Matco Mustang T3 ECO Basic Manual

2 SAFETY ....................................................................................................................................................... 3 2.1 SAFE USE ..................................................................................................................................................... 3 2.2 QUALIFIED PERSONNEL ................................................................................................................................... 4 2.3 ACCIDENT PREVENTION .................................................................................................................................. 4 3 USE ............................................................................................................................................................. 5 3.4 OTHER RISKS ................................................................................................................................................ 6 3.5 THE SCOPE OF THIS MANUAL............................................................................................................................ 6 4 INSTALLATION ............................................................................................................................................ 7 4.1 UNPACKING ................................................................................................................................................. 7 4.2 TRANSPORT ................................................................................................................................................. 7 4.3 STORAGE ..................................................................................................................................................... 7 4.4 WASTE DISPOSAL .......................................................................................................................................... 7 4.5 INSTALLING .................................................................................................................................................. 7 4.6 ELECTRICAL CONNECTION ................................................................................................................................ 8 4.7 MOUNTING ................................................................................................................................................. 8 5 MAINTENANCE ........................................................................................................................................... 9 5.1 GENERAL ..................................................................................................................................................... 9 5.2 SPARE PARTS ................................................................................................................................................ 9 5.2.1 Maintenance schedule ................................................................................................................... 10 5.2.2 Lubricants ...................................................................................................................................... 10 5.3 INSPECTIONS .............................................................................................................................................. 11

- It is safe to use; - One is able to make settings; - One can perform maintenance. Additionally included in this basic manual are: • Machine specific manual • CE declaration SERVICE In the event of a malfunction, contact: Matco International. Tel: +31 (0) 850 49 49 90 E-mail: [email protected] SPARES Order spare parts at: Matco International Hamburgweg 16, 7418 ES Deventer, Nederland Tel: +31 (0) 850 49 49 90 E-mail: [email protected] 1 Foreword

We use the following symbols to warn about dangers and possible sources of risk. Get to know them well! Ignoring a warning can lead to personal injury and/or damage to this equipment or other machinery. Attention: Failure to observe warnings may result in a fatal accident, personal injury or damage to equipment. Attention: Live electrical components. Failure to observe warnings may result in a fatal accident, personal injury or damage to equipment. Attention: Danger from rotating parts Prohibited: Risk of entering a dangerous area. Prohibited for unauthorised personnel! Attention: Heat hazard, burn hazard

Our definition of "qualified personnel" in this context is "personnel with a thorough knowledge of the equipment itself and how to operate and maintain it safely". Qualified personnel must be physically fit enough to perform the necessary tasks, have a good knowledge of all the relevant safety precautions and be trained to install, operate and/or maintain the equipment safely. The company using the equipment is responsible for ensuring that the personnel comply with these conditions. 2.3 Accident prevention 1. Before starting to work with the installation, the manual must first be studied. 2. Use of the installation by unauthorised personnel is prohibited. • 3. Never allow persons to use the equipment if they are under the influence of medication that may impair reaction times or are not in physically fit condition for operating the installation. 4. Ensure at all times that work / maintenance / service on the installation is done safely and without voltage. Make sure that the installation cannot be switched on accidentally by locking the main switch. 5. Safety guards must be checked before starting the machine – they may not be loose or removed. This also applies to the foot protection under the film carriage. • 6. If it is necessary to remove any safety device to allow installation, repairs or maintenance, the safety device must be replaced immediately after completing the task. • 7. Keep limbs and clothes away from rotating parts. Do not wear neckties or loosely hanging clothes when using or maintaining machines with rotating parts. Remove wristwatches, chains and similar jewellery. Cover or tie up long hair before carrying out any task on or with the machine. • 8. Only machines with a suitable protection rating may be used in humid conditions. • 9. Do not use the equipment in an area with risk of explosion. • 10. Always use the equipment in a well-ventilated space. • 11. If a pneumatic hold-down plate is used, the supply air line will remain under pressure when entering the danger zone. Other parts will become voltage / energy-free. Dangerous situations may result from failure to comply with the conditions listed above.

