USER MANUAL

BALL LOLLIPOP WRAPPING

MACHINE

MODEL CWL-400

MANUAL IDENTIFICATOR: 708

 CWL-400 AGREEMENT “CE” STATEMENT

AGREEMENT “CE” STATEMENT

Company: CARUGIL, S.L.

Address: Pol. Ind. “El Tiro”, Avda. del Este, nº 6

301000 – Espinardo, MURCIA – ESPAÑA

C.I.F. B – 30164800

Tephone: + 34 (968) 306443

Fax: + 34 (968) 835910

WE DECLARE, UNDER OUR UNIQUE RESPONSIBILITY, THE MACHINE:

Brand: CARUGIL, S.L.

Model : CWL – 400

Machine number:

Manufacture Year: 2001

DESCRIBED IN THE DOCUMENTATION ENCLOSED IS IN ACCORDANCE WITH

THE EUROPEAN PARLIAMENT 98/37/CE DIRECTIVE AND THE 22ND JUNE 1998
COUNCIL CONCERNING (TO) “THE LEGISLATION APPROXIMATION OF THE
MEMBERS STATES ABOUT MACHINES” AND IT HAS BEEN DESIGNED RESPECTING
THE INDICATIONS CONTAINED IN THE EUROPEAN NORMS CONCERNING (TO)
“MACHINE SECURITY”, PARTICULARLY THE EN 292-1, EN 292-2, EN 294, EN 418, EN
563, EN 614-1, EN 1037, EN 842, EN 953, EN 1672-2 AND THE EN 60204-1, AS WELL AS
THE EN 1050 “MACHINE SECURITY. PRINCIPLES FOR THE RISK EVALUATION.”

In its name, Mr. CARLOS RUBIO GIL, as GENERAL MANAGER, signs this declaration.

Espinardo, April, 12th of 2001

- Carlos Rubio Gil -

GENERAL MANAGER
 CWL-400 MACHINE IDENTIFICATION

MACHINE IDENTIFICATION

Every communication you should establish with CARUGIL S. L. regarding the

machine whose manual is now in your hands, should mention not only the model but
also the machine number printed on the characteristics plate placed on the left side of
the machine, above the compressed air connection.

IMPORTANT NOTE
The machine number must correspond with the
identification number of this document: MANUAL
IDENTIFICATOR.

CWL-400 2001

2400Kg

16 KW 7 bar

415V+N 50Hz
 CWL-400 MANUAL CONTENTS

INDEX

• “CE” ACCORDANCE DECLARATION

• MACHINE IDENTIFICATION

• USER MANUAL CWL-400

- CHAPTER 1: PREVIOUS CONSIDERATIONS

- CHAPTER 2: TECHNICAL CHARACTERISTICS

- CHAPTER 3: SECURITY PRESCRIPTIONS

- CHAPTER 4: DESCRIPTION OF THE MACHINE

- CHAPTER 5: SECURITY ELEMENTS

- CHAPTER 6: TRANSPORT AND UNLOADING

- CHAPTER 7: INSTALLATION

- CHAPTER 8: SCREEN DESCRIPTION

- CHAPTER 9: MACHINE SET UP

- CHAPTER 10: MACHINE START UP

- CHAPTER 11: AUTOMATIC SPLICING SYSTEM

- CHAPTER 12: CLEANING, GREASING AND MAINTENANCE

- CHAPTER 13: PIECES REPLACEMENT

- CHAPTER 14: SEARCH OF ANOMALIES

- CHAPTER 15: GENERAL SCHEMES

- CHAPTER 16: PRINTING SCHEMES

- CHAPTER 17: SPARES

- CHAPTER 18: TECHNICAL CHARACTERISTICS OF COMPONENTS

 CWL-400 MANUAL CHAPTER I

CHAPTER I

PREVIOUS CONSIDERATIONS

1. INTEGRATION OF SECURITY PAGE 1

2. EXEMPTION OF RESPONSIBILITY PAGE 1

3. SPECIFICATIONS PAGE 2
 CWL-400 MANUAL PREVIOUS CONSIDERATIONS

PREVIOUS CONSIDERATIONS

1. INTEGRATION In accordance with what is established in point 1.1.2 “principles of

OF SECURITY
integration of security” belonging to point 1 “essentials requirements of
security and health” in ANNEXE 1 of the 98/37/CE Directive
concerning the legislation approximation of the members states
about machines

“the CWL-400 lollipop wrapping machine, because of its

construction, is fit for its purpose and is also fit for its
regulation and maintenance without any risk for those
persons who are exposed to or work with the machine,
provided that any operation carried out in the machine is
according to the conditions stated by the manufacturer on
this manual”.

2. EXEMPTION OF CARUGIL S. L., as manufacturer of the lollipop wrapping

RESPONSIBILITY
machine CWL-400, declines any responsibility for the
injuries caused to persons, animals or things as a
consequence of the non-fulfilment of the norms and use
and maintenance recommendations indicated in this
manual.

Chapter I Page 1 of 2
 CWL-400 MANUAL PREVIOUS CONSIDERATIONS

3. CAUTIONS Along the content of this manual you will find the symbol

associated to WARNING or CAUTION indications, with the following

meaning:

• WARNING: The non-fulfilment of the indications that

accompany the symbol can involve serious damages in person or
things, even death.

• CAUTION: The non-observation of the indications that

accompany the symbol can involve slight damages in persons or
things.

Chapter I Page 2 of 2
 CWL-400 MANUAL CHAPTER II

CHAPTER II

TECHNICAL CHARACTERISTICS

1. SPECIFICATIONS PAGE 1

2. OUTPUT PAGE 2

3. WRAPPING MATERIAL PAGE 2

4. COMMUNICATIONS PAGE 2
 CWL-400 MANUAL TECHNICAL CHARACTERISTICS

TECHNICAL CHARACTERISTICS

1. • Weight: 2.400 Kg
SPECIFICATIONS
• Power: 16 Kw
• Voltage: 415 v + N (transformer option)
• Air pressure: 6-7 bars
• Wording temperature: 20 – 22 ºC
• Working relative humidity: 50 – 60 %
• Level noise: Under 70 dB
• Dimensions: See drawing below

Chapter II Page 1 of 3
 CWL-400 MANUAL TECHNICAL CHARACTERISTICS

2. OUTPUT • The CWL-400 machine has a maximum output of 400

units/minute.
• It is possible, by replacing optional elements, to work with
lollipop formats from Ø16 mm to Ø33 mm and with wrapping
material from 80mm to 135mm .

3. WRAPPING • Wax-treated thermosealable opaline.

MATERIAL
• Cellulose plus aluminum thermosealable complex with wax.
• Any other thermosealable wrapping material

4. COMMUNI- • The machine is equipped with a modem that allows communication

CATIONS
with the manufacturer in case of need, at the rate of 9600 bauds.

Chapter II Page 2 of 3
 CWL-400 MANUAL TECHNICAL CHARACTERISTICS

• Connection::

Æ If the screen or the automaton is going to be checked, connect

cable labelled “KE” to socket DF1 of DH-4857RS-232
interface module of the automaton.

Æ If the servo program is going to be checked, connect cable

labelled AB 1394 to the socket indicated in “Generals
Schemes”.

Æ Connect a direct telephone line (not passing through the

switchboard) to the socket labelled “LINE” in the modem.

Æ Dial CARUGIL telephone number and the communication

will be established.

Æ An additional telephone line must be available in order to

receive instructions from the Manufacturer about how to
proceed while the modem communication lasts.

NOTE: On the screen of the machine must appear MAIN

MENU.

Chapter II Page 3 of 3
 CWL 400 MANUAL - CHAPTER III

CHAPTER III

SECURITY PRESCRIPTIONS

1. GENERALS CRITERIONS PAGE 1

2. PREVIOUS CHECKS PAGE 2

3. STARTING UP PAGE 2

4. MAINTENANCE OPERATIONS PAGE 3

5. OPERATIONS DURING PRODUCTION PAGE 6

6. GENERAL CONSIDERATIONS PAGE 6

 CWL- 400 MANUAL SECURITY PRESCRIPTIONS

SECURITY PRESCRIPTIONS

1. GENERAL CRI- Skilled labour must be selected depending on the type of work
TERIONS ABOUT
to be carried out on the machine: maintenance, cleaning,
WORKING WITH
THE MACHINE production, repairing, etc.

1.1. Definitions - WORKER: Person who is in charge of handling the

machine during the production cycle and for this sole
purpose.
- PERSON IN CHARGE OF THE MAINTENANCE: Skilled
worker under customer’s direct responsibility and expressly
authorized by the customer, who, after an specific course of
the machine, is the person in charge of carrying out the
maintenance and/or change of format operations.

CAUTION
THE MACHINE SHOULD NEVER BE HANDLED BY
MORE THAN ONE PERSON AT THE SAME TIME

Chapter III Page 1 of 8

 CWL- 400 MANUAL SECURITY PRESCRIPTIONS

2. PREVIOUS - Before installing the machine installation, the client must

CHECKS BEFORE
verify that the ground where the machine is going to be
INSTALLATION
placed is levelled and is designed to support the weight of
the machine.
- The client must also check that the electrical installation the
machine is going to be connected to, has an adequate
section area and earth connection, enough to support all the
power absorbed by the machine.

WARNING
PERSONNEL IN CHARGE OF THE TRANSPORT AND
HANDLING OF THE UNPACKED MACHINE, MUST
ALWAYS WEAR THE ADEQUATE INDIVIDUAL
PROTECTIVE CLOTHING AND MUST FOLLOW THE
REQUIRED SECURITY RULES IMPOSED BY THE
CORRESPONDING COUNTRY

3. STARTING UP The starting up of the machine has to be carried out only by the
person in charge of the maintenance, who is aware of the
residual risks of the machine

Chapter III Page 2 of 8

 CWL- 400 MANUAL SECURITY PRESCRIPTIONS

WARNING
THE RESIDUAL RISKS OF THE MACHINE ARE THE
FOLLOWING:
• RISKS OF BURNS, TRAPPING AND SQUASHING IN
THE WRAPPING HEAD.
• RISKS OF TRAPPING AND SQUASHING IN THE
SORTING DISC AND IN THE CONVEYOR CHAIN.
• RISKS OF CUTTING AND SHEARING IN THE
KNIVES.
• SUDDEN STARTS OF THE MACHINE ( CAUSED BY
REMOTE ELECTRONICS FAILURES AND/OR IN
ACTIONINGS).

4. MAINTENANCE - Before carrying out any type of cleaning, lubrication and/or

OPERATIONS
maintenance operation, the line switch and the master
switch have to be turned off; besides, it is advisable to
push the EMERGENCY STOP button.

- In case of any problem during the machine start up,

production cycle or any other circumstance, push
immediately the EMERGENCY STOP button.

- Remember that this button immediately stops all the

moving elements but the hot areas in the machine remain at
Chapter III Page 3 of 8
 CWL- 400 MANUAL SECURITY PRESCRIPTIONS

high temperatures, specially the following devices:

• WRAPPING HEAD
• HEATING EQUIPMENT

CAUTION
TO GET AT THESE AREAS DURING MAINTENANCE
AND CLEANING OPERATIONS, TURN OFF THE LINE
AND MASTER SWITCHES, PUSH “EMERGENCY STOP”
BUTTON AND WAIT FOR THE HOT AREAS TO COOL
DOWN TO THE ENVIRONMENT TEMPERATURE

WARNING
SHOULD IT NOT BE POSIBLE TO COMPLETELY
DISCONNECT THE MACHINE, IT HAS TO BE
INDICATED UIT A PLATE FIXED TO THE MASTER
SWITCH STATING:

DO NOT CONNECT, WORKS BEING

CARRIED OUT

Chapter III Page 4 of 8

 CWL- 400 MANUAL SECURITY PRESCRIPTIONS

- Reparation, cleaning and maintenance operations have to be

carried out by a unique person who always has to wear
protective glasses, gauntlets (against burns and cuts) and
security footwear, using them depending on the needs.
Besides, this person has to wear an overalls with elastics in
the wrists. If this person is long-haired, he must tie his hair
up.

- All the adjustments, changes of format, replacements or any

other operation on the different wrapping machine groups,
have to be carried out only by the qualified worker in
charge of the maintenance. This worker has to pay
maximum attention and be careful in order to not to be
exposed to any of the residual risks of the machine.

WARNING
THESE PERSONNEL WILL NEVER WEAR PENDANTS
OR TEARED CLOTHES: scarf, necklaces, etc.
NEVER PUT THE HANDS IN THE NEARNESS OF THE
WRAPPING MATERIAL DRAGGING ROLLERS NOR IN
CONTACT WITH THE LOLLIPOP CONVEYOR CHAIN.

Chapter III Page 5 of 8

 CWL- 400 MANUAL SECURITY PRESCRIPTIONS

- After every cleaning, lubrication, repairing or maintenance

operation, all the securities have to switched on and the
protections installed/closed again.

