Manual12

2,481 views

Published on

Published in: Business, Technology
0 Comments
2 Likes
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total views
2,481
On SlideShare
0
From Embeds
0
Number of Embeds
4
Actions
Shares
0
Downloads
34
Comments
0
Likes
2
Embeds 0
No embeds

No notes for slide

Manual12

  1. 1. TR1860 L1/6 FB use and service manual serial no. 740 F.B. Balzanelli avvolgitori spa w ww.fb-balzanelli.it 20158 milano Via Teglio, 11 Tel. 02.603572 Fax 02.603342 e-mail: marketing@fb-balzanelli.it 61030 Borgaccio di saltara (Pu) Via Buonarroti, 11 Tel. 0721.892168 Fax 0721.879602 e-mail: produzione@fb-balzanelli.it
  2. 2. TR1860 L1/6 FB Use and service Manual Serial No. 740 TR1860 L1/6 Serial No. 740 Client UPONOR A/S Code FB01061700SA740/mn Date 10.05 OVERVIEW As well as using the machine correctly, the operators should carefully read and fully understand this user manual and strictly follow the instructions it contains. Spending some time reading this manual will allow health and safety risks to people and financial losses to be avoided. For the entire life of the machine, the manual should be kept in a location easily accessible to all operators and maintenance engineers. Purpose of this manual This manual is supplied as part of the machine and has been written by the manufacturer to supply all the information required to those who are authorized to work with the machine. This manual describes the machine as it was at the time of publication and cannot therefore reflect any information whatsoever on future or non standard products. The accuracy of the information given in this manual and its conformity with the equipment described is correct at the time of printing. However, possible differences may still be present. F.B. Balzanelli Avvolgitori SpA is fully committed to continuous technological development of its machines and therefore reserves the right to make changes or improvements to its products at any time. No part of this manual may be reproduced or transmitted to third parties in any form or by any means, electronic or mechanical or otherwise, without the prior written permission of F.B. Balzanelli Avvolgitori SpA. All products or registered marks listed in this manual belong to their respective owners Manual Layout Apart from any differences which do not affect the accuracy of the information provided, this manual is divided into four parts. The first part, the introduction, contains all general health and safety information. The second part contains the information on the coiling machine and its components. The third part of the manual contains the information on the software supplied with the machine. The last part is a practical guide on how to use the coiling machine.
  3. 3. FB TR1860 L1/6 Index Part I SAFETy AND gENERAL INFORMATION Part II MACHINE INSTALLATION AND FUNCTIONINg Part III SOFTWARE USER MANUAL Part IV PRACTICAL gUIDE TO THE USE OF THE COILER Part V TECHNICAL ATTACHMENT Use and Service Manual Serial no. 740 - 10.05
  4. 4. FB TR1860 L1/6 Part I SaFeTy aNd geNeRaL INFoRMaTIoN 1. Rules . . . p. II 2. Machine manufacturer identification . . . p. II 3. Coiler description and use . . . p. III 4. Not allowed uses . . . p. III 5. Dangerous areas . . . p. IV 6. Safety devices. . . p. V 7. Acoustic and luminous indicators . . . p. VII 8. Safety general rules . . . p. VIII 9. Glossary . . . p. X 10. Symbols . . . p. XI Use and Service Manual Serial No. 740 - 10.05
  5. 5. Part I Safety and general information FB TR1860 L1/6 RULeS 1. Rules The coiler has been conceived and realised in compliance with the standards established by the European harmonised rules - EN Rules. Thus, it meets the requirements required by the Italian law and the European Directives relating to the production of machines. In particular: PublICATIoN ARGuMENT DATE Regulation 89/392/CE on machine manufacturing 14/06/1989 Regulation 91/368/CE (modified with the 89/392/CE) 20/06/1991 Regulation 93/44/CE (modified with the 89/392/CE) 14/06/1993 Regulation 93/68/CE (modified with the 89/392/CE) 22/07/1993 Regulation 98/37/CE (modified with the 89/392/CE) 22/06/1998 CEI EN 60204-1 • CEI EN 60204-2 Machine safety - Machine Electric equipment 2. MACHINe MANuFACTuReR IDeNTIFICATION The following identification tag is applied on the electrical control panel of the machine. logo Address identification of the Constructor Machine Model Machine number Manufacture year Conformity CE symbol Use and Service Manual 2 Serial No. 740 - 10.05
  6. 6. Part I Safety and general information FB TR1860 L1/6 USe 3. COIleR DesCRIpTION AND use The TR1860 is an automatic machine for industrial use for the winding and packaging of corrugated pipes made of plastics. It realizes coils having variable characteristics according to the data selected by the operator, packaged with 3 or 6 binding points with thermo-welded polypropylene strap. ThE fuNCTIoNING of ThE CoIlER DuRING ThE PRoDuCTIoN CyClE IS CoMPlETEly AuToMATIC. The intervention of the operator is required only for the initial preparation of the machine, according to the characteristics of the pipe to wind, the coils to realize and to solve eventual functioning anomalies. The coiler cannot be used to produce coils for manual strapping. The intervention of the operator is required only for the initial preparation of the machine, according to the characteristics of the pipe to wind, the coils to realize and to solve eventual functioning anomalies. The automatic functioning of the machine is controlled by a PlC (Programmable logic Control), an electronic device which can be programmed for the management and control of the production processes, and that uses a f.b. balzanelli Avvolgitori SpA original software, which is specific for this model of coiler. for further information on the programme, please refer to the third part of this manual. The operator drives and controls the functions of the PlC by means of a local PC equipped with a display and a keyboard placed on the Control board. The PlC directly manages, or by means of further devices (axis controls, activations for electric motors, pneumatic electro valves), the operations of the different actuators of the machine. 4. NOT AllOweD uses f.b. balzanelli Avvolgitori SpA could not be held responsible of the damages caused by an incorrect use of the machine or by a service not correctly carried out. IT IS AbSoluTEly foRbIDDEN ANy oThER uSE of ThE MAChINE oThER ThAN ThE oNE SPECIfIED. Use and Service Manual 3 Serial No. 740 - 10.05