The fully automatic wrapping machine, hereinafter also referred to simply as “the installation”, may only be used for wrapping pallets of the suitable products that meet the data as stated in the description. In case of doubt, the manufacturer must be consulted for permission. Using the installation in any way other than specified in the description can lead to danger, e.g. it can damage the wrapping machine and/or threaten the safety of operator or other persons near the installation. To ensure safety, all personnel must read these operating instructions thoroughly before commissioning the installation, troubleshooting or performing maintenance. We would like to call your attention to chapter 2 Safety, which specifies the intended use and the unsafe situations that cannot be prevented through the design and manufacture of the machine. 3.2 Improper use The installation may not be used in the following situations: • When it is in poor condition • In an environment with risk of explosion (unless the machine is specially adapted) • With unsuitable materials and consumables • Without full compliance with the values specified under "Technical data". • In a humid environment The following materials may not be processed in the installation: • Materials presenting a risk of explosion or fire • Caustic and corrosive materials • Foodstuffs (unless the machine is specially adapted) 3.3 Intended use The installation is intended for industrial applications.

In terms of design and construction, everything has been done to protect users from possible dangers. However, some risks cannot be entirely eliminated. Users must be aware of the following: • The risk of entering a dangerous area • Control line cylinder pressure plate remains under pressure in all cases • Control line of the film clamp remains under pressure (for turntable winder with 90 ° infeed or outfeed). The risk of entering a dangerous area It is possible to enter dangerous areas when loading and unloading products. Attention: Prohibited for unauthorised personnel! Risk of entering a dangerous area. 3.5 The scope of this manual This manual is only valid in combination with all the other documentation included in the user manual. For special versions, this manual may be supplemented with extra specifications and/or additional documentation. The images only show the installation's essential parts.

the safety instructions in this manual and all other relevant documentation. 4.1 Unpacking Unpack the installation carefully and check for any transport damage. Retain the pallet, fixings and wrapping material for possible future transport or dispose of it in accordance with the appropriate waste handling regulations. 4.2 Transport • For weight specifications check the “Machine specific manual”. Only use suitable lifting gear. • Protect the installation from damage, damp and dust, using suitable packing materials. • Avoid bumps and shocks. 4.3 Storage Do not store the installation outdoors! Protect it against dust and fluctuating temperatures (condensation formation). 4.4 Waste disposal When the installation reaches the end of its working life or there is no further use for it, the equipment should be handled according to the currently valid waste disposal regulations. 4.5 Installing Only install the installation in a location that conforms to the stated safety classification. Install the installation in a well-ventilated space. Do not put it in an area with any risk of explosion! Protect the installation against vibration. Remove transport protection materials (when present). Make sure there is enough free room, especially above the installation. Check the "Machine specific manual" for dimensions.

Attention: Hazardous electrical voltage. Failure to observe warnings and safety measures may result in a fatal accident, personal injury or damage to equipment. - Connecting to a power source: • The preferred way to connect the installation is via a power cable with a plug, connected to an earthed mains socked that is protected by a circuit breaker or fuse. • The power supply must, in principle, comply with applicable requirements regarding acceptable voltage variations, ripple, attenuation of higher harmonics, etc. 4.7 Mounting Attention: All of these activities may only be performed under the supervision of qualified personnel from the manufacturer or an authorised representative! - The concrete floor must be completely flat and horizontal within the tolerances set by the installation - Anchor machine parts to concrete floor.

any maintenance on the installation. - Ensure that no one else can switch on the installation. - Ensure that safety guards and suchlike are installed when the installation is activated. 5.1 General Preventive maintenance will ensure that the installation has a longer working life. This means that the condition of various parts of the installation must be inspected on a weekly, monthly or annual basis. The environmental conditions will affect the service life. The specified maintenance frequency applies to normal operational conditions (8 hours per day, 5 days per week, at 20C, in a clean environment). When subjected to more demanding conditions we recommend performing maintenance more frequently. Ensure that moving parts are free of dirt. Please refer to the maintenance schedule in section 5.2.1 Maintenance schedule for information about the maintenance frequency required for the different systems and parts. 5.2 Spare parts The parts lists for the machine parts describe the parts used, which can be ordered as spare parts. Bij bestelling van onderdelen dient op het volgende gelet te worden: 1 Provide the machine's serial number. 2 For electrical parts, provide the (schematic) position number, description, article number and manufacturer's name. 3 For mechanical parts, provide the drawing number, position number, article number and description. To facilitate the rapid repair of a possible malfunction, we recommend keeping a number of spare parts in stock.

