TR1860 L1/6 Use and Service Manual

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

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.

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

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

Serial No. 740 - 10.05

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




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

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Serial No. 740 - 10.05

Part I

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.

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Part I

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

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Part I

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

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Part I

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.

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Part I

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.

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Serial No. 740 - 10.05

Part I

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.

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Part I

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.

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Part I

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

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Part I

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.

11
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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
2.5.4 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
2.6.4 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
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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.

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Part II

o
1.2 overall dimensions

7400

2100
3750

Matr. 740 - 10.05
3

Part II

o
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


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

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Part II


o
1.4 unloading and positioning


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.

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Part II

o
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

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Part II

o
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

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Part II

o
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

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Part II

o
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)

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Part II

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


Part II

o
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.

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Part II

o
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

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Part II

o
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.

Matr. 740 - 10.05
13

Part II

o
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.


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

Avanzamento Legatore

Spatola bassa Aspo 2
Contropressione
braccio oscillante

Disabilita contropression
braccio oscillante
14

Part II

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.

15
Matr. 740 - 10.05

Part II

o
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.
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

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

Part II

o
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.

17
Matr. 740 - 10.05

Part II

o
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.

-

+


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)

18
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Part II

o
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

19
Matr. 740 - 10.05

Part II

o
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

Matr. 740 - 10.05
20

Part II

o
iro reggia Legatore Avanzamento Legatore
Espulsori Aspo 1 e 2 Scivoli Aspo 1 e 2

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

Reel 1 Low paddle braccio oscillante
Adjusts the pressure of the low paddle onto the reel 1 coil.
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
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

Spatole alte Aspo 1 e 2


Pressione legatore

Disabilita contropression
braccio oscillante

21

Part II

o
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

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.

22
Matr. 740 - 10.05

Part II

o

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

Matr. 740 - 10.05

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

Part II

o
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


improper adjustments could cause the strapping system malfunctioning!

24
Matr. 740 - 10.05

Part II

o
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

25
Matr. 740 - 10.05

Part II

o

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.


Part II

o

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.

Avanzamento Legatore

Tiro reggia Legatore

Contropressione
braccio oscillante

Pressione legatore
Friziona tubo

27

Part II

o

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.


Part II

o
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

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

29
Matr. 740 - 10.05

Part II

o
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.

30
Matr. 740 - 10.05

TR1860 L1/6 Use and Service Manual

TR1860 L1/6 Use and Service Manual

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