SORTING BENCH and ACCESSORIES

SORTING BENCH and ACCESSORIES

Instruction manual

Code: MC004352
Revision: 02
ENGLISH
Publication issued by: SYSTEM CERAMICS - Via Ghiarola Vecchia, 73 - 41042 Fiorano Modenese (MO) - Italy
Edition: 10/22
Revision: 02

All rights for reproduction of this manual are reserved to SYSTEM CERAMICS; even partial reproduction is prohibited.

This manual has been written in compliance with the Directive in force. SYSTEM CERAMICS reserves the right to make any changes it
deems appropriate to this publication, at any time, without notice and without any obligation in relation to the versions already distributed.

This manual:
– is an integral part of the supply and must be carefully read for proper use, in compliance with the essential safety requirements;
– contains the technical information necessary to perform all the procedures in a correct and safe way;
– must be kept with care (protected by a transparent watertight cover to prevent deterioration) and must accompany the machine
throughout its lifespan, even if sold to third parties.
Should the manual be lost or damaged, a copy can be requested to SYSTEM CERAMICS, reporting the data on the identification
plates;
– was drawn up in Italian as original language.

SYSTEM CERAMICS shall not be held responsible for damage caused by operations not covered in this manual.

II
TABLE OF CONTENTS
1. GENERAL INFORMATION.............................................................................................. 1-1
1.1. Introduction...........................................................................................................................1-1
1.2. Suggestions to the buyer......................................................................................................1-1
1.3. Suggestions to the user........................................................................................................1-1
1.4. Purpose of this manual.........................................................................................................1-2
1.5. Documentation supplied with the machine...........................................................................1-2
1.6. How to find and consult the information................................................................................1-3
1.6.1. Symbols used in this manual ..................................................................................1-4
1.7. Operators for which the manual is intended.........................................................................1-5
1.8. Warranty and exclusion of liability.........................................................................................1-6
1.9. Request for technical assistance .........................................................................................1-6
2. GENERAL DESCRIPTION.............................................................................................. 2-7
2.1. General description...............................................................................................................2-7
2.2. Identification data plates.......................................................................................................2-8
3. MACHINE SPECIFICATIONS.......................................................................................... 3-9
3.1. Intended use and forbidden use...........................................................................................3-9
3.1.1. Intended use............................................................................................................3-9
3.1.2. Forbidden use..........................................................................................................3-9
3.2. Machine composition..........................................................................................................3-10
3.2.1. Single U.V. sorting bench...................................................................................... 3-11
3.2.2. Double U.V. counterposed sorting bench..............................................................3-13
3.2.3. Double U.V. sorting bench in series.......................................................................3-13
3.2.4. Informer sorting bench...........................................................................................3-15
3.3. Electric system....................................................................................................................3-16
3.4. Pneumatic system...............................................................................................................3-17
3.5. Technical data.....................................................................................................................3-18
3.5.1. Dimension layout ..................................................................................................3-19
3.5.2. Intended use environment.....................................................................................3-20
4. DEFINITIONS................................................................................................................. 4-21
4.1. Terminology and abbreviations...........................................................................................4-21
5. PREPARING THE MACHINE FOR USE....................................................................... 5-23
5.1. Requirements for preparation of the work environment......................................................5-23
5.2. Unloading from transport vehicle and handling...................................................................5-24
5.2.1. Single sorting bench..............................................................................................5-25
5.2.2. Double sorting bench and diverter (option)............................................................5-26
5.3. Unpacking - Checking the contents....................................................................................5-27
5.4. Storage...............................................................................................................................5-27
5.5. Installation conditions..........................................................................................................5-28
5.6. Installation...........................................................................................................................5-28
5.7. Commissioning...................................................................................................................5-28
6. OPERATING INSTRUCTIONS...................................................................................... 6-29
6.1. Safety and accident prevention...........................................................................................6-29
6.1.1. General warnings...................................................................................................6-29
6.1.2. Protections and safety devices..............................................................................6-31
6.1.3. Emergency stop devices........................................................................................6-34
6.1.4. Personal protective equipment (PPE)....................................................................6-34
6.1.5. Residual risks........................................................................................................6-35
6.1.6. Safety signs...........................................................................................................6-40
6.2. Operating description..........................................................................................................6-42
6.2.1. Single U.V. sorting bench......................................................................................6-42
6.2.2. Informer single sorting bench................................................................................6-45
6.2.3. Double U.V. sorting bench.....................................................................................6-48
6.2.4. Diverter Unit (Option for double bench).................................................................6-49
6.2.5. Conveyor Unit (Option for double bench)..............................................................6-50
6.2.6. Tile turning device..................................................................................................6-51
6.2.7. Profile aligner.........................................................................................................6-51
6.2.8. Pneumatic self-centring guides..............................................................................6-52

III
 6.2.9. Equipment Section Unit........................................................................................6-52
6.2.10. Lighting Unit...........................................................................................................6-53
6.3. Conventions........................................................................................................................6-54
6.4. Description of control and signal equipment.......................................................................6-55
6.4.1. Operator work station and position of control equipment......................................6-55
6.4.2. Main Operator Panel..............................................................................................6-56
6.4.3. Secondary operator panel (only for double bench)...............................................6-58
6.4.4. Secondary operator panel (only for double bench with independent conveyors)..6-59
6.4.5. Console display sound (only for informer bench)..................................................6-60
6.4.6. Mouse (only for informer bench)............................................................................6-61
6.5. Machine use........................................................................................................................6-62
6.5.1. Starting the Line.....................................................................................................6-62
6.5.2. Switching off the Line.............................................................................................6-63
6.5.3. Alarms....................................................................................................................6-64
6.5.4. Machine switching off............................................................................................6-64
6.5.5. Emergency stop.....................................................................................................6-64
6.5.6. Restoring operation after an Emergency stop.......................................................6-65
6.5.7. Visual signalling devices .......................................................................................6-65
6.5.8. Acoustic signalling devices....................................................................................6-66
7. MAINTENANCE AND CLEANING................................................................................. 7-67
7.1. Operator safety warnings....................................................................................................7-67
7.2. General requirements for efficient maintenance.................................................................7-68
7.3. Safe maintenance procedure..............................................................................................7-69
7.4. Routine maintenance..........................................................................................................7-70
7.4.1. Routine maintenance schedule.............................................................................7-71
7.4.2. Check proper operation of safety devices.............................................................7-72
7.4.3. Machine cleaning...................................................................................................7-75
7.4.4. Diverter Unit (Option for double bench).................................................................7-76
7.4.5. Conveyor Unit (Option for double bench)..............................................................7-77
7.4.6. Printer....................................................................................................................7-78
7.4.7. Equipment Conveyor Unit......................................................................................7-79
7.4.8. Self-centring guides...............................................................................................7-80
7.4.9. Profile aligner.........................................................................................................7-81
7.4.10. Check, lubrication - linear guide unit - tightening torques......................................7-82
7.4.11. Check wheel side guides for wear.........................................................................7-83
7.4.12. Clean air handling unit filter...................................................................................7-84
7.4.13. Check tensioning and replace belts, if necessary..................................................7-86
7.4.14. Check polyzene belt V-guides for wear.................................................................7-88
7.4.15. Check pneumatic movement.................................................................................7-89
7.4.16. Bearing support lubrication....................................................................................7-90
7.4.17. Check of gearmotors.............................................................................................7-91
7.4.18. Clean electric panels.............................................................................................7-92
7.4.19. Check lighting unit.................................................................................................7-93
8. DECOMMISSIONING..................................................................................................... 8-95
8.1. Introduction.........................................................................................................................8-95
8.2. Disassembly, scrapping and waste disposal.......................................................................8-95

IV
 GENERAL INFORMATION

1. GENERAL INFORMATION
1
1.1. Introduction
Thank you for choosing the SORTING BENCH and ACCESSORIES.
Carefully read and store this manual; the information contained in it will be essential for the correct
use of the machine.

Through this manual, SYSTEM CERAMICS intends to establish a collaboration with you, in order to
improve our product and make it more flexible for your needs. For this reason, we invite you to report
any error, inaccuracy, malfunction, or suggestion, remark, opinion, through the contacts indicated in
this manual.

Since a coordination among all the professional figures involved in production is required to ensure
a proper and safe operation of the machine, this manual has been conceived and drafted in order
to provide details and suggestions (responsibilities, training, procedures, use and maintenance) for
each type of operator.

1.2. Suggestions to the buyer

We recommend incorporating the indications provided in this manual into your internal safety
procedures. In particular, pay attention to the following points:
- Analyse the machine documentation (in the event of an accident, the manual is the first document
acquired by the competent authorities).
- Perform an analysis of the evident risks of the machine and of its introduction in your working
environment.
- Draft procedures for all the activities required on the machine (according to the instructions contained
in this manual).
- Define the list of personnel in charge for each procedure (affixing it near the machine).
- Carry out and document the training of the personnel in charge for the use of the machine or being
part of the above mentioned lists (repeat training and update the lists when hiring new staff).

In this way, the buyer shows to have used all the possible methods to provide the users with a safe
working environment. Moreover, in case of accident caused by failure to respect the defined procedures,
the buyer can thus decline any liability.

1.3. Suggestions to the user

As far as users are concerned, we recommend paying attention to the following points:
- Read this manual from start to finish (to better understand the procedures).
- Operate by fully respecting the company procedures and those indicated in this manual.
- Do not perform any actions or take any initiatives different from those indicated without the
agreement of the supervisor.

In this way the user will show to have operated in full compliance with the procedures. Any intervention
other than those indicated might be interpreted as an unsolicited and arbitrary action for which the
single user is liable.

1-1
GENERAL INFORMATION

1.4. Purpose of this manual

This manual:
- it contains the technical information necessary for the correct handlingof the package, the
commissioning, the use and maintenance of the sorting bench and its accessories;
- must be carefully read in order to use the machine correctly.

The SORTING BENCH and ACCESSORIES will be hereinafter called “machine”.

For the sake of simplicity, some illustrations show parts of the machine without the guards or with
them disabled.

Before carrying out any operation on the machine, carefully read all the documentation provided
in order to prevent possible damage to the machine, persons or objects. Do not operate if in doubt
regarding the correct interpretation of the instructions.

SYSTEM CERAMICS shall not be held responsible for improper use of the machine, nor for any
damage caused by operations carried out which are not dealt with in this manual and in the attachments.

1.5. Documentation supplied with the machine

• Declaration of Conformity

• Use and maintenance manual

• Wiring diagrams

• Pneumatic diagram

• Operator interface manual

• Spare parts manual

1-2
 GENERAL INFORMATION

1.6. How to find and consult the information

The manual consists of: 1
- a summary of the topics;
- a series of information divided into chapters, paragraphs and sub-paragraphs.

The beginning of each chapter features an odd-number page indicating the number and title of the
chapter.

Page numbering is progressive.

Figure numbering refers to the relative paragraph.