Maintenance frequency 8 hours 40 hours 100 hours 200 hours 500 hours 1000 hours 2000 hours Clean daily X Check cutting wire X Check cutting blade X Clean photocell lens X Chain under turntable 3 Sprockets turntable X Timing belt pulley for pre- stretch X String for pre-stretch X Bearings X Running wheels film carriage X Running wheel turntable X Limit-/proximity switch X Gearmotors X 1 Electrical system X The numbers in the maintenance schedule refer to the applicable products as shown in the lubricants table. Attention: Check safety/instruction stickers. If they are damaged or missing, they must be replaced. 5.2.2 Lubricants SYMBOL LUBRICANT SHELL BP ESSO MOBIL OIL TEXACO GLEITMO 1 OMALA 220 ENERGOL GR-XP 220 SPARTAN EP 220 MOBILGEAR 630 MEROPA 220 2 OMALA 680 ENERGOL GR-XP 680 SPARTAN EP 680 MOBILGEAR 636 MEROPA 680 3 TONNA T68 MACCURAT 68 FEBIS K 68 EP220 VACTA.4 WAX LUBRI- CANT X68 4 ALVANIA R ENERGREASE L2 BEACON 2 MOBILUX 2 MULTIFAK EP2 5 TELLUS 46 HPL 46 NUTCO H46 DTE 26 RANDO HD46 6 TORCULA 32 ENERGOL RD-E 80 AROX EP 56 ALMOBIL 1 ARIES 32 7 TELLUS 15 RANDO HDZ 15 8 RETINAX WB STARPLEX PREMIUM 1 (depends on the application) 9 FIN GREASE OG 10 UNIREX EP

safety instructions in this manual and all other relevant documentation. Attention: Tracing faults can possibly require checking while the installation is under power. Take care to observe the safety regulations concerning working on live equipment (active parts). Ignoring them can lead to danger of electric shock. Inspections Tasks Electrical system - Check the switches, emergency stops and other operating buttons to ensure they are working correctly. - Check the indicator lights. - Check and test the thermal protection devices. - Check the contactors and relays for burned contacts and humming. - Check the cabling and connections. - Check the photocells and reflectors to ensure correct operation and adjustment (lenses must be clean). - Check the limit and proximity switches for correct operation and adjustment. Motors/gear units - Check the fan. - Check that the fan cover is undamaged. - Check the oil level in the gearbox (top up if required). - Check that the fastening bolts are tightened and tighten them when required. - Check and lubricate moving parts if required. Turntable - Check the tooth flank wear of the chain wheels / sprocket / slewing bearing - Check and lubricate the chain wheels / sprocket / slewing bearing - Check whether the drive gear on the motor shaft has expired. If necessary, align and secure with the locking bolts. Column - Checking the lifting strap for wear. If wear is visible, the tire should be replaced Film carriage - Check that there are no film residues in the brake system. - Check the conductivity of the film carriage in the mast via running wheels. - The running wheels must have a max. clearance of 2mm in relation to the guide. Replace if necessary due to wear. - The guiding construction for the film carriage in the mast must NEVER be lubricated! - Check the parallel running of the film carriage. - The film carriage may max. 2 - 3mm at an angle - Check the timing belt pulley and the timing belts of the front rack for wear. Replace if necessary. AW ( implementation ) Pneumatic system - Regularly check that the filter is clean. If required, clean or change. - Regularly drain any accumulated condensation - Check hoses, cylinders, hose connections and valves for leaks Film inlay-unit - Check the condition of the rubber of the film inlay jaws. These must not have become too hard and / or damaged. Replace if necessary. - Check that the film inlay jaws close properly. These must close properly over the entire length. Readjust or replace if necessary. - Check that the sides on which the film slides are smooth and without damage. Update or replace as necessary. - No film residues in the film inlay. These can prevent proper operation.