- In case it is necessary to replace pieces, use only original

spares provided by CARUGIL.

5. OPERATIONS - During the production cycle, the correct worker position is

DURING PRO-
in front of the control panel so that the he can see not only
DUCTION
the incoming product and the production process but also
the possible presence of another person in the nearness of
the machine.

- If the machine is working, the worker will never put his

hands close to the pincers of the wrapping head.

6. GENERAL CON- - Never lean nor sit on any part of the machine, no matter
SIDERATIONS
whether the machine is working or in emergency state or
stopped.
- Do not leave nor lean any container with liquids in the
nearness of the electrical components (i.e. control panel,
electric chart, heating device).
- Keys of access doors to the inside of the machine must
always and only be kept by the person chosen for this
purpose.

Chapter III Page 6 of 8

 CWL- 400 MANUAL SECURITY PRESCRIPTIONS

CAUTION
NEVER HANDLE IN THE WRONG WAY OR
DISCONNECT THE SECURITY MICROS NOR REMOVE
OR HIDE THE WARNING PLACARDS. IN CASE THEY
CANNOT BE CLEARLY READ BECAUSE OF
DETERIORATION, NEW ONES MUST BE INMEDIATLY
REQUEST TO "CARUGIL S.L."

Chapter III Page 7 of 8

 CWL-400 MANUAL CHAPTER IV

CHAPTER IV

DESCRIPTION OF THE MACHINE

1. GENERALITIES PAGE 1

2. LOLLIPOP FEEDING PAGE 3

3. TRANSPORT AND WRAPPING OF LOLLIPOPS PAGE 3

4. FEEDING OF WRAPPING MATERIAL PAGE 4

5. CONTROLS PAGE 4

- General switch. PAGE 4

- Emergency stop PAGE 4

- “RESET” push button PAGE 5

- Electronic wheel for speed regulation PAGE 5

- Beacon lamp PAGE 7

- Selector - key “DISABLE SECURITIES” PAGE 7

- Touch sensitive screen PAGE 8

6. OPTIONAL ELEMENTS PAGE 9

FIGURES PAGE 10
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

DESCRIPTION OF THE MACHINE

1. GENERALITIES • Machine Model CLW-400, with a maximum output of 400

pieces/minute, is able (by changing some optionals elements) to
work with lollipop formats from Ø 16mm to Ø 33mm and wrapping
material formats form Ø 80mm to Ø 135mm.

• The movements of each stage in the machine are electronically

achieved. All these elements are adjusted from a touch sensitive
terminal. This avoids waste of time caused by the wear and tear of
some transmission elements like gears, axes, etc. and also allows the
easy regulation, adjustment and modification of the parameters.

• In the CWL-400 machine, big problems of other machines in the

market have been eliminated.

1. Heating resistances in the sealing tongs of the wrapping

head. These resistances have a very short working life
because of the continuous movements and vibrations. The
CLW-400 does not use these heating resistances, thus
achieving a higher reliability. Since the heating device is
static, less maintenance is required (Fig. 4-1, end of the
chapter).

Chapter IV Page 1 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

2. The wrapping material is continuously fed, thus avoiding sharp stops and
starts. The paper feeding stops only when there are more than two non-
fed lollipops. This stop and the subsequence start are gradually achieved
so as to avoid sharp movements of the paper. Anyway, wrapping material
will never be fed if there is no incoming lollipop. As there are no sharp
decelerations nor accelerations, there is a lesser wear and tear of the
rubber drawing rollers and therefore, their working life is longer

3. Corrections in the feeding of the wrapping material are

automatically carried out. The control unit accurately places
and cuts the wrapping material no matter the wear and tear of
the rubber dragging roller. No need to change any piece when
working with a different size of wrapping material

4. Effective antistatic device which blows ionised air on the

wrapping material surface (Fig. IV-2)

• In the CWL-400 machine, the adjustment of the format

parameters and different elements is carried out through a touch
sensitive screen which, together with the auotomaton and
control unit, commands all the elements, including the hopper
vibrator (Fig. IV-3.1.), securities, temperatures, speeds, cycles,
etc. It is also possible to have a complete historial of the
machine functioning.

Chapter IV Page 2 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

2. LOLLIPOP
• Lollipops are loaded into the hopper. A feeding vibrator feeds the
FEEDING
sorting disc with these lollipops. (Fig. 4-3.2.)

• Lollipops fall into the holes of the sorting disc (Fig. 4-3.3.) and
the turning brushes (Fig. 4-3.4.) place the sticks in their correct
position. A guide (Fig. 4-3.5.) finally leads the lollipops to the
conveyor chain

3. TRANSPORT • The conveyor chain (Fig. 4-5 ) takes the lollipops to the
AND WRAPPING
wrapping head
OF LOLLIPOPS

• The wrapping material (Fig. 4-6.11) is placed in front of the

lollipop. Three pincers (Fig. 4-6.3.-4) pick the ball of the lollipop
together with the wrapping material already cut.

Chapter IV Page 3 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

• Wrapping material is folded around the lollipop (Fig. 4-6.3.). The

wrapping is made in the wrapping head (Fig. 4-6.5.).

• The product already wrapped and sealed, is taken out through an

exit tray.

4. FEEDING OF • In order to secure always the same tension on the wrapping

WRAPPING
material, the reel holders (Fig. 4-7.1.) have an adjustable break
MATERIAL
which tension can be regulated by the regulator placed on the
upper part of the machine (Fig. 4-7.2.), next to the beacon lamp.

5. CONTROLS 1. General switch. (Fig. IV-8.1)

- Position 1 = Current activated.

- Position 0 = Current not activated.

WARNING
IN POSITION “0” ALL THE ELECTRIC LINE TO
THE MACHINE REMAINS ON TENSION

2. Emergency stop (Fig. IV-9.1)

- Once it is pushed, all the movements in the machine are stopped.

Chapter IV Page 4 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

WARNING
- IT DOESN’T REMOVE TENSION IN THE ELECTRIC
CABINET.
- IT DOESN’T REMOVE TENSION IN THE CONTROL
PANEL.
- PARTS IN THE MACHINE EXPOSED TO THE HEAT
REMAINS HOT.

CAUTION
WAIT FOR THESE PARTS TO COOL
DOWN TO THE ENVIRONMENT
TEMPERATURE

3. "RESET" push button (Fig. IV-9.2)

- Once the anomalies are solved, we will start again the

machine program by pushing this button.

4. Electronic wheel for speed regulation (Fig. IV-9.3)

- With this wheel we will make slow movements of the machine in

order to make adjustments and check synchronisms.

Chapter IV Page 5 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

- To enable this wheel:

• In "WORK" menu

WORK MENU

Select “RESTRICTED MENU” icon. The menu n.5 “ENTER

PASSWORD” will appear. Introduce the corresponding
password to enter menu n.6 and the following screen will
appear, on which you will be able to push the “MANUAL”
icon. It will activate the electronic wheel

• To quit manual mode (electronic wheel) push icon “BACK

TO WORK MENU”.

Chapter IV Page 6 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

RESTRICTED ACCESS 1 MENU

5. Beacon lamp (Fig. IV-9.4)

• Red: the machine is not operative or rearmed.

• Amber: the machine has some kind of anomaly. There are two
positions:
- Fix amber: advise of message on screen or anomaly (with
machine on).
- Blinking amber: advise message “LOW PRODUCT LEVEL
IN FEEDING HOPPER”

• Blue: machine working.

6. Selector - key “DISABLE SECURITIES” (Fig. IV-8.2)

- This selector is placed on the door of the electric cabinet, at the

back of the machine

Chapter IV Page 7 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

- It allows, by turning it with the key, to temporary disable the

securities, to carry out the necessary adjustments on the machine,
or any maintenance operation.

WARNING
ONCE THE MACHINE IS ADJUSTED OR
REPARED, SECURITIES MUST BE
INMEDIATLY ENABLED SO THAT NO
WORK WITHOUT THEM.

CAUTION
KEY WILL ALWAYS BE KEPT BY THE
PERSON IN CHARGE OF THE
MAINTENANCE OR BY AUTHORIZED
PERSONNEL.

7. Touch sensitive screen(Fig. IV-9.5)

- By this screen we will carry out the following operation:

Chapter IV Page 8 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

• Working operations (start and stop the machine, select

manual, …)

• Synchronize the different stages in the machine (sorting disc,

wrapping material feeding, knives, …).

6. OPTIONAL • Second reel holder for wrapping material and automatic

ELEMENTS
splicing system for a unique wrapping material. The machine is
equipped with a second reel holder (Fig. 4-7.2.). Once the first reel
of wrapping material is exhausted, the splicing system automatically
(Fig. 4-7.3.) switches to the second reel of wrapping material, thus
allowing the machine to continue wrapping product without being
necessary to stop the machine.

• Third and fourth reel holder for wrapping material and second
automatic splicing system to use a second wrapping material.
The machine can also be prepared to wrap with two different
wrapping materials at the same time; for this purpose, the machine
will be provided with two reel holders and automatic splicing system
for the additional wrapping material.

Chapter IV Page 9 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

HEATERS

FIGURE IV-1

Chapter IV Page 10 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

AIR PIPES

IONIZING
DEVICE

FIGURE IV-2

Chapter IV Page 11 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

4
2 4

4
3

4
2
4
5

FIGURE IV-3

Chapter IV Page 12 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

FIGURE IV-4

Chapter IV Page 13 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

FIGURE IV-5

Chapter IV Page 14 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

FIGURE IV-6

Chapter IV Page 15 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

2. Regulator for 1. Reel

the brake holder

3. Automatic
splicing
system

FIGURE IV-7

Chapter IV Page 16 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

2. Selector - key
“DISABLE
SECURITIES”

1. General
switch

FIGURE IV-8

Chapter IV Page 17 of 18
 CWL-400 MANUAL DESCRIPTION OF THE MACHINE

1 2 3

FIGURE IV-9

Chapter IV Page 18 of 18
 CWL 400 MANUAL CAPÍTULO V

CHAPTER V

SECURITY DEVICES

1. SWITCHES AND PUSH BUTTONS PAGE 1

2. PROTECTIONS PAGE 1

3. SECURITY LOCKS PAGE 1

4. SIGNALS PAGE 1

FIGURES PAGE 2
 CWL-400 MANUAL SECURITY DEVICES

SECURITY DEVICES
1. SWITCHES AND • General switch with clutch (Fig. 5-1) that prevents the
PUSH BUTTONS
electric cabinet door from being in case this general
switch is not switched off.
• EMERGENCY STOP button placed on the control
panel. (Fig. 5-2.1.)

2. PROTECCTIONS • Access to the moving parts involving risk for the

operator or the person in charge of maintenance through
screwed doors and/or with security end of run switches,
that immediately stop the machine should any of these
doors open while the machine is running.

• Security relay, according to the normative concerning

the emergency stop circuit and security end of run
switches. Once the doors are closed and/or the
emergency stop button is rearmed, this relay must be
enabled to allow the machine to start again. To enable
this relay, the corresponding push button on the control
panel must be pressed (Fig. 5-2.2.)

3. SECURITY • Door with key lock to access the electric cabinet.

LOCKS
• Screwed door to access the control panel.
• Screwed door to access the main motor.

4. SIGNALS • Beacon lamp that indicates the state of the machine

(Fig. 5-2.3.).
• Warning placards.

Chapter V Page 1 of 3
 CWL-400 MANUAL SECURITY DEVICES

FIGURE V-1

Chapter V Page 2 of 3
 CWL-400 MANUAL SECURITY DEVICES

1 2

FIGURE V-2

Chapter V Page 3 of 3
 CWL-400 MANUAL CHAPTER VI

CAPTER VI

TRANSPORT AND UNLOAD

1. TRANSPORT PAGE 1

2. UNLOAD PAGE 1

FIGURES PAGE 3
 CWL-400 MANUAL TRANSPORT AND UNLOAD

TRANSPORT AND UNLOAD

1. TRANSPORT • the machine is transported wrapped (Fig. VI-1), into a container or a

wooden box

• The machine will be anchored to the floor of the container with

lateral belts and wooden pads.

2. UNLOAD • The machine will be unloaded as follows:

1) Remove the lateral belts and wooden pads.

2) Move the machine to the edge of the container using a fork-lift.

CAUTION
MACHINE WIGHT: 2400 Kg

QUALIFIED PERSONNEL IN CHARGE OF THE

TRANSPORT OF THE UNPACKED MACHINE WILL
ALWAYS WEAR THE ADEQUATE INDIVIDUAL
PROTECTIVE EQUIPMENT AND FOLLOW THE
REQUIRED SECURITIES RULES IMPOSED BY THE
CORRESPONDING COUNTRY.

Chapter VI Page 1 of 4
 CWL-400 MANUAL TRANSPORT AND UNLOAD

3) Remove the wrapper.

