Stretch wrapper model GL 1000

Manual

Ver. 2.1

ENGLISH

Model: GL 1000

Serial number:........................

Delivery date:...............................
YY-MM-DD

This machine is equipped with the following options on delivery:

610001 CONVEYOR FOR BIG LOADS 610002 CUSTOM COLOR 610003 MAST MOVED BACK 610004 CABINET MOVED BACK 610005 FORMAT CONTROL 610006 HALF PALLET 610007 CABINET EXCLUDED 610008 SEPARATE CABINET 610009 ALLEN BRADLEY CONTROL 610012 LIGHTBEAM, 1 PC 610013 LIGHTBEAMS, 2 PCS 610014 LIGHTBEAMS, 3 PCS 610148 TOP PLATE, RECTANGULAR 610149 TOP PLATE, ROUND 610150 FREQ. CONTROL OF TOP PLATE 610159 ALARM, FILM ALMOST AT AN END 610179 GALVANIZATION OF BOTTOM CHASSIS 610184 CUSTOM MAST HEIGHT 610188 CHAIN CONVEYOR, 3 CHAINS 610189 CHAIN CONVEYOR, 2 CHAINS 610191 INFILL CONVEYOR FOR LARGE CONVEYOR 610192 INFILL CONVEYOR FOR STD CONVEYOR

610194 LARGER FILM ROLL DIAMETER 610198 POWERED OUTER ROLLERS 610206 INCREASED TRANSP. HEIGHT, 575-700 mm 610207 INCREASED TRANSP. HEIGHT, 625-750 mm 610208 INCREASED TRANSP. HEIGHT, 750-875 mm 610209 CUSTOM CONVEYOR HEIGHT 610254 WELDING UNIT 610261 90 DEGREE IN OR OUT TRANSPORTATION 610324 STRING ROLLER 610325 PNEUMATIC STRING ROLLER 610481 PALLET GUIDING DISCS 610210 AIR CONDITIONED ELECTRICAL CABINET 610010 INTEGRATION CI 1110 610011 CONTROL OF 1 CONVEYOR 610012 CONTROL OF 2 CONVEYORS 610013 CONTROL OF 3 CONVEYORS 610014 CONTROL OF 4 CONVEYORS 610015 CONTROL OF 5 CONVEYORS 610016 FREQ. CONTROL OF CONVEYOR 610199 SEPARATE START BOX 610663 PASSIVE ANTISTATIC 610664 ACTIVE ANTISTATIC

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

Particularly important information

Must be executed by an operator

Must only be executed by a Cyklop service engineer

Hazard

"Fast return" to a page. To access this menu/page, press the buttons in order in the grey eld. (This is an example.)

Rights to make any technical modications are reserved. This manual must not be copied or otherwise duplicated. Nor may its content be amended or passed on without our written permission. All rights reserved. Copyright by Cyklop Teknik AB Burseryd 2010 /mka

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Contents
Chapter Machine configuration Positioning of safety decals EC declaration General safety instructions Main machine parts Control cabinet Overview Explanation of buttons Lamp test Display Overview Home menu Information menu for film Name program Manual operation Service Language selection, date set Alarm / Status sensor Contact information Setting program parameters Program selection Operate the machine Activation Load film Set prestretching of film Set film tension Start the machine Pause automatic mode Description of film patterns Care and daily maintenance Cleaning Service & maintanence Resetting Film breakage / End of film Machine stop activated Emergency stop activated Light beam which has tripped (optional) Troubleshooting Transport Technical specications Table of set values, program parameters 1 2 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6 6.1 6.2 7 7.1 7.2 7.3 7.4 8 9 10 11 Page 2 4 5 6 10 11 11 11 12 12 12 12 13 13 14 15 15 17 19 19 20 21 21 21 22 22 22 23 23 24 24 24 26 26 26 26 27 27 29 30 31

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E NG L I S H
This user guide describes the operation, safe maintenance and adjustment of the machine. ATTENTION! Connection to the power grid is not included. Machine design and use and maintenance. the installation is done use, 9. HAZARD! Rotating rollers. Crush hazard. 12. HAZARD! Sharp egdes. Risk of cutting. 3. VARNING! Rotating rollers. Crush hazard. 5. HAZARD! Crush hazard. 8. HAZARD! Crush hazard. 7. HAZARD! The turn table rotates in the direction of the arrrow. 18. HAZARD! Aggregate travels in the directions of the arrows. Crush hazard. 2. HAZARD! Topplattans slde rr sig i pilarnas riktning. Crush hazard. (For option: Top plate) MANDATORY Outtakes for forks. Lift the machine here. 17. HAZARD! Dangerous electrical voltage. 13. HAZARD! Hot surface. (For option: Weld) 4. INFORMATION 1. Tread the stretch lm according to the picture. 2. Gear ratio.

construction allows for safe This is true provided that as is described in this guide.

The warning labels that have been applied to the machine should be kept in such condition that the content is easy to read. If not, the label must be replaced. Explanations and positioning below. Design may differ slightly on label afxed to the machine, but the meaning is the same. Part No: 400777

15.

1. 14. 16.

10.