(for A700 AW machine) - Check the condition of the glow / cutting wire - Check, and if necessary adjust the cutting wire to the correct tension. - Check whether the cutting wire is clean of dust or impurities - Check that the cutting wire does not come into unwanted contact with other parts (such as cables and air hoses) Cutting blade construction (for A900 AW machine) - Check the band tension of the band cylinder. - If the band is not tight on the cylinder, the band must be readjusted or replaced. Adjust or replace in accordance with the regulations of the supplier. - Check the condition of the band. The ribbon must not be damaged. Replace if necessary. - Check the condition of the cutting blade. The cutting knife should cut and cut through the foil. Replace if necessary. - Check free height space between the bottom of the cutting blade fixation arm and the conveyor track construction. The bottom of the cutting blade fixation arm must remain at least 5mm above the top of the conveyor track. Adjust if necessary.

Table of Contents 1 OPERATION .............................................................................................................................................1-1 1.1 ESSENTIAL COMPONENTS ............................................................................................................................ 1-1 1.2 EXPLANATION ESSENTIAL COMPONENTS ......................................................................................................... 1-2 1.3 DESCRIPTION ............................................................................................................................................. 1-2 2 TECHNICAL DETAILS .................................................................................................................................2-3 2.1 MACHINE ................................................................................................................................................. 2-3 2.2 ELECTRICAL ............................................................................................................................................... 2-3 2.3 SIZE AND WEIGHT ...................................................................................................................................... 2-3 3 OPERATION .............................................................................................................................................3-4 3.1 INSERTING FILM ROLL .................................................................................................................................. 3-4 3.2 MACHINE SETTINGS .................................................................................................................................... 3-4 3.2.1 Load height ................................................................................................................................... 3-4 3.3 OPERATOR PANEL ...................................................................................................................................... 3-5 3.4 EXPLANATION OPERATOR PANEL ................................................................................................................... 3-6 3.5 OPERATING SCREENS .................................................................................................................................. 3-7 4 TREE STRUCTURE ................................................................................................................................... 4-10 5 COMPONENTS ....................................................................................................................................... 5-11 5.1 TURNTABLE ............................................................................................................................................. 5-11 5.2 COLUMN ................................................................................................................................................ 5-13 5.3 FILM CARRIAGE ....................................................................................................................................... 5-15

Matco International 1 Operation 1.1 Essential Components 3 2 4 1 5 Attention: The machine may not be used if protective covers are not present Essential Components 1 Turntable 4 Operation 2 Film carriage 5 Ramp 3 Mast

Matco International 1.2 Explanation Essential Components 1. Turntable The pallet to be wrapped is placed on this turntable. When installation is started, it will start turning. It automatically stops at its '0 position' at the end of the cycle. 2. Film carriage The film carriage controls the supply of the film to the pallet. The entire pallet is wrapped due to the up and down movement of the film carriage. 3. Mast The mast contains chains and a motor that make the foil carriage move. It also contains the control box that contains all electrical components. 4. Operation The controls are located on the side of the mast. There is also a light that indicates whether the installation is switched on. 5. Ramp The machine can be supplied with a ramp of various dimensions. 1.3 Description This semi-automatic pallet wrapper makes it possible to wrap pallets with just 1 push of a button. The pallet turns automatically on the turntable, while the film carriage moves vertically along the pallet. The pallet will be wrapped from head to toe on all sides.

Matco International 2 Technical Details 2.1 Machine Speed 3-12 revolutions per minute Clear height Min. 2800 mm Environment Clean, dry, not aggressive Operating temperature 0 to +45oC 2.2 Electrical Connection 1x230 VAC - 50 Hz, with protective earth Installed power 0.9 kW Insulation class IP 54 2.3 Size and Weight Weight Approx. 435kg (Depending on model and version) Dimensions (length x width x height) 2600x750x2600mm, turning table Ø1500mm (Depending on model and version) Product dimensions 1200x800mm Loaded height Min. 500mm / max. 2200mm Weight loaded pallet turntable Min. 200 kg / max. 1000 kg Width of film to be processed 500mm Thickness of Film 17 - 35 μ

