USE AND MAINTENANCE MANUAL

TRANSPORT SYSTEM

Translate of the
original instructions

Rev. 01-2022

Read this operator manual carefully before the first use.

The manual contains pictures and description that have a training use and
can be different from the final realize. Complete manual is provided at final
installation.
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 INDICE GENERALE - GENERAL INDEX
CODIFICA DEI CAPITOLI
CODING OF CHAPTERS

01 CAP. 01_0 GENERAL INFORMATION........................................................... PAGE 6 ÷ 8

1.2 WARRANTY
1.3 FOREWORDS
1.3.1 LIMITED RESPONSIBILITY OF THE CONSTRUCTOR
1.3.2 VALIDITY OF THE MANUAL, ITS CONTENT AND CONSERVATION
1.3.3 ADAPTION OF THE DIRECTIVES
1.4 IDENTIFICATION OF THE MACHINE

02 CAP. 02_0 MACHINE IDENTIFICTION DATA AND SAFETY MEASURES PAGE...9 ÷ 18

2.1 EXPECTED USE, IMPROPER USE
2.2 DESCRIPTION OF THE GROUPS OF THE "TR SYS 00”
2.3 MACHINE TECHNICAL DATA
2.3.2 TECHNICAL AND ELECTRICAL DATA
2.3.3 ADMISSIBLE ENVIRONMENT DATA
2.4 SAFETY INFORMATION
2.4.1 GENERAL SAFETY NORMS
2.4.2 SPECIFIC SAFETY NORMS
2.4.3 INELIMINABLE RESIDUAL RISK
2.4.4 SAFETY SIGNS ON THE WORKPLACE
2.4.5 INDIVIDUAL PROTECTION DEVICES
2.4.6 TRAINING OF THE PERSONNEL
2.4.7 INDICATION OF THE SOUND LEVEL
2.4.8 ADOPTED SAFETY MEASURES

03 CAP. 03_0 PREPARATION OF THE MACHINE;

ADJUSTMENTS AND PRELIMINARY CHECK.......................... PAGE 19 ÷ 23
3.1.1 INSTRUCTIONS FOR THE CONNECTION TO THE VARIOUS ENERGY
SOURCES
3.2 ADJUSTMENTS AND PRELIMINARY CHECKS
3.3 CONTROL OF THE SAFETY SYSTEMS

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04 CAP. 04_0 USE OF MACHINE........................................................................ PAGE 24 ÷ 32

4.1. GENERAL INFORMATION

4.2.1 THE WORKPLACE
4.2.2 DESCRIPTION OF THE WORK CYCLE
4.2.3 DESCRIPTION OF THE CYCLE PHASES
4.3 MACHINE COMMANDS
4.3.1 ARRANGEMENT OF THE ELECTRIC BOARDS AND CONTROL PANELS
4.3.2 GENERAL AUTOMATIC TRANSPORT SYSTEM LINE ELECTRIC PANEL
4.3.3 GENERAL AUTOMATIC TRASPORT SYSTEM PLC PANEL
4.5 MACHINE STOP FOR EMERGENCY
4.6 MACHINE QUICK START
4.7 INCONVENIENCES, CAUSES AND SOLUTIONS

05 CAP. 05_0 MAINTENANCE............................................................................. PAGE 33 ÷ 35

5.1 INSTRUCTIONS FOR THE PERSONNEL

5.2 ORDINARY MAINTENANCE OPERATIONS
5.2.1 ADJUSTMENT INTERVENTIONS
5.2.2 REPLACEMENT OPERATIONS
5.2.3 CLEANING OPERATIONS
5.2.4 LUBRIFICATION OPERATIONS
5.4 EXTRAORDINARY MAINTENANCE

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 CHAPTER 01

General Information

1.1 METHOD OF CONSULTATION AND PUR- POSE OF THE MANUAL

The consultation of the present manual is simplified by the general index as first page which per-
mits a rapid spotting of the topic of interest.
The chapters are organized with a structure that simplifies the search for needed information.
Before starting any operational action referring to the activities described following, it’s obligatory
to read the present manual “Instruction and maintenance manual

1.2 WARRANTY

With the general Warranty terms ECOPROGETTI s.r.l. declares as follows:

1) The warranty period on Ecoprogetti’s machines is 12 months.

2) ECOPROGETTI s.r.l. guarantees that all machines and material supplied by ECOPROGETTI
are constructed only by material of finest quality.
3) The warranty does not cover defects and/or malfunctions caused by inexperience and operating
errors or by inadequate maintenance and normal corrosion and wear.
4) Parts that are found defective during the warranty period, will be replaced free of charge.
5) If the defect is of such a nature that it requires a reparation at the location of the machine, the
costs for the travel, accommodation, local transport and work hours for ECOPROGETTI’S person-
nel shall be paid by ECOPROGETTI. If the defect is caused by improper use, inexperience, op-
erating errors and/or inadequate/missing maintenance, all concerning costs will be calculated on
the basis of the current standard rates and charged to the buyer. The reason of the defect will be
settled by ECOPROGETTI’S technicians.
6) All consumable parts are excluded from the warranty.
7) It is important that the purchaser carefully inspects the machine after the delivery in order to
verify any possible damage. ECOPROGETTI will not, in any case, be held responsible for damage
caused during the transport. Transport damages will be discussed individually between the buyer
and its forwarding company as the delivery term is EX. WOrKS.
8) Any claims must be communicated to ECOPROGETTI S.r.l. in written form within eight days
from the delivery date.
9) THE WARRANTY SHALL BE FORFEITED IF:
a) The instructions of the machine’s instruction and maintenance manual are not respected;
b) Any modification is made without the prior authorisation of ECOPROGETTI S.r.l.
c) The programmed and/or ordinary maintenance is neglected; d) Maintenance and operation is
performed by unauthorized personnel;
e) The machine is used in a different manner than what’s prescribed