Example Figure 2-1 means:

2-1
PARAGRAPH CONTAINING THE IMAGE

PROGRESSIVE NUMBER (BEFORE THE IMAGE OF CHAPTER 2)

Information regarding:
- Procedures or informative descriptions are in normal characters;
- Danger warnings for the operator, possible causes of anomalies or damage to the machine, search
of descriptions in the manual or in the attachments are in bold italic characters and accompanied
by a symbol (see para. 1.6.1);
- Specialised operators or a specific type of intervention are in normal characters and accompanied
by a symbol (see para. 1.6.1).

Technical or product terminology that may not be understood by all operators are listed in para. 4.1.

1-3
GENERAL INFORMATION

1.6.1. Symbols used in this manual

Symbols indicating situations of risk or very important information.

CAUTION!
Indicates situations of risk for people, recalls accident prevention regulations and suggests
behavioural procedures.

WARNING!
Indicates situations of risk for the machine and/or the product under manufacturing.

N.B.!
Provides useful information when consulting the manual and for correct machine operation.

Symbols indicating information for specialised operators.

MECHANICAL MAINTENANCE OPERATOR

Indicates the routine and scheduled maintenance procedures to be performed by the mechanical
maintenance operator.

ELECTRICAL MAINTENANCE OPERATOR

Indicates the routine and scheduled maintenance procedures to be performed by the electrical
maintenance operator.

SERVICE TECHNICIAN
Indicates the installation, commissioning and/or special maintenance procedures (electrical/
mechanical), which must be carried out by the service technician employed or authorised by
SYSTEM CERAMICS.

GENERAL STAFF

Indicates the number of persons in charge of maintenance.

Example: = 1 person

= 2 persons

Symbols indicating information concerning maintenance.

Service schedule
Indicates how often a maintenance operation must be carried out.

NECESSARY TOOLS
Indicates the tools required to perform maintenance, followed by a detailed list.

INFORMATION
General information and suggestions to help the operator that must perform the maintenance.

1-4
 GENERAL INFORMATION

1.7. Operators for which the manual is intended

• 1st LEVEL operators 1
Operators who are trained and authorised:
- to operate the machine, by means of the control panel, to carry out normal work procedures (box
magazine loading, glue loading, printer ink loading roller, restoration of normal work conditions);
- to check proper operation.

• 2nd LEVEL operators

Operators who are trained and authorised:
- to carry out the operations reserved to 1st LEVEL operators;
- to operate the machine, by means of the control panel, to set new production data or to vary
existing data (format changeover);
- to make adjustments on mechanical parts.

• Mechanical maintenance operators.

Qualified, trained and authorised operators:
- to perform operations reserved to machine operators;
- to perform maintenance of mechanical parts;
- to move functional units in manual mode with protections removed or disabled.
The mechanical maintenance technicians are not allowed to operate on live electrical parts.

• Electrical maintenance operators.

Qualified, trained and authorised technicians:
- to perform operations reserved to machine operators;
- to perform maintenance on electric or electronic parts, also when live (only if necessary);
- to move functional units in manual mode with protections removed or disabled.

• Service technicians
Specialised technician, made available by SYSTEM CERAMICS or by the Technical Assistance
Centre (TAC) to perform complex operations.

Apart from the Service Technician, the scale used for defining expertise is not binding. If properly
authorised by the employer or his/her delegate, a person can be trained to perform more than
one task.

Maintenance technicians can perform operations not specified in this manual only if authorised
by the manufacturer. Untrained persons cannot operate the machine.

The allocation of duties and tasks must be carried out in accordance with the safety manager,
in compliance with the prevailing regulations in the field of health and safety at the workplace.

All the operators must have the necessary authorisations to operate the machine, must carefully
read all the safety instructions contained in this manual and in the enclosed ones.

The manufacturer will not be held liable for damage deriving from non-compliance with the
above-mentioned requirements.

1-5
GENERAL INFORMATION

1.8. Warranty and exclusion of liability

Complete warranty clauses are indicated in the sales contract.

The warranty is subject to the following conditions:

- the machine shall be used within the limits stated in the contract and specified in this manual;
- the machine shall be used according to the instructions of the manual;
- maintenance shall be carried out within the time limits and according to the methods provided by
the manual, using original spare parts and referring to qualified personnel for interventions.

SYSTEM CERAMICS shall not be held responsible for:

- improper use;
- use by unauthorised and/or untrained personnel;
- total or partial failure to observe the instructions;
- defects in the working environment (excessive lighting, excessive temperature and humidity);
- poor maintenance;
- external machine contamination;
- unauthorised modifications and repairs;
- use of non-original spare parts;
- exceptional events such as earthquakes or flooding, fires (if not directly caused by the machine).

1.9. Request for technical assistance

The assistance service is at your disposal for clarifications, for interventions at the customer's premises
with specialised personnel or for sending spare parts.
Always specify:

- Customer name and identification data;

- machine identification data, such as: type; serial no. (job order); year of manufacture.

When necessary, contact:

SYSTEM CERAMICS
Via Ghiarola Vecchia, 73
41042 Fiorano Modenese (MO)
Tel. +39 0536 836111
info@systemceramics.com


Please note that the Customer must always purchase original spare parts (or equivalent parts
authorised in writing by SYSTEM CERAMICS or the T.A.C.).

1-6
 GENERAL DESCRIPTION

2. GENERAL DESCRIPTION

2.1. General description

The SORTING BENCH can be supplied as an integral part of a SYSTEM CERAMICS sorting line, or
it can be supplied separately.

The tiles are sorted in automatic or manual mode on the sorting bench.
2
A further selection is made by the size and flatness checking equipment.
The stacker prepares the stacks of tiles that will be delivered to the packaging machine.

The selection line usually consists of:

• automatic sorting devices;
• sorting bench;
• size and flatness checking equipment (optional machine);
• stacker;
• packaging machine.

Unit Unit Unit Unit

SORTING BENCH DEVICES STACKING PACKAGING

INDICATIVE IMAGES

Unit Unit Unit Unit

SORTING BENCH DEVICES STACKING PACKAGING

2-1

2-7
GENERAL DESCRIPTION

2.2. Identification data plates

Machine identification data and CE marking are shown on the plates positioned on the electric panel
as shown in the figure 2-2.

This information always has to be quoted whenever contacting the manufacturer or service centres.

The CE marking is present only if the machine is sold within the European Union or in case of specific
contractual request.

CAUTION!
Both plates described below are located on the sorting bench only if it has been sold individually.
If the sorting bench is sold with a stacker, the CE plate is applied to the stacker.

It is forbidden to remove, damage or modify the data on the plates.

2-2

2-8
 MACHINE SPECIFICATIONS

3. MACHINE SPECIFICATIONS

3.1. Intended use and forbidden use

3.1.1. Intended use

The tiles are sorted in automatic or manual mode by the SORTING BENCH.

Other types of materials are not allowed without prior written consent of SYSTEM CERAMICS.

Any other use of the machine is to be considered improper, unintended and therefore dangerous.

CAUTION!
The machine described in this manual has been designed to be placed along a line with other
machines and/or partially completed machines. 3
It is mandatory to contact SYSTEM CERAMICS Engineering Department before carrying out the
following operations:
• machine re-positioning along the same line;
• transfer of the whole line in a place other than the original one;
• significant changes to the original layout.
SYSTEM CERAMICS declines any liability for malfunctions, personal injuries or property
damages due to the above-mentioned operations, if not previously authorized.

3.1.2. Forbidden use

The use of the machine is forbidden under the following conditions:

• outdoors;
• in environments with non-admitted temperature and humidity conditions (paragraph 3.5.2);
• in places with altitudes over 1000 m above sea level;
• near acids, corrosive agents or salt;
• near ionising and non-ionising radiation (Lasers, microwaves, ultraviolet radiations);
• for purposes other than those agreed upon in the contract of sale.

The machine must not be used in explosive atmospheres since it does not meet the requirements
of ATEX Directive.
“Explosive atmospheres” are defined as areas in which flammable gas and combustible
mixtures of dust and/or vapours may form.
It is prohibited to use products that release flammable vapours (alcohol, solvents, gasoline, etc.).

It is forbidden to use the machine for purposes other than those for which it was designed; or
to obtain production values exceeding the prescribed limits.
Any tampering with or alteration of the machine is prohibited.
Maintenance is prohibited while the machine is in operation.
It is forbidden to use spare parts that are not original or not authorised by SYSTEM CERAMICS.

SYSTEM CERAMICS shall not be held responsible for any liability arising from failure to comply
with these requirements.

3-9
MACHINE SPECIFICATIONS

3.2. Machine composition

The sorting bench is produced in several versions that differ in functioning, composition and
size.

The configurations available are summarised in the following table:

Sorting method Line width (mm)

Bench type
U.V. Informer 1120 1720 (BS)
SINGLE X X X X
DOUBLE
X X X X
COUNTERPOSED
DOUBLE
X X X -
IN SERIES
DOUBLE
IN SERIES X X X -
COUNTERPOSED

X : provided
- : not provided

The Informer type bench differ from U.V. type for the presence of the “mouse” 1.

3-1

3-10
 MACHINE SPECIFICATIONS

3.2.1. Single U.V. sorting bench

The material transits in single rows.

The operator uses master references located on a special shelf.
The inclination of the material is perfected according to the angle of incidence of the white light coming
from a specific upper ceiling light.

3-2

The SINGLE U.V. sorting bench consists of the following units:

1 inclinable motorised conveyor belt with bearing frame and platform;

2 motorised conveyor for equipment used to automatically control planarity and gauge;
3 white, diffused ceiling light with support and shelf to hold master samples;
4 tiles classification photocells with encoder synchronism photocells;
5 emergency mushroom-head button;
6 equipment downgrading stack light;
7 sorting bench entry guides;
8 self-centring guides at equipment conveyor entry;
9 electric panel;
10 conveyor stop microswitch for overlaying tiles;
11 adjustable mirror (only for BS - Big Size bench);
12 turning device;
13 profile aligner;
14 stop ropes.

3-11
MACHINE SPECIFICATIONS

13
14

12

7
5
11

3
9

6
10
12
14

8
13
2

3-3

3-12
 MACHINE SPECIFICATIONS

3.2.2. Double U.V. counterposed sorting bench

Usually the double row requires two operators situated on the two sides of the sorting bench.
Each operator classifies his/her own side of the conveyor.
Then the two flows of material are conveyed to the area where the fluorescent marking will be scanned
in single row, duly spacing the tiles before accessing the scanning area of the equipment.
Decision of the U.V. and equipment reading is transmitted to the selection line control logic for the
sorting processing.

3-4

The equipment belts are crossed in the case of DICO 2, straight for LINER 2000 or RED LINE.

3.2.3. Double U.V. sorting bench in series

In this case the two operators are located on the same side of the sorting bench.