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The declaration of incorporation of the partly completed machinery under the ECs Machinery Directive 2006/42/EC, Annex 2B. We: Cyklop Teknik AB Villstadsvgen 1 330 26 BURSERYD Org. Nr. 556224-0001 declare under our sole responsibility that the partly completed product: Model: Stretch wrapper GL 1000 Type designation: 100050-100050/99 Machine Number: ________________________

is designed to be incorporated in a larger machinery or assembled with another machine, which together will constitute machinery covered by Directive 2006/42/EC Machinery Directive and which shall be made in accordance with Directive 2006 / 42/EC. conforms to the applicable sections of annex 1 regarding essential health and safety in the design of machines have been performed and that the relevant technical documentation is compiled in accordance with Annex 7, Section B. 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 request of national authorities relevant documents on the partly completed machinery will be presented. and declares, moreover, that the machinery should not be put into any use until the machinery it must be incorporated in, or forming part of, has been found and declared in accordance with Directive 2006/42/EC and national legislation, namely the overall including the machine, referred to in this declaration. declaration in conformity are the following directives: Machinery Directive, Basic safety regulations Low Voltage Directive (LVD) Electromagnetic Compatibility (EMC)

Covered by this 2006/42/EG 2006/95/EG 2004/108/EG

SS-EN 415-6

The following harmonized standards apply: EN ISO 14121 Machine safety - Principles for risk assessment EN ISO 12100-1 Machine safety - Basic terminology, methodology EN ISO 12100-2 Machine safety - Technical principles SS-EN 60204-1 Machine safety - Electrical equipment of machines SS-EN 954-1 Machine safety - Control systems
Packaging machines safety

Burseryd Place and date (YY-MM-DD)

Bo Eriksson

Managing director Position

Burseryd Place and date (YY-MM-DD)

Lars Karlsson

Responsible for Technical le Position Ph: +46 (0)371 50800 Fax: +46 (0)371 50775 info@cyklopteknik.se www.cyklopteknik.se

Cyklop Teknik AB Villstadsvgen 1 SE-330 26 BURSERYD

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1. General safety instructions

GENERAL Machine design and construction allows for safe use and maintenance. This is true provided that the installation is done as described in this guide. The guide should be read and the instructions followed by anyone working with the machinery. It is the customers responsibility to ensure that the instructions are complied with by staff. In some countries or some companies more safety regulations are to be observed, mainly related to personnel. This documentation does not take account of such company-specic or national guidelines. The technical specications in the manual shall be sufcient to base for decisions on any local safety regulations. Consult with the appropriate the authorities or with company safety representatives. This documentation distinguishes between normal operation (see Chapter 3-4 Running the machine) and other management (see Chapter 5 Care and daily maintenance). The reason is that they place different demands on operators and service personnel, specially in regards to security. Easier maintenance, as described in Chapter 4, may also be performed by operators. Maintenance only described in Chapter 5, only carried out by skilled service personnel. SAFETY Here are the rules to be observed: Ensure that no children or animals in the vicinity of the installation. Only people who have read and understand this manual may work with this machinery. Do not tamper with the machine while it is working or is on. Warning! Even if the machine is not working, it may be switched on. Safety devices shall not be removed or eliminated. All the protection of electrical and mechanical compo nents must be correctly installed when the installation is in operation. The safety devices are essential for safety in the work environment. Thus, it is strictly forbidden in any way ignore or circumvent them. Keep the work area clean and free of foreign objects. Make sure the lighting in the work area is adequate. UNAUTHORIZED USE Some use may lead to unnecessary security risks because they are not in conformity with the machines specications and therefore unlawful. You may not: wrap pallets that do not meet specications wrap pallet goods exceeding the maximum allowable weight wrap pallet goods which have not been stacked properly. Keep in mind that even if the goods look like it is stacked properly, packages can still fall due to other causes wrap pallets that are in poor condition wrap pallets that extends outside the periphery of the turn table negligering of installation specications wrap unpackaged foods daily standard maintenance This means for example cleaning of photocells - no major tasks may be performed. ensure that dangerous situations can not arise. keep the work area clean and free from foreign objects.

Service Specic skills, experience and / or training is required. Service personnel should also master the entire contents of this documentation. Service typically have the following types of tasks: maintenance of the installation repair of defects give support to operators

Service personnel shall after rectifying an error restore the machine to original state. With security in mind, this means for example, re-installation of protective caps and also return safety switch to its original position. When a service person take their own initiatives to implement changes in the installation, the customer forfeits the moment of their warranty claims in the case of any problems as a consequence of the change. PERSONAL PROTECTION Some personal protection measures are not to be taken by operators of the machine. However, a number of measures are recommended. For example shoes with steel caps, hearing protection, etc.. Some products used, however, may require protective measures - advice the documentation of those devices. When handling sheet metal take certain precautions to prevent injuries such as hand injuries and the likes. When performing service local safety regulations must be folowed. Discuss personal safety with company safety representatives. The whole installation was designed and tested to work with the specied substances. Unforeseen dangers may arise from the use of substances other than those specied. The manufacturer can not accept responsibility for the complications arising from the use of substances other than those specied. TRANSPORTATION When transporting the installation on a public road, there may be local regulations to follow. Consult with national and local authorities on these kinds of regulations and if application for a permit is needed. ENVIRONMENTAL CONCERNS Potential environmental risks are in the form of, for example, oil, grease and detergent. This type of substances are to be disposed of in accordance with national environmental regulations. DISPOSAL OF THE MACHINE / INSTALLATION If and when the machine is disposed local environmental regulations must be observed. The machine contains only material that can be considered public knowledge. All the materials in the machine was at the time of manufacture of such a nature that they could be disposed of in an environmentally sound manner and without risk of personal injury. DISASTERS Disasters include re, ood, and the like. There are no specic rules for the conduct of disaster relief. Fire ghting can be done under the usual standards.