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1.3 FOREWORDS

The purpose of the present manual is to describe in detail the automatic station to transport glass-
es, multicomposite material, laminated module or framed module along the line trought each sta-
tion (from now on simply referred to as “TR SYS 00”) manufactured by Ecoprogetti S.R.L. in Car-
mignano di Brenta, dell’Industria e dell’Artigianato, 27/C (PD) Italy.

In the manual you find the description of the machine parts, the methods for a correct functioning,
the precautions to take and the maintenance to perform. the TR SYS 00 line must be used accord-
ing to the prescriptions in the present manual, for this it’s important to read carefully its content
before installing and using the machine. Respecting the norms and recommendations given allows
to have a machine that works correctly during time and possibility to work in safety.
Non observance of the indications given in the present manual or an improper use of the machine
can nullify the warranty that covers the transfer.
The instruction and maintenance manual forms an integrated part of the machine, for this it’s nec-
essary to conserve it intact in a proper place during the complete life of the machine. In case the
machine changes owner to another user, the manual must follow the machine.

ECOPROGETTI is always completely at the purchaser’s service to assure prompt and careful
technical assistance and any other service that might be useful to guarantee an optimum operation
and to obtain the maximum capacity of the plant.

1.3.1 Limited responsibility of the constructor the machine rapresent the current state of
the art for its construction and its use by the manufacturer.

The manufacturer is not held responsible for damages and inconveniences if these depend on an
inadequate use, not correct applications and/or an improper use of the machine. The buyer must
observe the instructions indicated in the manual and in particular:
- always work within the limits of the machine use;
- always perform a constant and diligent maintenance;
- enable for the machine use personnel with proved capacity, capable for the work task, trained
and instructed adequately for the work purpose;
- use only and exclusively original spare parts from the constructor.

Possible modifications, adjustments or other things that are brought to the machines launched
later on the market are not obligating the manufacturer to intervene on the machine supplied previ-
ously neither to consider the machine and relating manual insufficient and inadequate.

The instructions given in this manual are not replacing but they are integrating the obligations of
the employer for the respect of the legislation in force regarding the norms of prevention and safe-
ty.

1.3.2 Validity of the manual, its content and conservation

The manual reflects the status of the machine at the moment of its purchase and is valid for the
whole life of the machine.
The manufacturer remains at the customers’ disposal to supply ulterior information and to consider
improvement proposals in order to make the manual more answerable to the needs for which it
was prepared.

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The manual must be kept in a suitable place for its conservation and to be available for consulta-
tion on behalf of:
- THE EMPLOYER;
- MAINTENANCE PERSONNEL;
- MACHINE OPERATOR;
- THE PERSONNEL IN CHARGE OF THE INSTALLATION AND DISPOSAL.

In order to avoid possible accidents involving persons and/or material, caused by a not correct
instruction translation, the customer is recommended to:
- not perform any operations or manoeuvres on the machine if insecurity or doubts should arise
regarding the operation to be performed.
- Ask the assistance service for clarifications regarding the instructions given in the manual.

1.3.3 Adaption to the directives

The production and manufacturing, as well as the assembling of all the machines which form part
of the TR SYS 00 line have been accomplished in compliance with the following directives:
• 2006/42/CE (Machine directives), • 2006/95/CE (Low tension directives), • 2004/108/CE (EMC
directives).

1.4 IDENTIFICATION OF THE MACHINE identification plate is applied on the master boxes, in a
well visible position and in such a way that it cannot be easily removed. On this plate all the line
identification data are shown (Fig. 1 Detail 1).

1 Fig. 1

Following data is shown on the label:

- name of the manufacturer.
- Machine model.
- Serial number.
- year of construction.
- Weight [Kg].
- Installed power [kW] .
- Work frequency [HZ].
- CE mark.

And possible other data like:

- reference.
- Patent.

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 CHAPTER 02

MACHINE IDENTIFICATION DATA AND SAFETY MEASURES

2.1 EXPECTED USE, IMPROPER USE

FOREWORD
The aim of the present manual which includes information on how to run the line is that of provid-
ing all correct information on how to use and run the transport system, focussing attention on the
activation control commands, on the production cycle, on the potential residual risks and on the
necessary specifications, adjustment and/or maintenance procedures relevant to the whole sys-
tem.