3-5

3-13
MACHINE SPECIFICATIONS

The DOUBLE U.V. sorting bench consists of the following units:

1 diverter from single row of tiles to two rows, by means of a device controlled by pneumatic cylinder
(optional);
2 motorised belt sorting bench with bearing frame and two platforms;
3 conveyor from two to one row with converging belts and transmissions to compact the flow
of material, complete with tile recirculation devices according to the logic of
acceleration of the material first arrived under the outfeed photocells on each side;
4 motorised conveyor controlled by encoder preset for control equipment for planarity and gauge;
5 white, diffused ceiling light with support;
6 tiles classification photocells with encoder synchronism photocells;
7 control push-button panel for first operator;
8 control push-button panel for second operator;
9 emergency push-button for first operator;
10 emergency push-button for second operator;
11 equipment downgrading stack light;
12 sorting bench entry/exit guides;
13 self-centring guides at equipment conveyor entry;
14 electric panel;
15 conveyor stop microswitch for overlaying tiles.

5 11 6

14

8 2 10 3 4
1

12 9 7 12 13 15
3-6

3-14
 MACHINE SPECIFICATIONS

3.2.4. Informer sorting bench

The INFORMER sorting bench has been designed for a visual selection in line on a single row of
ceramic tiles, in particular for materials that do not accept marks on the surface, as they are porous
materials. In fact, the quality classification takes place by means of a “mouse” 1 (fig. 3-7)
that associates the decision made by the operator at the passage of the tiles. This decision is transmitted
to the sorting line control logic for the sorting processing.
The operator can make up to nine decisions for material classification with reference to the master
samples situated on the special shelf.
The inclination of the material is perfected according to the angle of incidence of the white light coming
from a specific upper ceiling light.

3-7

3-15
MACHINE SPECIFICATIONS

3.3. Electric system

The electric system consists of:
1. electric cabinet placed on the stacking unit;
2. electric panel of the sorting bench;
3. operator push-button panel.

The electric cabinet provides protection of the electric components against external agents. The
electric control panels are accessed through a front door.
Only authorised personnel holding the key may access this panel.

A. MAIN SWITCH
It is a disconnecting switch.
Pos. ”0”: Electric control panel off (machine not powered).
Pos. ”I”: Electric control panel on (machine live).

2 3

3-8

All the components inside the electric cabinets and in the system on the machine can be
identified in the wiring diagram.

3-16
 MACHINE SPECIFICATIONS

3.4. Pneumatic system

Distributes compressed air to the various devices that use it.
It consists of a padlockable pneumatic shut-off valve (1).
The operating pressure (5.5 bar) can be set using knob 2 (fig. 3-9) on the pressure regulator.
The connection point to the pneumatic line is located in the area indicated by the red arrow (fig. 3-9).
Use a 12 PK pipe.

The pneumatic system is in the stacking unit.

2
1

3-9

All the components of the pneumatic system can be consulted in APPENDIX I “Pneumatic
diagrams”.

The adjustment of the pneumatic supply of the single units installed on the line
(e.g. pneumatic counter) is carried out on the regulators and pressure gauges placed near
the units.

3-17
MACHINE SPECIFICATIONS

3.5. Technical data

Main technical specifications

• Overall dimensions:....................................................................................see paragraph 3.5.1
• Vibrations:.......................................................................................................... no risk involved
• Sound pressure level:...............................................................................................< 70 dB (A)
• Site installation:...........................................................................................see paragraph 3.5.2

Electrical system features

• Power supply frequency and voltage:..........................................................see machine plates
• Total installed power:........................................depending on the version (see wiring diagram)

Pneumatic system features

• Supply pressure:........................................................................................ 6 bar (1/2” gas pipe)
• Operating pressure:.........................................................................................................5.5 bar
• Total air consumption up to:..................................................................................... 1000 nl/min

Machine technical data, performance and limits of use not indicated in this paragraph are
contained in the attached manuals.

Do not deviate from the processing values or limits described in the “Technical Data”
paragraph of this manual and in the attached documents. Any other unintended use, being
not conforming with the design and technical specifications, must be deemed as “NOT
ALLOWED”.

3-18
 MACHINE SPECIFICATIONS

3.5.1. Dimension layout

DOUBLE COUNTERPOSED
BENCH SINGLE ROW

4500
3
8740

DOUBLE COUNTERPOSED
BENCH DOUBLE ROW

SINGLE BENCH

X
FORMAT X

600 L=3400

1200 L=4400

1800 L=6000

3-10

For detailed information about the Layout of the purchased machine, refer to the specific layout shown
in the sales contract of the machine.

3-19
MACHINE SPECIFICATIONS

3.5.2. Intended use environment

Environmental operation conditions

• Min. working temperature:.................................................................................................+ 5°C

• Max. working temperature: .............................................................................................+ 45°C
• Relative humidity (not condensed):........................................ max. 90% at 20°C (50% at 40°C)

Workplace specifications
The machine must only work indoors, protected from atmospheric agents and where there is
no risk of explosion or fire since it is not explosion-proof. It is therefore prohibited to install
it or operate it in rooms subject to the risk of explosion.
The workplace must be provided with sufficient natural light and adequate artificial lighting to
protect the health and safety of the operator.
The minimum lighting of the room must guarantee good visibility at every point of the machine,
whereas the maximum lighting must not dazzle the operator (for normal use 250 - 300 lux of
artificial or natural light; for maintenance 500 lux of light localised at the point of intervention).
The floor must be perfectly flat and level.
The required space for use and maintenance (aisles around the machine for personnel and forklift
trucks) should:
- remain dry, clean and free from obstructions;
- comply with the minimum distances permitted by laws in force in the country where the machine
is installed.

INDICATIVE IMAGE

WALL

800 GAP
1500
1500

GAP 1500
800

WALL

3-11

3-20
 DEFINITIONS

4. DEFINITIONS
4.1. Terminology and abbreviations
SYNCHRONISED STOP: Machine shutdown that does not entail the interrpution of the
processing cycle.

LENGTHWISE FEED: Feed direction of the product with length greater than width.

ACROSS FEED: Feed direction of the product with width greater than length.

T.A.C.: Technical Assistance Centre.

CONSOLE: Control unit/Control panel with virtual push-button panel.

PPE: Personal protective equipment.

TILE WIDTH: Side of the tile orthogonal to the feeding direction.

SLAB: Ceramic product with large size and reduced thickness.

TILE LENGTH: Side of the tile parallel to the feeding direction.

MACHINE:
Sorting Bench.
4
OPERATOR: The person or persons in charge of installing, operating,
adjusting, cleaning, repairing and moving a machine or
performing maintenance operations (see paragraph 1.7).

EXPOSED PERSON: Anybody entirely or partially in a hazardous area.

OPERATOR POSITION: Station from where the operator controls the machine in
manual or automatic mode through controls
on push-button panel, keypad or console.

E.C.P.: Electric control panel.

HAZARDOUS AREA: Any area inside or near the machine

where the presence of a person represents a risk for
the safety and/or health of that person.

4-21
 PAGE LEFT INTENTIONALLY BLANK

4-22
 PREPARING THE MACHINE FOR USE

5. PREPARING THE MACHINE FOR USE

5.1. Requirements for preparation of the work environment

Correct preparation and inspection of the environmental conditions where the machine operates is
certainly a fundamental requirement for it to work properly and safely. Therefore, we underline the
importance of the following preliminary checks:

- the set up of the room (brickwork, foundations, piping) must be suitable and comply with the
requirements foreseen by European Directives, which regulate safety in the workplaces. In particular,
it must have the necessary space for use and maintenance. Important requirements regarding the
safety and productivity of the operators;

- The set-up of the electrical systems, up to the points where the machine is powered, must
be done in compliance with the laws in force. The electric power supply network is therefore to be
provided with appropriate earthing connection for the power absorbed by the machine, with differential
switches and/or safety valves upstream from the machine, dimensioned in accordance with the data
indicated in paragraph 3.5;

- the compressed air supply must be dimensioned in compliance with the data indicated in
paragraph 3.5.

The compressed air required for the operation of all the pneumatic units must be clean. The
presence of impurities in the air coming from the compressor and condensed moisture, favour
wear of the seals and running surfaces, jeopardising operation and life of the pneumatic
components.

- the workplace must be provided with sufficient natural light or adequate artificial lighting (see
paragraph 3.5.2);
5

5-23
PREPARING THE MACHINE FOR USE

5.2. Unloading from transport vehicle and handling

The packages must be unloaded from the transport vehicle and handled:

- by qualified personnel authorised for this job;

- using lifting systems and devices able to sustain the weight indicated in the transport documents;

- using the fastening or lifting points identified by the pictograms on the packages (figure 5-1).

5-1

The lifting devices MUST HAVE A CAPACITY AT LEAST 20% GREATER THAN THE WEIGHT TO
BE LIFTED.

During unloading and handling operations, an assistant must provide any signals.

Lifting operations must be carried out smoothly, without jerks or sudden movements.
During handling nobody must be within the working area, and the whole surrounding area must be
considered as hazardous area. The person in charge of handling shall check load stability before
lifting and handling.

It is forbidden to walk or stand under hanging loads.

Closely follow the site safety plan when lifting the load.

The machines are normally shipped unpackaged, protected by a cloth, closed with tape bearing
our brand, suitably anchored with belts to the sides of the truck or container.
The Selection bench is shipped partly dismantled for transport.

If a crane or overhead travelling crane is employed, sling with belts having a suitable capacity, securing
them in the same positions as those for a forklift truck.

The platform is used as a rest surface and is shipped in a separate package with the most
fragile parts and the manuals.

5-24
 PREPARING THE MACHINE FOR USE

5.2.1. Single sorting bench

To ship and lift the SINGLE SORTING BENCH, stiffening brackets, under which the forklift truck forks
or the belts should be inserted, are fitted in positions 1.
After the installation, the stiffening brackets should be removed and stored for any future movement.

CAUTION!
Check that the centre of gravity is well centred in relation to the forks.

Single sorting bench (900 kg)

Single sorting bench BS (1400 kg)

1 1 5

Platform and accessories (150 kg)

5-2

5-25
PREPARING THE MACHINE FOR USE

5.2.2. Double sorting bench and diverter (option)

To ship and lift the DIVERTER (option), stiffening brackets, under which the forklift truck forks or the
straps should be inserted, are fitted in positions 2.
After the installation, the stiffening brackets should be removed and stored for any future movement.

To ship and lift the DOUBLE SORTING BENCH, stiffening brackets, under which the forklift truck
forks or the straps should be inserted, are fitted in positions 3.
After the installation, the stiffening brackets should be removed and stored for any future movement.

CAUTION!
Check that the centre of gravity is well centred in relation to the forks.

Diverter (450 kg)

Double sorting bench (1100 kg)

3 3

Platform and accessories (200 kg)

5-3

5-26
 PREPARING THE MACHINE FOR USE

5.3. Unpacking - Checking the contents

Upon receiving the supply, make sure the machine has not been damaged during transport or
the packing has not been tampered with and parts removed from inside.

