure 4). Press and hold down the valve button "D" to<br />

open the clamp. Note that the clamp will close again as soon as the<br />

valve button is released.<br />

B<br />

Fig. 2. Fig. 4.<br />

Risk of cutting!<br />

The flanges on the<br />

roller may be sharp.<br />

Fig. 3.<br />

A<br />

Warning!<br />

The machine has a number of points where<br />

there is a risk of getting trapped or cut.<br />

Take great care when in the machine's<br />

operating range.<br />

D<br />

21 EN


5.3 SET PRESTRETCH OF FILM<br />

Use the gear control (see the figure on the left) directly above the<br />

roll of film to set different degrees of prestretch.<br />

Gear 1= 60%<br />

Gear 2= 100%<br />

Gear 3= 130%<br />

Gear 4= 160%<br />

Gear 5= 200%<br />

Gear 6= 280%<br />

Gear 7= 340%<br />

Gear 8= 400%<br />

If you select a high gear, the film will be thinner on the pallet goods.<br />

This means less film consumption per pallet, but it also requires a<br />

higher film quality than a lower gear. Start with gear 6, for example,<br />

to see whether the film holds. If it breaks, switch to a lower gear or<br />

a higher film quality.<br />

5.4 SET FILM TENSION<br />

Film tension parameters are set via the display.<br />

See section 4.10, page 19 for information on the buttons.<br />

The film tension is adjustable for every program and for different<br />

parts of the film cycle.<br />

Value set to "0" = Low film tension<br />

Value set to "90" = High film tension<br />

This value corresponds to the percentage reduction in motor torque.<br />

Example:<br />

If a value "25" is set, this is equivalent to the pallet/rotary board<br />

pulling 25% and the motor feeding 75%.<br />

5.5 START THE MACHINE<br />

<br />

IF THE MACHINE HAS A PALLET<br />

STANDING ON THE CONVEYOR<br />

Make sure that the machine is in start mode.<br />

See section 5.1, page 19.<br />

IF THE MACHINE DOES NOT HAVE A<br />

PALLET STANDING ON THE CONVEYOR<br />

<br />

Make sure that the machine is in start mode.<br />

See section 5.1, page 19.<br />

<br />

Select a program. See section 4.11, page 18.<br />

<br />

Select a program. See section 4.11, page 18.<br />

<br />

Press the "Start" button. This needs to be<br />

done only if the machine has a pallet on the<br />

conveyor.<br />

<br />

Press the "Automatic" button to switch to automatic<br />

mode.<br />

<br />

Press the "Automatic" button to switch to automatic<br />

mode.<br />

The machine is now ready for operation and in<br />

automatic mode.<br />

The machine is now ready for operation and in<br />

automatic mode.<br />

22 EN


5.6 PAUSE IN AUTOMATIC MODE<br />

<br />

<br />

Pause in automatic mode can be used if the<br />

operation needs to enter the machine's operating<br />

area.<br />

Press the button "Request open door". This<br />

button then starts to flash.<br />

The machine stops and the lamp for the button<br />

"Request open door" is on continuously.<br />

<br />

<br />

<br />

Check that nobody is present within the safety<br />

fencing before closing the gate.<br />

Acknowledge with the button "Start mode /<br />

Reset alarm".<br />

The lamp for alarms on the light tower should<br />

now have gone off and the button "Start<br />

mode / Reset alarm" comes on.<br />

<br />

Open the gate and do what has to be done.<br />

The alarm lamp comes on at the light tower.<br />

<br />

Press the "Automatic" button to return to automatic<br />

mode.<br />

Warning!<br />

The machine has a number of points where<br />

there is a risk of getting trapped or cut.<br />

Take great care when in the machine's<br />

operating range.<br />

The machine will now continue in<br />

automatic mode from the position<br />

in the sequence<br />

where it was interrupted.<br />

5.7 DESCRIPTION OF FILM PATTERN<br />

Pattern 1 - Dust-protected /<br />

‎Secure<br />

This film program starts at the bottom<br />

and ends at the top. With the parameter<br />

"Down before cutting" and the<br />

value set to "999", the hoist moves<br />

down to the lowest height for cutting.<br />

(Gives one to two layers of film.)<br />

The number of bottom and top turns, film<br />

tension, film overlap, etc. can be selected<br />