4) Using a crane, lift the machine by the lifting rings (Fig. Vi-2.1.) and put it on
the ground.

5) Remove the lifting rings and put in their place the plugs provided with the
machine.

6) Proceed with the installation according to Chapter “INSTALLATION”.

Chapter VI Page 2 of 4
 CWL-400 MANUAL TRANSPORT AND UNLOAD

FIGURE VI-1

Chapter VI Page 3 of 4
 CWL-400 MANUAL TRANSPORT AND UNLOAD

FIGURE VI-2

Chapter VI Page 4 of 4
 CWL-400 MANUAL CHAPTER VII

CHAPTER VII

INSTALLATION

1. TRANSPORT AND PLACING PAG. 1

2. ELECTRIC CONNECTION PAG. 2

3. COMPRESSED AIR CONNECTION PAG. 7

4. FITTING THE WRAPPING MATERIAL REEL PAG. 8

5. FINAL CONSIDERATION PAG. 8

FIGURES PAG. 10
 CWL-400 MANUAL INSTALLATION

INSTALLATION

1. TRANSPORT • Before installing the machine, foresee the necessary free space
AND PLACING
for the opening of the different doors, the product feeding and
output, a comfortable worker handling, maintenance and possible
reparations.

• The machine must be correctly installed in a place where the

machine will not be exposed to direct sunlight and climatically
conditioned:

- Environment temperature: 20-22ºC.

- Relative humidity: 50-60%.

• The machine has two rings (Fig. VII-1) for its transport with a
crane. Be sure that all the material used for the lifting of the
machine is able to support the machine weight.

WARNING
MACHINE WEIGHT: 2400 Kg
QUALIFIED PERSONNEL IN CHARGE OF THE
TRANSPORT OF THE UNPACKED MACHINE
WILL ALWAYS WEAR THE ADEQUATE
INDIVIDUAL PROTECTIVE EQUIPMENT AND
FOLLOW THE REQUIRED SECURITIES RULES
IMPOSED BY THE CORRESPONDING
COUNTRY

Chapter VII Page 1 of 20

 CWL-400 MANUAL INSTALLATION

Be careful when fitting the hooks to the rings so as not to loose

balance and prevent the machine from falling or being damaged.

• When putting the machine on the ground, be careful in order to

avoid any damage.

• It is necessary to place the machine on a levelled ground to avoid

the wear and tear of the mechanisms. Loose the nuts and turn the
legs (Fig. VII-2.1.) until the machine is levelled. After that, tight
the nuts.

CAUTION
AN INADEQUATE INSTALLATION CAN LEAD
TO A LOW MACHINE OUTPUT AS WELL AS
TO POSSIBLE BREAKDOWNS.

2. ELECTRICAL • Check that the voltage in the line corresponds to the voltage
CONNECTION
stated on the placard and that the electric installation is able to
support the consumption of the machine. It is recommended the
installation of a current stabilizer.

• Switch off the line switch and the power switch of the machine.
(Fig. VII-3.1.)

• Push the EMERGENCY STOP button. (Fig. VII-4.1.)

Chapter VII Page 2 of 20

 CWL-400 MANUAL INSTALLATION

• Open the doors of the electric cabinet by turning the securities

switch to the “securities disabled” position and remove the door
of the main motor cabinet. The back of the machine will look as
shown in figure VII-5.

• Open also the transparent doors that covers the sorting disc area
(Fig. VII-2.2.).

• Check that magnetothermic swtich F9, that allows the heaters to

work, is in “OFF” position. If it is not. then push it to the “OFF”
position.

WARNING
IF THE MACHINE IS STARTED WITH
MAGNETOTHERMIC SWITCH F9 IN
POSITION “ON”, THE HEATERS (LEISTERS)
MAY BURN AS A RESULT OF THE LACK OF
AIR CAUSED BY A POSSIBLE INCORRECT
TURNING OF THE BLOWER (FIG. VII-5.1.)

• Put some wrapping material pieces in the wrapper presence

detectores (Fig. VII-7), in order to simulate the wrapping
material feeding. Otherwise, the machine will not start running.

Chapter VII Page 3 of 20

 CWL-400 MANUAL INSTALLATION

There are three detectors if the machine is equipped with two reel
holders and splicing system and only one detector if the machine is
equipped with a unique reel holder.

• Connect to the electrical installation.

WARNING
PERSONNEL IN CHARGE OF THE
INSTALLATION MUST TAKE INTO ACCOUNT
THAT, AS FROM THIS MOMENT, THE
SECURITIES ARE DISABLED AND THE
MACHINE, WITH THE DOORS OPEN,
PRESENTS POINTS WITH RISK OF BURN,
TRAPPING AND SQUASHING. THEREFORE,
THEY MUST PROCEED WITH MAXIMUM
CAUTION.

• Switch on the line switch and the power switch of the machine
(Fig. VII-3.1.). The touch sensitive screen (Fig. VII-4.2.) should
now light up; if it does not, turn off the switches and check the
connections and/or the electrical installation. The touch sensitive
screen will show the following sequence of indications: checking
program, “CARUGIL S.L.” screen and then the “ALARMS”
screen like the one shown below indicating “emergency stop” and
“machine not rearmed”.

Chapter VII Page 4 of 20

 CWL-400 MANUAL INSTALLATION

MAIN SCREEN

“ALARMS” SCREEN

• Rearm the EMERGENCY STOP button(Fig. VII-4.3.)

• Rearm the machine by pushing RESET (Fig. VII-4.3.)

• Once the machine is rearmed, the touch sensitive screen will

show the following screen:

Chapter VII Page 5 of 20

 CWL-400 MANUAL INSTALLATION

“WORK” SCREEN

Apart from other indications, in this screen we will find the

“TRABAJO” (WORK) icon to enter the next work screen.

• Start the machine by pushing START on the work screen

(“TRABAJO”).

• The turning direction of the main motorreductor (Fig. VII-5.1.) is

independent of the electric wiring which can vary depending on
the country.

However, the turning direction of some elements depends on the

wiring and, therefore, it is necessary to check the wiring of these
elements.

Particularly, check that the turning brushes (Fig. VII-8.1.) in the

sorting disc area (Fig. VII-8.2.) turn as shown in Figure VII-8. Also
check that the fan placed below the wrapping head turns clockwise
and that the blower blows air in the direction printed on its surface
(to the heaters).

Chapter VII Page 6 of 20

 CWL-400 MANUAL INSTALLATION

• Once these elements turn in the correct direction, switch the

magnetothermic switch F9 to ON position.
• Close all the doors.

• Check that pressure in the compressed air installation is between

3. COMPRESSED
AIR CONNECTION 6 and 7 (bars).

• Open the left side door of the machine that leads to the pressure
regulator (Fig. VII-9), placed under the sorting disc, on the left.

• Check that the pressure regulator (Fig. VII-9.12.) is closed and

that the valve (Fig.VII-9.2.) is in discharge position (down).

• Connect the machine to the compressed air supply with a 6mm

tube (minimum inner diameter).

• Switch the valve (Fig. VII-9.2) to charge position (up).

• Set the pressure to 6 bars using the pressure regulator (Fig.VII-

9.1.).

• Check there are no compressed air leaks.

• Switch the valve (Fig. VII-9.2.) to discharge position (down).

• Close the access door to the pressure regulator.

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 CWL-400 MANUAL INSTALLATION

4. FITTING THE • Push the “STOP MACHINE” operative icon on the “WORK”
WRAPPING menu shown above.
MATERIAL REEL.

• Push the “EMERGENCY STOP” button.

• Switch off the GENERAL SWITCH.

• The reel of wrapping material (Fig. VII-10) must be fit according

to the Figure VII-10, reel to the left on the figure, removing
previously the pieces of wrapping material introduced into the
wrapper detectors during the electrical connection process
already described on this chapter (the piece of wrapping material
introduced into the wrapper detector of the second reel will not
be removed so as to avoid “alarm” messages on the screen).

Figure VII-10 shows the correct position of the wrapping

material through the rollers and splicing system.

Finally, introduce the wrapping material between the dragging

rollers (Figure VII-11) in the cutting device and close this device.

5. FINAL • At this moment, the machine should be perfectly installed and ready
CONSIDERATION
for being used for the first time. This will be possible after the
adequate machine set up process, according to the instructions
included in the corresponding chapter of this manual..

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 CWL-400 MANUAL INSTALLATION

WARNING
THE NON FULFILMENT OF THE DIRECTIVES IN THIS
CHAPTER MAY RESULT IN SERIOUS CONSEQUENCES
NOT ONLY FOR THE MACHINE BUT ALSO FOR THE
PERSON IN CHARGE OF THE MAINTENANCE, THE
WORKER OR ANY OTHER PERSON EXPOSED.

Chapter VII Page 9 of 20

 CWL-400 MANUAL INSTALLATION

FIGURE VII-1

Chapter VII Page 10 of 20

 CWL-400 MANUAL INSTALLATION

2. PROTECTION
SORTING DISC
AREA

1. LEGS

FIGURE VII-2

Chapter VII Page 11 of 20

 CWL-400 MANUAL INSTALLATION

2. SECURITIES
SWITCH

1. POWER
SWITCH

FIGURE VII-3

Chapter VII Page 12 of 20

 CWL-400 MANUAL INSTALLATION

2. SCREEN

3. “RESET”
BUTTON
1. “EMERGENCY
STOP” BUTTON

FIGURE VII-4

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 CWL-400 MANUAL INSTALLATION

3. BROWER FOR
THE HEATHERS
1. MAIN
MOTORREDUCTOR

2. AIR
OUTLET

FIGURE VII-5

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 CWL-400 MANUAL INSTALLATION

MAGNETOTHERMIC
SWITCH F9

FIGURE VII-6

Chapter VII Page 15 of 20

 CWL-400 MANUAL INSTALLATION

WRAPPER
DETECTOR

FIGURE VII-7

Chapter VII Page 16 of 20

 CWL-400 MANUAL INSTALLATION

FIGURE VII-8

Chapter VII Page 17 of 20

 CWL-400 MANUAL INSTALLATION

1. REGULATOR
LOCK

2. VALVE

FIGURE VII-9

Chapter VII Page 18 of 20

 CWL-400 MANUAL INSTALLATION

FIGURE VII-10

Chapter VII Page 19 of 20

 CWL-400 MANUAL INSTALLATION

FIGURE VII-11

Chapter VII Page 20 of 20

 MANUAL CWL-400 CAPÍTULO VIII

CAPÍTULO VIII

DESCRIPCIÓN DE PANTALLAS

1. PASOS PREVIOS PAG. 1

♦ MENÚ Nº 0 “PRINCIPAL” PAG. 1

2. DIÁLOGO OPERARIO-MÁQUINA PAG. 2

3. CONTROL DE FUNCIONAMIENTO PAG. 2

♦ MENÚ Nº 1 PAG. 3
♦ MENÚ Nº 2 “TRABAJO” PAG. 3
♦ MENÚ Nº 3 “MENÚ DIVISOR” PAG. 5
♦ MENÚ Nº 4 “MENU TIEMPOS DE FUNCIONAM.” PAG. 6
♦ MENÚ Nº 5 “ACCESO MENÚ RESTRINGIDO” PAG. 8
♦ MENÚ Nº 6 “MENÚ RESTRINGIDO AJUSTES” PAG. 8
♦ MENÚ Nº 7 “MENÚ TEMPERATURA” PAG. 9
♦ MENÚ Nº 8 “MENÚ RESTRINGIDO FASES” PAG. 10
♦ MENÚ Nº 9 “ALARMAS” PAG. 11
♦ MENÚ Nº 10 “AJUSTES FASE PAPEL” PAG. 12
♦ MENÚ Nº 11 “AJUSTE DE FASES” PAG. 14
♦ MENÚ Nº 12 “MENÚ TIEMPOS” PAG. 15
♦ MENÚ Nº 13 “MENÚ AJUSTES PAPEL” PAG. 16
♦ MENÚ Nº 14 “SELECCIÓN MANUAL” PAG. 18
♦ MENÚ Nº 15 “MENÚ AJUSTE RECHAZO” PAG. 19
♦ MENÚ Nº 16 “MENÚ HOME” PAG. 21
♦ MENÚ Nº 17 “MENÚ ALARMA” PAG. 22
♦ MENÚ Nº 18 “VELOCIDAD MÁQUINA” PAG. 23
♦ MENÚ Nº 19 “MENÚ FORMATO” PAG. 25

FIGURAS PAG. 26

ANEXO
 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

DESCRIPTION OF DISPLAYS

1. PRELIMINARY 1. Check that all guards are closed.

STEPS
2. Switch on the line switch and main switch of the machine (Fig. VIII-
1).
3. Switch on the compressed-air supply (Fig. VIII-2).
4. Reset the “EMERGENCY STOP” button (Fig. VIII-3.1) and reset
the machine by pressing the “RESET” button (Fig. VIII-3.2). If no
anomaly is detected, after a series of alarm messages the “JOB”
menu will appear on the display (Fig. VIII-3.3).