Expected use
The Transport System automatic station has been designed and manufactured with the aim of ac-
complishing in automatic mode transporting horizontally a glass, a multilayer/composite system of
material, a laminated module or a framed module.
A belt system equipped with sensor and manual or automatic devices to move the material from
one working station to another working station.

The automation units, electric and electronic consent devices, and management of the whole
system is controlled by two PLC box, the whole process is carried out in automatic mode, enabling
optimization of the work process times.

The production cycle is controlled by the two Master boxes' PLCs (front line and backline) by
means of an appropriate control panel located along the line on which controls are located on top
of the Master box and on the PLC display, necessary for controlling the activation units enabling
accomplishment of the working cycle both in automatic and in manual mode.

The Transport System operates in automatic and continuous mode, and the production cycle is
repeated according to the modes described in chapter 5 of the present manual, provided the line is
correctly supplied with glasses/laminates, and provided no inconveniences occur to cause an
emergency arrest of the machine (see chapter 5).

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Improper use
The use of the system for any operation other than automatic loading of glass panes having
shape, thickness and length as established during the contract negotiation phase is forbidden.

The use of the machine by not qualified and trained personnel is forbidden. It is forbidden to use
the machine if the safety devices are not working correctly
It is improper to use the machine if the operating and control devices are not working correctly.

2.2 DESCRIPTION OF THE GROUPS OF THE “TR SYS 00”:

The TRANSPORT System is manufactured with first quality materials and it is accurately sized for
the production of photovoltaic modules of the most common dimensions.

With reference to figure 1, the TWO SYSTEMS (Pre and Post lamination) consist of the following
main groups:
- Automatic conveyor with transport belts
- Interface with previous and following working station
- Safety button near the single part of the machine
- Main board with Control PLC Box
- Change direction system
- Pneumatic gate
For smaller production lines only one Master box is installed.

In FIG. 1 the parts highlighted in "yellow" are under control of the transport system - TR SYS

The image displayed is for illustrative purposes only.

Indeed it does not refer to any specific production line's layout

Fig. 1

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Automatic conveyor with transport belts (FIG2)

Fig. 2

Each section is composed of a conveyor with 4 belts, a moving electrical engine, with Belts suit-
able for ARC glasses.
The conveyor is interfaced with the machineries between which is placed, it can detect the pres-
ence of a module trough photocell sensor. Every two or three conveyor belts a power box is
embedded inside a conveyor, it can be activated trough a knob disconnector (Fig.3 Detail 1) the
electrical power. All the conveyor are controlled trough an external PLC control box. In the line
are installed two PLC control box, one for the prelamination line, one for the after lamination
line.
1

Fig. 3

Safety on Conveyor (FIG.4)

Each PLC control box have a red button for 1

safety stop(Fig4 Detail 1). Along the line near
each working station where is fixed an extra red
button to stop the movement of the conveyor in
case of accident.

Fig. 4

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Main board with Control PLC Box (fig5 and FIG 6)

Outside the line, the Control PLC Box (Fig. 5 Detail 1) contains a power box and the electrical ma-
chine control and command.

(Fig.6) The electric panel is protected by an access door which is locked by a key and it is
equipped with a mains power supply switch (detail 2), enabling opening of the door only if the
switch itself is in the “0” (removal of main power supply) position.

The control commands for cycle startup and stop are prompted by the operator in charge of run-
ning the line by a PLC interface. A description of the function of the individual components present
on the control panel is provided in chapter “Use of the machine” of the present manual (Detail 3).

The image displayed is for illustrative purposes only.

Indeed it does not refer to any specific production line's layout

Fig. 5

Fig. 6

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Pneumatic Gate (Fig7)
The Pneumatic Gate makes the crossing a transport belt a quick operation. It can be lowered or
elevated just by pressing the button placed on each side (Det.1 Fig.3). Opening and closing
cannot be performed if the belt is in motion. If the gate is open the belt will not go to unload or vice
versa to load.

1 Fig. 7

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2.3 MACHINE TECHNICAL DATA
In the tables that follow all the technical data of the automatic transport system are shown.

The dimension of the conveyor depend on the position in which they are utilized in the production
line.

2.3.2 Technical and electrical data

TECHNICAL DATA
Power supply 380 3pahse + neutral + 2x24Volt
Frequency 50-60 hz
Compressed air (where needed) 6 bar

2.3.3 Admissible environment data

Environment temperature 5 ÷ 40 C°
Relative humidity 30 ÷ 50 %
Altitude Up to 1000mt above sea level
Minimum brightness working environment 150 lux

2.4 SAFETY INFORMATION

2.4.1 General safety norms

The purchaser is responsible for instructing his personnel about the risks of using the automatic
transport system, about the security details for the operator as glasses and gloves and about the
risks of noise and about the general accident prevention regulations prescribed by the directives
and the legislation of the country where the machine is to be used.

Operator security depends directly on the correct utilization of the plant. The robotized line cor-
responds with the Machine Directive and to the norms UNI EN ISO 12100-1:2005 e UNI EN ISO
12100-2:2005.