  7. 7. Part I Safety and general information FB TR1860 L1/6 daNgeRoUS aReaS 5. DANgeROus AReAs here follow the areas where the operator can stay during the functioning of the machine and those where the stay is forbid- den. Aluminium and polycarbonate structure Aluminium and polycarbonate structure Use and Service Manual 4 Serial No. 740 - 10.05
  8. 8. Part I Safety and general information FB TR1860 L1/6 SaFeTy devIceS 6. sAFeTy DevICes DANgeR-ATTeNTION Tempering wiTh and/or removing The safeTy devices from The coiling machine may compromise operaTor’s safeTy. emergency mushroom buttons pneumatic valve by pressing this button, the machine Placed inside the pneumatic cabinet, immediately stops in emergency. The it allows you to disconnect the main buttons is placed on the electrical machine from the pneumatic supply panel, the other four are placed in four line by discharging the residual energy different points of the machine photocell Barriers Main switch Whenever there is an obstacle along Allows the machine to be disconnected from the trajectory of at least one of the two the electrical power supply. pairs of photocells, the machine stops The switch is located on the front of the immediately in the emergency state electrical control panel Use and Service Manual 5 Serial No. 740 - 10.05
  9. 9. Part I Safety and general information FB TR1860 L1/6 SaFeTy devIceS The coiler is equipped with a protection device from the mechanical and electrical risks. All the moving mechanical parts are placed in a cage made of aluminium sections and polycarbonate. opening the access doors (safety barriers) during machine operation will immediately stop the coiling machine, which cannot be restarted until the doors have been closed again. DANgeR-ATTeNTION The safeTy barriers may be disabled by inserTing The key provided in The elecTrical conTrol panel (see picTure) (on=1). This condiTion is conTinually shown by a blue warning lighT (see paragraph 7). The key used To disable The safeTy barriers musT be kepT by The safeTy manager. DANgeR-ATTeNTION accessing The inside of The coiling machine wiTh The safeTy barriers disabled is only allowed To qualified sTaff. Use and Service Manual 6 Serial No. 740 - 10.05
  10. 10. Part I Safety and general information FB TR1860 L1/6 acoUSTIc aNd LUMINoUS INdIcaToRS 7. ACOusTIC AND luMINOus INDICATORs DANgeR-ATTeNTION Tampering wiTh and/or removing These Two signalling columns fiTTed To The coiling machine may impair The correcT operaTion of The machine and increase The risk To The operaTor An acoustic and visual indicators column is pla- ced on the upright of the pipe guide. A. Acoustic signal A It indicates the starting up of the coiler by means B of the button AIR RESET. C The signalising goes on for 5 seconds, after then the machine will be pneumatically supplied. Should you be inside the coiler and hear the acoustic signalising, press immediately one of the stop buttons placed on the columns of the coiler or on the keyboard. b. yellow light It indicates the presence of alarms or a coiling stop caused by an anomaly. Check the kind of alarm on the operator’s terminal. A selector on the operator panel permits associating an audible alarm with the visible alarm. C. blue light It indicates the DISAblING of the protection bars, when the key placed on the electrical panel has been turned on oN =1. DANgeR-ATTeNTION if necessary, before inTervening inside The elecTrical cabineT, cuT The Tension by operaTing on The power swiTch placed in The elecTrical panel. To enTer The elecTrical cabineT, open The door by means of The suiTable key kepT by The Technical responsible. A second column fitted with visual indicators is located on the upper section of the rear of the coiling machine, near the coil exit side D. blue light It indicates the expulsion of the coil from the D coiler and stays on all the time that is necessary for the expulsion. be very careful because from the lighting of the blue indicator the photocell is disabled. Use and Service Manual 7 Serial No. 740 - 10.05
  11. 11. Part I Safety and general information FB TR1860 L1/6 SaFeTy geNeRaL RULeS 8. sAFeTy geNeRAl Rules The manufacturer, during project and construction, has paid particularly attention to those aspects which can cause risks to the safety and health of the people who interact with the machine. further to the respect of the relating laws in force, he has adopted all the rules of the good technique of construction. The aim of this information is to make the users aware about paying a particular attention in order to avoid all risks.  however, the most important thing is to operate with caution. Safety also depends on all the operators who interact with the machine.  Read carefully the instructions reported in the manual supplied with the machine and the instructions directly applied on the machine; in particular, it is necessary to respect the instructions relating to safety.  Do not alter, eliminate or by-pass the safety devices installed on the machine. If this instruction is not respected, this can cause serious risks to the safety and health of people.  The personnel who carries out any type of intervention during the whole life of the machine, must have special technical competencies, particular capacities and a know how and experiences in the specific sector. The lack of these require- ments can cause damages to the safety and health of people.  