2. OPERATOR– • The CWL-400 model has a touch display (Fig. VIII-3.3) that acts as
MACHINE
the operator’s interface with the machine, showing:
INTERFACE

- The buttons required to operate the machine

- Alarm or anomaly messages via different menus.

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 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

3. CONTROL OF • Operational control touch display (Fig. VIII-3.3)

OPERATIONS

This display is used to operate the machine (Start, Stop, Manual,

etc.) and adjust the timing between the different sections of the
machine (feeder plate, wrapping-material feed, cutting blades and
wrapping material in relation to the wrapping head).

• Details of the various menus and buttons available via the touch
display are provided below.

♦ MENU 1 • Shows details of the manufacturer of the machine, CARUGIL.

(as shown below; the first display to appear)

♦ MENU 2 ™ Information icons

"JOB"
• MACHINE WARMED UP AT LOW SPEED. This text
appears when "MACHINE RUNNING” is pressed. The
machine starts running at low speed for a period of time that

Chapter VIII Page 2 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

can be set from MENU 12, “TIME ADJUSTMENT MENU”,

until a minimum temperature is reached to optimise the
sealing of the wrapping material. Once this time has elapsed,
the machine changes to the selected working speed.

NOTE: This process occurs every time the

machine is started up. The selected working speed
can be obtained by pressing “MACHINE
RUNNING” again, without having to wait for the
programmed warming-up time to elapse..

• TOTAL AND PARTIAL WORKING TIME OF THE

MACHINE.

• SAFETY DEVICES OFF OR ON.

• NO PAPER MARK READ.

• WRAPPING OUT OF RANGE.

• WRAPPING CORRECTION SYSTEM ON OR OFF.

The appearance of menu 2, "JOB,” is as follows:

Chapter VIII Page 3 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

™ Functional icons

WRAPPING TIMING. Selects the exact spot from which the

first wrapping paper will be dispensed when the sweet reaches
the wrapping head, making several cuts until the ideal position is
achieved. It is important to remove any fragments of wrapping
before starting up the machine. Start-up occurs automatically
when the paper is reset with, "HOME PAPER" and "HOME
BLADE".

MACHINE RUNNING. Starts the machine. MENU 3 then

appears.

JOB MENU. Press to access MENU 3.

RESTRICTED MENU. Press to access the menu to enter the

access code for the restricted menus. Next up is MENU 5.

STOP MACHINE. Press to effect a controlled shutdown of the

machine, which remains ready to be restarted without losing any

Chapter VIII Page 4 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

of the programmed timings. MENU 2 continues to appear.

♦ MENU 3 ™ Information icons

"JOB MENU "

PLATE TEMPERATURE. The temperature at the feeder plate.

LEISTER TEMPERATURE. The temperature of the heaters.

• UPM SPEED. The machine’s speed expressed as units per

minute.

• SAFETY DEVICES OFF OR ON.

• NO PAPER MARK READ.

• WRAPPER OUT OF RANGE.

• WRAPPING CORRECTION SYSTEM ON OR OFF.

Depending on whether working with or without marks.

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 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

™ Functional icons

• VIBRATOR ON OR VIBRATOR OFF. Press to activate

or deactivate the vibrating tray that feeds the feeder plate.

• BACK. Press to go back to the JOB menu (MENU 2).

• SPEED ADJUSTMENT. Press to access the “MACHINE

SPEED” menu (MENU 18).

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without
losing any of the programmed timings. The display goes back
to MENU 2.

♦ MENU 4 ™ Indicates whether the machine is ready to be started up, once the
"START-UP” following procedures have been carried out:

HOME PLATE
HOME BLADE
HOME PAPER
PLATE TEMPERATURE

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 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

™ Functional icons.

BACK. Press to go back to the JOB menu (MENU 2) .

STOP MACHINE. Press to effect a controlled shutdown of the

machine, which remains ready to be restarted without losing any
of the programmed timings. The display goes back to MENU 2.

♦ MENU 5 ™ There are three different menus that can be accessed depending on the
"RESTRICTED code that is entered.
ACCESS MENU ”

The codes are: **** **** **** (which take you back to one of the
following displays: MENU 6, 8 or 17).

Chapter VIII Page 7 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

™ Functional icons

####. Press to access a pull-down dialogue where you enter the

relevant four-figure code, depending on which menu you wish to
access, i.e. 6, 8 or 17, according to the code entered via the
numeric keypad located to the right of the touch display.

• JOB MENU. Press to go back to the JOB menu (MENU 3).

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without
losing any of the programmed timings. The display returns to
MENU 2.

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 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

♦ MENU 6 ™ Functional icons

"RESTRICTED
ACCESS MENU 1"

• PAPER REGULATION. Accesses MENU 13, to select

wrapping-material lengths or no-mark mode.

• ADJUST FEEDER PLATE LEVEL CELL. Press this icon

to make this adjustment according to the amount of web
supplied by the vibrator.

• FORMATS. Press to access MENU 20, which indicates the

preset format currently in use and enables an existing format
to be pre-programmed or a new one to be generated.

• MANUAL. Press to access MENU 14, which gives you the

option of controlling the different sections of the machine
(paper phase, divider phase, blade phase and manual mode),
separately or together.

• BACK TO JOB MENU. Press to return to the JOB menu

(MENU 3).

Chapter VIII Page 9 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

• RESTRICTED MENU 2. Press to access MENU 15, when

enables temperatures and times to be set.

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without
losing any of the programmed timings. The display goes back
to MENU 2.

♦ MENU 7 ™ Functional icons.

"TEMPERATURE
REGULATION
MENU"

• WORK PLATE TEMPERATURE. Press the temperature-

value icon to adjust the temperature to suit the product.

• PLATE TEMPERATURE RANGE. Used to adjust the

value such that, even though the temperature set under
“WORKING PLATE TEMPERATURE”, the machine can
be started, since a temperature range can be programmed
between the set temperature and the temperature reached.

Chapter VIII Page 10 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

• LEISTER TEMPERATURE. Press the temperature value

to indicate the minimum temperature required for the
machine to start running. The temperature is regulated via the
dimmer switches located at the back of the hot-air blower
unit.
For the air circulation, it is not advisable to work below
position 2 on the selector located on the back of the unit next
to the air-flow dimmer switches.

• BACK TO RESTRICTED MENU 2. Press to go back to

the restricted menu (MENU 15).

• BACK TO JOB MENU. Press to go back to the JOB menu

(MENU 3).

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without
losing any of the programmed timings. The display goes back
to MENU 2.

♦ MENU 8 ™ This menu is used to make adjustments to the timing of phase 1,

"PHASE 1 controlling the paper settings.
ADJUSTMENT
MENU"

Chapter VIII Page 11 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

™ This menu CAN ONLY BE ACCESSED be entering the relevant code

from MENU 5.

™ Functional icons

MAXIMUM PAPER OFFSET. Press the value icon to select

the maximum correction offset.

SET MAXIMUM OFFSET. Press the value icon to select the

maximum correction setting between marks.

SET PAPER PHASE. Press the value icon to shift the position
of the mark in relation to the sweet, with no need to alter the
mechanical position of the photoelectric cell that detects marks
on the wrapping material.

• BACK TO RESTRICTED MENU. Press to go back to

MENU 5.

• BACK TO JOB MENU. Press to go back to MENU 3.

Chapter VIII Page 12 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

• SET PHASE 2. Press to access MENU 16.

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without
losing any of the programmed timings. The display goes back
to MENU 2.

♦ MENU 9 ™ This menu is displayed whenever any kind of alarm or anomaly

"ALARMS 1" affecting the functioning of the machine occurs.

™ The display includes four information icons representing alarms or

anomalies, shown in progressive order.

™ Functional icons

ALARM 2. Use this icon to access MENU 11, displaying a

further four alarm or anomaly icons.

RESET ALARMS. Press to reset the programme and go back to

MENU 2.

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 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

If the anomalies have not been remedied after a few seconds, the
display will return to the "ALARMS MENU".

STOP MACHINE. Press to effect a controlled shutdown of the

machine, which remains ready to be restarted without losing any
of the programmed timings. The display goes back to MENU 2.

♦ MENU 10 ™ This is an information display that shows the error codes for the
"AXLE ERROR different axles on the machine (movements):
SCREEN"

PLATE AXLE FAULT NUMBER

BLADE AXLE FAULT NUMBER
PAPER AXLE FAULT NUMBER.
GENERAL FAULT NUMBER.

™ For further information see Chapter XIV, “TROUBLESHOOTING”.

Chapter VIII Page 14 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

™ Functional icons.

BACK TO JOB MENU. Press to go back to the JOB menu

(MENU 3).

♦ MENU 11 ™ Similar to MENU 11

"ALARMS 2"

♦ MENU 12 ™ Functional icons.

“TIME
ADJUSTMENT
MENU 1”

Chapter VIII Page 15 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

AUTOMATIC CHANGE A. Press the value icon to alter the

time during which electro-valve A for the automatic changing of
the wrapping material is activated.

AUTOMATIC CHANGE B. Press the value icon to alter the

time during which electro-valve B for the automatic changing of
the wrapping material is activated.

FEEDER LEVEL PHOTOELECTRIC CELL. Press the value

icon to alter the interval between when the detector identifies the
presence of a sweet and the moment when the vibrator stops.

HOPPER LEVEL PHOTOELECTRIC CELL. Press the

value icon to alter the interval between detection by the
photoelectric cell and receipt of the “low hopper level” signal .

DELAY IN STOPPING BLOWER. Enables the time to be

selected during which the blower will be on after the heaters
have been switched off.

• BACK TO RESTRICTED MENU 2. Press this icon to

return to MENU 15.

Chapter VIII Page 16 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

• BACK TO MAIN MENU. Press to go back to the main JOB

menu (MENU 3).

• TIMES 2. Press this icon to go to MENU 19, “TIME

SETTINGS 2”.

STOP MACHINE. Press to effect a controlled shutdown of the

machine, which remains ready to be restarted without losing any
of the programmed timings. The display will go back to MENU
2.

♦ MENU 13 ™ Functional icons

"SPOT
ADJUSTMENT
MENU "

• LENGTH. Press the value icon to set the length of the paper
(in millimetres), adapting it to the format that you want to
work with.

• WORK WITH MARK. Press this icon to select the

working mode that corrects the paper according to the
reading of printed marks.

Chapter VIII Page 17 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

NO MARK. Perss this icon to select the working mode that does
not correct the wrapping material.

BACK TO RESTRICTED MENU 1. Press this icon to go back

to MENU 6.

BACK TO JOB MENU. Press this icon to go ack to the JOB

menu (MENU 3).

STOP MACHINE. Press to effect a controlled shutdown of the

machine, which remains ready to be restarted without losing any
of the programmed timings. The display will go back to MENU
2.

♦ MENU 14 ™ Thuis menu is used to make any adjustments needed to synchronise the
"MANUAL machine’s actions. Press the "MANUAL" icon to display the
SELECTION"
“MANUAL ON” function.

™ Functional icons.

• PAPER PHASE. Press this icon to numericall synchronise

the centre of the wrapping material with the centre of the
sweet on a stick.

• DIVIDER PHASE. Press this icon to numerically

suynchronise the feeder plate in relation to the grips on the
transport chain.

• BLADE PHASE. Press this icon to numerically synchronise

the curring of the warpping material with the sweet on a
stick.

Chapter VIII Page 18 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

• MANUAL. Press thsi icon to activate manual mode, ie. The

“ELECTRONIC WHEEL”.

IMPORTANT NOTE: In “MANUAL ON” mode

various corrections (PAPER PHASE, DIVIDER PHASE
and BLADE PHASE) can be made to the operation of the
machine.

• BACK TO AUTOMATIC. Press this icon to cancel any

changes made in manual mode and return to automatic mode.

• BACK TO RESTRICTED MENU 1. Press this icon to

access MENU 6.

• WRAPPING TIMING. Has the same function as the

“WRAPPING TIMING” option in MENU 2.

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without

Chapter VIII Page 19 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

losing any of the programmed timings. The display goes back

to MENU 2.

♦ MENU 15 ™ This menu enables the temperature and times to be set.

"RESTRICTED
ACCESS MENU 2"

™ Functional icons.

• SET TIME. This icon enables MENU 12 to be accessed, in

order to alter certain movements or operations that are
subject to changes in execution times.

Chapter VIII Page 20 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

• SET TEMPERATURE. This icon enables MENU 7 to be

accessed, in order to make working-temperature adjustments.

RESET TIME. Press for at least 5 seconds to rest the partial

machine time counter to zero.

RESET PRODUCTION. Similarly, zeroes the production

counter.