If any type of damage is noted, this is to be reported to the carrier, and the dealer or SYSTEM
CERAMICS is to be notified immediately.

If there is no packing, the components are to remain intact in the storage area until a dealer
or SYSTEM CERAMICS technician has checked their integrity.

In all cases, make sure the machine has not been damaged during transport or the packaging
has not been tampered with and parts removed from the inside. This is to be carried out in the
presence of a technician assigned by the dealer or SYSTEM CERAMICS.
.
If any type of damage is noted, this is to be reported to the carrier, and the dealer or SYSTEM
CERAMICS is to be notified immediately.

SYSTEM CERAMICS shall not be liable for damage caused to the machine if it is transported
and placed in the plant by third parties.

5.4. Storage
If the machine is not to be installed within a short period, but has to be stored for a length of time, it
is recommended to keep the components in the original packing.
Store in a protected environment, appropriate for the degree of protection required.

- Make sure that the environmental specifications correspond to:

- Temperature: +2/+45 °C; 5

- Relative humidity Max. 90% (no condensate);

- Closed environment protected against weathering.

Temperature or humidity values that exceed those indicated above could seriously damage the
machine components.

- Place the machine on the ground.

- Do not rest anything on the packing (boxes, crates or heavy equipment).

- Do not place it near inflammable material.

SYSTEM CERAMICS is not liable for any machine damage possibly encountered once it has
been handed over to the shipping company.

5-27
PREPARING THE MACHINE FOR USE

5.5. Installation conditions

The customer is responsible for:

- the preparation of the premises (masonry, foundations, channelling). The customer must
have suitable premises in compliance with the requirements foreseen by the European Directives
that regulate safety in the workplace. In particular, they must have the space required for use and
maintenance purposes.

- the flatness of the floor. It must meet the requirements requested by SYSTEM CERAMICS
during designing.

- The area intended for installation, testing and use of the machine must be free from all objects
not normally used, in order to allow SYSTEM CERAMICS technicians to perform the operations
requested for a correct installation.

5.6. Installation
Installation and commissioning operations are to be carried out by qualified SYSTEM CERAMICS
technicians.

5.7. Commissioning

Upon commissioning, the calibrations are performed by SYSTEM CERAMICS technicians.

5-28
 OPERATING INSTRUCTIONS

6. OPERATING INSTRUCTIONS
6.1. Safety and accident prevention

6.1.1. General warnings

Before starting to operate, it is very important to carefully read this chapter entirely since
it contains important information regarding risks the operator can encounter in case of incorrect
use of the machine.

IT IS PROHIBITED:

• to introduce any part of the body into the machine, in particular into the moving parts of
the conveyor line;

• to start the machine with people inside it. Make sure that the start-up is not dangerous
for people or the machine, making sure that there are no foreign objects (screwdrivers,
wrenches, screws, etc.) left on the machine after an intervention;

• to service or adjust the machine while it is running or electrically powered;

• to by-pass the safety systems in any way;

• to use the machine without the safety systems working, without the protections fitted or
fitted incorrectly;

• to remove panels, doors and guards, only when necessary for maintenance operations;

• to use the machine for purposes other than those for which it has been designed and
defined in this manual and also in the sales contract;

• to tamper with or remove the safety plates on board the machine;

• to modify data on the identification plates;

• make modifications to the machine without obtaining authorisation from SYSTEM 6

CERAMICS;

• to use the machine if it is faulty;

• to throw water on the motors or electric components.

IT IS MANDATORY:

• to read all the documentation supplied with the machine before starting to operate;

• that every operation on the machine is only carried out by specifically authorised personnel;

• for operators to be aware of the precautions concerning them and the pictograms (adhesive
labels) applied to the machine;

• to take care of operating clearance and passages around the machine. These must be free
from obstacles, clean and with appropriate lighting;

• to entrust the electric control panel access keys to a specialised and authorised person;

6-29
OPERATING INSTRUCTIONS

• to keep the safety systems and emergency buttons perfectly efficient;

• to carefully make sure that there is nobody or any goods in areas adjacent to machine
moving parts when operating in manual mode;

• to make sure there are no oil leaks when running. Verify that the electrical components
operate correctly and no smoke is emitted by the motors. Do not neglect suspicious odours
or noises;

• use appropriate protective equipment for the operations to be carried out. Close-fitting
clothes must be worn. Do not wear ties, necklaces or belts that could get caught-up or
stuck between moving parts;

• before adjusting or repairing components on the machine, carry out the procedures
indicated in chapter 7.

6-30
 OPERATING INSTRUCTIONS

6.1.2. Protections and safety devices

Pulleys and belts are protected against crushing with finger guards and belt V-guides.
Further protection devices would limit in an unacceptable way the production process that requires
the vicinity or contact with the material to be selected.

The following stop devices are provided:

1A, 1B, 1C EMERGENCY STOP push-buttons of the entire sorting line (red mushroom-head button
on yellow background);
A stop push-button of the SORTING BENCH and UPSTREAM LINE conveyors (black mushroom-
head button);
C stop push-buttons of the DOWNSTREAM LINE of the sorting bench and STACKER;
2 stop ropes of the conveyors of the SORTING BENCH and UPSTREAM LINE.

All emergency stop push-buttons have a self-latching mechanism.

Activating the emergency stop causes all machine functions to stop.

It is absolutely forbidden to disable/tamper with, modify or try disabling the safety systems on the
MACHINE. The manufacturer shall not be held responsible for the MACHINE safety in case of
failure to respect such prohibition.

In case of malfunctions of the control and safety devices, operators must stop using the MACHINE
and contact the manufacturer immediately.

6-31
OPERATING INSTRUCTIONS

SINGLE SORTING BENCH A B C D

1A

1A 2

6-1

6-32
 OPERATING INSTRUCTIONS

DOUBLE SORTING BENCH A B C D N

(*)

1B 2

1C 2

1B
2
1C

(*) Secondary operator push-button panel with independent drives.

6-2

6-33
OPERATING INSTRUCTIONS

6.1.3. Emergency stop devices

The emergency stop devices are used to stop the operating cycle
instantaneously in case of danger for the operators or in case of anomalous situation for the machine
and are made up of emergency mushroom-head buttons (5) and by the stop ropes (6).

6-3

6.1.4. Personal protective equipment (PPE)

During machine use and maintenance, SYSTEM CERAMICS imposes the use of the following PPE:

- ACCIDENT-PREVENTION SHOES. For any operation.

- GLOVES. When inks, Glues and Hot Parts are handled.

- GOGGLES. When topping up the glue or printer ink.

6-34
 OPERATING INSTRUCTIONS

6.1.5. Residual risks

Residual risk means a potential hazard that cannot be eliminated or that has just been partially
eliminated.

In any case, the final user must always carry out a complete risks analysis after installing the
machine in the workplace, and as a consequence apply further necessary safety systems.

Pulleys and belts are protected against crushing with finger guards and belt V-guides.
Further protection devices would limit in an unacceptable way the production process that requires the
vicinity or contact with the material to be selected.

Therefore, some residual risks are reported due to:

• contact with mobile elements (pulleys, belts and transverse support elements);
• contact with hot or pressurised parts;
• machine reset;
• power voltage.

If during maintenance or adjustment operations the operator has to manually work on hot or
cutting parts, suitable gloves must be compulsorily used.

For system operations to be carried out not at ground level, we recommend using work
platforms or other suitable people lifting means in compliance with the prevailing standards.

The operations to be carried out on the system must be carried out under optimal lighting
conditions (at least 300 lux); should it be necessary to use an additional light source, its
position must be adjusted so that the operators can carry out the maintenance works without
being exposed to any risk.

Should some operations be performed under machine elements, adopt special precautions
to prevent any parts from falling.

Should protections be removed – for example to carry out maintenance operations – do not
start the system for any reason before all protections have been refitted and correctly secured
in place.
6
Electrocution hazards in case of contact with live parts are present. Warning notices signalling
the presence of live electric parts have been affixed on the covers of junction boxes, on the
power supply ducts, on the electric panel doors and on all electric cableways.

6-35
OPERATING INSTRUCTIONS

1) Burning hazard due to hot material ejection.

During maintenance/adjustment of the glue/polymer unit circuit [oven (1) fittings (2) and guns (3)], the
circuit might remain under pressure and generate ejections of very hot material.

BEFORE ANY OPERATION ON THE GLUE / POLYMER SYSTEM, DEPRESSURISE THE

CIRCUIT AS DESCRIBED IN THE INSTRUCTION MANUAL OF THE MANUFACTURER OF THE
GLUE UNIT (SUPPLIED WITH MACHINE DOCUMENTATION).
WEAR PROTECTION GLOVES AND GOGGLES.

6-4

2) Burning and intoxication hazards when topping up the hot glue reservoir.

BEFORE TOPPING UP THE GLUE RESERVOIR:

- PROTECT HANDS AND EYES WITH APPROPRIATE PPE;
- READ THE SAFETY INSTRUCTIONS CONTAINED IN THE INSTRUCTION MANUAL
SUPPLIED BY THE HOT GLUE SYSTEM MANUFACTURER.
TOP UP, POURING THE GLUE SLOWLY INTO THE RESERVOIR, TAKING CARE NOT TO SPLASH.

IN CASE OF CONTACT WITH THE GLUE:

- DO NOT INGEST;
- DO NOT TOUCH DELICATE PARTS SUCH AS EYES AND MUCOUS MEMBRANES;
- WASH THE CONTACT AREA WITH RUNNING WATER;
- SEEK MEDICAL ATTENTION.

FOR MORE INFORMATION REFER TO THE SAFETY DATA SHEET OF THE GLUE.

3) Fibrillation and/or electrocution hazards due to high voltages (400 VOLTS) inside the electric
panel.

THE ELECTRIC PANEL REMAINS LIVE EVEN WITH

THE DOORS OPEN, DO NOT OPERATE WITH
SCREWDRIVERS OR POINTED OBJECTS BEFORE
SETTING THE MAIN SWITCH TO ZERO.

SOME PARTS REMAIN LIVE (NOTIFICATION

PRESENT ON THE WIRING DIAGRAM) EVEN WHEN
THE MAIN SWITCH IS SET TO ZERO.

6-5

6-36
 OPERATING INSTRUCTIONS

4) Risk of crushing limbs, cutting, contusions and death, when operating in the area adjacent
to the stacker, because the machine downstream is still running.

5) Risk of cutting and upper limb crushing during extraction of jammed material.

In case of material jamming especially on the pneumatic parts (centring devices, pushers,) DO
NOT ATTEMPT TO EXTRACT THE MATERIAL WITH YOUR HANDS AS THERE STILL COULD BE
RESIDUAL POTENTIAL ENERGIES THAT CAUSE DANGEROUS MOVEMENTS.