via film parameters.<br />

TS<br />

Topsheet<br />

Pattern 4 - Water-protected (Requires<br />

optional top film equipment)<br />

This film program starts at the bottom,<br />

then pauses at the top where top<br />

film is applied. The film sequence<br />

then continues and can be<br />

terminated at either the top<br />

or the bottom of the pallet.<br />

The number of bottom and top turns, film<br />

tension, film overlap, etc. can be<br />

selected via film parameters.<br />

Pattern 2 - Secure<br />

This film program starts at the bottom,<br />

applies film up to the top and then<br />

applies film down to the bottom and<br />

up to the lowest height for cutting.<br />

(Gives two-and-a-half layers of film.)<br />

The number of bottom and top turns, film<br />

tension, film overlap, etc. can be selected<br />

via film parameters.<br />

Pattern 5 - Custom (Optional)<br />

Pattern 3 - Extra secure<br />

This film program starts at the bottom,<br />

applies film up to the top and then<br />

applies film down to the bottom and ends<br />

at the top. With the parameter<br />

"Down before cutting" and the value<br />

set to "999", the hoist moves<br />

down to the lowest height for<br />

cutting. (Gives three to four layers of<br />

film.)<br />

The number of bottom and top turns,<br />

film tension, film overlap, etc. can be<br />

selected via film parameters.<br />

Pattern 6 - Through-transport<br />

The pallet is transported through the<br />

machine without film being applied.<br />

23 EN


6.1 CLEANING<br />

6. Care and daily maintenance<br />

(Trained personnel only)<br />

Always keep the area inside and around the machine clean and tidy. Get into the habit of checking over the machine at least once a<br />

week, and clean if so required. Use a damp cloth with water and washing-up liquid.<br />

ATTENTION !<br />

The installation should be turned off before<br />

cleaning. Lock the master switch located<br />

on the mast so that the installation<br />

can’t be turned on while cleaning is in<br />

progress.<br />

WARNING !<br />

Ensure that electrical components are<br />

not in contact with water or other liquids.<br />

When the machine is cleaned by<br />

staff other than the operator, eg a cleaner,<br />

he or she must be given instructions<br />

regarding cleaning of the machine<br />

6.2 SERVICE & MAINTENENCE<br />

Within the warranty period, repairs may only<br />

be performed under the supervision of a<br />

technichian of the supplier.<br />

The quality of any replacement part must at least<br />

correspond to the one of the original part (compare specifications).<br />

All parts can be ordered from the manufacturer.<br />

As a precaution, it may be advisable to stock some spare<br />

parts to minimize downtime. Consult the manufacturer. See<br />

”Recommended spare parts list” last in the spare parts section.<br />

The installation consists mainly of standard parts (which<br />

can be purchased on the open market), but also of original<br />

parts (which are available from the manufacturer).<br />

Standard parts:<br />

• Use preferably the same make as the original. If in doubt,<br />

consult the supplier.<br />

Original parts:<br />

• Replacement parts must be ordered from the supplier.<br />

WARNING !<br />

Deviations from the above rules can<br />

have consequences that endanger the<br />

safe operation of the installation and<br />

the warranty period will be forfeited.<br />

The manufacturer is not responsible for<br />

events resulting from such deviations.<br />

SERVICE AND MAINTENANCE<br />

The power should be broken with the<br />

power main switch during service or<br />

maintenance. Also the main switch must<br />

be locked to prevent unplanned actuation.<br />

ELECTRICAL WORKS<br />

Although the power switch is turned off<br />

some electricity may remain in the<br />

installation, eg in capacitors or in the<br />

form of potential energy differences.<br />

Therefore wait a few minutes before<br />

work with electrical wiring can begin.<br />

24 EN


Air and power must be switched off before work may commence on the machine. Make sure that there are no goods on the machine.<br />