USERS Operators The machine may be operated by any adult person who has read and understood the contents of Chapters 1-4. It is not necessary that the operators have any special knowledge. Machine operators are trained by personnel from Cyklop or by Cyklop designated dealers. The operator is normally involved in the following tasks: operation of the machine

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Basic operation Before use, please read the handbook and safety instructions carefully. The operator handbook is to be stored ready for use in direct machine proximity. Maintenance and inspection intervals are to be adhered to. The machine/plant must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operating manual, and only by safetyconscious persons who are fully aware of the risks involved in operating the machine/plant. Any functional disorders, especially those affecting the safety of the machine/ plant, should therefore be rectied immediately. The machine/plant may be operated only for its designated use. Organizational measures In addition to the operating instructions, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection. These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment, or trafc regulations. For reasons of security, long hair must be tied back or otherwise secured, garments must be closetting and no jewellery such as rings may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts. Use protective equipment wherever required by the circumstances or by law. Observe all safety instructions and warnings attached to the machine/plant. See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible. In the event of safety relevant modications or changes in the behaviour of the machine/plant during operation stop the machine/plant immediately and report the malfunction to the competent authority/person. Never make any modications, additions or conversions, which might affect safety without the suppliers approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on loadbearing elements. Spare parts must comply with the technical requirements specied by the manufacturer. Spare parts from original equipment manufacturers can be relied to do so.

Never modify the software of programmable control systems. Replace hydraulic hoses within stipulated and appropriate intervals even if no safety relevant defects have been detected. For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable. The personnel must be familiar with the location and operation of re extinguishers. Observe all rewarning and reghting procedures. Accident preventing devices, which are not included in the scope of supply, such as protective guarding, are to be provided by the customer in accordance with the local safety regulations. Selection and qualication of personnel Any work on and with the machine/plant must be executed by reliable personnel only. Statutory minimum age limits must be observed. Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, setup, maintenance and repair. Make sure that only authorized personnel works on or with the machine. Dene the machine operators responsibilities also with regard to observing trafc regulations giving the operator the authority to refuse instructions by third parties that are contrary to safety. Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine/plant without being permanently supervised by an experienced person. Work on the electrical system and equipment of the machine/plant must be carried out only by a skilled electrician or by instructed persons under the supervisions and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. Work on gasfuelled equipment (gas consumers) may be carried out by specially trained personnel only. Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

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Safety instructions governing specic operational phases Avoid any operational mode that might be prejudicial to safety. Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state. Operate the machine only if all protective and safety oriented devices, such as removable safety devices, emergency shutoff equipment, soundproong elements and exhausters, are in place and fully functional. Check the machine/plant at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machines working behaviour) to the competent organization/person immediately. If necessary, stop the machine immediately and lock it. In the event of malfunctions, stop the machine/plant immediately and lock it. Have any defects rectied immediately. Before starting up or setting the machine/plant in motion, make sure that nobody is at risk. Never switch off or remove suction and ventilation devices when the machine is in operation. Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities. Ensure that the maintenance area is adequately secured! Lift units must be secured by mechanical fallsafety units (clamps), before entering the machine! If the machine/plant is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: locking the principal control elements and removing the ignition key and/or attaching a warning sign to the main switch. Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movement and buckling! To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be care-fully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads! The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The mars-holler giving the instructions must be within sight or sound of the operator.

For carrying out overhead assembly work always use specially designed or otherwise safetyoriented ladders and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out maintenance work at greater heights. Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice. Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never use aggressive detergents. Use lintfree cleaning rags. Before cleaning the machine with water, steam jet (high pressure cleaning) or detergents, cover up or tape shut all openings which for safety and functional reasons must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switchgear cabinets. Ensure during cleaning of the machine that the temperature sensors of the re warning and reghting systems do not come into contact with hot cleaning agents as this might activate the reghting system. After cleaning, remove all covers and tapes applied for that purpose. After cleaning, examine all fuel, lubricant, and hydraulic uid lines for leaks, loose connections, chafe marks and damage. Any defects found must be rectied without delay. Always tighten any screwed connections that have been loosened during maintenance and repair. Any safety devices removed for setup, maintenance or repair purposes must be retted and checked immediately upon completion of the maintenance and repair work. Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact. Before setting the machine in motion always check that the accessories have been safely stowed away. Avoid any operation that might be a risk to machine stability. Do not step on conveying equipment.

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Warning of special dangers Electric energy Use only original fuses with the specied current rating. Switch off the machine/plant immediately if trouble occurs in the electrical system. Work on the electrical system or equipment may only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such electrician and in accordance with the applicable electrical engineering rules. If provided for in the regulations, the power supply to parts of machines and plants, on which inspection, maintenance and repair work is to be carried out must be cut off. Before starting any work, check the deenergized parts for the presence of power and ground or shortcircuit them in addition to insulating adjacent live parts and elements. The electrical equipment of machines/plants is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectied immediately. Necessary work on live parts and elements must be carried out only in the presence of a second person that can cut off the power supply in case of danger by actuating the emergency shutoff or main power switch. Secure the working area with a red andwhite safety chain and a warning sign. Use insulated tools only. Before starting work on highvoltage assemblies and after cutting out the power supply, the feeder cable must be grounded and components, such as capacitors, short circuited with a grounding rod. EMERGENCY OFF equipment must not be bridged nor set out of function. Close area by means of a red and white chain and a warning panel. Use voltage insulated tools only. Actuation of the sensors can trigger hazardous machine functions. Use covers, protective fence or safety light barriers to prevent access. Set up warning signs. Plug or unplug quick disconnects only when mains off. Hydraulic and pneumatic equipment Work on hydraulic equipment may be carried out only by persons having special knowledge and experience in hydraulic systems.