BACK TO JOB MENU. Press to go back to MENU 3.

• RESTRICTED MENU 1. Press to go back to MENU 6.

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without
losing any of the programmed timings. The display goes back
to MENU 2.

♦ MENU 16 ™ This menu is used to set the synchronisation of phase 2 (blade and
"PHASE 2 feeder plate settings).
ADJUSTMENT
MENU 2"

Chapter VIII Page 21 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

™ Functional icons

SET BLADE PHASE. Press this value icon to set the cutting of
the wrapping material at the right spot in relation to the wrapping
head, according to the type of product being wrapped.

SET PLATE PHASE. Press this value icon to set the timing
between the feeder plate and the transport chain.

BACK TO RESTRICTED MENU. Press this icon to go back

to MENU 5.

BACK TO JOB MENU. Press this icon to go back to the JOB

menu (MENU 3).

SET PHASE 1. Press to go back to MENU 8.

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without
losing any of the programmed timings. The display goes back
to MENU 2.

Chapter VIII Page 22 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

♦ MENU 17 ™ This display shows the number of divisions set for the divider plate.
"PHASE 3
ADJUSTMENT
MENU"

NOTE: Before making any changes, note down the value of divider
phase setting from menu 16 for the plate installed.

™ Operational icons

BACK TO RESTRICTED MENU. Press this icon to go back

to MENU 5.

BACK TO JOB MENU. Press to go back to the JOB menu

(MENU 3).

STOP MACHINE. Press to effect a controlled shutdown of the

machine, which remains ready to be restarted without losing any
of the programmed timings. The display goes back to MENU 2.

STOPPAGE DELAY OFF. Deactivates the stoppage delay set.

Chapter VIII Page 23 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

♦ MENU 18 ♦ Functional icons.

"MACHINE
SPEED"

• LOWER. Press this icon to decrease the speed of the

machine in UPM (units per minute).

• HIGHER. Press this icon to increase the speed of the

machine in UPM (units per minute).

• SET SECOND SPEED. The speed set while the machine is

reaching the working temperature.

• BACK. Press to go back to MENU 3.

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without
losing any of the programmed timings. The display goes back
to MENU 2.

♦ MENU 19 ™ Functional icons.

"TIME
Chapter VIII Page 24 of 29
 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

ADJUSTMENT
MENU 2"

• DELAY IN STOPPING BLOWER. This icon is used to

select the delay before stopping the blower in relation to the
cutting-out of the heaters (to prevent wear).

• BACK TO RESTRICTED MENU 2. Press to go back to

MENU 15, “RESTRICTED ACCESS MENU 2”.

• BACK TO JOB MENU. Press to go back to MENU 3.

• TIMES 1. Press to go to MENU 12, “TIME SETTINGS 1”.

• STOP MACHINE. Press to effect a controlled shutdown of

the machine, which remains ready to be restarted without
losing any of the programmed timings. The display goes back
to MENU 2.

Chapter VIII Page 25 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

♦ MENU 20 ™ Functional icons

" FORMAT MENU"

• CURRENT FORMAT. Indicates the number of the format

that is being used (corresponding to one of the preset
formats).

• NEW FORMAT SELECTED. A new pre-established

format can be selected.

• SAVE. Press to save a newly configured format that differs

from the existing ones..

• QUIT. Press to go back to MENU 6.

• CANCEL. Press to cancel any changes made to a pre-

established format.

• LOAD. Press to recover and work with the values

corresponding to the new format selected.

Chapter VIII Page 26 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

MACHINE
MAIN SWITCH

FIGURE VIII-1

Chapter VIII Page 27 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

FIGURE VIII-2

Chapter VIII Page 28 of 29

 CWL-400 MANUAL DESCRIPTION OF DISPLAYS

1 2

FIGURE VIII-3

Chapter VIII Page 29 of 29

 CWL-400 MANUAL CHAPTER IX

CHAPTER IX

FINE-TUNING

1. SAFETY POINTS PAGE 1

2. PREPARING THE MACHINE PAGE 2

3. INITIAL ADJUSTMENTS PAGE 3

4. ADJUSTING THE MAIN DRIVE BELT PAGE 6

5. CHECKING OPERATION OF THE WRAPPING HEAD PAGE 6

6. ADJUSTING THE TRANSPORT PLATE–CHAIN PAGE 6

7. ADJUSTING THE SWEET-POSITIONING CAM PAGE 6

8. ADJUSTING THE SWEET POSITIONER ON CHAIN PAGE 7

9. ADJUSTING SWEET-INJECTOR-GRIPS PAGE 7

10. ADJUSTING GAP BETWEEN BLADES PAGE 7

11. ADJUSTING GAP BETWEEN DRAG ROLLERS PAGE 8

12. ADJUSTING THE PHOTOELECTRIC CELL PAGE 9

13. SYNCHRONISING SWEET CUTTING & WRAPPING PAGE 10

14. FEEDING WRAPPING MATERIAL PAGE 10

15. ASSEMBLY OF WRAPPING MATERIAL REELS PAGE 11

16. ADJUSTING ELECTRONIC CONTROL ITEMS PAGE 11

FIGURES PAGE 14
 CWL-400 MANUAL FINE-TUNING

FINE-TUNING

1. SAFETY POINTS • The fine-tuning work on this machine requires moving or

removing the guards and overriding the protection devices, with
the machine running. Accordingly, under section 1.2.5 of
Appendix I of Directive 98/37/CE, this work may only be carried
out in MANUAL MODE, using the relevant access code via the
touch screen (RESTRICTED ACCESS MENU 1)

• Checking the functioning of any adjustments made usually

requires the machine to be running in automatic mode, so this
check must be made with the machine in a safe condition, i.e.
with the guards in position and without overriding the safety
devices.

WARNING
NEVERTHELESS, CONSIDERING THE
DELAYS CAUSED TO THE ADJUSTMENT
PROCESS BY RUNNING THE MACHINE IN
SAFE CONDITION, THE OPERATOR MAY
ATTEMPT TO PERFORM THIS WORK
HAVING OVERRIDDEN THE SAFETY
DEVICES, WHICH MAY BE HAZARDOUS.

Chapter IX Page 1 of 27
 CWL-400 MANUAL FINE-TUNING

WARNING
WITH THIS IN MIND, THE MACHINE
SHOULD BE RUN AT THE SLOWEST SPEED
POSSIBLE, WITH THE EMERGENCY STOP
BUTTON ALWAYS AT HAND, AND WITH THE
OPERATOR ACTING AS A MERE OBSERVER,
NEVER EXPOSING ANY PART OF HIS BODY
OR CLOTHING OR ANY TOOL WITHIN
REACH OF THE MOVING PARTS OF THE
MACHINE.

2. PREPARING 1. Turn the key of the door of the electrical cabinet in the “SAFETY
THE MACHINE
OVERRIDE” position.

WARNING
BEFORE REMOVING ANY PROTECTION DEVICE,
THE EMERGENCY STOP BUTTON MUST BE
PRESSED.

2. Remove all the protection devices on the machine in order to be able

to access any areas where adjustments are needed. Also remove the
rear protection from the area of the main motor, belt and blower,
leaving the machine as shown in the photograph (Fig. IX-1).

Chapter IX Page 2 of 27
 CWL-400 MANUAL FINE-TUNING

WARNING
HANDLING THE MACHINE UNDER THESE
CIRCUMSTANCES MAY BE HAZARDOUS, SO
PERSONS CARRYING OUT THIS WORK MUST
BE AWARE OF THE RISKS INVOLVED AND
TAKE EVERY POSSIBLE PRECAUTION.

3. Deactivate the "EMERGENCY STOP " and press "RESET"

NOTE: THE MOVEMENT OF THE DIFFERENT

MECHANISMS ON THE MACHINE IS DRIVEN
BY BELTS, CHAINS AND SERVOMOTORS. IF
ANY OF THESE PARTS SHOULD BREAK OR BE
REMOVED, THE MACHINE WILL FAIL TO BE
SYNCHRONISED.

3. INITIAL 1. After making the corresponding “HOME” actions, check that the
ADJUSTMENT
machine automatically positions one of the eight grips on the
wrapping-head in the highest position on the head, in the vertical
plane containing the grips. This is necessary because of the fitting of
two fixed parts in the fixture of the axle that drags the wrapping
head.

If the situation described above does not occur, contact the technical
staff of CARUGIL S.L.

Chapter IX Page 3 of 27
 CWL-400 MANUAL FINE-TUNING

2. Manually place eight sweets with sticks in the grips on the transport
chain close to the wrapping-head.

3. Start up the machine, pressing the "MACHINE RUNNING" icon on

the "JOB" menu display (MENU 2).

4. Check that the grips on the transport chain transfer the sweet on a
stick properly towards each of the grips on the transfer guides to the
wrapping-head. The stick of the sweet must fit over the bevelled
edge of the fixed foot of the grip and clear the bevelled edge
completely. If this occurs as described, move on to step 5.

Otherwise, i.e. if any or all of the grips on the transport chain should
fail to carry out the transfer properly, follow this procedure:

• Stop the machine by pressing the operational icon "STOP

MACHINE " on the menu displayed (MENU 2).

• Select the "RESTRICTED MENU" icon from the display.

Menu 5, "ENTER ACCESS CODE ", will be displayed

• Enter the relevant code to access menu 6 "RESTRICTED

ACCESS MENU 1", and select the operational icon
“MANUAL", in order to carry out work on the machine using
the electronic wheel.

• Loosen the screw (Fig. IX-1.1) that tenses the drive belt from
the main motor (Fig. IX-1.2).

• Move the chain drag axle (Fig. IX-1.3) until proper transfer
between the grips occurs.

Chapter IX Page 4 of 27
 CWL-400 MANUAL FINE-TUNING

• Tighten the screw of the drag belt tensor until the belt is
tense.

• If this adjustment does not have the desired effect, a finer

adjustment can be made by loosening the fixing screws on
the drag crown of the transport chain (Fig. IX-2), in order to
make a slight coupling movement to the required position.

NOTE: This adjustment can only be made the first time

an adjustment is attempted on one of the transfer grips to
the wrapping-head; for other adjustments, if necessary,
proceed as follows.

• The specific adjustment of each transfer grip to the wrapping-

head may be carried out by loosening the two screws on each
grip and moving the grip slightly to the position required.

• Tighten any screws that have been loosened and check that
the drag belt tensor from the main motor is in the correct
position.

4. ADJUSTING THE • Check that the belt (Fig. IX-1.4) is tense over its entire length and
MAIN DRIVE
make sure that there is no sideways give of the belt when the
BELT
machine is running.

Chapter IX Page 5 of 27
 CWL-400 MANUAL FINE-TUNING

5. CHECKING THE • Check that the entire wrapping and sealing process is carried out
FUNCTIONING OF
properly at the wrapping-head.
THE WRAPPING
HEAD

6. ADJUSTING THE • Adjust the rotary feeder plate (Fig. IX-3.1) to ensure that the sticks
FEEDER PLATE –
of the sweets (Fig. IX-3.2) are aligned with the transport-chain grips
TRANSPORT
CHAIN (Fig. IX-3.3) when the sweets are picked up from the rotary feeder
plate.

• This adjustment should be made from the touch screen (see relevant
section).

7. ADJUSTING THE • The sweet on a stick (Fig. IX-4.1) is carried to the grips (Fig. IX-
SWEET-
4.2) on the transport chain by means of the articulated roller (Fig.
POSITIONING
CAM – CHAIN IX-4.3). To regulate the grip, loosen the screw (Fig. IX-4.4) and
GRIP
then retighten it.

8. ADJUSTING THE • First, make a rough adjustment by placing the positioning unit (Fig.
SWEET
IX-8.1) in such a way as to position the back of the head of the
POSITIONER ON
THE TRANSPORT sweet on a stick about 120 mm away from the main front of the
CHAIN
machine. To achieve this, loosen the screw shown in Fig. IX-8.2.

Chapter IX Page 6 of 27
 CWL-400 MANUAL FINE-TUNING

9. ADJUSTING THE • Select “Manual Activated” on the touch screen, and turn the
SWEET INJECTOR
electronic wheel to adjust the movement.
– WRAPPING
HEAD GRIPS
• Position a sweet on a stick (Fig. IX-5) when the grips and the
central support properly hold the head of the sweet with the stick
perfectly aligned.

• Now loosen the screw (Fig. IX-6.1) and adjust the injector (Fig. IX-
6.2) until it pushes up against the stick of the sweet.

• Once this adjustment has been made, tighten the screw (Fig. IX-
6.1).

• The grips must be adjusted to diameter of 1 mm more than that of

the stick of the sweet. To achieve this, loosen the screws (Fig. IX-7),
make the relevant adjustment and retighten the screws.

• This process must be repeated for all eight sets on the wrapping-
head.