The manufacturer declines any liability in case of failing to observe the safety and risk prevention
norms described below. The manufacturer also declines any liability for damage caused by im-
proper use of the plant and by changes carried out without authorization by the manufacturer.

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2.4.2 Specific safety norms

- Handling and use of the system must be carried out by specifically instructed personnel who
have read and understood the contents of the present manual and of all the use and maintenance
manuals relevant to the individual machines installed in the robotized island (supplied as enclo-
sures).

- The operating personnel must be provided with the equipment required to protect them from
problems that could arise: this is the normal appropriate workshop equipment, except for other
specific instructions, also shown on the safety signals.

- Before the automatic transport system is set to operation, the personnel in charge of running the
system must check that the safety devices are in sound conditions and perfectly in operation.

- Before starting to work with the system, the operator must be familiar with the system commands
and with particular attention to the emergency controls and procedures.

- Safety signs located on the machine and on the fixed safety barriers (if present) must be kept
clean and well visible at all times.

-Operators and technicians in charge of maintenance must be aware of the potential residual risks
before carrying out adjustment/maintenance operations inside the system.

-It is forbidden to remove or tamper with the passive or active safety devices of the machine.

- Do not carry out any maintenance operation to the machines included in the line before having
removed electric and pneumatic power supply from the machines themselves.

- Rigorous observance of periodical maintenance operations as outlined in the present manual

and in the use and maintenance manuals supplied as enclosures is necessary for both working in
safety conditions and keeping the production line efficient.

REMEMBER THAT A CAREFUL OPERATOR IN GOOD PHYSICAL AND PSYCHOLOGICAL

CONDITIONS IS THE BEST GUARANTEE FOR SAFETY AGAINST ALL ACCIDENTS.

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2.4.3 Ineliminable residual risk

Residual risk means a partially eliminated potential hazard that may cause operator injury when
incorrect work methods or practices are adopted or incorrectly interpreted. The following table de-
scribes the residual machine risks and relevant warnings, prohibitions and precautions to be taken.

With the aim of protecting wellbeing and safety of the workers in charge of running the production
line, all the machines equipped with moving devices are installed inside an area which is complete-
ly protected by safety barriers made with intrusion prevention net, fastened onto the floor in a fixed
and not removable manner OR with moving part device covered by hulls.
In the ordinary operation of the line all moving devices are therefore installed in a position which
cannot be reached by the operators.

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In case it is necessary to carry out specific maintenance/adjustment interventions on the machines
present inside the protected area, the production area must be brought to a complete stop trough
the red safety bottom (Fig.7 Detail 1).

Fig. 7

The personnel in charge of running of the production line must be informed on the residual risks
relevant to the individual machines which form the line, and they must be equipped with the ad-
equate individual safety protection devices.

Careful risk assessment to protect health and safety of the operators, carried out on the working
place and on any other piece of equipment be used, will enable the EMPLOYER to evaluate the
presence of any further risks.

2.4.4 Safety signs on the workplace

An adequate safety signals on the workplace as prescribed in the directive 92/58/CEE informs the
personnel using the machine about the behavior obligations and about the residual risks.
The employer is responsible to indicate the most suitable place for their application.
The risk evaluation for the safety and health of the operators performed for the workplace and for
other possible used equipment and tools permits the employer to evaluate the need of using ulte-
rior signs.

This system has been constructed in accordance with all the norms and regulations regarding
the safety of the worker. There may be ulterior risks for the operator and they are pointed out with
symbols attached on the machine, and also shown below:

1. Use protective gloves.

2. Use protective footwear.
3. Use work overalls.
4. Before working with the machine, read the use and maintenance Manual carefully.
5. Indication of attachment points for lifting
6. DANGER - of electric shock.
7. DANGER - Before performing maintenance operations, disconnect all electric power.
8. Danger of crushing hands.
9. DANGER - Do not open or remove safety barriers or protection hulls while the machine parts
are in motion.

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2.4.5 Individual protection devices

The risk evaluation for the safety and health of the operators performed for the workplace, for other
possible used equipment and the residual risk evaluation indicated for the machine permits the
employer to evaluate the possible need of giving the operators more appropriate individual protec-
tion devices (Fig. 7).

Considering the type of machine, the following list of PPE (Personal Protection Equipment) should
be included.
- Protection device for the hands: Protective gloves.
- Protection devices for the feed: Protective shoes.

It is remembered, as per the disposal of the law in force, that the worker is obligated to:
- Observe the devices and the instructions given by the employer.
- To use correctly the machines, the equipment and the protection devices

2.4.6 Training of the personnel

The instructions how to use the machine will be given by ECOPROGETTI’s technician during the
installation phase to the personnel in charge for the use and maintenance of the machine. The
user instructions are moreover described in this manual.

The employer is responsible to verify that the level of training of the personnel is suitable for the
work given.

2.4.7 Indication of the sound level

All the machines installed inside the glass loading system are equipped with electric-pneumatic
activation devices which do not produce any noticeable noise during their operation.
It is therefore declared that the Automatic Transport System does not expose the operators to any
hearing impairment during its ordinary operation.