To extract the material proceed as follows:

1) Set the machine to manual mode;
2) Open the moving parts through manual controls;
3) Stop the machine;
4) Extract the material manually.

6) Risk of scalding caused by contact with overheated electric motors.

DO NOT TOUCH ELECTRIC MOTORS BEFORE THEY HAVE COOLED DOWN.

7) Risk of crushing/shearing fingers/hands.

THE MATERIAL IS TRANSFERRED BY CONVEYOR BELTS. A DEPENDING ON THE CONDITIONS,

BELTS CAN BE SUPPORTED BY TRANSVERSE ELEMENTS. IT IS FORBIDDEN TO INTRODUCE
HANDS OR FINGERS BETWEEN THE BELTS.
FINGERS MAY GET JAMMED BETWEEN TRANSITING MATERIAL AND BELT TRANSVERSE
SUPPORTS.

6-6

6-37
OPERATING INSTRUCTIONS

8) Risk of crushing/shearing fingers/hands.

ACCORDING TO THE FORMAT, THE CONVEYED MATERIAL MAY ALSO HAVE A SIGNIFICANT
WEIGHT AND, DEPENDING ON THE CASES, THE TILES MAY ALSO MOVE CLOSER TO ONE
ANOTHER.
DO NOT INSERT FINGERS / HANDS BETWEEN THE TILES.

6-7

9) Risk of hitting/crushing lower limbs.

EVEN IF SPECIFIC ENABLING SIGNALS ARE PROVIDED, BEFORE STOPPING THE SORTING
BENCH (AND THE RELEVANT CONVEYOR), MAKE SURE THAT THE UPSTREAM MACHINES
WILL STOP IN A SYNCHRONISED MANNER. IF THIS IS NOT THE CASE, THERE COULD
BE MATERIAL BUILD-UPS THAT BY FALLING FROM THE CONVEYOR COULD HIT THE
OPERATORS.

10) Risk of crushing/shearing of the head (in particular with large formats).

PROHIBITION TO CROSS THE LINE BY WALKING UNDER THE CONVEYOR.

11)Risk of crushing/shearing the upper limbs.

THE CONVEYING LINES ARE MADE UP OF BELT SYSTEMS WITH PULLEYS.

ACCORDING TO THE CONFIGURATIONS SOME CRUSHING OR ENTANGLEMENT POINTS
COULD FORM. DO NO TOUCH THE CONVEYORS AND CENTRING DEVICES WITH THE UPPER
LIMBS IF THEY HAVE NOT BEEN STOPPED FIRST.

6-38
 OPERATING INSTRUCTIONS

12) Risks due to maintaining an incorrect posture over time.

THE MACHINE IS PROVIDED WITH ONE OR MORE OPERATOR STATION FOR MATERIAL
SELECTION.
THIS STATION IS DESIGNED TO CONTAIN A STOOL TO SIT ON.
THE CHOICE OF THE STOOL IS TO BE DECIDED BY THE USER WHO KNOWS THE
ANTHROPOMETRIC DATA OF THE OPERATORS. WHEN CHOOSING THE STOOL IT IS
RECOMMENDED TO COMPLY WITH THE ERGONOMIC PRINCIPLES FOR THE WORKSTATIONS.

6-8

6-39
OPERATING INSTRUCTIONS

6.1.6. Safety signs

To make the operator aware of residual risks and behavioural procedures, safety signs have been
applied on the machine (adhesive pictograms) indicating hazardous areas (residual risks and protected
risks) or forbidding certain operations.

The signs must be kept in good, legible condition. If they become worn or are removed from
the machine, new labels identical to the previous ones must be applied in the same points.

Ref. Symbol Description

HIGH VOLTAGE HAZARD

It is forbidden to carry out any operation inside the
electric control panels since the circuit is under
1 voltage also when the panel is open.
Only specialised and authorised technicians are
allowed to perform these interventions.

Applied on all electric control panels.

HIGH VOLTAGE HAZARD

It is forbidden to carry out any operation inside the
electric panels since, even if the disconnecting
2 switch is set to "0" OFF, some circuit parts are still
live.
Only specialised and authorised technicians are
allowed to perform these interventions.

Applied near the main switch.

HIGH TEMPERATURE HAZARD

It is forbidden to touch the nozzles and fittings
of the hot glue system as well as the welding
area of the strapping machine.
3 Wait for them to cool down before carrying
out maintenance or touching them.

Applied on all glue melters, on all hot glue

guns and on strapping head.

HIGH VOLTAGE HAZARD

Indicates the presence of live electrical

devices and warns the operator of the
4 existence of electrical hazards.
Operate only with main switch set to "0".

PRESENT ON THE TERMINAL BOARDS OF

ELECTRIC MOTORS

6-9

6-40
 OPERATING INSTRUCTIONS

1 2

6-10

6-41
OPERATING INSTRUCTIONS

6.2. Operating description

6.2.1. Single U.V. sorting bench
Tiles arriving in a single row (1) are compacted, when possible, to contain the transit speed to the
minimum compatible with the production requested, according to the classification difficulty.
The tiles are appropriately inclined (2) to facilitate the visual comparison with the master samples.
During the transit of the tiles, operator (3) can classify them according to a set code that is assigned
by fluorescent signs marked in zones predetermined by the program.
A photocell (4) detects the presence of the tile and, through the encoder count, the logic is able to
divide it into areas, optimising the spaces, variable in size according to the format. If there is a marking
in the zone, a special photocell emits a signal that forms part of a classification binary code.
For special requirements there may be two photocells to read the fluorescent marking.
The tiles classified by the fluorescent marks continue to be conveyed towards the control equipment
for planarity and gauge that, according to the set parameters, will define the final selection and a
stacker through a criterion programmable via operator interface.

1 4

2
6-11

6-42
 OPERATING INSTRUCTIONS

DESCRIPTION AND OPERATION OF U.V. SORTING METHOD

The selection with felt tip pen or fluorescent chalk allows customising the marking method of the tile
surface according to predetermined zones using the Copilot program.
These zones are established and used by the logic control system by means of a photocell that detects
the front of the tile and an encoder that divides the tile size set by the program into transverse bands.
The photocell that detects the fluorescent marks transmits a signal once the mark made has actually
been read and determines the zone it belongs to.
Marks in two zones must be avoided as the pulse will be assigned to both zones thereby causing
erroneous quality assignment.
The series of pulses, that may come from one or two photocells, constitutes the basis
of a binary code 0/1 able to define the quality based on the following criteria:

UV reader 1 →
2 HEADS / 1 ZONE
Reader with 1 or 2 marking detectors,
without tile division into zones.

UV reader 2 →

UV reader 1 →
2 HEADS / 2 ZONES
Reader with 1 or 2 marking detectors,
with tile division into 2 zones.

UV reader 2 →

1 HEAD / 3 ZONES
6
Reader with 1 marking detector,
with tile division into 3 zones. UV reader 1 →

1 HEAD / 4 ZONES
Reader with 1 marking detector,
with tile division into 4 zones. UV reader 1 →

6-43
OPERATING INSTRUCTIONS

The marking is to be carried out using:

• yellow or transparent fluorescent water-based felt tip pen only on cold material;
• yellow or transparent fluorescent wax chalk on cold or hot material.

An example follows of correct marking made in the case of tile division in three zones with 1
marking and related code reader.
Below are also some examples of wrong marking.
Correct Marking Code Wrong Marking

6-44
 OPERATING INSTRUCTIONS

6.2.2. Informer single sorting bench

Tiles arriving in a single row (1) are compacted, when possible, to contain the transit speed to the
minimum compatible with the production requested according to the classification difficulty.
The tiles are appropriately inclined (2) to facilitate the visual comparison with the master samples. A
photocell (3) detects the position of the tile on the conveyor and the operator (4) defines the classification
of the product through an assigned code by means of the mouse (5). The operator receives an acoustic
feedback (6) that selection has taken place by specific tones according to the classification. In this
way the congruity between intention and manual actuation by the operator is verified.

3 4 5
1

2 6

6-12

6-45
OPERATING INSTRUCTIONS

DESCRIPTION AND OPERATION OF INFORMER SORTING METHOD

Material classification is carried out by the operator using a mobile push-button panel (“mouse”).

6-13

The ability to slide smoothly and the light weight of the mouse allows for a fast handling, without
fatiguing the operator, who needs to activate the buttons in correspondence of the tile being
examined, while it is conveyed. With reference to the drawing, in C, which is the area of mouse
movement for classification, the mouse has to point to the tiles (in one of zones A).

If the mouse points to the zones between the tiles, i.e. zones B, the bench stops.
To start again after a stop caused by wrong pointing or wrong calibration, press the SORTING
BENCH STOP bistable button E twice.

If the operator classifies a tile pressing the mouse two or more times, the code assigned is
that of the last key combination pressed.
If the operator does not press any key, code 0 is assigned (see table).
Do not move the tiles on the conveyor, because the position is memorised.

A B A B A

C
E

6-14

6-46
 OPERATING INSTRUCTIONS

CALIBRATION OF INFORMER SORTING BENCH

Preliminary operations: 1
1) Check the correct operation of the mouse: DATA IN DATA OUT
moving the mouse in the direction of the
moving tile, the displays DATA IN and DATA
OUT must increase the values.
2) On the line Copilot set the format length (see
Copilot handbook).
3) On the line Copilot set the length of the piece
on the sorting bench (see Copilot handbook).
4) On the Copilot set the distance d between
the infeed photocell and the mouse centre,
measuring it directly on the machine
(see Copilot handbook).

6-15
Calibration:
5) Stop the upstream line and wait until all the material has transited on the sorting bench.
6) Stop the sorting bench pressing button E.
7) Select the calibration procedure with button Q.
8) Press calibration button P; the warning buzzer 1 starts to sound.
9) Start the sorting bench pressing button B.
10) Place a tile on the conveyor before infeed photocell 2.
11) Wait for the tile to pass the outfeed photocell 3; the warning buzzer switches off.
12) Select the check procedure with button Q.
13) Press verification button P; the warning buzzer 1 starts to sound (with a different tone from the
previous tone).
14) Wait for the tile to pass outfeed photocell 3; the warning buzzer switches off.
15) Take the tile and place it before the infeed photocell.
16) Stop the sorting bench pressing button E so that the tile stops at the centre of the mouse C
movement zone.
17) Check that by pointing the mouse in correspondence of the tile (zone X) and by pressing any
key of the mouse, the warning buzzer emits a sound.
18) Check that by pointing the mouse outside the tile and by pressing any key of the mouse, the
warning buzzer does not emit any sound.
19) If on the other hand it is found that there is a misalignment W between zone X and zone Y
6
where a sound is emitted, move the infeed photocell by a value W. Otherwise, modify the value of
the parameter “bench infeed photocell/carriage zero photocell distance”.
20) Repeat the check and if necessary correct again, until the conditions described in steps 17 and
18 are obtained.