10. ADJUSTING • The wrapping material is cut by two blades (Fig. IX-9), one fixed
THE GAP
and the other rotary.
BETWEEN THE
BLADES

• To adjust the blades, override the servomotor of the blade by

pressing EMERGENCY STOP. Loosen the nuts (Fig. IX-10.1) and
turn the screws (Fig. IX-10.2) until the blades gently touch during
their spinning motion.

ALWAYS ANTI-CLOCKWISE, to prevent wear of the blades.

Chapter IX Page 7 of 27
 CWL-400 MANUAL FINE-TUNING

• Once this adjustment has been made, retighten the nuts. The gap
between the blades should be such that the wrapping material is cut
with the minimum pressure between the blades.

• Feed the wrapping material up to the drag rollers and check by

manually turning the wheel (Fig. IX-10.3) that the wrapping
material is cut easily and cleanly.

• After this adjustment has been made, reconnect the servomotor of

the blade by releasing the EMERGENCY STOP and perform test
runs in MANUAL mode on the touch screen.

11. ADJUSTING • The wrapping material is dragged by two rollers, one made of
THE GAP
rubber (Fig. IX-9.1) and the other of steel (Fig. IX-9.2). The
BETWEEN THE
DRAG ROLLERS pressure between the two rollers can be regulated. This pressure
should be the minimum possible required to drag the wrapping
material without it slipping.

• Adjust the rollers as follows:

1. Feed in two narrow strips of wrapping material, one at each end

of the rollers.

2. Loosen the nuts (Fig. IX-10.1) and adjust the screws (Fig. IX-
10.2) until the tension on both strips of wrapping material is the
same and they do not slip.

3. Retighten the nuts (Fig. IX-10.1).

Chapter IX Page 8 of 27
 CWL-400 MANUAL FINE-TUNING

12. ADJUSTING • Along the path of the wrapping material (Fig. IX-11) there is a
THE PHOTO-
photoelectric cell that reads changes in contrast of the wrapping
ELECTRIC CELL
material. As soon as the photoelectric cell detects a contrast, it sends
an electrical signal.

• With the machine switched on, check that the printing on the
wrapping material is properly positioned. If it is not, adjust the
detection point of the cell as follows:

1. Position the printing mark on the wrapping material under the

lens of the cell.

2. Adjust the sensitivity level using the dimmer switch located on

the back of the photoelectric cell, observing the LEDs that
indicate the cell’s status (see technical characteristics in the
relevant technical manuals). With the mark centred in the light
beam, the LEDs of the cell should change to detection status.

3. Position the mark in the centre of the light beam of the

photoelectric cell by shifting the cell horizontally. Do this after
centring the wrapping towards the wrapping head.

13. • The cutting of the wrapping material can be regulated during

SYNCHRONISING
operation (depending on the format); the correct position is when the
THE CUTTING OF
THE WRAPPING wrapping material is centred in relation to the sweet on a stick at the
MATERIAL WITH
time of cutting.
THE SWEET

• To regulate the cutting, loosen the two screws and using the wheel

Chapter IX Page 9 of 27
 CWL-400 MANUAL FINE-TUNING

(Fig. IX-11), adjust the position, finally retightening the two screws.

14. FEEDING THE • This depends on several circumstances.

WRAPPING
MATERIAL
1. A sweet on a stick to be wrapped being detected by the
photoelectric cell (Fig. IX-11) and located on the transport chain.

2. Prepared wrapping material being fitted onto the reel carrier (Fig.
IX-12).

3. The wrapping material (Fig. IX-13) is fed by the drag rollers,

which are controlled by a servomotor.

4. The photoelectric cell that detects the printing mark on the

wrapping material is used to make any corrections necessary to
centre the material in relation to the sweet on a stick.

5. A touch screen function is available for any necessary checks and

adjustments, advancing and cutting the paper each time it is
pressed, thereby making adjustments easier to make.

6. Detector for wrapping material jams.

15. ASSEMBLY OF • The reel (Fig. IX-14.1) is held in place between the two reel-carrier
THE WRAPPING-
disks.
MATERIAL REELS

• The outer disk (Fig. IX-14.2) can be removed easily thanks to a

quick-fit system.

• The outer disk (Fig. IX-14.3) can be moved on its axis by loosening
the fixing screws (Fig. IX-14.4).

Chapter IX Page 10 of 27
 CWL-400 MANUAL FINE-TUNING

• To fit the reel (Fig. IX-14.1) onto the reel carrier, turn the outer disk
(Fig. IX-14.2) to the right and, pressing the button (Fig. IX-14.6)
move it outwards.

• Place the reel and replace the outer disk of the reel carrier. The
centre of the wrapping material must be aligned with the centre of
the sweet.

• Minor corrections to the distance can be made with the machine

running by turning the adjustment screw (Fig. IX-14.5) to the right
or left to shorten or lengthen the distance, respectively, and also
adjusting the photoelectric cell until it detects the centre of the mark,
provided that the paper is centred in relation to the sweet on a stick.

16. ADJUSTMENT • See the chapter “STARTING THE MACHINE” and proceed as
OF PARTS UNDER
indicated from MENUS 8 and 16 for phase adjustments.
ELECTRONIC
CONTROL
• Adjusting the part controlled by the “servomotores” is carried out
once all the mechanical parts have been fine-tuned.

‰ Adjusting the photoelectric cell that detects the presence of a

sweet on a stick on the transport chain.

- Position the photoelectric cell such that when the

sweet passes by, the wrapping material is dispensed to
synchronise with the arrival of the sweet at the
wrapping head.

- The cell should detect that a sweet is missing, so no

wrapping material will be fed.

Chapter IX Page 11 of 27
 CWL-400 MANUAL FINE-TUNING

VERY IMPORTANT NOTE. The distance between the

photoelectric sweet-detection cell and the wrapping
head must be as set by the manufacturer, and should
never be altered.

‰ Adjusting the feeder plate.

- Access the menu “Enter access code” (MENU 5),

enter the relevant code and the menu “Adjustment
Phase 1” (MENU 8) will appear. Now. press the icon
“Adjustment Phase 2) to access the phase-2 adjustment
menu (MENU 16).

This menu displays the value set for the “plate phase
adjustment” in relation to the transport-chain grip.
Proceed as follows:

™ By increasing the set value the feeder plate

will turn in the direction of motion.

™ By decreasing the set value the feeder plate

will turn in the opposite direction until the
groove of the feeder plate is positioned with
the transport grip when the grip is open and
ready to grab the sweet on a stick and carry it
to the wrapping head.

Chapter IX Page 12 of 27
 CWL-400 MANUAL FINE-TUNING

‰ Adjusting the wrapping-material cutting blades.

- When the wrapping material is cut, the centre of the

wrapping material must coincide with the centre of
the sweet on a stick.

- To adjust the blade, access the menu

“Enter access code” (MENU 5). Enter the relevant
code and the menu “Adjustment Phase 1” (MENU 8)
will appear. Press the icon “Adjustment Phase 2” and
the phase-2 adjustment menu (MENU 16) will appear,
from where the blade- phase adjustments can be
made.

- By increasing or reducing the setting of the blade

phase, the time of cutting can be advanced or retarded.

Chapter IX Page 13 of 27
 CWL-400 MANUAL FINE-TUNING

3 4

FIGURE IX-1

Chapter IX Page 14 of 27
 CWL-400 MANUAL FINE-TUNING

CROWN FIXING
SCREWS

FIGURE IX-2

Chapter IX Page 15 of 27
 CWL-400 MANUAL FINE-TUNING

3
2

FIGURE IX-3

Chapter IX Page 16 of 27
 CWL-400 MANUAL FINE-TUNING

FIGURE IX-4

Chapter IX Page 17 of 27
 CWL-400 MANUAL FINE-TUNING

FIGURE IX-5

Chapter IX Page 18 of 27
 CWL-400 MANUAL FINE-TUNING

FIGURE IX-6

Chapter IX Page 19 of 27
 CWL-400 MANUAL FINE-TUNING

FIGURE IX-7

Chapter IX Page 20 of 27
 CWL-400 MANUAL FINE-TUNING

FIGURE IX-8

Chapter IX Page 21 of 27
 CWL-400 MANUAL FINE-TUNING

FIGURE IX-9

Chapter IX Page 22 of 27
 CWL-400 MANUAL FINE-TUNING

3
1

FIGURE IX-10

Chapter IX Page 23 of 27
 CWL-400 MANUAL FINE-TUNING

WRAPPING
MATERIAL CUTTING
SYNC WHEEL

PHOTOELECTRIC
CELL TO DETECT
PAPER MARK

PHOTOELECTRIC
CELL TO DETECT
PRESENCE OF SWEET

FIGURE IX-11

Chapter IX Page 24 of 27
 CWL-400 MANUAL FINE-TUNING

FIGURE IX-12

Chapter IX Page 25 of 27
 CWL-400 MANUAL FINE-TUNING

FIGURE IX-13

Chapter IX Page 26 of 27
 CWL-400 MANUAL FINE-TUNING

FIGURE IX-14

Chapter IX Page 27 of 27
CWL-400 MANUAL CHAPTER X

CHAPTER X

STARTING THE MACHINE

1. PRELIMINARY CHECKS PAGE 1

2. STARTING OPERATION PAGE 1

3. OPERATOR’S TASKS PAGE 2

4. PAPER JAMS PAGE 3

FIGURES PAGE 4
 CWL-400 MANUAL STARTING THE MACHINE

STARTING THE MACHINE

1. PRELIMINARY • Before carrying out the following procedure, the operator who is
CHECKS
going to run the machine must make these checks:

Æ Open the doors of the electrical cabinet, the divider plate

guard and the displacement of the guards around the head and
blade-carrier roller, and check that no foreign body is inside
the machine that could interfere with normal operations, or
any tools that could have been left behind by maintenance
personnel.

Æ Check that any leftover material has been removed from the
collection trays; otherwise remove any such material.

Æ The condition of the power hose and compressed-air lead

must be checked on a daily basis for wear, splits, etc.

2. STARTING THE • After making the above checks, either before starting up the machine
MACHINE
for the first time that day or after stopping and switching off the
machine for any reason, proceed as follows:

1. Check that the electrical and hydraulic systems are

connected. This check should be done thoroughly,
particularly in terms of the correct voltages, and that the
power supply that has been used previously is the one that it
is to be used now. Also ensure that the pressure of the
compressed-air supply to the machine is within the permitted
range.

Chapter X Page 1 of 6
 CWL-400 MANUAL STARTING THE MACHINE

2. Switch on the main power switch (Fig. X-1.1).

3. Check that the safety-device switch (Fig. X-1.2) is on.

4. Press “RESET” on the control panel (Fig. X-2.1). The

machine will carry out certain synchronisation movements on
the feeder plate, paper-dragging rollers and paper blade.

5. Press “MACHINE RUNNING” on the touch display (Fig. X-

2.2); the machine will start to run at low speed until working
temperatures have been achieved, then reaching the working
speed that was preset.

3. OPERATOR’S • Feed the sweet hoper and collect the wrapped sweets from the
TASKS
machine’s product outlet point.

• Fit the reels and prepare them for automatic changing (as explained
in the relevant section).

• Deal with any paper jams as explained below.

4. JAMMED PAPER • Press EMERGENCY STOP (Fig. X-2.3) to ensure that the machine
cannot be started up.

• Remove the guards that prevent access to the wrapping-material

cutting area.

• Open the cutting head (Fig. X-3), thoroughly remove any jammed
paper and close the roller.

Chapter X Page 2 of 6
 CWL-400 MANUAL STARTING THE MACHINE

• Refit the cutting-area guard.

• Reset the EMERGENCY STOP button (Fig. X-2.3).

• Check that no alarms are indicated on the touch screen except

MACHINE NOT RESET

• Press “RESET” (Fig. X-2.1) to reset the machine, which will carry
out a few synchronisation movements and cut a piece of paper.

• Open the guard again, press EMERGENCY STOP (Fig. X-2.3) and
remove the cut paper. Refit the guard.

• Reset the EMERGENCY STOP button (Fig. X-2.3) and then press
“RESET” (Fig. X-2.1). If no alarms are indicated on the touch
display, press “MACHINE RUNNING” on the touch display
(Fig. X-2.2).

Chapter X Page 3 of 6
 CWL-400 MANUAL STARTING THE MACHINE

2. SAFETY –
DEVICE SWITCH

1. MAIN SWITCH

FIGURE X-1

Chapter X Page 4 of 6
 CWL-400 MANUAL STARTING THE MACHINE

2. TOUCH DISPLAY

1. RESET
BUTTON
3. EMERGENCY
STOP BUTTON

FIGURE X-2

Chapter X Page 5 of 6
 CWL-400 MANUAL STARTING THE MACHINE

FIGURE X-3

Chapter X Page 6 of 6
 CWL-400 MANUAL CHAPTER XI

CHAPTER XI

AUTOMATIC REEL CHANGING

1. CHANGE EQUIPMENT PAGE 1

2. FITTING THE BACKUP REEL PAGE 1

FIGURES PAGE 3
 CWL-400 MANUAL AUTOMATIC REEL CHANGING

AUTOMATIC REEL CHANGING

1. CHANGE • The automatic wrapping-material change unit enables reels to be

EQUIPMENT
replaced without stopping the machine.