During the normal use or for any intervention on the machine, keep the perimetrical spaces in safe conditions, in order not to cause risks to the safety and health of people. for some phases it could be necessary the aid of one or more assistants. In these cases, it will be necessary to train and inform them about the kind of activity to carry out in order not to cause damages to the safety and health of people.  The operator must be informed about the use of the machine and must have capacities and competencies related to the kind of the activity to carry out. Even after being suitably informed, at the first use of the machine, if necessary, simulate some test operations in order to identify the commands and their main functions.  use the machine only for the uses foreseen by the manufacturer. The use of the machine for improper uses can cause risks to the safety and health of people and economic damages.  The machine has been conceived and manufactured in order to meet all the operational conditions indicated by the manu- facturer. Altering any device to obtain performances other than those foreseen can cause risks for the safety and health of people and economic damages.  Do not use the machine with the safety devices non perfectly installed and efficient. The non respect of this requirement can cause serious damages for the safety and health of people.  Keep the machine in conditions of maximum efficiency by carrying out the programmed service operations indicated by the manufacturer. A good service will allow you to obtain better performances, a longer time of exercise and a constant level of the safety requirements.  before carrying out any service and adjustment intervention on the machine, activate all the safety devices and evaluate if it is necessary to inform the personnel who operates on the machine and the personnel nearby. In particular it is neces- sary to signal the nearby areas and avoid the access to all those devices which could, if activated, cause sudden danger conditions by causing damages to the safety and health of people. Use and Service Manual 8 Serial No. 740 - 10.05
  12. 12. Part I Safety and general information FB TR1860 L1/6 SaFeTy geNeRaL RULeS  The service and adjustment intervention must be carried out by authorized people, which must prepare all the necessary safety conditions according to the procedure indicated by the manufacturer.  All the service intervention requiring a special technical competence or particular capacities must be carried out only by qualified personnel having a know how and experience in the specific intervention. In order to carry out service interven- tions in those areas which are not easily accessible or dangerous, prepare all the suitable safety conditions for everyone in compliance with the law in force relating to the safety in the work areas.  Replace the used particulars by using original spare parts. use oils and greases suggested by the manufacturer. All this could ensure the functionality of the machine and the foreseen safety level. Use and Service Manual 9 Serial No. 740 - 10.05
  13. 13. Part I Safety and general information FB TR1860 L1/6 gLoSSaRy 9. glOssARy operator: a person who has been chosen and authorized among those who have the requirements, the competencies and the necessary information relating to the use and ordinary service of the machine or of the installation in object person charged of the service: a technician who has been chosen and authorized among those who have the requirements to carry out the interventions of ordinary and extraordinary service on the machine or on the installation in object. he/she must have certain information and competencies with particular capacities in the intervention sector installer: a technician chosen and authorized by the manufacturer or his mandatory among those who have the requirements in order to carry out the installation and the test of the machine or of the installation in object responsible of the installation: a technician chosen and authorized to organize all the organization and operational aspects of the personnel working at the installation and charged of the production activities assistant: a subordinate person assisting the production activity of the machine or of the installation in object ordinary service: all the necessary operations in order to keep the good functioning and efficiency of the machine or of the installation in object. Generally, these operations are programmed by the manufacturer who defines the necessary competencies and the intervention modalities Use and Service Manual 10 Serial No. 740 - 10.05
  14. 14. Part I Safety and general information FB TR1860 L1/6 SyMBoLS 10. syMBOls In order to outline some parts of the text which are particularly important or to indicate some important specifications, some symbols, whose meaning is described below, have been adopted. Interventions which can be carried out only by the personnel charged of the service. DANgeR-ATTeNTION iT indicaTes siTuaTions of greaT danger ThaT, if noT Taken inTo consideraTion, can cause serious damages To The safeTy and healTh of people. Caution - precaution it indicates that it is necessary to adopt special rules in order not to cause damages to the safety and health of people and economical damages. Information It indicates technical information which are particularly important. Use and Service Manual 11 Serial No. 740 - 10.05