B
2 X W 3

Y
d

C
E P Q 6-16

6-47
OPERATING INSTRUCTIONS

6.2.3. Double U.V. sorting bench

Tiles arriving in a single row (1) are duly spaced and diverted in an alternated manner on a
diverging belt conveyor (2) so that they are equally distributed on two rows, up to the two-operator
sorting bench (3).
Tiles arriving in a double row (4) are compacted, when possible, to contain the transit speed to the
minimum compatible with the production requested according to the classification difficulty. While
the tiles are conveyed, the operator defines the tone and checks that no superficial defects are
present classifying the material according to a pre-set code that is defined by means of fluorescent
marks in predetermined zones.
At the outfeed on both sides of the sorting bench, a photocell (5) together with a motorised belt (6)
create the synchronism between the conveyed tiles, ensuring the correct alternated insertion of the
pieces coming from both sides.
The insertion of the two conveyors takes place with converging belts (7), and therefore through the
synchronised approach between empty and full, respectively.
Once the single row (8) conveying has been carried out, the flow is regulated with suitable
slowdowns and then recirculated with the conveyor under the equipment.
A photocell (9) detects the presence of the tile and, through the encoder count, the logic is able
to divide it into areas, optimising the spaces, variable in size according to the format. If there is
a marking in the zone, a special photocell emits a signal that forms part of a classification binary
code. To meet special requirements, there may be two photocells to read the fluorescent marking.
The tiles classified by the fluorescent marks continue to be conveyed towards the control
equipment for planarity and gauge that, according to the set parameters, will define the final
selection and a stacker through a criterion programmable via operator interface.
The double selection bench also exists in an optional version with independent conveyors. The two
conveyors (6) can be started and stopped independently from one another by means of separated
control push-button panels (10) and (11), available to the two operators.

1 2 4 6 10 5 7 8 9

6 11 5
6-17

6-48
 OPERATING INSTRUCTIONS

6.2.4. Diverter Unit (Option for double bench)

Tiles arriving in a single row ae duly spaced and diverted in an alternated manner
on a diverging belt conveyor, so that they are equally distributed on two rows up to
the two-operator sorting bench.

6-18

The diverter consists of a few powered sections with differentiated speed transmissions.
The speed is set so that the flow of the incoming material is first recirculated to create a detachment,
then diverted to the right or to the left alternatively so that the tiles will be divided equally on the two
diverging sections.
Afterwards, the tiles are slowed down again and reach the area where they are visually checked at
the lowest possible speed.
6
The conveyor speed can be adjusted and the right compromise must be set from time to time compatibly
with the production requested and the difficulty to assess the quality to the material being
examined, also according to the ability of the operator.

6-49
OPERATING INSTRUCTIONS

6.2.5. Conveyor Unit (Option for double bench)

Tiles arriving in a double row are duly spaced and conveyed in an alternated manner
on a conveyor with converging belts so as to ensure an homogeneous
material flow.

6-19

The Conveyor Unit consists of some motorised sections with transmission at different speeds.
At the exit on both sides of the sorting bench, a photocell together with a motorised belt create a
synchronism between the tiles conveyed, ensuring the correct alternated insertion of the pieces
coming from both sides.
The insertion of the two conveyors takes place with converging belts, and therefore through the
synchronised approach between empty and full, respectively.
Once converged in a single row, the flow is evened out by appropriate decelerations and then
recirculated with the conveyor under the equipment.

6-50
 OPERATING INSTRUCTIONS

6.2.6. Tile turning device

It allows orienting the tile format based on the sorting needs of the line.
Act on the hand-wheel “A” for vertical adjustment and hand-wheel “B” for the adjustment of the belt
centre-to-centre distance, based on the width of the format.
It is also necessary to change the belt speed to obtain the perfect rotation.
The tile turning device is preceded or followed (or both solutions) by a profile aligner, to allow its
correct operation.

6-20

6.2.7. Profile aligner

Its function is to orient the format so that the long side is perpendicular to its feeding direction. It consists
of two photocells. If both of them detect the presence of the format, they will enable the stop cylinders 6
to allow the format to pass. They will be disabled as soon as the photocells are no longer engaged.

6-21

6-51
OPERATING INSTRUCTIONS

6.2.8. Pneumatic self-centring guides

Their function is to pneumatically centre and align the format on the conveyors, according to the
detection of the photocell that establishes when to intervene.
It is possible to adjust the tightening force through the pressure regulator “A”.

6-22

6.2.9. Equipment Section Unit

This conveyor allows the material to arrive inside the STACKER by transferring all the information
relevant to the code read by the FLUORESCENT READING PHOTOCELL and by the equipment.
This is carried out by means of an encoder that saves the position of the material and the information
(or data) concerning the selection.
Upstream the equipment there are self-centring wheel guides, coupled to a profile aligner unit, able
to position the tile perpendicularly andaligned with the conveyor.

6-23

6-52
 OPERATING INSTRUCTIONS

6.2.10. Lighting Unit

The sorting Bench is provided with a special diffused white light which is able to highlight the different
colour shades.
Four neon tubes are inserted in the ceiling light and suitably protected against accidental impacts in
compliance with the safety rules.
The neon lights are protected against accidental impacts with tubes, as required by the regulations.

6-24

6-53
OPERATING INSTRUCTIONS

6.3. Conventions

3
4
1. Input
2. Output
3. Right
4. Left
6-25

Operator’s side: it is the side of the machine where the push-button panel is present.

Right and Left: the position for identifying the right or left of a machine is the one where an operator
stands ideally in the middle of the stack conveyor and watches the stack move away in front of him/her.

Machine hand: when the right and left side of the machine have been identified, the hand of the
machine is where the electric control panel is positioned. E.g.: if the electric control panel is on the
right, then the machine is right-handed.
In the sorting bench the hand is the one in the operator work station.

Machine infeed: it is the tile infeed area on the sorting line.

Machine outfeed: it is the tile outfeed area on the sorting line.

Machine upstream: machine infeed.

Machine downstream: machine outfeed.

Longitudinal direction: direction z, the tile feeding direction.

Transversal direction: direction x, the direction orthogonal to tile feeding.

Vertical direction: direction y, the direction orthogonal to the floor.

6-26

6-54
 OPERATING INSTRUCTIONS

6.4. Description of control and signal equipment

6.4.1. Operator work station and position of control equipment

1 Control position
Machine control area using the Main Operator Panel

The operator can work in safe conditions in these areas

(no dangers deriving from machine movements) as long as the recommendations given in the next
paragraphs are complied with.

1
STOP ROPE STOP ROPE

STOP ROPE
6

6-27

6-55
OPERATING INSTRUCTIONS

6.4.2. Main Operator Panel

A SORTING BENCH AND UPSTREAM LINE STOP
This button stops the conveyor belt of the selection bench and the line that feeds the table.

B SORTING BENCH AND DOWNSTREAM LINE START

This button starts the conveyor belt of the selection bench and the line that feeds the table.

C EASY-LINE STOP
Stop button of the conveyors downstream the sorting bench and stacker (excluding the Sorting bench,
the feeding line of the sorting bench and the packaging machine).
D EASY-LINE START
Start button of conveyors downstream the sorting bench and stacker (excluding the Sorting bench, the
feeding line of the sorting bench and the packaging machine).
E SELECTION BENCH CONVEYOR STOP
This button stops the conveyor belt of the sorting bench (green LED on when the function is active).

F BUTTON NOT USED

G UPSTREAM CONVEYORS STOP

This button stops all conveyors at sorting bench infeed (green LED on when the function is active).
H FEEDING STOP
This button stops the material feeding machine positioned upstream the Sorting bench (green LED on
when the function is active).
I SIREN MUTING
Button to deactivate the buzzer indicating an alarm.
L EQUIPMENT CONVEYOR STOP
This button stops the conveyor belt at the outfeed of the Sorting bench (green LED on when the
the function is active).

M A B C D

E L N

F O

P Q 6-28

6-56
 OPERATING INSTRUCTIONS

M BUZZER
This buzzer sounds when there are faults present in the sorting/stacking unit.
N ALARM AND MALFUNCTION SIGNALS

DEGRADING ALARM
This indicates that the degrading threshold set in the statistics program of the line has been
exceeded.
SELECTION BENCH BLOCK
Signals that the selected bench is not running.
STACKER BLOCKED
Signals that the Stacker is not running.
WRAP BLOCK
Signals that the Wrap is not running.
FEEDING STOP
Signals that there is no enabling signal to the machine feeding material to the line.
NO STACKER FREE
Signals that no stacking station is available for the selection to be fed in.
O CHANGE TONE
Button to change the selection mode.
P SETTING VERIFICATION (only for Informer bench)
Activates the operation selected with key Q.
Q VERIFICATION OR SETTING SELECTION (only for Informer bench)
Selects the type of operation to be executed: Off = check / On = setting.

6-57
OPERATING INSTRUCTIONS

6.4.3. Secondary operator panel (only for double bench)

P SORTING BENCH STOP
This button stops the Sorting bench and material feeding upstream line.
It has the priority over the stop button R.
Q SORTING BENCH START
Sorting bench start button to be activated after an emergency stop using button A or P.
R SORTING BENCH STOP AND START
Red bistable button that when pressed stops the selection bench conveyor for rapid interventions. When
pressed again the conveyor re-starts with no need for other actions.

6-29

6-58
 OPERATING INSTRUCTIONS

6.4.4. Secondary operator panel (only for double bench with independent
conveyors)
P1 SORTING BENCH STOP
This button stops the Sorting bench and material feeding upstream line.
It has the priority over the stop button R1.
Q1 SORTING BENCH START
Sorting bench start button to be activated after an emergency stop using button A or P1.
S EASY LINE STOP BUTTON
Stop button of conveyors downstream the sorting bench and stacker (excluding Sorting bench, feeding
line of sorting bench and packaging machine).
T STACKER START BUTTON
Stacker start button to be activated after an emergency stop using button C or S.
R1 SORTING BENCH STOP AND START
Red bistable button that when pressed stops the selection bench conveyor for rapid interventions. When
pressed again the conveyor re-starts with no need for other actions.

P1

Q1
6

R1

6-30

6-59
OPERATING INSTRUCTIONS

6.4.5. Console display sound (only for informer bench)

A Alphanumeric display
B Acoustic indicator

The DISPLAY SOUND console, only installed on the Informer bench, gives visual and sound indications
regarding:

a) Classification of material in transit during operation

DATA IN displays the numeric code of the classification made by the operator
pressing a combination of keys of the mouse.
DATA OUT displays the numeric code sent to the sorting line. It is activated when the
product passes on outfeed photocell 1.
ACOUSTIC TONE each combination of mouse keys has a different acoustic tone.

b) System calibration procedure

DATA IN and DATA OUT

display, with numeric characters and letters, a system calibration
verification code (see paragraph 6.2.2).
ACOUSTIC TONE confirmation that verification/calibration button has been pressed (see
paragraph 6.4.2).