• Reel changes are carried out automatically, slowing down the

production speed.

• The unit is pneumatically operated, and cuts the remaining paper on

the reel that has finished or when the material has torn, and then
drags the material to the second reel to ensure continuity of supply.

• To fit the feed reel see Chapter VII, “INSTALLATION” and Fig.
XI-1 y XI-2, in order to position the paper accurately and set the
printing-centring cells in the correct position.

• To fit the backup reel, follow the instructions below.

2. FITTING • Obtain double-sided adhesive tape (Fig. XI-2.6) and stick a 2–3 cm
BACKUP REEL
strip onto the end of the wrapping material.

• Fit the reel onto the corresponding reel carrier (Fig. XI-2.3).

• Unroll the wrapping material and feed it towards the automatic

change unit (Fig. XI-2.4) so that the adhesive is between the rollers
(Fig. XI-2.1) and facing the wrapping material on the other reel.

Chapter XI Page 1 of 4
 CWL-400 MANUAL AUTOMATIC REEL CHANGING

• Turn the counterweight roller (Fig. XI-2.2) onto the roller (Fig. XI-
2.3), so that the end of the backup reel is fixed in the correct position
between the rollers (Fig. XI-2.1).

• Feelers (Fig. XI-2.4) located on the wrapping material send and

electrical signal when the wrapping material on a reel is finished,
and the machine performs the change automatically.

Chapter XI Page 2 of 4
 CWL-400 MANUAL AUTOMATIC REEL CHANGING

FIGURE XI-1

Chapter XI Page 3 of 4
 CWL-400 MANUAL AUTOMATIC REEL CHANGING

FIGURE XI-2

Chapter XI Page 4 of 4
CWL-400 MANUAL CHAPTER XII

CHAPTER XII

CLEANING, LUBRICATION AND

MAINTENANCE

APPENDIX

MAINTENANCE
CHART
 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

CLEANING, LUBRICATION AND MAINTENANCE

1. PRELIMINARY • The frequency with which the machine should be cleaned will depend
POINTS
on the type of product in production. CARUGIL S.L. recommends that
cleaning be carried out at least every 24 hours.

• SAFETY REGULATIONS TO BE COMPLIED WITH BEFORE

CLEANING THE MACHINE:

- Switch off the power supply and general machine switch (Fig.
XII-1).

- Press the EMERGENCY STOP button (Fig. XII-2).

- Wait for hot areas of the machine to return to room

temperature. These areas are:

Æ HEATER UNIT (Fig. XII-3)

Æ WRAPPING HEAD AREA (Fig. XII-4)

Æ FEEDER PLATE (Fig. XII-5)

• Equipment required for cleaning tasks: scraper, brush and authorised

detergents.

2. OUTER • Use vacuum suction in areas where there are electrical components; in
CLEANING
other areas use compressed air.

Chapter XII Page 1 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

• The only areas that require special cleaning are those over or through
which the product passes.

3. DAILY • Remains of sweets must be removed on a daily basis.

CLEANING

DON’T USE STEAM FOR CLEANING, EVER!!

• Clean the wrapping area of the wrapping head (Fig. XII-4) with
compressed air (THE AIR USED MUST CONTAIN NO
GREASE).

• Clean the Teflon rollers (Fig. XII-6) along the route of the wrapping
material to remove any wax residue.

• Clean the drag rollers (Fig. XII-7.1) and wrapping-material cutting

blades (Fig. XII-7.2).

• Clean the two brushes (Fig. XII-8).

• Clean the feeder plate (Fig. XII-9.1) and drop ramp (Fig. XII-9.2), as
web as the guiding area for the sweets on sticks (Fig. XII-9.3).

NOTE: When cleaning using water, which must always contain an

antioxidant additive, thoroughly dry all parts cleaned before using the
machine.

4. WEEKLY • Grease the transport chain (Fig. XII-10).

LUBRICATION

Chapter XII Page 2 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

• Grease the cam (Fig. XII-11) of the wrapping-head injector torlley.

• Grease the cam of the wrapping-head grips.

5.MONTHLY • Grease the injector-trolley guides (Fig. XII-11) for the sweets on sticks
LUBRICATION
via the grease nipples on the trolley (Fig. XII-11).

NOTE 1: ALWAYS USE FOOD-GRADE GREASE OF

MOLIKOTE SOODSLIP EP-2 TYPE (REF.88.235).
NOTE 2: BEFORE GREASING, THE RELEVANT AREA
MUST BE THOROUGHLY CLEANED; ANY
GREASING DONE SHOULD NOT BE EXCESSIVE.

6. MAINTENANCE • The regular maintenance of this machine should be carried out only by
trained technicians.

WARNING
THE MAIN POWER SWITCH OF THE
MACHINE MUST ALWAYS BE SWITCHED OFF
AND THE “EMERGENCY STOP” BUTTON
PRESSED DURING ALL MAINTENANCE
WORK.

9 Areas to be checked DAILY by authorised technical personnel (at

the start of the working day):

Æ Check that nothing is hindering the rotation of the feeder plate

by gripping the partition between the two consecutive holes

Chapter XII Page 3 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

and making light twisting movements. This light movement

should be noted in both directions; otherwise, this is a sure sign
that the plate is rubbing, either because of a build-up of residue
or because a foreign object or sweet stick is jamming it.

This problem must be remedied by removing the feeder plate,

as described in the corresponding section of Chapter XIII,
“REPLACEMENT OF PARTS”. Having done this, clean or
remove anything that could be hindering the movement of the
plate. Refit the plate.

Æ Check that there are no losses from the reducers of the motors
that drag the rollers located on the feeder plate.

9 Areas to be checked WEEKLY by authorised technical personnel:

Æ The cooling fins of the electric motors must be cleaned with

dry compressed air.

Æ Check the tension of the drive belt of the motor (Fig. XII-
12.1)and make any necessary adjustments.

Æ Clean the blower (Fig. XII-12.2) and ventilators (Fig. XII-

12.3).

Æ Clean all the photoelectric cells: i.e. the wrapping-material cell,

the transport-chain cell and the feeder-hopper cell (Fig. XII-
13), as web as the “feeder plate level” ultrasound position
detector” (Fig. XII-5).

Æ Check the oil level and filter of the compressed-air

maintenance unit (Fig. XII-14).

Chapter XII Page 4 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

MAIN MACHINE
SWITCH

FIGURE XII-1

Chapter XII Page 5 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

“EMERGENCY
STOP” BUTTON”

FIGURE XII-2

Chapter XII Page 6 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

HEATER UNIT

FIGURE XII-3

Chapter XII Page 7 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

FIGURE XII-4

Chapter XII Page 8 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

ULTRASOUND
DETECTOR

FIGURE XII-5

Chapter XII Page 9 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

TEFLÓN
ROLLERS

FIGURE XII-6

Chapter XII Page 10 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

2. CUTTING
BLADES

1. DRAG
ROLLERS

FIGURE XII-7

Chapter XII Page 11 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

FIGURE XII-8

Chapter XII Page 12 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

FIGURE XII-9

Chapter XII Page 13 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

FIGURE XII-10

Chapter XII Page 14 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

INJECTOR
TROLLEY
GUIDES

INJECTOR
TROLLEY
CAM

INJECTOR
TROLLEY GREASE
NIPPLES

FIGURE XII-11

Chapter XII Page 15 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

3 2

FIGURE XII-12

Chapter XII Page 16 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

FEEDER HOPPER
PHOTOELECTRIC
CELL

FIGURE XII-13

Chapter XII Page 17 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION & MAINTENANCE

FIGURE XII-14

Chapter XII Page 18 of 18

 CWL-400 MANUAL CLEANING, LUBRICATION AND MAINTENANCE

MAINTENANCE CHART
ACTION FREQUENCY PART AFFECTED
Æ REMOVE REMAINS OF SWEETS FROM: FEEDER PLATE, WRAPPING HEAD
DAILY Æ REMOVE REMAINS OF WAX FROM TEFLON ROLLERS
Æ REMOVE REMAINS OF PAPER FROM DRAG ROLLERS AND BLADES

CLEANING Æ USE BLOWER TO REMOVE WASTE FROM AREAS WITH ELECTRICAL PARTS
Æ AIR FOR COOLING WINGS OF ELECTRIC MOTORS
WEEKLY
Æ BLOWER AND VENTILATOR
Æ PHOTOELECTRIC CELLS AND ULTRASOUND POSITION DETECTOR
Æ TRANSPORT CHAIN
WEEKLY Æ INJECTOR TROLLEY CAM
LUBRICATION Æ WRAPPING HEAD GRIPS CAM

MONTHLY Æ INJECTOR TROLLEY GUIDES VIA GREASE NIPPLES

Æ CHECK NO BLOCKAGE OF FEEDER PLATE
DAILY Æ CHECK NO LOSS OF DIFFERENTIALS ON MOTORS OF BRUSHES LOCATED ON

MAINTENANCE PLATE

Æ CHECK TENSION AND ADJUST CONVEYOR BELT

WEEKLY
Æ CHECK OIL LEVEL AND FILTER, COMPRESSED-AIR MAINTENANCE UNIT

Chapter XII APPENDIX

 CWL-400 MANUAL REPLACEMENT OF PARTS

REPLACEMENT OF PARTS

1. PRELIMINARY • During its working life, the machine is subject to the wear and
POINTS
breakage if certain parts. This fact is quite normal and has been
incorporated in the design of the machine. The parts involved can be
replaced by the user, provided that these simple procedures are
followed, thereby enhancing the functionality of the CWL-400
wrapping machine and saving on indirect user’s costs.

• Also, to optimise the versatility of the machine, it is possible to make

quick changes of the feeder plate, in order to be able to wrap sweets
of different sizes. The relevant procedure is set out in detail in
section 4 below.

2. PREPARING • Before proceeding to replace any of the parts mentioned in this

THE MACHINE
chapter, the machine must be made ready, as follows:

1. Switch off the line switch and main switch of the machine.

2. Press the “EMERGENCY STOP” button.

3. Open all the guards and protection devices in order to access

the parts of the machine that are to be replaced

Chapter XIII Page 1 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

WARNING
THE MACHINE MUST BE LEFT TO STAND IN
ORDER FOR ANY HOT PARTS TO COOL DOWN
TO ROOM TEMPERATURE, IF ANY PARTS NEAR
THE HEATERS ARE TO BE REPLACED AND THE
MACHINE HAS BEEN IN USE IMMEDIATELY
PRIOR TO CARRYING OUT THE REPLACEMENT
WORK.

3. REPLACING • Replacing the spring on the trasnport-chain grips.

WORN OR
DAMAGED PARTS
Æ Free the holding clip from the chain grip (see Fig. XIII-1, in
which it is shown in released position)

Æ Remove the fixing plate from the chain grip

Æ Remove the grip from its housing (Fig. XIII-2)

Æ Replace the spring in the grip (Fig. XIII-3)

Æ Refit the grip in its housing.

Æ Refit the fixing plate and holding clip, taking care to fit it in
the opposite direction to that of the movement of the grip.

Chapter XIII Page 2 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

• Replacing the spring on the transfer-trolley grips

Æ Loosen the screw that fixes the grip (Fig. XIII-4)

Æ Remove the grip from its housing

Æ Loosen the fixing screw from the mobile grab

Æ Replace the spring

Æ Refit the grab and grip in their respective housings

Æ Retighten the screw that fixes the grip

Æ Adjust the grip (as per the procedure set out in Chapter IX,
“FINE-TUNING”)

• Replacing the sealing grip

To replace or simply clean the sealing grip of one or both of the

grabs, proceed as follows:

Æ Loosen and remove the screw that fixes the grab of the grip
that you want to replace (Fig. XIII-5) and then remove the
grip (Fig. XIII-6)

Æ Clean or replace the grab

Æ Fit the new or cleaned grab in position

Æ Position the adjustment tool (Fig. XIII-7) as shown in Figure

XIII-8

Æ Retighten the screw that fixes the grab

Chapter XIII Page 3 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

• Replacing the counter-push rod

If for any reason (the most common being bending out of shape) it is
necessary to replace one or more of the counter-push rods, proceed
as follows:

Æ Remove the screws that fix the metal ring K30 to the
wrapping head and remove the ring (Fig. XIII-9).

NOTE – This can be done with the head installed on the

machine, although for reasons of clarity the photograph
shows the head after disassembly.

Æ Loosen the screw (Fig. XIII-9.1) that fixes the closure to

open the aperture through which the rear-trolley bearing must
be cleared (Fig. XIII-9.2) from the trajectory of the counter-
push rod.