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and re. Depressurize all system sections and pressure pipes (hydraulic system, compressedair system) to be removed in accordance with the specic instructions for the unit concerned before carrying out any repair work. Hydraulic and compressed air lines must be laid and tted properly. Ensure that no connections are interchanged. The ttings, lengths and quality of the hoses must comply with the technical requirements. Noise During operation, all sound bafes must be closed. Always wear the prescribed ear protectors. Hazardous substances environment for humans and the

When handling oil, grease and other chemical substances, observe the product related safety regulations. Be careful when handling hot consumables (risk of burning or scalding)! Mobile Machine For loading only use lifting gear and tackle of sufcient capacity. Appoint a competent marshaller to assist in the lifting operations. Lift machinery and equipment properly with suitable lifting gear and only in accordance with the operating instructions (xing points for lifting tackle, etc.). Only use suitable means of transport of adequate carrying capacity. Do not stay or work below suspended loads. Fasten the loads safely using the suitable xing points. Before or immediately after completion of the loading operations the machine/plant must be secured by means of recommended/supplied devices against unintentional changes of position and a corresponding warning sign attached to the ma-chine/plant. Before re-commissioning the machine/plant these devices must be properly removed. Carefully ret and fasten all parts to be removed for transport purposes before re-commissioning the machine/plant. Cut off the external power supply of the machine or plant even if only minor changes of place are envisaged. Properly re-connect the machine to the supply mains before re-commissioning.

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2. Main machine parts

CYKLOP TEKNIK AB

CYKLOP TEKNIK AB

Machine plate

Mast Top plate (optional) Control cabinet Prestretch unit Weld (optional)

Cutter unit Film retainer arm Conveyor (roller conveyor is shown in the illustration) Chassis

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3. Control cabinet
3.1 OVERVIEW

Pos Type

Function Main switch, lockable Control voltage Start mode / Alarm reset Automatic Start Machine stop Emergency stop Request open door / Part-automatic

Rotary switch Rotary lamp button Lamp pushbutton Lamp pushbutton Pushbutton Pushbutton

Pushbutton Lamp pushbutton

Control system / Display Program selection/ Parameter setting Light tower

Alarm / Indicator, machine to automatic

3.2 EXPLANATION OF BUTTONS 3.2 EXPLANATION OF BUTTONS

"Main switch on / off"

Switch on or off all power to the machine. Remember always to switch off the power when working on the machine.

"Machine stop" Press the stop button and the lm cycle comes to a soft stop. If you hold down the machine stop button for at least 2 sections, a lamp test is executed which is controlled via the CPU. "Emergency stop" Stops the machine and other connected equipment. Reset the emergency stop to restart machine operation. This is done by turning the button clockwise. "Request open door / Part-automatic" Press this button to request door opening. Automatic operation is interrupted and the machine continues to the end of the cycle. When this is complete, the lamp comes on and the door can be
opened.

"Control voltage on / off" Turn clockwise to switch on the control voltage: the lamp will come on. (Once you have turned the main switch, wait 7 seconds before the control voltage can be switched on.) "Start mode / Reset alarm" Press the lamp button to acknowledge an alarm. If alarm does not stop, the fault is still present. If you press the button when there are no alarms, the machine returns to start mode.
"Automatic" Press the lamp button to switch to automatic mode. The lamp comes on. If automatic is enabled and you press this, the automatic lamp goes off and set the machine to "part-automatic".

"Display" All parameter settings and program selections are made here.

"Start" If the lm cycle is interrupted (e.g. because the lm has run out), you can restart it after rectifying the problem (e.g. loading a lm). Once the lm cycle is complete, the pallet remains in place on the machine's conveyor. If you press "Automatic " at the start of the cycle, the machine returns to continuous automatic operation.

"Light tower" When the red light is on, an alarm has been activated. When the green light is one, the machine is in automatic mode.

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3.3 LAMP TEST A lamp test can be executed by pressing the "Automatic" button and holding it down for more than two seconds. If any of the buttons with integral lamps does not come on when this test is executed, the lamp is broken. Replace the lamp.

4. Display
4.1 OVERVIEW 4.1.1 GENERAL GL 1000 settings are implemented by navigating in the pressure-sensitive display. Press the relevant button in the display to go to the required submenu or change a value. Some buttons with a dark blue background cannot be pressed and are there only for information.

4.1.2 PASSWORDS Some of the pages cannot be accessed without a password. These can be accessed by service personnel only, for example. The login box on the right is displayed if the page is to log in. A keypad password-protected. Press then appears in the display. Type your password and then "ENT"; the login page is then displayed again. Then press password-protected page. to return to the

4.2 HOME MENU Continue to the alarm page. When an alarm has been triggered, the button lamp is red. See section 4.8, page 15. Continue to pages showing Cyklop contact information. See section 4.9, page 19. Continue to the program parameter menu. See section 4.10, page 17. settings

The above menu is displayed when the machine is started. This is the top menu, which is called "home menu" from this point on in the manual. Continue to the information See section 4.3, page 11. Continue to the manual See section 4.5, page 12. menu for lm.

Displays the selected program. Continue to the program selection menu. See section 4.11, page 18.

operation

menu.

Step up or down to select a program. See section 4.11, page 18.

Continue to the service menu. See section 4.6, page 14.

PROGRAM 1

Displays the selected gram. Continue to the gram selection menu. section 4.11, page 18.

proproSee

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4.3 INFORMATION MENU FOR FILM The illustration on the left shows the rst page below the information menu. The information menu consists of three pages in total. Shows on the right the total number of pallets with lm applied. Resets the number of pallets with lm applied. On the right, you can see the number of pallets with lm applied since the last reset. Shows the number of metres of lm used by the preceding pallet. Press the button to change lm data. (Password required.) Shows the number of grams of lm used by the preceding pallet. Requires the correct data to be input for the lm. Press the button to change lm data. (Password required.) Shows the number of turns for the preceding lm application or the lm application in progress. Switches to the contact information menu. Switches to the screen containing information on the degree of prestretch for different gear modes. Switches to a page with a graphic overview of sensor status. See section 4.8.2, page 16.