Matco International 3 Operation 3.1 Inserting film roll 1 - Insert new film roll (unwinding direction depends on which side the “cling” is). 2 - Apply film according to the drawing below. CI = CLING INSIDE (Adhesive side on the inside) The film must be loaded into the braking system like this when using a "differential cling" film, the adhesive side being on the inside of the film as it is unwound from the film roll. CO = CLING OUTSIDE (Adhesive side on the outside) The film must be loaded into the braking system this way when using a "differential cling" film, the adhesive side being on the outside of the film as it is unwound from the film roll. When using a "double side cling" film, it does not matter in principle how the film is inserted. This machine is only used with Cling Inside film. Properties of the Film: Diameter film roll : Max. 300 mm Sleeve diameter : 76.2 mm (3") Width : 500 mm Thickness : 17 - 35 μ 3.2 Machine Settings 3.2.1 Load height This is an adjustable photocell (probe) mounted on the film carriage. By adjusting the photocell higher or lower, the film overlap on the top of the pallet will respectively be smaller or larger.

Matco International 3.4 Explanation Operator Panel From the operator panel you can directly apply manual operation to the wrapper. Menu keys Selection up/change screen Exit selection Select page select Select down confirm Manual operation Turn turntable Film carriage up Film carriage up Automatic operation Faster while turning Faster during ascent or descent Slower slower Turntable (this refers to the top 2 icons Film carriage Reinforce wrapping Push buttons or indicators Voltage on machine. Start or reset wrapper. Stop during wrapping cycle. Emergency stop stops everything immediately on impact. Pull out before resetting.

Matco International 3.5 Operating Screens From the panel you can change the parameters of your wrapping program. Changing values Set-> Ent Change field Set-> Set Exit input field Esc Switch screen selection up/down Set speed for the turntable/film carriage. T/T Spd: Turntable speed. F/C Raise: Increase speed film carriage. F/C Lower: Decrease speed film carriage. Number of windings. Bottom: Bottom wraps: number of windings on the bottom of the pallet. Top-Wrap Top wraps: number of windings on top of load. Other options Over: Runtime film carriage above pallet. Reinforce: Number of windings after pressing the reinforce button. Film break test: 1=film break on 0=film break off.

Matco International Top sheet settings. Time: The time the film carriage is lowered before the machine stops for placing top sheet. After placing the top sheet, press start again for the continuation of the wrapping program Top sheet: Top sheet on=1 off=0 Single/spiral: single wrap (only up) =0 spiral=1 Inputs This screen displays incoming signals in the operator panel. Home: Turntable in home position.Height: height sensor Door: Door film carriage closed. Up limit: Top limit switch Start: machine on automatic . Down limit: Bottom limit switch E/S: Emergency stop. F/F Dispensing film. Outputs the outgoing signals from the operating screen. T/T Start: Turn turntable. Carriage up: Film carriage up. Carriage down: Film carriage down.

Matco International The login screen for changing the language. Via machine state-> page button Some screens are protected against modifications. Password 111 for language adjustment Language choice after logging in. Choose language set 1 to 4

Matco International 5 Components Machine parts with quantity and part number 5.1 Turntable

Matco International Turntable Type III NO. QTY. Part number Description 1 1 3010185 Turntable 2 1 3010619 motor mast 3 1 3010620 Motor reductor 4 8 9000 M10X30 Hexacon bolt 5 8 9000 spring washer 10 6 8 9000 flat washer 10 7 4 9000 M6x10 Sunk bolt 8 1 3010621 cover plate 9 1 3010622 reducer bottom plate 10 1 3010623 small sprocket 11 1 9000 large washer10 12 1 9000 M10X20 Hexacon bolt 13 1 3010624 turntable base assemble 14 4 9000 M5X10 Hexacon socket bolt 15 1 9000 M12x80 Hexacon bolt 16 6 3010098 turntable wheel assemble 17 1 3010088 main shaft 18 4 9000 spring washer 8 19 4 9000 M8X20 Hexagon socket head cap screws 20 1 3010084 Thrust ball bearing 51120 21 1 3010089 big sprocket 22 1 3010085 Double sealed deep groove ball bearings6010-2z 23 1 3010087 stop washer 48 24 1 3010086 small round nut M48 × 1.5 25 4 3010089 connect post 26 4 9000 M10x30 hex socket sunk bolt 27 1 3010625 Reflector plate 28 2 9000 M5X20 Hexagon socket bolt 29 2 9000 spring washer 5 30 6 9000 flat washer 5 31 1 3010626 photocell frame