To be checked Adjustment and/or lubrication Range<br />

General<br />

Cleaning should be carried out around the rotary board and<br />

unit in order to<br />

minimise the risk of problems<br />

Weekly<br />

To be checked Adjustment and/or lubrication Range<br />

Knife, Catcher<br />

Check that the knife blade (A) is not blunt or cracked.<br />

Replace where necessary.<br />

Check that the blade steels (B) are<br />

not cracked or bent. Replace where<br />

necessary.<br />

As necessary<br />

As necessary<br />

Risk of cutting!<br />

The knife and blade steels are sharp.<br />

Discard any worn-out knives/blade<br />

steels in a container for sharp waste.<br />

Do not discard among ordinary waste.<br />

B<br />

A<br />

To be checked Adjustment and/or lubrication Range<br />

Roll of film<br />

- Brake<br />

A<br />

B<br />

Check the friction brake by pulling on the film at<br />

normal film speed and then suddenly releasing the film.<br />

The roll of film should then stop after approx. 1/5 of a turn.<br />

3 mths<br />

Basic setting: Screw down the nut (A) until the spring washer<br />

(B) is fully compressed.<br />

Then unscrew the nut by (A) ¾ turn.<br />

Lubrication!<br />

Apply a lubricant spray with a<br />

pipe. Avoid applying lubrication in<br />

locations not specified.<br />

25 EN


7. Resetting<br />

7.1 FILM BREAKAGE / END OF FILM<br />

If the film has run out or broken, the machine<br />

goes automatically to its starting position.<br />

The alarm lamp comes on at the light tower.<br />

<br />

The lamp for alarms on the light tower should<br />

now have gone off and the button "Start<br />

mode / Reset alarm" comes on.<br />

<br />

<br />

<br />

<br />

Press the button "Start mode / Reset" to<br />

acknowledge the alarm. The button lights up.<br />

Press the button "Request open door" and<br />

the button will light up.<br />

Open the gate and go in and - if the film has<br />

run out - switch to a new roll of film. If the<br />

film has broken, secure the end of the film in<br />

the film retainer. See section 5.2, page 19 for<br />

further information.<br />

Check that nobody is present within the safety<br />

fencing before closing the gate.<br />

Once the gate is closed, the contactor<br />

automatically applies the gate switch.<br />

Acknowledge by pressing either "Request<br />

open door" or "Start mode / Reset alarm".<br />

<br />

<br />

The button for semiautomatic operation in<br />

the display has lit up. The machine is now in<br />

start mode and semiautomatic mode.<br />

If there is a pallet in the machine which needs<br />

to have film applied again, press the button<br />

"Cycle start" to start the film cycle.<br />

Press the "Automatic" button once the cycle<br />

has started.<br />

When the film cycle is complete, the pallet<br />

will be transported out of the machine and<br />

the machine will continue to operate in<br />

automatic mode.<br />

7.2 MACHINE STOP ACTIVATED<br />

<br />

<br />

If the button "Machine stop" has been<br />

depressed during any sequence, the<br />

sequence in progress will be terminated. The<br />

alarm lamp comes on at the light tower.<br />

Press the button "Start mode / Reset".<br />

Press the button "Start mode / Reset" again.<br />

Any parts of the machine which are not in<br />

starting position will be moved to there.<br />

<br />

<br />

<br />

If there is a pallet in the machine which<br />

needs to have film applied again, press the<br />

button "Cycle start" to start the film cycle.<br />

Press the "Automatic" button once the cycle<br />

has started.<br />

When the film cycle is complete, the pallet<br />