  15. 15. FB tR1860 l1/6 Part II MachIne InstallatIon and FunctIonIng 1. Coiler installation . . . .2 1.1 Technical data and perimetric areas. . . 2 1.2 Overall dimensions . . . 3 1.3 Transport and handling . . . 4 1.4 Unloading and positioning. . . 5 1.5 Removal of blocks for transport . . . 6 1.6 Assembling the shields . . . 7 1.7 Main power supply line connections . . . 8 2. operation, adjustments and Control . . . ...10 2.1 Machine main parts. . . 10 2.2 Automatic functioning . . . 11 2.3 Operating cycle stage description. . . 11 2.4 Pipe-guide Unit . . . 12 2.4.1 Mechanical adjustments . . . .13 2.4.2 Pneumatic adjustments . . . ..14 2.4.3 Adjustments of the pipe guide by the Operator panel. . . ...15 2.5 Reel Unit . . . 16 2.5.1 Functioning . . . ..17 2.5.2 Mechanical adjustments . . . .18 2.5.3 Pneumatic adjustments . . . ..21 2.5.4 Adjustments of the reel from the Operator panel . . . ...22 2.6 Strapping machine and Strap unwinding machine . . . 23 2.6.1 Functioning . . . ..24 2.6.2 Strap introduction or change . . . .25 2.6.3 Pneumatic adjustments . . . ..27 2.6.4 Adjustments of the strapping machine by Operator panel . . . ..28 2.6.5 Adjustments by operating on the electrical board . . . ...28 2.6.6 Sealing blade replacement . . . ..29 2.7 Command Panel . . . 30 2.7.1 Operator’s terminal . . . ..30 2.7.2 Additional buttons . . . ...31 2.7.3 Damper battery replacement . . . .32 3. maChine starting up and stop . . . ..33 3.1 Machine starting up. . . 33 3.2 Machine stop caused by an emergency device (mushroom shaped emergency button) . . . 34 3.3 Machine stop caused by the opening of the safety barriers or by the stop button. . . 35 3.4 Switching the machine off . . . 36 4. serviCe . . . .37 4.1 Ordinary service general indications. . . 37 4.2 Materials supplied . . . 39 4.3 Spare parts . . . 39 4.4 Consumption materials . . . 40 4.5 Machine dismantling . . . 40 use and service Manual 1 Matr. 740 - 10.05
  16. 16. Part II Machine installation and functioning o FB tR1860 l1/6 coIleR InstallatI n 1. Coiler installation 1.1 technical data and perimetric areas description Features Type of coilable pipe Corrugated Coilable pipe diameter (*) 16-20-25-32-40-50-63 mm Reel flange diameter (coil maximum external diameter) 1860 mm Minimum and maximum width between reel flanges (coil width) 150÷450 mm Reel drum minimum and maximum diameter (*) 400÷1500 mm Recommended strap (W x T) 12 x 0,8 mm Strap coil internal diameter 200 mm Strap coil external diameter 400 mm Strap coil height 190 mm Length 7400 mm Width 3750 mm Height 2950 mm Total weight 11.000 kg (ca) Number of strapping machines 1 Number of strapping operations 3-6 Number of reels 2 Control PLC Input voltage 3~ + N / CA 380V +Earth Average power consumption 11 A Start up current 32 A Installed power 6 kW Compressed air operating pressure 0,6 .. 0,7 MPa (*) Warning: the range of coilable pipes and the coil diameter achievable with a single machine depend on what was agreed at the time of ordering. use and service Manual 2 Matr. 740 - 10.05
  17. 17. Part II Machine installation and functioning o FB tR1860 l1/6 coIleR InstallatI n 1.2 overall dimensions 7400 2100 3750 use and service Manual Matr. 740 - 10.05 3
  18. 18. Part II Machine installation and functioning o FB tR1860 l1/6 coIleR InstallatI n 1.3 transport and handling danger-attention in order to reduCe the risk oF tilting, the liFting oF the Coiler by means oF a Crane should be Carried out by qualiFied personnel Caution - precaution taking into consideration the complexity and dimensions of the machine, you should define at the moment of the contract, the responsibilities and modes to handle, install, and carry out the final test. those who carry out these operation should previously organize a “safety plan” to safeguard the health of the people concerned and, if necessary, should organize a training for the operators charged of the use of the machine. Lifting with crane It is possible to lift the coiler up by means of a crane as shown in the figure, by fixing the special ropes on the suitable openings placed in the frame of the machine. Back charging bands Place the pipe guide in the central position with the lowered vertical axis. Front charging bands Hooking rings  Before charging, verify the block of all the moving parts by means of the suitable mechanical red stops (see 1.4).  Use the charging bands in the 4 points of passage indicated in the drawing  The fore bands must be longer than the back ones. If they are not available, use some hooking rings to reset the required charging conditions
  19. 19. use and service Manual 4 Matr. 740 - 10.05
  20. 20. Part II Machine installation and functioning FB tR1860 l1/6 coIleR InstallatI n o 1.4 unloading and positioning Caution - precaution it is suggested to make the F.b. balzanelli avvolgitori spa qualified personnel carry out the installation and test the machine. position the machine on an even floor suitable to withstand heavy loads.  To rest the machine on the floor, use the lugs provided at the bottom of bedplate (a). A A A  Check with a spirit level that the machine is perfectly flat. If necessary, adjust the threads on the rubber feet to stabilise and balance the machine.  The distance between the coiler and the pipe output point from the extrusion line must range between 5 and 10 m.  For a better functioning of the system, it is recommended that the coiler longitudinal axis lines with the pipe to wind point. use and service Manual 5 Matr. 740 - 10.05
  21. 21. Part II Machine installation and functioning o FB tR1860 l1/6 coIleR InstallatI n 1.5 removal of blocks for transport To avoid dangerous mouvements and damages during transport, some mechanical blocks are applied to the moving parts of the coiler. Identify all the red stops applied to the moving part and remove them as indicated in the figures.  binding of the moving parts cut the eventual bands which blocks the mechanical particulars  pipe guide translation block indentify on the pipe guide group one or more red mechanical blocks (A) and remove them  reel moving basement translation stop identify on the moving basement of each reel one or more red mechanical blocks and completely remove the screw (B).  strapping machine feeding stop identify in the front or back part the mechanical blocks (C) and remove them. b a d C
  22. 22. use and service Manual 6 Matr. 740 - 10.05