Switches to the previous screen/menu. Switches to the rst information menu. If you are on the rst page, nothing happens. Displays explanations for the menu page displayed. Switches to the home menu. Switches to the next screen/menu.

Press to display an explanation on the digits: this will appear on the right. (See the illustration below.) Return by pressing "?".

Page number two.

Switches to a page with a graphic overview of sensor status. See section 4.8.2, page 16.

4.4 NAME PROGRAM Go into the information menu from the home menu, then scroll to the third page of information by pressing the down arrow. To edit a program name, press the required program button. A button pad will be displayed. Type the required name, then press "ENT".

Page number three.

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4.5 MANUAL OPERATION The machine can be operated manually using buttons in the display. The illustrations shown below may vary slightly depending on what options are installed on the machine. Sometimes manual operation is not possible; when an alarm has been activated or the lm cycle is in progress, for example. If manual operation is not possible, the button with . is replaced Switches to the previous screen/menu. Switches to the rst manual operation If you are on the rst page, nothing happens. menu.

Indicates whether manual operation is possible. If a green tick is displayed, manual opertion is possible. If a red cross is displayed, manual operation is not possible. Switches to the home menu. Switches to the next screen/menu. Press the relevant button to move the pallet on the stretch lm applicator to the right or left. Press the relevant button to move the pallet towards or away. (Only on machines with the option 90 input or output transport.) If the board is not in the correct position, the board is rotated rst.

Page number one.

Press the relevant button to rotate the board clockwise or counterclockwise.

Press the relevant button to open or close the lm clamp.

Page number two.

Press the relevant button to raise or lower the top plate. (Only on machines with the option: Top plate.)

Press the relevant button to raise or lower the hoist with the stretch lm unit. When moving downwards, the hoist stops in the starting position. Page number three.

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Press the left arrow button to operate the left conveyor in combination with the shrink lm applicator conveyor. Press the right arrow button to operate the left conveyor in combination with the shrink lm applicator conveyor. Press the button with the green tick when the pallet is in position on the shrink lm applicator conveyor. Positioning has to take place manually as there is no automatic pallet sensing on the board.

Page number four.

Manual operation of conveyor. (Optional.) Click on the relevant conveyor to activate manual operation. The shrink lm applicator conveyor can also be operated manually. The conveyor is marked when it is activated by means of a green eld which lights up beneath the conveyor. No more than two adjacent conveyors can be operated simultaneously. The rst two conveyors are activated in the illustration. The rst one also indicates that there is a pallet on the conveyor. Press the left arrow button to start transport to the left, or the right arrow button to start transport to the right. (Requires the machine to have the option installed which permits transport forwards / back.)

Page number ve.

Remove control of top lm applicators such as CTFP, TF or PLR. Applicable to the functions automatic mode and reset. (This page is included only if the top lm applicator option is installed.) Sets the top lm applicator to automatic mode.

Resetting the top lm applicator. Page number six.

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4.6 SERVICE The service pages are accessible to service personnel only. Press to log in. A keypad then appears in the display. Enter your password and then press "ENT".

4.7 LANGUAGE SELECTION, DATE SET Press to access the service menu.

Press

to access the login page.

Then enter your password and close by pressing "ENT".

The service menu screen should now have changed as shown in the illustration on the left. (The language button should have been displayed.) Press to
Language

continue to language selection.

The language selected is shown in the top right corner. If you want to select a language different to the one selected, click on the relevant language button to switch to that language.

Input password & press "ENT"

Language

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Press

to continue and set the date and time.

The date and time are used to "time-stamp" alarms, among other things.

Input password & press ENT

Language

4.8 ALARM / STATUS SENSOR 4.8.1 ALARM MESSAGES Continue to the alarm page. It is possible to press this button even when no alarm has been triggered. (The lamp on the button is white in this instance.)

Current alarms are displayed here. Continue to alarm history.

The alarm history shows the latest alarms triggered.

Current alarms are also displayed as scrolling text across the bottom of the display. Displayed in all menus.

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4.8.2 GRAPHIC OVERVIEW OF SENSOR STATUS This machine has a function whereby the sensor status is displayed graphically. Some sensors are normally in "on" mode, and some sensors are normally in "off" mode. The ones with an erroneous status are framed red. Other sensors affected have a green frame. Press the relevant part of the machine display to move on to a more detailed position indication. See below for a display overview.

To the left, you can see an example of how an erroneous signal from a sensor might look. If an erroneous signal is displayed, try to move the machine to start mode and see whether it disappears. If the erroneous signal is still displayed, the sensor may be faulty.

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4.9 CONTACT INFORMATION The contact pages contain information to allow you to contact your nearest Cyklop company to book a service or place an order for consumables or spares.

4.10 SETTING PROGRAM PARAMETERS Values in brackets are max and min values that can be set.

Select a program for parameter editing. (1-9) Film tension at start of lm cycle. (0-90) Film tension at top of pallet. (0-90) Film tension in middle of pallet. (0-90) Page number one. Film tension at bottom of pallet. (0-90) Change lm pattern. (1-6) Number of top turns. (0-15) Number of bottom turns. (1-15) Rate of lm application upwards. (12-75) Rate of lm application downwards. (12-75)

Fig. 2

The above explanations are also available in English in a submenu (Fig. 2). Press to go to this page.

This explanation menu also includes a submenu graphic explanation (Fig. 3) for the relevant lm pattern. Press or to go to this page.

with

See section 5.7, page 21 for further information.