Note: It should however be reminded that the system is usually installed within premises
where other machines are present, which are necessary for the production of semi-finished
units requested for manufacturing photovoltaic modules, and that the noise level within the
installation area may reach higher levels.

It is up to the person in charge of safety in the working place to carry out the necessary overall
noise level detection procedures in the production line installation area.

Warning: In case the average level of sound pressure within the working place should
exceed 80 dB (a) all personnel must wear adequate hearing protection devices (earplugs
and/or noise prevention earphones).
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2.4.8 Adopted safety measures

In order to guarantee safety of the operators in charge of using and running the automatic trans-
port system, the system is equipped with a series of mechanical and electronic protections and
safety devices.

In particular the machine is equipped with the following safety devices for the operator:

- Main general power supply switch, located on the main production line control panel

- Emergency stop buttons, located on the pushbutton board available on the access gate (Detail 1)

Fig. 8

Moreover, on the system the following machine safety devices and cycle control are provided:

- Safety magnetic-thermal switches for the activation units of the individual machines (located
inside the relevant power electric panels), the function of these is to protect the various activation
units from any power overload or voltage changes.

- Magnetic, optical sensors, as well as end of stroke micro-switches installed on the individual
machines present inside the robotized island. The status signals (activated/deactivated) of each
individual sensor enable prompting start-up, stop and synchronisation of all the movements carried
out by the various machines in order to perform the automatic production cycle correctly.

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 CHAPTER 03

Preparation of the machine; Adjustmnets and premiliminary checks

3.1.1 Instructions for the connection to the various energy sources

CONNECTING THE MACHINES TO THE ENERGY FEED:

The connection of the machines to the energy feed must be performed by qualified and expertise
personnel.

- Make sure that the line voltage is the same as required for the machine (see manufacturer’s la-
bel) and that the wiring has a suitable section for the declared electrical input.

- Make sure, before connecting the machines, that the tension tolerance of the grid feed doesn’t
vary with more than 10% from its nominal value.

- The frequency of the voltage feed must be constant.

- The connection of the machines to the energy grid must be done perfectly and the connection
must have an earth connection and an equipotential circuit according to the law in force where the
machine is installed.

-The earth cable should be connected to the space provided inside the electrical board that is
marked with a conventional symbol.

- The electrical connection of the machines to the main power supply is carried out on the termi-
nals of the switch present inside the main electric panel of each individual machine (for example
Fig.4 Detail 1)

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ATTENTION – Call ECOPROGETTI’s technical assistance service if clarifications are needed.

Attention: Verify that the electrical connection is done correctly by measuring the presence of the
three phases and neutral. It is recommended to measure the tension of each phase compared to
neutral that must correspond to the nominal tension of the country where the machine is installed.
Verify the electrical power requested by the machine and the Amperage Rate of the industrial elec-
trical knob.

ECOPROGETTI S.R.L. DENIES ANY LIABILITY AND RESPONSIBILITY FOR DAMAGES AND / OR AC-
CIDENTS CAUSED BY A NON OBSERVANCE OF THE NORMS RELATED TO THE SYSTEMS.

CONNECTING THE MACHINES TO THE PNEUMATIC FEED

Some of the section installed in the transport system are provided with electro-pneumatic driven
devices; it is therefore necessary to provide connection of the individual machines to the main
compressed air distribution network present in the place of installation of the system. Connection
of the machines to the compressed air network is arranged on the appropriate groups, “Pressure
adjustment unit – Filter – Lubrication unit” installed onboard of the machine (see for example Fig.
5).

Verify that the main supply pressure is not lower than the calibration limit and that the diameter
of the pipe is higher than 8 mm; also periodically verify that the condensate does not exceed the
maximum allowed level.

ECOPROGETTI S.R.L. DENIES ANY LIABILITY AND RESPONSIBILITY FOR DAMAGES AND
/ OR ACCIDENTS CAUSED BY A NON OBSERVANCE OF THE NORMS RELATED TO THE
SYSTEMS.

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3.2 ADJUSTMENTS AND PRELIMINARY CHECKS

It is considered necessary to indicate a series of minor general controls to be performed before the
installation and before the start of every work shift to consent a correct functioning of the robotized
island and its use in safe conditions

3.3 CONTROL OF THE SAFETY SYSTEMS

Before giving electrical tension to the machines verify that:

• All stationary protective machine barriers are correctly closed (if installed).
• All micro switches with mechanical interlocks are operative (if installed)

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-Verify that the main switches located on the machines electric panels (eg Fig.2 Details 1) are
equipped with a key padlock to lock them when rotated to the "O" position (Fig.2 Part.2), to enable
any maintenance operations inside the panels and/ or to the individual parts of the line to be car-
ried out in safety conditions in absence of electric power supply.

- That all emergency buttons present in the automatic transport system, when pressed, immediate
stop of all the activation units in operation.

Fig. 8

GENERAL CONTROLS

Approximate list of adjustments and checks to carry out:

• Check that the machine main power supply sources (electric and pneumatic) are correctly ar-
ranged and in compliance with the requirements;

• Verify efficiency of the stop microswitches;

• Check correct sense of rotation of all the motors. To verify the rotation direction of each individu-
al motor the following must be done:

1) Provide voltage to the machine by rotating the main switch to the "I" position;
2) Start-up the individual groups through the "Manual commands" page displayed on the touch-
screen;
3) Verify that the activated motor rotates in the correct operation direction.