  23. 23. Part II Machine installation and functioning o FB tR1860 l1/6 coIleR InstallatI n 1.6 assembling the shields The shield are not assembled on the machine as delivered. Certain safety precautions must be observed in order to guarantee the safety of the personnel operating the machine.  The shields must be assembled on the coiler as soon as it has been positioned.  Never start the machine if the shields are not in place.  Do not replace the original machine shields with different barriers and/or materials. The mounting brackets must be fitted both on the right (see picture), and on the left hand side of the machine (the fitting location for the mounting brackets on both sides is identical). These mounting brackets are provided to fasten the safety barriers by means of screws inserted in the central holes (see picture). The operator should pay special attention to the connections between the mounting brackets and the safety barriers as the latter must be firmly fastened to avoid any problems arising during the coiling machine working cycle. Regularly check that the mounting bracket, the safety barriers and the bedplate are firmly fastened. Brackets
  24. 24. use and service Manual 7 Matr. 740 - 10.05
  25. 25. Part II Machine installation and functioning o FB tR1860 l1/6 coIleR InstallatI n 1.7 main power supply line connections Electrical supply Connect the coiler to an electrical line at 380/400V alternating current (3 phases + 1 neutral + 1 earth) by using an anti-flame cable in compliance with the rules in force, having a minimum section of 25 mm2. Carry out a connection which is able to support a maximum absorption of 64A. Pneumatic supply C Connect the machine to a compressed air line supply by means of a pipe having a diameter of 12 mm. Use an exercise pressure ranging between 0,6 ÷ 0,7 mPa by means of the pressure adjuster (a) placed outside the pneumatic board. (see image). A The coiler is equipped with two filters (a drier filter and an extracting oil filter) for the collection of the condensate and oil on the supply circuit having micro-pores of different sections, both filters are eBuipped with a float for the automatic discharge (b). thus, it is suggested to check that the level of condensate does not exceed the indicated one. The plant of air treatment is equipped with a progressive starting up electrically activated valve (C). C A B A B C information A if the compressed air general supply circuit of the plant produces too much condensate, it is suggested to install a dryer device upward the coiler or at the outlet of the compressor. C B Caution - precautio n do not use lubrication oil for cylinders on this machine; if necessary install a lubricating device downward the condensate filters and use esso nuray 32 use and service Manual 8 Matr. 740 - 10.05
  26. 26. Part II Machine installation and functioning o FB tR1860 l1/6 coIleR InstallatI n Telephone connection Fit a phone doubler with RJ11 (a) C coupler to provide a direct phone line with the factory in order to seek remote A technical support with F.B. Balzanelli Avvolgitori SpA engineers, if required (For more information, see Part III “Software User Manual”). B Before seeking remote technical support, connect the C phone cable to the RJ11 (b) modem connector, as shown in the picture. Check that the modem on/off switch (C) is pressed. information For each assistance request, communicate the data reported on the identification tags (see part i - paragraph 2)
  27. 27. use and service Manual 9 Matr. 740 - 10.05
  28. 28. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2. operation, adjustments and Control 2.1 machine main parts D C E F B A G ref. part desCription a reel 1 Pipe coiling devices b reel 2 C strapping machine Coil strapping device on both reels d pipe guide Pipe guide device during coiling e electrical/pneumatic control panel Cabinet containing the electrical and pneumatic components F operator’s terminal Data visualization and introduction device g slides Devices for the expulsion of the coiled coils use and service Manual
  29. 29. 10 Matr. 740 - 10.05
  30. 30. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.2 automatic functioning The pipe, exiting from the extrusion line, is manually introduced by the operator in the oscillating arm device. This has the function to detect the tension of the pipe, between the extrusion line and the coiler, in order to adjust automati- cally the coiling speed. Always manually, the pipe is introduced in the pipe guide device which will hook it in the first reel that has received the authorization to run. From this moment on, operation is fully automatic. Principal phases of operation: 2.3 operating cycle stage description stage desCriptoion 1 hooking the pipe guide moves to a position suitable for hooking the pipe on the first reel ready for the coiling phase. Pipe hooking onto the reel is fully automatic 2 Coiling the reel begins to rotate at every turn of the reel, the pipe guide translates laterally by a length equal to the diameter of the pipe reel rotation terminates when the number of turns or meters of pipe set by the operator has been reached 3 paddle approaChing once coiling has been completed, the reel spattles move toward the coil in order to prevent the pipe from uncoiling after cutting 4 Cut the shear cuts the pipe 5 hooking when cutting has been completed, the pipe guide moves to the first free reel ready for coiling; the pipe is again hooked and coiling restarts 6 translation the strapping system translates laterally to the reel on which the coiling phase has just been completed 7 paCking the strapping system performs 3 or 6 bindings according to the number programmed by the operator following each strapping operation, the reel rotates by 60° or 120° to the position for performing the next 8 expulsion at the end of the packaging phase, the spattles move away from the coil and the mobile portion of the reel opens. An automatic expulsion system unloads the coil from the drum and slides it out of the machine 9 Waiting the reel waits for the pipe to be hooked again Should one of the two coils be stopped by the operator or a functioning anomaly, the winding will take place on one reel only.