Fig. 3

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Change programs. (1-9) How high lm is to be applied in relation to the top of the pallet. (0-500) Value indicating how far down from the top edge of the pallet lm is to be applied. The value is given in millimetres. Adjustable values are "0" to "999" mm. The values between "0" and 998 correspond to the number of millimetres from the top edge of the pallet. If you input a value of "999", the hoist for the lm unit always goes down to the lowest height for cutting. (0-999) Interim speed before high speed. (0-999) Top plate. (Optional.) Top lm. (Optional.) Top rotary board speed during lm cycle. (25-100) Weld time. (0.05-2.00) Fig. 2 The above explanations are also available in English in a submenu (Fig. 2). Press to go to this page. rotary board reaches

Page number two.

The next page shows an overview of the preset program parameters. There is also space there for noting your own program settings.
4.11 PROGRAM SELECTION
PROGRAM 1 Programs can be selected in three ways. press 1 , or . The third way is to step up and down using the arrow up and arrow down keys ( ).

Step up or down to select a program.

Displays the selected program. Press the button and a keypad is displayed. Then select the relevant number and press "ENT".

PROGRAM 1

Displays the selected program. Continue to the program selection menu. See Fig. 2.

Programs are selected by pressing the relevant program button. The program number selected is displayed in the bottom left corner. Programs can also be selected using an external signal when the machine is in automatic mode. Fig. 2

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5. Operate the machine

5.1 STARTUP - START UP THE MACHINE AND RUN IT TO STARTING POSITION

Make sure that the machine is powered up and has a compressed air feed to it. Check that the emergency stop button is not depressed. Turn the main switch. Wait for about 7 seconds before step 4. Turn the rotary lamp button "Control voltage" clockwise. The alarm lamp in the light tower comes on. Press the alarm button "Start mode/Alarm reset". If alarms are shown in the display, acknowledge these rst and then press the button again. Any parts of the machine which are not in starting position will be moved to there.

The lamp for alarms should now have gone off. The lamp button "Start mode/Alarm reset" comes on. The button for semiautomatic operation in the display has lit up. The display should look as shown below, possibly with a different program selection. The machine is now in start mode and semiautomatic mode.

5.2 LOAD FILM

NOTE: If the machine is placed in an cold environment and equipped with the -6 or -28 option, keep in mind that the lm must have the same temperature as the surroundings where it will be used. Store the lm in the same room as the machine for at least 24h before use. 1. Check which side of the lm is sticky. If the outside is sticky (most common), the roll of lm must rotate counterclockwise (Fig. 1). If the inside is sticky, it must rotate clockwise (Fig. 2). Insert a new roll of lm by pressing it down over the roller "A" (Fig. 3). Take care to make sure the roll bottoms out. NOTE: Handle the roll of lm with care so as not to damage it, as this may cause the lm to break. Pull the lm as shown in Fig. 1 or 2. The easiest thing to do is fold the end of the lm in four and pull it between the top part of the rollers as shown in Fig. 3, B (grey area). Secure the end of the lm in the clamp on the lm retainer arm on the rotary board on the machine (Figure 4). Press and hold down the valve button "D" to open the clamp. Note that the clamp will close again as soon as the valve button is released.

2.

3.

Fig. 1.
4.

A
Fig. 2. Fig. 3.
Risk of cutting! The anges on the roller may be sharp. Warning! The machine has a number of points where there is a risk of getting trapped or cut. Take great care when in the machine's operating range.

D
Fig. 4.

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5.3 SET PRESTRETCH OF FILM Use the gear control (see the gure on the left) directly above the roll of lm to set different degrees of prestretch. Gear Gear Gear Gear Gear Gear Gear Gear 1= 2= 3= 4= 5= 6= 7= 8= 60% 100% 130% 160% 200% 280% 340% 400%

If you select a high gear, the lm will be thinner on the pallet goods. This means less lm consumption per pallet, but it also requires a higher lm quality than a lower gear. Start with gear 6, for example, to see whether the lm holds. If it breaks, switch to a lower gear or a higher lm quality.

5.4 SET FILM TENSION Film tension parameters are set via the display. See section 4.10, page 19 for information on the buttons. The lm tension is adjustable for every program and for different parts of the lm cycle. Value set to "0" = Low lm tension Value set to "90" = High lm tension This value corresponds to the percentage reduction in motor torque. Example: If a value "25" is set, this is equivalent to the pallet/rotary board pulling 25% and the motor feeding 75%.

5.5 START THE MACHINE

IF THE MACHINE HAS A PALLET STANDING ON THE CONVEYOR

IF THE MACHINE DOES NOT HAVE A PALLET STANDING ON THE CONVEYOR

Make sure that the machine is in start mode. See section 5.1, page 19. Select a program. See section 4.11, page 18. Press the "Start" button. This needs to be done only if the machine has a pallet on the conveyor. Press the "Automatic" button to switch to automatic mode. The machine is now ready for operation and in automatic mode.

Make sure that the machine is in start mode. See section 5.1, page 19. Select a program. See section 4.11, page 18. Press the "Automatic" button to switch to automatic mode. The machine is now ready for operation and in automatic mode.

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5.6 PAUSE IN AUTOMATIC MODE Pause in automatic mode can be used if the operation needs to enter the machine's operating area.

Check that nobody is present within the safety fencing before closing the gate. Acknowledge with the button "Start mode / Reset alarm". The lamp for alarms on the light tower should now have gone off and the button "Start mode / Reset alarm" comes on. Press the "Automatic" button to return to automatic mode. The machine will now automatic mode from sition in the where it was interrupted. continue in the posequence

Press the button "Request open door". This button then starts to ash. The machine stops and the lamp for the button "Request open door" is on continuously. Open the gate and do what has to be done. The alarm lamp comes on at the light tower. Warning! The machine has a number of points where there is a risk of getting trapped or cut. Take great care when in the machine's operating range.