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• Should the motor rotate in reverse direction, it is necessary to change over two of the three sup-
ply phases arranged on the R.S.T. terminals of the relevant motor inside the electric panel (see
example in Fig.4).

Fig. 8

WARNING: Before carrying out any intervention to the motor power supply cables it is compul-
sory to remove power supply to the machine, by rotating the mains power supply switch to the
"O" and by applying the safety lock to the switch itself.

• After having reversed the two phases, provide power supply to the machine and repeat the
check to verify correct rotation direction of the motor involved.

Verify correct tensioning of all the belts present on the centring unit and on all product loading
and unloading belts.

WARNING: In case there is the need to adjust tensioning of one or more belts follow the in-
structions laid out in chapter " Maintenance and lubrication".

• Provide mains power supply to the machine by bringing the main switch to
the "I" position and ensure that the touch-screen display lights up loading the line management
and control software main page correctly.

In case the display fails to light up, although the machine is power supplied from the mains,
verify that the electric connections and the cabling of the operator’s panel are correctly linked to
the relevant connectors.

WARNING: If the touch-screen display fails to show any screen and the relevant cabling is cor-
rectly done, get in touch with the ecoprogetti S.r.l. Customer care service.

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 CHAPTER 04

USE OF MACHINE

4 .1 GENERAL INFORMATION

The instructions for the use of the automatic transport system are described in this chapter and
conveyed by ECOPROGETTI’s technician to the machine operator, who is therefore instructed
and trained on how to use it.

Attention: The EMPLOYER is responsible to verify if the level of training of the personnel is suit-
able for the assigned task.

INFORMATION FOR THE PERSONEL

4.2.1 the workplace

The TR SYS00 automatic transport system operates in automatic mode and, after cycle startup,
does not require the fixed presence of an operator.

In particular the phases of the cycle carried out in automatic mode are:
- Loading of the glass/multicomposite/laminate/module onto the station;
- Unloading of the glass/multicomposite/laminate/module out of the station;

During all these phases the operator in charge of running the system is only expected to carry out
startup parameter setting operations and to control the automatic cycle by means of the relevant
line general control console located outside.

From this position (Fig. 2 Zone "A") the operator in charge of running the system can constantly
monitor the whole production cycle.

4.2.2 Description of the work cycle

In this paragraph the automatic work cycle of the Automatic Trasprot System is described, divided
into two phases.

The work cycle of the Automatic Transport System, when correctly supplied and ready for startup
of the cycle, can be summarised in the following main phases:
Phase 1 – Loading phase.
Phase 2 - Unloading phase.

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4.2.3 Description of the cycle phases

To start the cycle, the machine must be placed in “automatic mode”

Phase 1 - Loading phase.

A Photocell sensor detect the presence or absence of a glass; when the sensor detect that the po-
sition is empty, it gives a signal to the PLC control board; the PLC activate the previous conveyor
section or working position and let the material be moved into the empty conveyor section, until the
glass doesn’t reach the sensor position.

Phase 2 - Unloading phase.

A Photocell sensor detect the presence or absence of a glass; when the sensor detect that the
position is full, it gives a signal to the PLC control board; the PLC memorize the position as “occu-
pied”. When the following conveyor station or working position is free, the PLC activate the motori-
zation and move the modules to following position.

4.3 MACHINECOMMANDS

The TR SYS 00 is an automatic system consisting of several section of different length and pos-
sibility of movement which operate in automatic mode and are controlled by the operator in charge
of running the system by means of a general on line console, from which the production automatic
cycle can be controlled, by relevant control commands, in manual operation mode.

All commands to control the TR SYS 00 are located in the PLC control panel placed near the line;
however, every two individual section are equipped with its own power electric panel which must
be power supplied before startup of the production cycle (red switch).

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Codice: Transport System
Here below a description of all electric and control panels included in the line is provided.

4.3.1 Arrangement of the electric boards and control panels - (Fig. 4)

With reference to Fig. 5, the power supply elec¬tric and control panels are:
Detail 1 – PLC panel.
Detail 2 – Conveyor electrical power box (1 every two or three conveyors)
Detail 3 - Emergency button.
Detail 4 - Ligh-signalling acoustic column.
Detail 5 - General line electric panel.

4.3.2 General Automatic Trasnport System line electric panel - (Fig.5)

The TR SYS 00 island is equipped with its own electric power panel (see figure 5) inside which all
the electric power and control components for its activation units are arranged.

All the electrical com¬ponents are protected by two steel doors with lock, and the doors must be
opened only when the main switch "IG" is rotated to the "O" position (machine NOT electrically
power supplied).

1
5
3

2
Fig. 5

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Codice: Transport System
On the line general electric panel the following control commands are available:

1. General switch (Fig.5 Detail1).

This is a magnetic-thermal switch or automatic "IG" switch, for enabling electric power supply to
the machine. This switch may be handled only if the door of the electric cabinet is correctly closed;
subsequent opening may only take place with the switch placed in "O" position. This switch is fitted
with a padlock, to lock it in "O" position, to enable maintenance operations in conditions of utmost
safety.