  31. 31. use and service Manual 11 Matr. 740 - 10.05
  32. 32. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.4 pipe-guide unit The pipe guide distributes the coils during the coil winding and the shear cuts the pipe. The translation of the pipe guide is carried out by means of an axis numerical control. Main parts A C B ref. part desCription a gauge A device that guides the pipe during coiling b shear A device that cuts the pipe C oscillating bar A device that adjust the coiling speed
  33. 33. use and service Manual 12 Matr. 740 - 10.05
  34. 34. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.4.1 mechanical adjustments Install the suitable gauge Fit a gauge with a suitable size for the pipe to be coiled. According to the agreements made with the customer at the time of ordering, the coiling machine is supplied with different types of gauges. Each gauge supplied is printed with the diameter in milli- metres of the matching pipe (A). To replace it, unscrew the suitable screw as shown in the picture. use and service Manual Matr. 740 - 10.05 13
  35. 35. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l Inserting the pipe The oscillating arm (a) is a device for regulating F machine coiling speed according to the approach angle (b) (which will vary with pipe tension). The pipe is to be introduced in a suitable ring (C) - - placed at the base of the oscillating arm (a) and must pass under the first sliding roll (d), which can be adjusted by loosening the suitable screws indi- cated in the figure. + + Push the pipe until the meter counter wheel is A reached (d) then adjust the exiting roll (e), so as C to avoid up and down movements of the meter E counting wheel during coiling. D When small diameter pipes are being coiled, the shoulder plate (F) must be adjusted so as to keep the meter-counter wheel from jumping or bouncing B during coiling. Caution - precaution the procedure of introduction of the pipe in the oscillating arm/pipe guide is extremely important for an optimal functioning of the machine and thus it is to be carried out with the utmost attention by the qualified personnel having particular technical specifications. Tiro reggia Legatore use and service Manual 2.4.2 pneumatic adjustments Matr. 740 - 10.05 Pipe guide arm back pressure Adjust the guide pipe arm back pressure to offset the pipe lifting motion during the coiling operation. Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2 Spatola bassa Aspo 1 Friziona tubo Disables oscillating arm back pressure By turning the two position selector switch clockwise, pressure can be discharged from the oscillating arm back pressure circuit. By turning it anticlockwise, pressure can be restored. Braccio alto / basso Spatole alte Aspo 1 e 2 Pressione legatore
  36. 36. Avanzamento Legatore Spatola bassa Aspo 2 Contropressione braccio oscillante Disabilita contropression braccio oscillante 14
  37. 37. Part II Machine installation and functioning Tiro reggia Legatore Espulsori Aspo 1 e 2 o FB tR186 0 l1/6 Avanzamento Legatore oPeRatIon, adjustMents and contR l High/low arm (Pipe guide back pressure) This device regulates the pressure that holds the pipe guide in the low position during the coiling phase. Friziona tubo Contropressione Braccio alto / basso Pipe braking device braccio oscillante Controls the pressure applied by the cylinder which locks the pipe in position during the cutting stage and the sideways movement towards the other reel. Carefully set the pressure to the required value to firmly tighten the pipe without damaging it. Tiro reggia Legatore Scivoli Aspo 1 e 2 Spatola bassa Aspo 1 Spatola bassa Aspo 2 Frena tubo Pipe pressing cylinder Adjusts the pressure applied by the pipe pressing cylinder during the coiling stage.Adjusts the pressure in order to ensure the correct pressure on the pipe; however attention must be paid so that the pipe is not damaged and can be smoothly and consistently coiled Friziona tubo patole alte Aspo 1 e 2 Pressione legatore Disabilita contropressione braccio oscillante 2.4.3 adjustments of the pipe guide by the operator panel By means of the coiler management software, it is possible to modify several parameters which define the pipe guide device. A detailed description is contained in the third part of this dossier (Manual for the software user) or by pressing HELP directly in line on the display of the control panel.
  38. 38. use and service Manual 15 Matr. 740 - 10.05
  39. 39. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.5 reel unit The reel is the heart of the machine. As it allows the user the make several manual adjustments and can easily be programmed by means of a PLC, it ensures a fully and correctly coil the pipe. All the mechanical and pneumatic adjustments required to ensure a correct use of the coiling machine are listed below. A detailed description of how to program the software of the reel unit is available in Part III of the Software User Manual or on the on line HELP, displayed directly on the screen of the control panel. use and service Manual Matr. 740 - 10.05 Main parts G ref. part A Moving reel flap B Fixed flange flap C Pipe hooking D Format Change E Casings F High paddles G Low paddles
  40. 40. D C E F A B desCription They allow you to adjust the width of the coil to be coiled They allow to contain the coil during coiling Adjustable device for the pipe hooking on the reel Device for automatic regulation of the petals of the movig reel and of the shells They allow you to select the internal diameter of the coil to be coiled Device to prevent the coil unpicking during the strapping phase 16
  41. 41. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.5.1 Functioning After entering the correct settings for a specific production run, the pipe guide unit is moved to the first available reel ready to latch the pipe. The reel moving section is closed by latching the pipe and by starting the coiling stage. The initial speed, i.e. the take-up speed, is higher than the normal operating speed and enables the operator to take up any pipe that may have been left on the floor during the production run change or during the pipe guide sideway motion from one reel to the next. The fully taken up pipe is then pulled taut and, by means of the controls on the PLC, the oscillating arm unit is lifted, thus slowing down the reel turning speed. The coiling operation is ended when the number of turns or metres set by the operator is reached. At this point, the paddles will come closer and will lock the coil in position, stopping it from uncoiling during the strapping and cutting stages. At the same time, the strapping machine will be moved closer and the strapping operations will be carried out. At the end of this stage, the paddles will move away and the reel will be opened, whilst the ejectors will push the coiled pipe out of the drum. At the end of the full reel working cycle, the reel is automatically closed after the coil has been ejected and waits for a new pipe to be latched. Should one of the two reels be manually stopped by an operator or stop because of a fault, the second reel will carry on coiling the pipe.