Matco International Lifting frame Type III NO. QTY. Part number Description 1 1 3010627 reducer bottom board 2 4 9000 M10x30 Hex bolt 3 8 9000 Flat washer 10 4 8 9000 Spring washer 10 5 2 9000 Nut M8 x12 6 1 3010628 Motor with reduction 7 2 3010629 Chain wheel A 8 4 3010630 slider plates 9 4 3010631 slider 10 8 9000 M8x50 Hex bolt 11 16 9000 Flat washer 8 12 8 9000 Spring washer 8 13 8 9000 Nut M8 14 1 3010632 film holder install board 15 1 3010633 carriage unit 16 4 3010634 adjustable screw 17 8 9000 Nut M12 18 4 9000 Nut M12 19 6 9000 Flat washer 12 20 6 9000 Spring washer 12 21 2 9000 M12x45 Hex bolt 22 2 3010635 Chain wheel B 23 2 3010636 Ball bearing 6203-2Z 24 2 3010637 Circlip Hole 40 25 2 3010638 Circlip axle 17 26 1 3010639 axle 27 2 3010640 limit switch install board 28 1 9000 M16x30 Hex bolt 29 1 9000 Flat washer 16 30 1 9000 Spring washer 16 31 1 3010641 column seaming 32 1 3010642 electrics install board 33 1 3010643 inner protect board A 34 1 3010644 lower door 35 1 3010645 middle door 36 1 3010646 upper door 37 18 9000 M6x12 Hexacon socket bolt 38 18 9000 Flat washer 6 39 1 3010647 inner protect board B 40 4 9000 M10x25 Hex bolt

Matco International Film head brake Type III NO. QTY. Part number Description 1 2 9000 M5x20 Hexacon socket bolt 2 2 9000 Flat washer 5 3 1 3010648 Sprocket cover 4 2 3010649 Supporting rod 5 1 3010037 Star grip button M8 6 1 3010024 Adjusting shaft 7 1 3010036 Adjusting belt wheel 8 1 3010019 Flat belt 9 2 3010650 Pressing plate for flat belt 10 4 9000 M4x10 Hexacon socket bolt 11 1 3010651 Tensioning spring 12 1 3010652 Tensioning shaft 13 1 9000 M6 x20 Hex bolt full thread 14 1 9000 Washer 6 x 15 1 3010017 Locating sleeve 16 1 9000 Pin 5x22 17 2 3010013 Thrust ball bearing 51104 18 2 9000 M6 x20 Hex bolt full thread 19 10 9000 Flat washer 6 20 4 9000 Spring washer 6 21 1 3010065 Brake roller 22 2 9000 M6 Nut 23 1 3010653 Guiding roller 24 2 9000 m6x20 Hex sunk screw 25 1 3010654 Mounting frame 26 1 9000 M12 Nut 27 1 3010035 Friction washer 28 1 3010034 Supporting seat fixed screw 29 4 9000 m5x12 Hex sunk screw 30 1 3010031 Film roll bottom supporting seat 31 1 3010655 Film roll top supporting frame 32 1 3010656 Tensioning wheel seat 33 1 3010033 Film roll top supporting 34 1 3010026 Adjusting bolt 35 1 3010030 Pressing spring 36 1 9000 Flat washer 37 1 3010023 Star grip button M8x32 38 1 3010028 Thrust ball bearing 51104 39 1 9000 M18 Nut 40 1 3010024 Star grip button M12 41 4 9000 M6x16 Hexacon socket bolt 42 2 9000 M6 x20 Hex bolt full thread 43 1 3010657 Spring locating sleeve