2. Mushroom shaped emergency stop button (Fig.5 Detail 2). This enables immediate stop of the
machine. When pressed, it removes power supply to the motors of the machines and of the robot,
at it activates their braking devices.
This switch is a contact-fitted type, with forced opening and mechanical coupling. It must be pulled
to be resumed.

3. Button fitted with green lamp for activation of the auxiliary circuits (Fig. 5 Detail 4). This is ena-
bled in presence of line power supply (white lamp Detail 3 lit) and emergency not intervened.
When pressed and then released the lamp remains lit. It is turned off when an emergency occurs
(for example emergency button pressed).

4. Jog (Fig. 5 Detail 5). This enabled the movement of the conveyor basing on the setting chosen
on the PLC Panel.

6. PLC Pannel (Fig. 5 Detail 6). This is core of the machine that visually show the status of the line
and can control and move manually all the conveyor section.

4.3.3 General Automatic Trasnport System PLC panel - (Fig.6)

To make working the PLC panel, give power to the general electric box.
System will start with alarm ring and visual alarm blinking. Press bottom “Auxiliar” to activate the
system and to stop the alarm ring.

General page of the PLC

Fig. 6

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Codice: Transport System
Before press start check that the position of the modules on the line are occupied, and o modules
have been removed by hand. When the module occupies a position, it appears on the render of
the line.

List of the controls:

START: Pressing bottom start the system is automatically activated.

AUTO: Pressing auto mode, the operator come back to the general page of the system
MANUAL: pressing manual the operator can have access to manual mode control
ALARMS: pressing alarm the operator can check the list of historic errors and to new error
MENU: to move to menu interface
MAN/AUTO: to move from automatic mode to manual mode and back

A) MANUAL MODE: to go to manual mode move the selector from AUTO to MAN, then press
MANUAL. on manual mode is possible to have access to every conveyor and to make manual
activities. There’re different screen for different position, to activate or disactivate the position, and
to move manually forward and back the laminate.

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Codice: Transport System
 29
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B) ALLARM: when the machine is still on AUTO mode is possible to check the cause of an alarm
blinking and ringing

With Acknowledge is possible to buy off the ring

With Reset Alarm is possible to delate the alarm. Not always is possible to delate an error just with
Reset; you have to follow the instruction indicated by PLC.

C) MENU: from Menu is possible to modify the configuration, the parameters and the settings of
the system. It is also possible to make the TEST I/O of all the transport system.

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Codice: Transport System
From the botton Login is possible to add different level of password

4.5 MACHINE STOP FOR EMERGENCY

The operator may, at any time, stop operation of the line by simply pressing one of the emergency
stop buttons located on the General PLC box and along the transport of the machine and on the
various electric panels.

4.6 MACHINE QUICK START

In this paragraph a table is included where all the operations to be carried out are listed, by phase,
to startup the transport system.

Note: It is to be reminded that these instructions are addressed to operators who have already
been instructed and training for the use of the system and who have read and understood what is
laid out in the previous paragraphs of the present chapter.

Warning: Before proceeding to start-up of the line the operator must ensure that all the safety
devices are correctly installed and operating.

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Codice: Transport System
Phase Operation/Command

1 Verify presence of the expected power supply sources (electric and pneumatic).
2 Verify that the safety devices are operating and in the correct position.
3 Power supply all the PLC General Box and the Conveyors Boxes of the line by bringing
to the "I" position all the relevant general switches of the invididual machines, and power
supply the pneumatic circuits.
4 Verify that all material indicated on the PLC screen is present in the indicated place.
5 Verify that there are not emergency stop but¬tons pressed down (should this be the
case, rotate the button to reset it).
6 Activate all the auxiliary units by pressing the relevant button from the control console.
7 Verify there’s no error active, and if it’s there reset or solve and reset.
8 Press the Auto Mode, then Start Cycle from the PLC interface.

4.7 INCONVENIENCES, CAUSES AND SOLUTIONS

During ordinary operation of the machine inconven¬iences may occur which provoke stop of the
TRANSPORT SYSTEM.

Here below the most frequent inconveniences are listed, with their possible causes and the opera-
tions to carry out to solve the inconvenience and resume ordinary machine operation.

Inconvenience: The auxiliary circuit is not acti¬vated after pressing the "Start Auxiliary units" but-
ton.

Cause: The main "IG" switch available on the main electric panel is not rotated to the "I" position.
Solution: Rotate the main switch to the "I" posi¬tion.

Cause: The emergency stop button has been pressed and never reset.
Solution: Verify that the cause that brought to pressing the emergency stop button has been
solved and see to resetting the emergency button.

Cause: Serious wiring problem in the power supply line (discontinued wires, disconnected power
supply sockets, etc.).
Solution: Verify that the electrical connections and wiring are correctly connected to the relevant
sockets. If necessary, see to replacing any damaged component.