  42. 42. use and service Manual 17 Matr. 740 - 10.05
  43. 43. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.5.2 mechanical adjustments Flange width (automatic adjustment) The adjustment of the width of flanges (width of the coil) is completely automatic and it is managed by the PLC. By setting the desired value through the format change device, the flange width is automatically adjusted to set the length of the coil to be wound. + - Drum diameter (automatic adjustment) The adjustment of the diameter of the drum (internal diameter of the coil) is completely automatic and it is managed by the PLC. By setting the desired value through the format change device, the internal drum diameter is automatically adjusted to set the internal diameter of the coil to be wound. - + Caution - precaution before adjusting the drum diameter, check that the pipe hooking device is in the limit stop position at the farthest point from the center of the reel; that is, in a position not reachable by the spacer skirts of the drum (see the section on pipe hooking)
  44. 44. use and service Manual 18 Matr. 740 - 10.05
  45. 45. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l Pipe hooking (manual adjustment) To achieve an optimal wounding action, it is essential to make sure that the pipe latches on to the moving reel is as accurately and as firmly as possible, in order to avoid malfunctions during production. The picture shows an example of a pipe perfectly latched onto the reel. To achieve this, pipe latcher (a) plate must be replaced at every B production change according to the diameter of the pipe to be produced, by removing the screws which fasten it to moving flap (b). Further changes to the latching position are achieved by moving the device along axis Y (vertically) on one of the differently spaced out rear holes (C). Essentially, these holes serve the purpose of adjusting the spring pulling action in order to stop undesired movements of the pipe after latching onto the A reel. C
  46. 46. use and service Manual 19 Matr. 740 - 10.05
  47. 47. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l High paddle position (manual adjustment) Adjust the transversal position of the paddle arm by referring to the position that the coil queue end will take. C Slacken the paddles of both reel. C B B A A A. Screw for the transversal adjustment B. Reel 2 high paddle C. Reel 1 high paddle Low paddle position (manual adjustment) Adjust the transversal position of the paddle arm by referring to the position that the coil queue end will take. Slacken the paddle with the locking screws and slide it along the support pin. Slacken the paddles of both reel. B B C C A A A. Screw for the transversal adjustment B. Reel 2 low paddle C. Reel 1 low paddle use and service Manual Matr. 740 - 10.05 20
  48. 48. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l iro reggia Legatore Avanzamento Legatore Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2 2.5.3 pneumatic adjustments Reel 1 and 2 High paddles It adjusts the pressure of the high paddles on the coil of both reels Operate on the pressure adjuster according to the production being carried out (length, diameter, number of turns, layers of pipe…). Make sure that the paddle is not overtightened as this would cause the pipe to be unevenly wound (minimum pressure about 1 bar). use and service Manual Matr. 740 - 10.05 Friziona tubo Contropressione Braccio alto / basso Reel 1 Low paddle braccio oscillante Adjusts the pressure of the low paddle onto the reel 1 coil. Operate on the pressure adjuster according to the production being carried out (length, diameter, number of turns, layers of pipe…). Make sure that the paddle is not overtightened as this would cause the pipe to be une- venly wound (minimum pressure about 1 bar). anzamento Legatore Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2 Reel 2 High paddle It adjusts the pressure of the high paddle on the coil of reel 2 Operate on the pressure adjuster according to the production being carried out (length, diameter, number of turns, layers of pipe…). Make sure that the paddle is not overtightened as this would cause the pipe to be une- venly wound (minimum pressure about 1 bar) Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2 Spatola bassa Aspo 1 Contropressione Braccio alto / basso Spatole alte Aspo 1 e 2 braccio oscillante Braccio alto / basso Spatole alte Aspo 1 e 2 Pressione legatore
  49. 49. Spatole alte Aspo 1 e 2 Spatola bassa Aspo 1 Spatola bassa Aspo 2 Pressione legatore Disabilita contropression braccio oscillante 21
  50. 50. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l Reel 1 and Reel 2 ejectors Regulates the pressure applied by the ejectors on the coils of both reels Set the pressure regulator according to current production taking into consideration factors such as dimensions and weight. Make sure the pipe is not ejected too quickly or to suddenly. Tiro reggia Legatore Avanzamento Legatore Espulsori Aspo 1 e 2 Friziona tubo Contropressione Braccio alto / basso braccio oscillante Reel 1 and Reel 2 Slide Sets up reel 1 and 2 slide ascent Set the pressure regulator according to current production, taking into consideration, for example, the weight of the coil. iro reggia Legatore Avanzamento Legatore Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2 Suser)ole alte Aspo 1 e 2 Friziona tucbo alto / basso Ctiontropressione isrdoccio braccio oscillante 2.5.4 adjustments of the reel from the operator panel By means of the coiler management software, it is possible to modify several parameters which define the reel devi- e. A detailed descrip on is contained in the third part of th ssier (Manual for the software or by pressing HELP directly in line on the display of the control panel.