B
DATA OUT

DATA IN

6-31

6-60
 OPERATING INSTRUCTIONS

6.4.6. Mouse (only for informer bench)

Material classification is carried out by the operator using a mobile push-button panel (or “mouse”)
that has five keys arranged for the fingers of the right hand.
The function of the thumb key is only to switch the function of the other four, so as to obtain a total
of eight classification possibilities (besides the one corresponding to no key pressed), based on the
following table.

Keys pressed Code

none 0

1 1
2 2
3 3
4 4
5+1 5
5+2 6
5+3 7
5+4 9

1 2 3 4

5
SHIFT

6-32

6-61
OPERATING INSTRUCTIONS

6.5. Machine use

6.5.1. Starting the Line

To start the line take into account that the sorting line is managed as if it were divided into three blocks
controlled by two panels with electromechanical controls for start-up and switch-off:

1st block - sorting bench and downstream conveyors

2nd block - transfer with conveyor, control equipment section, stacking unit (EASY LINE)
3rd block - packaging machine and product outfeed line.

When the machine is completely empty (for example after a maintenance intervention):
• check that there are no problems indicated by signboards, or any other doubts
regarding safety;
• bring the main switch on the stacker electric cabinet to pos. “I-ON”;
• press the packaging machine start button on the relevant push-button panel (refer to the
packaging machine manual), then press the EASY-LINE START button D and SORTING BENCH
AND UPSTREAM LINE START button B on the main control panel.

In this status the machine is powered, but not in automatic operation mode.

• check that no faults are indicated by the LEDs N;

• set the STACKER machine to AUTOMATIC mode (refer to the Stacker manual).

B D N

6-33

6-62
 OPERATING INSTRUCTIONS

6.5.2. Switching off the Line

The line is to be shut off by the main operator as the controls are found on the main push-button panel.

Proceed as follows:
• interrupt the material feed;
• wait until there are no tiles left on the conveyor belt;
• wait until the stacking stations have terminated the loading and unloading operations.

The state of the stackers is stored when the machine is shut off, that of the upstream tiles is
not stored.

The packaging machine should have completed the operations in progress.

Once these conditions have been satisfied, the line can be shut off by carrying out the operations in the following
order:
• press the SELECTION BENCH AND UPSTREAM LINE STOP button A;
• press the EASY-LINE STOP button C;
• press the PACKAGING MACHINE STOP button (refer to the manual of the packaging machine);
• set the main switch placed on the side of the main panel of the stacker to ”0-OFF”.

A C

6-34

6-63
OPERATING INSTRUCTIONS

6.5.3. Alarms
LEDs on the main operator console of the sorting bench come on to signal faults. A detailed description
is provided in point N in chapter 6.4.2.

6.5.4. Machine switching off

Before switching the machine off in standard conditions, wait for all the tiles to be removed from the
conveyors and check that the stackers have no tiles held in extraction and that all machine units are
stopped (CYCLE END).
To switch off the machine, bring the main switch from position “I ON” to position “0 OFF”

0 0
OFF OFF
I I
ON ON

6-35

If maintenance operations must be carried out on the machine, perform procedure “Lockout/
Tagout” described in chapter 7.3.

6.5.5. Emergency stop

The emergency stop devices are used to stop the operating cycle in the event of a dangerous situation
for the operators or in an anomalous machine condition.
They are mushroom-head buttons on yellow background that stop the entire sorting line.

6-36

Train the personnel on the use and position of the emergency buttons in order to intervene
promptly in emergency conditions.

6-64
 OPERATING INSTRUCTIONS

6.5.6. Restoring operation after an Emergency stop

To restart the line after an emergency stop:
• remove the cause of the emergency;
• release the pressed emergency button by turning it clockwise;
• press the start button D to start the line downstream the sorting bench and stacker;
• press the start button B to start the sorting bench and upstream line.

B D

The reset of the standard operating conditions must be performed after solving the cause of the
emergency condition.

6.5.7. Visual signalling devices

Light indicators: SIGNAL COLUMNS

The machine is provided with a stack light (fig. 6-37) placed on the sorting bench when there is an
equipment (Dico Planar, Dico Liner). This device warns the operator on particular machine and/or
operation statuses.
The stack light is configured at the factory as follows:

6
1) ORANGE LIGHT
When this light flashes, it indicates that there is an emergency
on Dico Planar. 1

2) YELLOW LIGHT 2
When this light flashes, it indicates that there is an emergency
on Dico Liner. 3

3) GREEN LIGHT
The flashing of this light is not configured at the factory.

The user can decide to modify the initial configuration of the

stack light, as preferred, provided that it is necessary to know
these indications to ensure a safe operation.

6-37

6-65
OPERATING INSTRUCTIONS

6.5.8. Acoustic signalling devices

Buzzer M on the main push-button panel is activated when an alarm is generated on the stacker.

6-38

6-66
 MAINTENANCE AND CLEANING

7. MAINTENANCE AND CLEANING

7.1. Operator safety warnings

Caution: strictly comply with the following instructions. SYSTEM CERAMICS shall not be held
liable for negligence or damage to operators who do not comply with the following warnings.

DO NOT PERFORM MAINTENANCE, LUBRICATION OR REPAIR OPERATIONS WITH THE

MACHINE RUNNING AND/OR POWERED.

Indicate maintenance is in progress by means of specific warning signs.

The cleaning, ordinary and extraordinary maintenance operations must be exclusively entrusted
to expert operators who know the machine (mechanical and/or electric maintenance technician).
Unauthorised personnel must keep at a safe distance from the machine. Untrained persons
cannot operate the machine or stand near it while it is working or being serviced.
Carry out the maintenance operations under the responsibility of a single person.

After each intervention, always refit the previously removed safety protections and restore
machine original conditions.
The work area must be adequately lit up during maintenance and repair operations.
Do not use matches, lighters, torches or open flames for lighting.
Always keep clean and dry the area where maintenance operations are performed. Always
remove any oil or water stains.
Where necessary, use personal protective equipment (slip-proof shoes, helmets, gloves, goggles)
in compliance with the standards in force in the country where the machine is used.
Use appropriate protective equipment for the operations to be carried out. Close-fitting protective
work clothing which stand up to the products used must be worn. Do not wear ties, necklaces
or belts that could get caught-up or stuck between moving parts.
Once maintenance and repair operations are complete, restart the machine only after being
authorised by the manager, who must make sure:

• that the work has been completed;

• that the machine operates perfectly;

• that the safety systems are active;

• that no one is still operating on the machine.

Always comply with all the safety standards listed in this manual and those in force in the
country where the machine is installed.
7

7-67
MAINTENANCE AND CLEANING

7.2. General requirements for efficient maintenance

Good maintenance is essential to maintain machine operation and productivity.
Lack of inspections and maintenance can cause serious damage. Pay special attention to
the following information in order to perform maintenance correctly.

In order to guarantee smooth operation and prevent unwanted anomalies, comply with
the intervention schedule indicated in the “ROUTINE MAINTENANCE PROGRAM” tables
described hereafter.

Keep the machine always clean for best performance. Only if the machine is easily
accessible and clean can faults be identified and repaired, malfunctioning can be prevented
and work can be carried out safely.

When dismantling components, do not allow dust residues to enter the work areas and the
components themselves, especially the pneumatic and hydraulic parts.

Do not use water, pieces of sponge, wet and/or abrasive cloths for cleaning. Fraying cloths
must never be used.

Never use water to clean electric panels, electronic boards, terminal boards and safety
devices. Do not spray on the electric motors and/or to clean the machine.

Do not use petrol or flammable solvents as detergent. Always use authorised non-
flammable, non-toxic commercial solvents.

Dust is to be removed and sucked, paying special attention to electronic components. Use
dry, clean compressed air.

Strictly follow the lubrication guidelines below. If there is difficulty in finding the lubricant,
lubricants of a different brand but with equivalent features can be used. However, it is
recommended not to mix different lubricants.

Do not perforate the structure, pipes, electric cables, ducts or electric panels.

It is recommended to use ORIGINAL SPARE PARTS when replacing parts. Otherwise, the
spare parts must match the technical requirements established by the manufacturer.

It is prohibited to activate and change the adjustment of control equipment or instruments

applied to the machine without authorisation and without being aware of how they work.

Before starting the machine, make sure there are no foreign objects on it (screwdrivers,
wrenches, screws, etc.) and any parts that have been adjusted or replaced are firmly
fastened.

Dispose of and handle consumables and auxiliaries as well as replaced parts in a safe
and biodegradable manner, complying with the applicable standards on environmental
protection.

7-68
 MAINTENANCE AND CLEANING

7.3. Safe maintenance procedure

The procedure requires the isolation of the machine from all energy sources and must be performed
before any routine maintenance, cleaning and special maintenance.

DISCONNECTING THE POWER SUPPLY

Set the disconnecting switch to “0 OFF” and lock it in this position with a padlock using the relevant
holes present on the switch itself;

0 0
OFF OFF
I I
ON ON

7-1

0
OFF
I
ON

7-2

DISCONNECTING THE PNEUMATIC SUPPLY

• Close the shut-off valve on the compressed air supply outlet(s): the circuit will be discharged.
• Refer to the enclosed pneumatic diagram.
• Lock with a padlock.

7-3

7-69
MAINTENANCE AND CLEANING

7.4. Routine maintenance

Routine and scheduled maintenance includes all the periodic operations required for the machine to
run efficiently and the functional and control equipment to be maintained in optimal condition.

Should the elements being serviced not be reachable from the ground, the maintenance operator
must use suitable means (ladder or platform that can be lifted) made available by the user, and be
instructed on the correct procedures to perform when working from a height.

The operations to be carried out, listed in the “Scheduled maintenance table” in paragraph
7.4.1 have been divided according to time intervals and are not to exclude each other, but are
to be added together.

7-70
 MAINTENANCE AND CLEANING

7.4.1. Routine maintenance schedule

Frequency of interventions
Ref. Maintenance type hours months every
shift
24 100 160 250 750 1 2 3 4 6 change
MAINTENANCE RELATED TO SAFETY SYSTEMS
Check proper operation of
7.4.2 X
safety devices
CHECKING - CLEANING

7.4.3 Machine cleaning X

7.4.4 Diverter unit X

7.4.5 Conveyor unit X

7.4.6 Printer X

7.4.7 Equipment conveyor unit X

7.4.8 Self-centring guides X X

7.4.9 Profile aligner X X

Check wheel side guides for
7.4.11 X X
wear

7.4.12 Clean air handling unit filter X

Check tensioning and

7.4.13 X
replace belts, if necessary
Check polyzene belt
7.4.14 X X
V-guides for wear

7.4.15 Check pneumatic movement X

7.4.17 Check of gearmotors X

7.4.18 Clean electric panels X

7.4.19 Check lighting unit X

7
LUBRICATION
Check, lubrication - linear
7.4.10 guide unit - tightening X
torques

7.4.16 Bearing support lubrication X

7-4

7-71
MAINTENANCE AND CLEANING

7.4.2. Check proper operation of safety devices

Every shift change

PPE: Safety shoes,

protection goggles and gloves.