Cause: transport system is moving the conveyor of a station without a laminate

Solution: one or more modules have been removed manually; the plc system is looking to find this
module. Replace the material in the running conveyor

If necessary, contact ECOPROGETTI S.r.l. Customer Care Service.

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Codice: Transport System
 CHAPTER 05

Maintenance

5.1 INSTRUCTIONS FOR THE PERSONNEL

The ordinary maintenance operations should be performed by the PERSON IN CHARGE OF THE
MAINTENANCE.

Before starting any operation it is necessary to put the machine in a status of maximum security for
who is operating, avoiding any possible unexpected start ups and dangerous events. In order to
obtain this status the PERSON IN CHARGE OF THE MAINTENANCE must:

- act on the main switch located on the electric panel of the machine for which maintenance is to
be undertaken, by rotating it to the “0” position so as to remove electric power supply to the ma-
chine; then apply the safety lock and remove the key.

-Cut off the pneumatic power supply to the machine, but closing the interception valve (Fig. 1 De-
tail 4) and ensure that the pneumatic system of the machine does not result to be under pressure.

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Codice: Transport System
5.2 ORDINARY MAINTENANCE OPERATIONS

In the tables that follow are summarized, in a sche¬matic way, all the routine maintenance required
to keep the machines of the production line in perfect conditions of use.

For each adjustment, replacement, cleaning, lubrica¬tion, where prescribed, the following proce-
dures are listed, in the sequence outlined here below:
• The type of intervention to carry out;
• Frequency for the intervention (in working hours);
• Reference to the specific paragraph where the procedure itself is described in detail.

5.2.1 Adjustment interventions

The transport system does not include mobile parts or components which are particularly prone to
wear and tear and/or which need adjustment interventions, therefore no adjustment interventions
are expected.

In case of replacement of electric components for control and command only (e.g. limit switches,
sensors, etc.) which should be necessary in case of faults or breaking, it is important to install new
components in the original position as arranged by the manufacturer.

5.2.2 Replacement operations

The transport system does not present mobile parts or components which are subject to wear and
tear and therefore planned interventions for replacement of the components are not advised.

Replacement interventions must take place only in case of breaking or faulty operation of electri-
cal, mechanical, pneumatic and/or electronic particular items, for which specific replacement pro-
cedures are not included in this manual.

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Codice: Transport System
Any replacement of broken components and/or which are operating incorrectly may be carried out
by any good electrician or mechanic members of the company staff.

Warning: Before performing any type of replace¬ment operations make sure that the machine is
placed in a condition of utmost safety, by dis¬charging the pneumatic system and by setting the
general switch to the “O” position and by locking it with a padlock. The person in charge of the
maintenance operations must personally take care of the padlock key until the operations are ter-
minated.

ATTENTION: Use only original spare parts supplied and/or recommended by the manufacturer.

5.2.3 Cleaning operations

The transport system does not produce scraps or waste material during its operation, which could
be disposed of in the environment, therefore no particular cleaning interventions are required.
However, it is important to keep the area around the machines clean, so as to guarantee operation
at the highest performance standard of the system.

A) General machines and surrounding area cleaning

When necessary, carry out cleaning of the machine and of the areas around them, by removing
layers of dust as well as paper remains from the surfaces of the machines and from the floor.
To clean the machines use a damp cloth, avoiding the use of acidic and/or corrosive detergents.

5.2.4 Lubrication operations

The transport system object of the present manual is not fitted with moving components for which
programmed lubrication interventions are necessary.
Lubrication interventions are to be carried out on the fan/shredder group and on to the horizontal
washing machine, for which reference should be made to the relevant use and maintenance man-
uals supplied as enclosures to the present manual.

5.3 EXTRAORDINARY MAINTENANCE

Extraordinary maintenance are the substitution ac¬tivities that can be necessary after a couple of
years because of normal wear and tear and/or breakage not predicted in the present manual.
For this machine no extraordinary maintenance op¬erations are programmed.

In case of an extraordinary operation it is recommended to contact ECOPROGETTI’s assistance

office that will evaluate if it is necessary to send a technician that, together with the persons in
charge of the maintenance, will evaluate the status of the machine and the pos¬sible need of nec-
essary spare parts.

In any case, before proceeding with any type of extraordinary maintenance operation, make sure
that the general switch of the machine’s electrical board is in OFF position “O”, blocked in position
with a padlock.

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Codice: Transport System
 ECOPROGETTI’s customer assistance service is at
disposal for any clarification regarding the machine.

In case technical assistance is needed the request should be sent to:

ECOPROGETTI S.r.l.
Via dell'Industria e dell'Artigianato, 27/C, 22/D
35010 Carmignano di Brenta (PD) - (Italy)
Tel. (+39) 049 7444 900
Fax. (+39) 0499459210
E-Mail: [email protected]

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Codice: Transport System
 37
Codice: Transport System
 ECOPROGETTI srl - Via dell'Industria e dell'Artigianato, 27/C, 22/D - 35010 Carmignano di Brenta - (PD) - Italy
Telephone: +39 0497444900 - Fax: +39 049 94 59 210 - E-mail: [email protected] - Web: www.ecoprogetti.com