will be transported out of the machine and<br />

the machine will continue to operate in<br />

automatic mode.<br />

7.3 EMERGENCY STOP ACTIVATED<br />

<br />

<br />

<br />

<br />

If the button "Emergency stop" has been<br />

depressed during any sequence, the<br />

sequence in progress will be<br />

stopped immediately and the alarm<br />

lamp will come on at the light tower.<br />

Release the emergency stop button.<br />

Rotate the button "Control voltage" clockwise<br />

to on position. The lamp comes on.<br />

Press the button "Start mode / Reset" to acknowledge<br />

the alarm.<br />

Press the button "Start mode / Reset" again.<br />

Any parts of the machine which are not in<br />

starting position will be moved to there.<br />

<br />

<br />

<br />

<br />

The lamp for alarms on the light tower should<br />

now have gone off.<br />

If there is a pallet in the machine which needs<br />

to have film applied again, press the button<br />

"Cycle start" to start the film cycle.<br />

Press the "Automatic" button once the cycle<br />

has started.<br />

When the film cycle is complete, the pallet<br />

will be transported out of the machine and<br />

the machine will continue to operate in automatic<br />

mode.<br />

26 EN


7.4 LIGHT BEAM WHICH HAS TRIPPED (OPTIONAL)<br />

<br />

<br />

In some cases, a reset can be executed<br />

without going into the machine's operating<br />

range. The following description is applicable<br />

if the operator needs to go in to reset light<br />

boom.<br />

Open the gate. The alarm lamp comes on at<br />

the light tower. Go in and reset light boom.<br />

When the gate is closed, acknowledge with<br />

the button "Start mode / Reset alarm".<br />

<br />

<br />

The lamp for alarms on the light tower should<br />

now have gone off and the button "Start<br />

mode / Reset alarm" comes on.<br />

If the machine was in automatic mode before<br />

the pause in automatic mode, press the<br />

button "Automatic".<br />

The machine will now continue at the point<br />

where it left off in the automatic sequence.<br />

The machine will continue working in automatic<br />

mode.<br />

27 EN


8. General troubleshooting<br />

8.1 TROUBLESHOOTING<br />

Problem<br />

If nothing works<br />

Action<br />

Check that the machine is powered up and that the main switch and the rotary knob for control<br />

voltage are set to position "1". Try holding down "Machine stop" for 3 s.<br />

Then press "Reset". Run to starting position.<br />

Error message "A2", main contactor not on, check that the emergency stop is not depressed. If it is,<br />

turn the button clockwise to release it.<br />

If the film breaks Check that the roll of film has sustained no damage. Replace the roll of film if it has. See section 7.1,<br />

page 23 for resetting.<br />

If the rotary board stops<br />

in the wrong position<br />

If the film is not applied<br />

right up to<br />

the top of the goods<br />

The display is not working.<br />

The hoist does not operate<br />

and gives error message<br />

"A15", "A16" or "A4"<br />

Press the button "Start mode / Reset alarm" to return the rotary table to home position.<br />

Check the goods height sensor. Check the film application settings: read "Display - Pallet parameters"<br />

(password required).<br />

The machine can be run, but only with the latest cycle setting (program selection) run. Contact<br />

Cyklop.<br />

The obstruction protection under the hoist or cutting unit may be activated. Check that there is nothing<br />

under the hoist or cutting unit. With error message "A4", check the hoist pulse sensor.<br />