5.7 DESCRIPTION OF FILM PATTERN Pattern 1 - Dust-protected / Secure This lm program starts at the bottom and ends at the top. With the parameter "Down before cutting" and the value set to "999", the hoist moves down to the lowest height for cutting. (Gives one to two layers of lm.) The number of bottom and top turns, lm tension, lm overlap, etc. can be selected via lm parameters. Pattern 2 - Secure This lm program starts at the bottom, applies lm up to the top and then applies lm down to the bottom and up to the lowest height for cutting. (Gives two-and-a-half layers of lm.) The number of bottom and top turns, lm tension, lm overlap, etc. can be selected via lm parameters. Pattern 3 - Extra secure This lm program starts at the bottom, applies lm up to the top and then applies lm down to the bottom and ends at the top. With the parameter "Down before cutting" and the value set to "999", the hoist moves down to the lowest height for cutting. (Gives three to four layers of lm.) The number of bottom and top turns, lm tension, lm overlap, etc. can be selected via lm parameters. Pattern 6 - Through-transport The pallet is transported through the machine without lm being applied. Pattern 4 - Water-protected (Requires optional top lm equipment) This lm program starts at the bottom, then pauses at the top where top lm is applied. The lm sequence then continues and can be terminated at either the top or the bottom of the pallet. The number of bottom and top turns, lm tension, lm overlap, etc. can be selected via lm parameters.

TS Topsheet

Pattern 5 - Custom (Optional)

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6. Care and daily maintenance

(Trained personnel only)

6.1 CLEANING 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 week, and clean if so required. Use a damp cloth with water and washing-up liquid.

ATTENTION !

The installation should be turned off before cleaning. Lock the master switch located on the mast so that the installation cant be turned on while cleaning is in progress.

WARNING !

Ensure that electrical components are not in contact with water or other liquids. When the machine is cleaned by staff other than the operator, eg a cleaner, he or she must be given instructions regarding cleaning of the machine

6.2 SERVICE & MAINTENENCE

Within the warranty period, repairs may only be performed under the supervision of a technichian of the supplier. The quality of any replacement part must at least correspond to the one of the original part (compare specications). All parts can be ordered from the manufacturer. As a precaution, it may be advisable to stock some spare parts to minimize downtime. Consult the manufacturer. See Recommended spare parts list last in the spare parts section. The installation consists mainly of standard parts (which can be purchased on the open market), but also of original parts (which are available from the manufacturer). SERVICE AND MAINTENANCE The power should be broken with the power main switch during service or maintenance. Also the main switch must be locked to prevent unplanned actuation.

Standard parts: Use preferably the same make as the original. If in doubt, consult the supplier. Original parts: Replacement parts must be ordered from the supplier.
WARNING !

Deviations from the above rules can have consequences that endanger the safe operation of the installation and the warranty period will be forfeited. The manufacturer is not responsible for events resulting from such deviations.

ELECTRICAL WORKS Although the power switch is turned off some electricity may remain in the installation, eg in capacitors or in the form of potential energy differences. Therefore wait a few minutes before work with electrical wiring can begin.

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

To be checked General

Adjustment and/or lubrication Cleaning should be carried out around the rotary board and unit in order to minimise the risk of problems

Range

Weekly

To be checked

Adjustment and/or lubrication

Range

Knife, Catcher

Check that the knife blade (A) is not blunt or cracked. As necessary Replace where necessary.
As necessary

Check that not cracked necessary.

the or

blade bent.

steels (B) Replace

are where

Risk of cutting! The knife and blade steels are sharp. Discard any worn-out knives/blade steels in a container for sharp waste. Do not discard among ordinary waste.

To be checked Roll of lm - Brake

Adjustment and/or lubrication

Range

Check the friction brake by pulling on the lm at 3 mths normal lm speed and then suddenly releasing the lm. The roll of lm should then stop after approx. 1/5 of a turn. Basic setting: Screw down the nut (A) until the spring washer (B) is fully compressed. Then unscrew the nut by (A) turn.

Lubrication! Apply a lubricant spray with a pipe. Avoid applying lubrication in locations not specied.

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7. Resetting
7.1 FILM BREAKAGE / END OF FILM If the lm has run out or broken, the machine goes automatically to its starting position. The alarm lamp comes on at the light tower.

The lamp for alarms on the light tower should now have gone off and the button "Start mode / Reset alarm" comes on. The button for semiautomatic operation in the display has lit up. The machine is now in start mode and semiautomatic mode. If there is a pallet in the machine which needs to have lm applied again, press the button "Cycle start" to start the lm cycle. Press the "Automatic" button once the cycle has started. When the lm cycle is complete, the pallet will be transported out of the machine and the machine will continue to operate in automatic mode.

Press the button "Start mode / Reset" to acknowledge the alarm. The button lights up. Press the button "Request open door" and the button will light up. Open the gate and go in and - if the lm has run out - switch to a new roll of lm. If the lm has broken, secure the end of the lm in the lm retainer. See section 5.2, page 19 for further information. Check that nobody is present within the safety fencing before closing the gate.

Once the gate is closed, the contactor automatically applies the gate switch. Acknowledge by pressing either "Request open door" or "Start mode / Reset alarm".

7.2 MACHINE STOP ACTIVATED If the button "Machine stop" has been depressed during any sequence, the sequence in progress will be terminated. The alarm lamp comes on at the light tower.

If there is a pallet in the machine which needs to have lm applied again, press the button "Cycle start" to start the lm cycle. Press the "Automatic" button once the cycle has started. When the lm cycle is complete, the pallet will be transported out of the machine and the machine will continue to operate in automatic mode.

Press the button "Start mode / Reset". Press the button "Start mode / Reset" again. Any parts of the machine which are not in starting position will be moved to there.