  51. 51. use and service Manual 22 Matr. 740 - 10.05
  52. 52. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.6 strapping machine and strap unwinding machine Each strapping unit is enabled for performing strapping on the coils of either reel. Main parts A B E C F D Fase desCdezione rif. part sCription a strap unwinding machine A device that contains and unrolls the strap during coiling b strap pressing rolls A device that pushes the strap towards the reel C sealing spout A device that glues the strap at high temperature d strapping machine grippers Strap gripper, sealer and cutter e strap puller device F strap tightening use and service Manual Matr. 740 - 10.05
  53. 53. A device that gives tension to the strap during the recovery phase during the sealing phase A device that supplies a certain and regular quantity of strap to the strapping machine 23
  54. 54. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.6.1 Functioning Its cycle develops as follows:  DROP  CRIMPING  RECOVERY  TENSIONING  CUT  SEALING. The drop is carried out by means of four rollers which, by rotating and pressing the strap, push it forward, by suitably guiding it by means of mechanical guides (cable run) (E), in order to wind the coil of wire. At this point slotted pincers (A) moves forward to block the strap and the rollers recover the coil of wire in excess. Then, it is put under tension by the couple adjusting of the launch motor. Pincers (C) pushed forward to block the ends of the free strap, while the sealing spout sealing blade is introduced between the two strap endings divided by the plate (D), by heating them. As the sealing blade removes, the plate goes downwards, pincers (B) moves forward, cuts the strap and press the two endings by sealing them. A B C D E E
  55. 55. Caution - precaution improper adjustments could cause the strapping system malfunctioning! use and service Manual 24 Matr. 740 - 10.05
  56. 56. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.6.2 strap introduction or change 1 Make sure that the machine has come to a full stop and the air supply has been disabled. 2 Unscrew the strap unwinding disc (A) by rotating it clockwise once and removing it (see the picture). 3 Place the strap coil on the coil mounting. 4 Refit the disc in the strap unwinder and lock rotating it anclockwise 5 Insert the strap end inside the strap tie rod, as shown by the arrows in the picture. For a better graphical representation, the strap is blue in the upper side and yellow in the lower one. AL LEGATORE OUT TO THE S TRAPPInG MACHInE A
  57. 57. use and service Manual 25 Matr. 740 - 10.05
  58. 58. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 6 Remove the strap from the last roll upwards and introduce it in the pincers by following the natural strap curve, as shown in figure (A). 7 Disable the roll pressure by lifting the lever (B), and push the strap until the strap guide channels are reached. 8 Lower again the lever. 9 Restore the air and power supply and cut the strap from the keyboard in order to remove any faults. use and service Manual
  59. 59. 26 Matr. 740 - 10.05
  60. 60. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.6.3 pneumatic adjustments Strapping machine Head feeding Adjust the pressure which is necessary to the strapping machine to press the coil during the final phase of the strapping operation. A high pressure causes a crush of the pipe. By operating on the pressure regulator, adjust the manometer according to the type of pipe being winding. use and service Manual Tiro reggia Legatore Matr. 740 - 10.05 Strapping machine Strap puller Device Adjust the pressure which is necessary for the cylinder to tension the strap. A high pressure can cause an obstruction of the pipe or the break of the strap. Adjust the pressure according to the characteristics of the pipe to wind. By rotating leftward the pneumatic switch, it is possible to cut the pressure to the anzamento Legatore Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2 Strapping machine pressure Friziona tubo pneumatic circuit of the strapping machine. Strap tensioning device pressure Contropressione Braccio alto / basso Spatole alte Aspo 1 e 2 braccio oscill ante It adjusts the pressure of the strap tensioning cylinder so as to have the strap intro- duced in the roll and so that it remains under the right tension. Too much pressure can break the strap.
  61. 61. Avanzamento Legatore Spatola bassa Aspo 1 Tiro reggia Legatore Contropressione braccio oscillante Pressione legatore Friziona tubo 27
  62. 62. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.6.4 adjustments of the strapping machine by operator panel By means of the coiler software, it is possible to modify several parameters which control the functioning of the strapping machine. The third part of this dossier will explain in details the subject (manual for the software user). 2.6.5 adjustments by operating on the electrical board Sealing blade temperature adjustment According to the type of strap used, it can be necessary to vary the temperature of the sealing spout. The thermo-adjuster is placed on the front panel of the electrical board. SET POInT RAPID PREPARATIOn This procedure allows you to fast prepare the active set-point. For further information about the thermo-adjuster, please refer to the Manual Rotfil attached to the documentation of the machine.  Press the button p and the display will visualize “SP n” (n is the Set Point number which is active in that moment) alter- nated to the selected value  Operate on buttons UP  and DOWN  to increase/decrease the value  After selecting the required values, press button p in order to leave the preparation of the Set Points. OUT2 OUT1 U P information attention: the temperature of the resistance is already selected at an optimal value. an improper modification can cause the strapping machine malfunctioning. Further specifications of the digital thermoregulator are contained in the attached manual. use and service Manual
  63. 63. 28 Matr. 740 - 10.05
  64. 64. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.6.6 sealing blade replacement Sealing blade positioning 1 If necessary, adjust the position of the sealing blade by means of the shoulder screw placed in the back part of the sealing spout (a). 2 Operate on the screw so that the sealing blade, by lowering, finds its position between the two strap endings (b). 3 If the above is not enough, also operate on the shoulder screw of the sealing spout (C). Check in particular that the sealing blade is introdu- ced in a perpendicular way in relation to the base of the small plate within the 2 strap stocks. Sealing blade replacement IIn case of break, the heating element (cartridge) can be replaced as follows. 1 Remove the sealing spout protection by operating on the suitable screws (a). 2 Unscrew by means of a special key the screw indicated in figure (b). 3 Remove the heating element (C) and replace it with one having the same technical characteri- stics, paying attention to reconnect correctly the electrical wires as shown in the electrical sche- me. danger-attention
  65. 65. danger oF burn, deviCes undergoing high temperature. avoid the ContaCt With the hot parts on the head oF the strapping maChine. the sealing spout oF the strap made oF polypropylene is heated at temperatures exCeeding 300 °C use and service Manual 29 Matr. 740 - 10.05
  66. 66. Part II Machine installation and functioning o FB tR1860 l1/6 oPeRatIon, adjustMents and contR l 2.7 Command panel The command panel is essentially composed of two parts: A the Operator’s terminal is the real interface between the machine and the user B the additional buttons that permit the operator to start or stop the machine. 2.7.1 operator’s terminal The TOUCH SCREEN operator panel displays machine operation status reports, instantaneous process values, and any anomalies in machine operation. The operator can also create “Recipes” consisting of the sets of parameters needed to compile a database relative to the different types of production. Thanks to the graphic interface, use of the various screens is simple and intuitive. The operator need only touch the screen to select menu items or enter data. For detailed information on how numerical control operates, refer to the Software User’s Manual, Part 3 of the Use and Maintenance Manual.
  67. 67. use and service Manual 30 Matr. 740 - 10.05

×