28 EN


9. Transport<br />

9.1 TRANSPORT<br />

The machine must be transported by truck. The machine can be<br />

lifted from the long sides or from the front. Do not lift from the side<br />

with the electrical cabinet. See illustrations.<br />

If the machine is lifted from the side, the truck must have forks<br />

which reach through the entire machine chassis.<br />

If the machine is lifted from the front, the truck must have forks<br />

long enough to reach the centre beam (A).<br />

Lift the machine carefully and transport it slowly.<br />

Risk to life!<br />

Remaining under any type of<br />

suspended load, or working<br />

there, may risk your life!<br />

A<br />

Service area: Minimum of 1 m around the machine is needed for service.<br />

The service places of the machine must be reachable by approved<br />

person lift or similar, alternatively, the customer takes responsibility<br />

that the machine’s service can be performed. NOTE! This will then<br />

be determined at the time of procurement.<br />

Transport<br />

National rules and regulations must be observed when transporting<br />

Cyklop film stretch machines and accessories.<br />

Individual parts and large components are carefully fixed during<br />

delivery. When the machine is assembled or moved, great care<br />

must be taken. Check that the lifting device is designed to take the<br />

weight and does not pose a safety risk.<br />

Only approved lifting devices with a lifting capacity greater than<br />

the total weight of the machine, plus packaging, may be used.<br />

Dimensions and weight<br />

The delivery note with the goods includes details on the weight and<br />

dimensions of the goods.<br />

General rules<br />

Unless stated otherwise, all parts must be transported in their original<br />

packaging to the installation site. When unpacked, all parts<br />

must be examined so that any transport damage can be found. If<br />

the goods have been damaged in transit, the shipping agent must<br />

be contacted immediately and unpacking must be stopped.<br />

Transport damage<br />

Any damage to the goods must<br />

be noted on the delivery note<br />

when the goods are received.<br />

No exceptions!<br />

Risk of damage!<br />

The centre of gravity of the machine may be high,<br />

which increases the risk of the machine tipping<br />

over. Check carefully where the centre of gravity<br />

is so as to eliminate the risk of tipping.<br />

29 EN


10. Technical specifications<br />

Machine<br />

Capacity<br />

Rotary board speed<br />

Hoist speed<br />

Temperature range<br />

Safety class<br />

Max 80 pallet/h (depending on goods type)<br />

Max 23 r/min<br />

Max. 0.6 m/s<br />

+5 to +35°C, for use in a dry, tempered area<br />

2<br />

Electricity<br />

Connection<br />

Output<br />

Safety norm<br />

EX-classification<br />

3x400 V + N + PE, 50 Hz<br />

t.b.a. kW<br />

IP54<br />

Not approved for ATEX classified areas<br />

Pallet goods<br />

Min size (length x width)<br />

Max size (length x width)<br />

Lowest inc. pallet<br />

Height inc. pallet<br />

Weight<br />

0.4 x 0.6 m<br />

1.2 x 1.2 m or 1.4 x 1.0 m<br />

>500 mm (depending on goods type)<br />

Std. height 2500 mm<br />

Max 1500 Kg<br />

<strong>Stretch</strong> film<br />

Diameter, core<br />

Outer diameter, max<br />

Film width, max<br />

Film thickness<br />

76.4 mm +-<br />

250 mm<br />

500 mm<br />

12-25 my, 20 my recommended<br />

The above values apply to standard machines. These values may differ if the machine is<br />

fitted with additional options.<br />

30 EN


11. Table of set values, program parameters<br />

Film parameters<br />

Prog 1 Prog 2 Prog 3 Prog 4 Prog 5 Prog 6 Prog 7 Prog 8 Prog 9<br />

1 1 1 6<br />

10 10 10<br />

15 15 15<br />

15 15 15<br />

15 15 15<br />

2 2 2<br />

3 3 3<br />

35 35 35<br />

35 35 35<br />

75 75 75<br />

100 999 999<br />

75 75 75<br />

60 60 60<br />

1,00 1,00 1,00<br />

No No No<br />

No No No<br />

31 EN


Version log<br />

1.0 Initial release<br />

1.1 Version log added.<br />

EC declaration updated according to new machine directive.<br />

2.0 EG-declaration updated with SS-EN 415-6, Packaging machines<br />

safety.<br />

General safety instructions uppdated with unauthorized use.<br />

Installation updated with service area.<br />

2.1 Temperature information for stretch film handling added.<br />

32 EN


33 EN


Ver. 1.0<br />

English<br />

Deutsch<br />

Svenska<br />

Art.no: 961010EN

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