7.3 EMERGENCY STOP ACTIVATED If the button "Emergency stop" has been depressed during any sequence, the sequence in progress will be stopped immediately and the alarm lamp will come on at the light tower.

The lamp for alarms on the light tower should now have gone off. If there is a pallet in the machine which needs to have lm applied again, press the button "Cycle start" to start the lm cycle. Press the "Automatic" button once the cycle has started. When the lm cycle is complete, the pallet will be transported out of the machine and the machine will continue to operate in automatic mode.

Release the emergency stop button. Rotate the button "Control voltage" clockwise to on position. The lamp comes on. Press the button "Start mode / Reset" to acknowledge the alarm. Press the button "Start mode / Reset" again. Any parts of the machine which are not in starting position will be moved to there.

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7.4 LIGHT BEAM WHICH HAS TRIPPED (OPTIONAL) In some cases, a reset can be executed without going into the machine's operating range. The following description is applicable if the operator needs to go in to reset light boom.

The lamp for alarms on the light tower should now have gone off and the button "Start mode / Reset alarm" comes on. If the machine was in automatic mode before the pause in automatic mode, press the button "Automatic". The machine will now continue at the point where it left off in the automatic sequence. The machine will continue working in automatic mode.

Open the gate. The alarm lamp comes on at the light tower. Go in and reset light boom. When the gate is closed, acknowledge with the button "Start mode / Reset alarm".

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8. General troubleshooting
8.1 TROUBLESHOOTING Problem If nothing works? Action Check that the machine is powered up and that the main switch and the rotary knob for control voltage are set to position "1". Try holding down "Machine stop" for 3 s. Then press "Reset". Run to starting position. Error message "A2", main contactor not on, check that the emergency stop is not depressed. If it is, turn the button clockwise to release it. If the lm breaks? Check that the roll of lm has sustained no damage. Replace the roll of lm if it has. See section 7.1, page 23 for resetting. Press the button "Start mode / Reset alarm" to return the rotary table to home position. Check the goods height sensor. Check the lm application settings: read "Display - Pallet parameters" (password required). The machine can be run, but only with the latest cycle setting (program selection) run. Contact Cyklop.

If the rotary board stops in the wrong position? If the lm is not applied right up to the top of the goods? The display is not working.

The hoist does not operThe obstruction protection under the hoist or cutting unit may be activated. Check that there is nothate and gives error mesing under the hoist or cutting unit. With error message "A4", check the hoist pulse sensor. sage "A15", "A16" or "A4"

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9. Transport
9.1 TRANSPORT The machine must be transported by truck. The machine can be lifted from the long sides or from the front. Do not lift from the side with the electrical cabinet. See illustrations. If the machine is lifted from the side, the truck must have forks which reach through the entire machine chassis. If the machine is lifted from the front, the truck must have forks long enough to reach the centre beam (A). Lift the machine carefully and transport it slowly. Risk to life! Remaining under any type of suspended load, or working there, may risk your life! Service area: Minimum of 1 m around the machine is needed for service. The service places of the machine must be reachable by approved person lift or similar, alternatively, the customer takes responsibility that the machines service can be performed. NOTE! This will then be determined at the time of procurement. Transport National rules and regulations must be observed when transporting Cyklop lm stretch machines and accessories. Individual parts and large components are carefully xed during delivery. When the machine is assembled or moved, great care must be taken. Check that the lifting device is designed to take the weight and does not pose a safety risk. Only approved lifting devices with a lifting capacity greater than the total weight of the machine, plus packaging, may be used. Dimensions and weight The delivery note with the goods includes details on the weight and dimensions of the goods. General rules Unless stated otherwise, all parts must be transported in their original packaging to the installation site. When unpacked, all parts must be examined so that any transport damage can be found. If the goods have been damaged in transit, the shipping agent must be contacted immediately and unpacking must be stopped.

Transport damage Any damage to the goods must be noted on the delivery note when the goods are received. No exceptions!

Risk of damage! The centre of gravity of the machine may be high, which increases the risk of the machine tipping over. Check carefully where the centre of gravity is so as to eliminate the risk of tipping.

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10. Technical specications

Machine

Capacity Rotary board speed Hoist speed Temperature range Safety class Connection Output Safety norm EX-classication

Max 80 pallet/h (depending on goods type) Max 23 r/min Max. 0.6 m/s +5 to +35C, for use in a dry, tempered area 2 3x400 V + N + PE, 50 Hz t.b.a. kW IP54 Not approved for ATEX classied areas 0.4 x 0.6 m 1.2 x 1.2 m or 1.4 x 1.0 m >500 mm (depending on goods type) Std. height 2500 mm Max 1500 Kg 76.4 mm +250 mm 500 mm 12-25 my, 20 my recommended

Electricity

Pallet goods Min size (length x width) Max size (length x width) Lowest inc. pallet Height inc. pallet Weight Stretch lm Diameter, core Outer diameter, max Film width, max Film thickness

The above values apply to standard machines. These values may differ if the machine is tted with additional options.

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11. Table of set values, program parameters

Film parameters Prog 1 1 10 15 15 15 2 3 35 35 75 100 75 60 1,00 No No Prog 2 1 10 15 15 15 2 3 35 35 75 999 75 60 1,00 No No Prog 3 1 10 15 15 15 2 3 35 35 75 999 75 60 1,00 No No Prog 4 Prog 5 Prog 6 6 Prog 7 Prog 8 Prog 9

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Version log 1.0 1.1 2.0 Initial release Version log added. EC declaration updated according to new machine directive. EG-declaration updated with SS-EN 415-6, Packaging machines safety. General safety instructions uppdated with unauthorized use. Installation updated with service area. Temperature information for stretch lm handling added.

2.1

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Ver. 1.0

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Art.no: 961010EN