No.

Ref.
figure Check Test result Remarks

1A Presence and operation of the OK

1B emergency buttons
1C (see assembly diagram) NOT ok
Presence and operation of the OK
2 stop rope
(see assembly diagram) NOT ok
Presence and operation of the OK
3 locked guard, if there is polymer
(see assembly diagram) NOT ok
NO OK
Presence of movable parts
PHOTO NOT ok
Operation of warning lights on OK
N
console NOT ok

7-72
 MAINTENANCE AND CLEANING

SINGLE SORTING BENCH N

1A

1A 2

7-5 7

7-73
MAINTENANCE AND CLEANING

DOUBLE SORTING BENCH A B C D N

(*)

1B 2

1C 2

1B
2
1C

(*) Secondary operator push-button panel with independent drives.

7-6

7-74
 MAINTENANCE AND CLEANING

7.4.3. Machine cleaning

Every shift change

PPE: Safety shoes,

protection goggles and gloves.

No.

Thoroughly clean the whole machine in particular the stack conveying area.
Remove any broken tile that could damage the machine.

Use a spray for electric components to clean the lens of all sensors and all photocells,
including their receiver.

During this operation, take care not to shift them from their original position.
NEVER use abrasive, corrosive products, solvents or alcohol that could damage the
area to be cleaned, or wool cloths to prevent the front surface from becoming electrified.

7-75
MAINTENANCE AND CLEANING

7.4.4. Diverter Unit (Option for double bench)

Every shift change

PPE: Safety shoes,

protection goggles and gloves.

No.

The diverter unit requires the periodical check of the pneumatic movement, the belts, the belt V-guides
and the bearings.
Use only material that conforms with that prescribed for by SYSTEM CERAMICS especially for the belts.

Special attention needs to be given to the degree to which the belts are tensioned while they
are being welded.

7-7

7-76
 MAINTENANCE AND CLEANING

7.4.5. Conveyor Unit (Option for double bench)

Every shift change

PPE: Safety shoes,

protection goggles and gloves.

No.

The conveyor and motorised recirculation systems require periodical replacement of the belts and
guides due to normal wear.
Use only material that conforms with that prescribed for by SYSTEM CERAMICS especially for the belts.

Special attention needs to be given to the degree to which the belts are tensioned while they
are being welded.

7-8

7-77
MAINTENANCE AND CLEANING

7.4.6. Printer

Every shift change

PPE: Safety shoes,

protection goggles and gloves.

No.

Printers require the periodical cleaning of the system, for the correct procedure refer to the supplier’s
manual.

7-9

7-78
 MAINTENANCE AND CLEANING

7.4.7. Equipment Conveyor Unit

Every shift change

PPE: Safety shoes,

protection goggles and gloves.

No.

The belts and guides of the conveyor need to be periodically changed as they are subject to wear.
Use only material that conforms with that prescribed for by SYSTEM CERAMICS especially for the belts.

Special attention needs to be given to the degree to which the belts are tensioned while they
are being welded.

7-10

7-79
MAINTENANCE AND CLEANING

7.4.8. Self-centring guides

Every month or 250 hours.

PPE: Safety shoes,

protection goggles and gloves.

No.

The self-centring guides require the periodical check of the pneumatic movement, the lubrication of
linear guides, wheel guides and their replacement, if necessary.

7-11

7-80
 MAINTENANCE AND CLEANING

7.4.9. Profile aligner

Every month or 250 hours.

PPE: Safety shoes,

protection goggles and gloves.

No.

The profile aligner requires the periodical check of the pneumatic movement and of the wear of the
plate stop block (1).

7-12

7-81
MAINTENANCE AND CLEANING

7.4.10. Check, lubrication - linear guide unit - tightening torques

Every months.

PPE: Safety shoes,

protection goggles and gloves.

No.

Visually check the areas featuring linear guide units.

RAIL:
If necessary, clean the rail with a cloth 1 and lubricate it with product WD40 or with one
having similar characteristics.
RECIRCULATING BALL CARRIAGE
2
Using a suitable greasing tool, gradually introduce grease in the grease guns until it comes out
of the accumulation chambers and/or the guns.

For greasing, use a high-viscosity mineral oil based grease with lithium
soap (e.g.: NLG12 or one having similar characteristics).

Repeat the lubrication procedure on all linear guides of the machine.

Failure to clean, lubricate and grease these units can cause wear
on them and frictions that may lead to the breakdown of drive components (motors, gear units,
supports).

TROLLEY

SCREWS 7-13

SCREW TIGHTENING TORQUE CHECK

Check the tightening torque of SCREWS. Use a torque wrench to make sure, that there are no
rotations. In case there are, tighten to the required torque.

Check the tightening torque again after 120 days.

See the table below for the tightening torques required, also based on the trolley size.

TROLLEY SIZE SCREW THREAD TIGHTENING TORQUE

SIZE 25 M8 23 Nm
SIZE 20 M6 9.5 Nm
SIZE 15 M5 5.5 Nm

7-82
 MAINTENANCE AND CLEANING

7.4.11. Check wheel side guides for wear

Every 3 months or 750 hours.

PPE: Safety shoes,

protection goggles and gloves.

No.

Disconnect the power supply through the main switch.

7-14

7-83
MAINTENANCE AND CLEANING

7.4.12. Clean air handling unit filter

Every month

PPE: Safety shoes,

protection goggles and gloves.

No.

For a correct operation of the pneumatic system, keep under control the quality of filtration.

When level indicator (A) on the air handling unit bowl indicates the presence of condensation, it must
be drained as follows.

Close valve (B) of the pneumatic circuit.

7-15

Release the bowl (C) and remove the filter (D).

Once both have been cleaned, first re-assemble the filter and then the bowl.

Once this operation is completed, re-open the valve (B).

7-16

7-84
 MAINTENANCE AND CLEANING

Valve (B) features a double-acting system preventing any UNINTENTIONAL COMMANDS.

Double action
Press the knob and then turn it: step 2 prevents the
accidental activation of controls.

Step 1
Press the knob
downward

Step 2
Turn the knob

7-17

7-85
MAINTENANCE AND CLEANING

7.4.13. Check tensioning and replace belts, if necessary

Every 6 months or 1500 hours.

PPE: Safety shoes,

protection goggles and gloves.

No.

Check tensioning of the belts 1, ensuring they are not excessively taut.
In case of excessive wear cut the belt to remove the damaged part.
Then, tension the belt and fasten it using the relevant tool 2.

Excessive tensioning causes noise and early wear.

7-18

7-86
 MAINTENANCE AND CLEANING

Check the tensioning of the belts 3, present in the tile turning device, that must not be excessively taut.
Replace them if worn out.

7-19

7-87
MAINTENANCE AND CLEANING

7.4.14. Check polyzene belt V-guides for wear

Every 3 months or 750 hours.

PPE: Safety shoes,

protection goggles and gloves.

No.

Check the wear of the polyzene belt V-guides (1) and (2) and replace them, if required.

7-20

7-88
 MAINTENANCE AND CLEANING

7.4.15. Check pneumatic movement

Every month

PPE: Safety shoes,

protection goggles and gloves.

No.

Check pneumatic movement.

7-21

7-22

7-89
MAINTENANCE AND CLEANING

7.4.16. Bearing support lubrication

Every 6 months or 1500 hours.

PPE: Safety shoes,

protection goggles and gloves.

No.

Lubricate the bearing supports through the relevant grease guns (1). Use a grease gun making sure
to keep bearing seats clean.
If during the operation the bearing supports are noisy, replace them.

1
7-23

7-90
 MAINTENANCE AND CLEANING

7.4.17. Check of gearmotors

Every 6 months

PPE: Gloves.

No.

Disconnect the power supply through the main switch.

Check and, if necessary, clean all the passages of gearmotor ventilation air in order not to affect
the cooling and noise level control.

7
7-24

7-91
MAINTENANCE AND CLEANING

7.4.18. Clean electric panels

Every 6 months

PPE: Gloves.

No.

Disconnect the power supply through the main switch.

Use a spray for electronic components and clean the inside of the electric panels with a dry antistatic
cloth.

7-25

7-92
 MAINTENANCE AND CLEANING

7.4.19. Check lighting unit

Every 6 months

PPE: Gloves.

No.

Disconnect the power supply through the main switch.

The sorting bench is provided with a special diffused white light which is able to highlight the
different colour shades.
Four neon tubes are inserted in the ceiling light and suitably protected against accidental impacts
with tubes, according to the safety rules.

Replace the neons with ones of the same strength and brand, if possible. This should be done to
avoid different colour shades from being assigned to the same material being examined.
It is well-known that light greatly affects colour definition as well as how opaque the surface
seems to be.
In addition, keep in mind that the operator’s have different degrees of vision as they are used to a
certain type of light.

7-26 7

7-93
 PAGE LEFT INTENTIONALLY BLANK

7-94
 DECOMMISSIONING

8. DECOMMISSIONING
8.1. Introduction
Decommissioning means setting the machine in non-operational conditions for a long period of time.

• Disconnect the electrical power supply.

The following is recommended if the machine is stopped for prolonged periods of time in abnormal
conditions:

• Do not expose the machine to weather agents, which could seriously damage many of its
electrical and mechanical components.

• Dispose of the fluids (hydraulic oil, grease). Comply with the provisions in force in the country
where the system is installed.

8.2. Disassembly, scrapping and waste disposal

Disassembly and scrapping operations must be carried out by specialised staff with the
necessary mechanical and electrical skills to work safely. It is recommended to contact SYSTEM
CERAMICS for these operations.

Comply with the safety standards in this manual.

For legal and tax aspects (reports, claims, etc.) comply with the laws in force in the country
where the machine is installed.

Disassembly procedure
Set up an ample work area free from obstructions and proceed as follows:
- disconnect the electrical power supply and comply with the instructions supplied by the
manufacturer for long periods of inactivity (see attached manual);
- drain lubricants and collect them inside the special containers;
- disconnect the cables of electric panel terminal board;
- dismantle all the parts of the machine and divide the components to be thrown away from those
to be reused.

Waste disposal
The materials used to build the machine do not pose hazards or risks for the operators.
They may however represent a risk to the environment if they are not handled properly.

All waste must be processed, disposed of or recycled according to its classification and the
legal requirements in the country of installation.

8-95
 PAGE LEFT INTENTIONALLY BLANK

8-96
 SYSTEM CERAMICS
Via Ghiarola Vecchia, 73
41042 Fiorano Modenese (MO)
Tel. +39 0536 836111
www.systemceramics.com info@systemceramics.com