Æ Remove the plastic sucker from the opposite end of the rod in
order to remove it from its housing

Æ Remove the nut and bolt and extract the counter-push rod
through the side where the metal ring K30 is located, as
shown in Figure XIII-9.

Æ Replace the rod

Æ Reassemble all the parts disassembled, following the above

procedure in reverse, taking care to ensure that all screws are
returned to their original tightness.

Chapter XIII Page 4 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

• Replacing the cutting blade from the removable part of the

cutting head

If faulty cutting of the wrapping material is detected, replace the

cutting blade from the movable part of the cutting head, as follows:

Æ Loosen and remove the three (of four) screws, located on the
P57 parts on each side of the blade holder, as shown in
Figure XIII-10

Æ Using a screwdriver or other tool that avoids damaging the

blade holder, lever the blade holder out of its housing (Fig.
XIII-11)

Æ Once the holder has been removed, removed the two screws
from the guide plate and the three screws that fix the blade to
the holder (Fig. XIII-12)

Æ Replace the blade

Æ Fit the guide plate so that it is free from any rubbing that
could occur during the movement of neighbouring parts.

Æ Reassemble the parts disassembling by applying the above

procedure in reverse order, taking care when fitting the blade
holder back in its housing. If necessary use a rubber-headed
mallet to do this.

Æ Adjust the blades as per the procedure set out in Chapter IX

“FINE-TUNING”

Chapter XIII Page 5 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

• Replacing the blade from the fixed part of the cutting head

As shown in Figure XIII-13, when this blade needs to be replaced,

proceed as follows:

Æ Loosen and remove the three screws that fix the blade to the
blade holder on the fixed part of the cutting head

Æ Replace the blade or, as appropriate, refit the current blade

with its second blade ready to make cuts

Æ Screw the three screws back in, returning them to their

original tightness

Æ Adjust the blades as per the procedure set out in Chapter IX,
“FINE-TUNING”

4. REPLACING • If it is necessary to remove the feeder plate because of a change in

THE FEEDER
the size of the sweet being wrapped or in order to clean the plate,
PLATE
proceed as follows:

Æ Remove the perspex top guard (Fig. XIII-14)

Æ Remove the two front rollers, as shown in Figure XIII-15

Æ Remove the rear motor-roller from its support, leaving it

hanging to the side (Fig. XIII-16)

Chapter XIII Page 6 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

Æ Remove the metal side guards, leaving the feeder plate freely
accessible, as shown in Figure XIII-17

Æ Remove the centre screw that fixes the plate in its housing
(Fig. XIII-18)

Æ Remove the plate from its housing, with the support base as
shown in Figure XIII-19

Æ Clean the support base thoroughly

Æ Fit the new plate on the base (there is only one possible
position, because of the fixing axle pin)

Æ Refit and tighten the plate’s fixing screw

Æ Refit the other parts removed (Fig. XIII-20)

Æ Check that the plate moves freely, making movements in the

direction opposite to its direction of travel (Fig. XIII-21)

Chapter XIII Page 7 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-1

Chapter XIII Page 8 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-2

Chapter XIII Page 9 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-3

Chapter XIII Page 10 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-4

Chapter XIII Page 11 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-5

Chapter XIII Page 12 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-6

Chapter XIII Page 13 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-7

Chapter XIII Page 14 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-8

Chapter XIII Page 15 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

RING K30

1
2

FIGURE XIII-9

Chapter XIII Page 16 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

SCREWS
FOR PARTS
P57

FIGURE XIII-10

Chapter XIII Page 17 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-11

Chapter XIII Page 18 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-12

Chapter XIII Page 19 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

BLADE
FIXING
SCREWS

FIGURE XIII-13

Chapter XIII Page 20 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-14

Chapter XIII Page 21 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-15

Chapter XIII Page 22 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-16

Chapter XIII Page 23 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-17

Chapter XIII Page 24 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-18

Chapter XIII Page 25 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-19

Chapter XIII Page 26 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-20

Chapter XIII Page 27 of 28

 CWL-400 MANUAL REPLACEMENT OF PARTS

FIGURE XIII-21

Chapter XIII Page 28 of 28

 CWL-400 MANUAL CHAPTER XIV

CHAPTER XIV

TROUBLESHOOTING

1. TROUBLESHOOTING THAT IS DISPLAYED PAGE 1

2. TROUBLESHOOTING THAT IS NOT DISPLAYED PAGE 4

FIGURES PAGE 7
 CWL-400 MANUAL TROUBLESHOOTING

TROUBLESHOOTING

FAULTS THAT ARE SHOWN ON TOUCH DISPLAY

INDICATION CAUSE SOLUTION
EMERGENCY BUTTON EMERGENCY STOP BUTTON pressed Turn button to reset
Reset relevant switch (Q1, Q2, Q3, Q4 or Q5) and, if this occurs
Magneto-thermal protection device
HEAT TRIGGER frequently, check consumption of relevant motor.
triggered

No wrapping-material reel on second reel

NO 2nd REEL Replace
carrier
No wrapping-material reel on first reel
st
NO 1 REEL Replace
carrier

Chapter XIV Page 1 of 13

 CWL-400 MANUAL TROUBLESHOOTING

Low level of sweets in feeder hopper

FEED SWEETS Activate sweet supply to hopper
(Fig. XIV-1).
Replace reel or replace paper on automatic change unit, as described
One of the wrapping material reels
OUT OF PAPER OR TORN in this manual, as appropriate. Once the problem has been solved,
finished or broken
press RESET ALARMS
• Make sure that there is compressed air in the general network.
• Check that the slide valve is open.

AIR PRESSURE Low air pressure for machine • Check that the pressure gauge shows 6 bars; otherwise use
regulator to obtain correct pressure.
• Once the problem has been solved, press RESET ALARMS.
Feeder plate temperature below preset Check whether the resistor is in proper working condition. If not,
PLATE OUTSIDE TEMPERATURE value, within normal limits. Wait until replace it.
RANGE
desired temperature is reached.
Check that the value set is within normal limits. If so, wait for
Wrapping head temperature below preset
LOW LEISTER TEMPERATURE programmed temperature to be reached; if not, check temperature of
level
air-blower unit and that it is working properly (Fig. XIV-2).

Chapter XIV Page 2 of 13

 CWL-400 MANUAL TROUBLESHOOTING

Machine not functional, immediately after

switching on main switch or after Solve emergency stop and, with guard doors closed, press the RESET
MACHINE NOT RESET
emergency stop or because guard doors button (reset machine).
are open.

DOORS OPEN Guard doors open Close doors and press RESET ALARMS
Wrapping material jammed or rolled up
on drag rollers (Fig. XIV-3.1 and Fig.
To solve this problem, open the wrapping-material drag roller (Fig.
XIV-3.2), with machine coming to dead
JAMMED PAPER XIV-3.2) and remove the jammed paper. Once the problem has been
halt to prevent wear of rubber roller (Fig.
solved, press RESET ALARMS.
XIV-3.1) or faulty production due to lack
of wrapping material at wrapper head.

Chapter XIV Page 3 of 13

 CWL-400 MANUAL TROUBLESHOOTING

FAULTS THAT ARE NOT SHOWN ON TOUCH DISPLAY

INDICATION CAUSE SOLUTION
Check that the main belt (Fig. XIV-4) is
If this is the case, replace and proceed as described in Chapter IX,
not broken
“FINE-TUNING”.

Check that the magneto-thermal device

MACHINE POWERED UP BUT NO If not the case, reset
PARTS MOVING Q1 is switched ON
If not the case (RED status LED), switch off machine, wait a few
Check that the “Axle Control” is showing
seconds and reset, checking that the status LED changes. Then follow
“OPERATIONAL” status (GREEN LED)
standard start-up procedure
If not the case (RED status LED), switch off machine, wait a few
WRAPPING HEAD AND Check that the “Axle Control” is showing
TRANSPORT CHAIN ARE THE seconds and reset, checking that the status LED changes. Then follow
“OPERATIONAL” status (GREEN LED)
OLY PARTS MOVING standard start-up procedure

Chapter XIV Page 4 of 13

 CWL-400 MANUAL TROUBLESHOOTING

Hot-air unit not providing enough heat to

If not the case, reset unit
wrap the sweet.
Check that the temperature selector (red
button) located behind the heater unit
Otherwise adjust
HOT-AIR UNIT NOT PROVIDING (Fig. XIV-5) is set to a suitable value for
ENOUGH HEAT TO WRAP THE
proper wrapping
SWEET
Check that the air-passage selector (black
button) located behind the heater unit
Otherwise adjust
(Fig. XIV-5) is set to a suitable level for
proper wrapping
Check that the finished or torn wrapping-
AUTOMATIC CHANGE NOT If not the case, locate the fault or replace
WORKING PROPERLY material micros are working properly

Chapter XIV Page 5 of 13

 CWL-400 MANUAL TROUBLESHOOTING

Check availability of air supply and that electrical signal reaches valves
Electro-valves not working
properly
AUTOMATIC CHANGE NOT • Check that double-sided adhesive is properly positioned. If so,
WORKING PROPERLY Electro-valves work properly but fail to check that the rollers are set for the type of wrapping material in use
perform automatic change • Finally, also check that the automatic-change blades are properly
adjusted
• Otherwise, reset and check functioning.
Check that magneto-thermal device F7 is
• To increase or decrease vibration level, use dimmer switch inside
SWEET FEEDER VIBRATOR NOT switched ON
WORKING PROPERLY OR AT electrical cabinet (Fig. XIV-6) to make adjustments
ALL Check that the feeder-plate level detector Otherwise, replace or adjust using dimmer switch inside detector case
(Fig. XIV-7) is working and set properly until desired sweet level is reached on feeder plate

Chapter XIV Page 6 of 13

 CWL-400 MANUAL TROUBLESHOOTING

FEEDER
HOPPER

FIGURE XIV-1

Chapter XIV Page 7 of 13

 CWL-400 MANUAL TROUBLESHOOTING

FIGURE XIV-2

Chapter XIV Page 8 of 13

 CWL-400 MANUAL TROUBLESHOOTING

1
2

FIGURE XIV-3

Chapter XIV Page 9 of 13

 CWL-400 MANUAL TROUBLESHOOTING

MAIN
BELT

FIGURE XIV-4

Chapter XIV Page 10 of 13

 CWL-400 MANUAL TROUBLESHOOTING

LOCATION OF
RED AND
BLACK

FIGURE XIV-5

Chapter XIV Page 11 of 13

 CWL-400 MANUAL TROUBLESHOOTING

DIMMER
SWITCH

FIGURE XIV-6

Chapter XIV Page 12 of 13

 CWL-400 MANUAL TROUBLESHOOTING

FIGURE XIV-7

Chapter XIV Page 13 of 13

CWL-400 MANUAL CHAPTER XV

CHAPTER XV

GENERAL DIAGRAMS
 CWL-400 MANUAL PRINTING DIAGRAMS

PRINTING DIAGRAMS

Chapter XVI Page 1 of 1

CWL-400 MANUAL CHAPTER XVII

CHAPTER XVII

SPARE PARTS
 CWL-400 MANUAL SPARE PARTS

SPARE PARTS
ARTICLE
QUANTITY NAME OF PART REF.
CODE No.
3 Rotary grips K19 9100212190
20 Rubber studs K21 9100212211
2 Wrapping material blades P32 P56 9100218320
9100218560
9100203010
5 Chain grips L1 L2 L3 9100203020
1091901003
1 Inductive paper-jam detector (SICK) IM050B8PSZW1 1162401015
1 Micro-switch V163 1161601000
1 Marker lamp 24v 5w 1161103015

1 Sealer grip K9A 1057502002

K9B 1057502003
10 Springs K52 1091901010
1 Rubber wrapping roller P19 9100218190
1 Roll of double-sided adhesive tape 1070600036
1 Paint can 1070600034
1 Catalyst can 1070000000
1 Paintbrush 1070401000
1 Feeder plate brush Q17 9100205170
1 Feeder plate brush Q37 9100205370
2 Leister resistors 33 A2 230v 3KW 1163206001
1 Temperature probe PT100 5x30 1163100002

TOOLS:

SET OF ALLEN KEYS 9 parts. Ref. 62647

ADJUSTABLE WRENCH 5/8. Ref.81406
FLEXIBLE HEXAGONAL TUBE SPANNER + ALLEN TIP 6. Ref.426-6
“T” WRENCH 200 mm: ALLEN 5.
TOOL FOR FITTING GRIPS K58

Chapter XVII Page 1 of 1

 CWL-400 MANUAL CHAPTER XVIII

CHAPTER XVIII

TECHNICAL CHARACTERISTICS
OF
COMPONENTS
CWL-400 MANUAL CHAPTER XVI

CHAPTER XVI

PRINTING DIAGRAMS