PRP

Painting Roller Positioners

User manual

EN/01
Contents

1 | Preface..................................................................................................................................................4
1.1 | Manufacturer information...............................................................................................................4
1.2 | System information........................................................................................................................4
1.3 | About this publication.....................................................................................................................5
1.3.1 | Purpose.......................................................................................................................................5
1.3.2 | Intention and limitations...............................................................................................................5
1.3.3 | Preservation.................................................................................................................................5
1.3.4 | Glossary of adopted terms and definitions..................................................................................6
1.4 | Safety information..........................................................................................................................7
1.4.1 | Generic aspects...........................................................................................................................7
1.4.2 | Warnings and good practices.......................................................................................................7
2 | System description................................................................................................................................9
2.1 | Generic aspects.............................................................................................................................9
2.2 | Painting rotational positioner.......................................................................................................10
2.2.1 | System overview........................................................................................................................10
2.3 | System layout..............................................................................................................................12
2.3.1 | General dimensions...................................................................................................................13
4 | Transportation......................................................................................................................................15
4.1 | Load handling and crane operation rules and preventive measures..........................................15
4.2 | Equipment and devices...............................................................................................................16
4.4 | Painting Rotational Positioners...................................................................................................17
5 | Operating instructions.........................................................................................................................18
5.1 | System installation ......................................................................................................................18
5.2 | System commissioning................................................................................................................18
5.3 | System operation and maintenance areas..................................................................................18
5.4 | Environmental operating requirements (temperature, moisture, work environment and lighting)
.............................................................................................................................................................18
5.5 | Mains supply connection instructions..........................................................................................19
5.6 | Waste control and environmental contamination........................................................................19
6 | System operation risks and warnings ................................................................................................20
6.1 | Risk assessment and preventive measures................................................................................20
6.2 | Personal Protective Equipment (PPE)........................................................................................21
7 | System related instructions.................................................................................................................21
7.1 | Machine and safety related devices description.........................................................................21
7.2 | Safety functions description........................................................................................................21
7.2.1. Safety functions operating instructions.......................................................................................21
7.2.2. Lock-out / Tag-out.......................................................................................................................22
8 | System operating instructions.............................................................................................................23
8.1 | Control units and operating devices............................................................................................23
8.1.1. ....................................................................................................................................................23
 8.2 | Operating mode ..........................................................................................................................23
8.3 | System adjustments....................................................................................................................23
8.4 | Emergency stop modes...............................................................................................................23
8.5 | Troubleshooting...........................................................................................................................23
8.6 | Restricted space..........................................................................................................................24
9 | Maintenance........................................................................................................................................25
9.1 | System commissioning and basic maintenance instructions and procedures............................25
9.1.1 | Machine layout...........................................................................................................................26
9.1.2| Transfer cart................................................................................................................................27
9.1.3 | Elevator cart...............................................................................................................................28
9.1.5 | Grease lubrication intervals.......................................................................................................30
9.1.6 | Grease lubrication procedures...................................................................................................30
9.1.7 | Oil lubrication procedures..........................................................................................................30
9.2 | Spare parts..................................................................................................................................31
10 | System decommissioning instructions..............................................................................................31
11 | Warranty terms..................................................................................................................................31
12 | Declarations of Conformity................................................................................................................31
13 | Electrical diagrams............................................................................................................................31
14 | Pneumatic diagrams..........................................................................................................................31
15 | Publication revision...........................................................................................................................32
1 | Preface

1.1 | Manufacturer information

Should any questions or doubts arise from the reading of this publication or about system
installation, operation or maintenance procedures please contact :

R. Tomé Barros Queirós, 135

Zona Industrial das Ervosas
3830-252 Ílhavo – PORTUGAL

Tel: +351 234 320 900

Fax: +351 234 320 916
www: www.motofil.pt
@: [email protected]

Notice
Failure to comply with any procedures or guidelines referred in his publication so
may result in further damage and more expensive repairs.

1.2 | System information

System type
PRP | Painting Roller Postioners

PRP - D5200
System model

Mains supply
frequency 50Hz
Make year
2010
Serial number
5698
Net weight
14 ton
Rated power
43 kVA
Mains supply
voltage 400 VAC + 220V AC
Mains supply
type 3 Phase + Neutral + Earth

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1.3 | About this publication

This publication including all illustrations and information contained herein are copyright
protected and sole property of Motofil Robotics, S.A. furnished for costumer use only.
Any kind of total or partial distribution, manipulation, reproduction, translation, electronic or
photographic copying or alteration without the express written consent of Motofil Robotics, S.A. is
strictly forbidden and any violations shall be cause for damage liability.
Although all data and information herein has been collected and compiled using of great
care there is no guarantee in respect of typographic.
Motofil Robotics, S.A. reserves the right to make any changes that contribute to technical
improvement.

1.3.1 | Purpose

This manual has the intent of supplying all instructions relating and necessary to system
installation, operation and maintenance regarding the purpose it was designed to serve. This
system complies with Annex I of Machinery Directive, currently being 98/37/CE, of 22/06.

1.3.2 | Intention and limitations

This publication is intended for all operators, technicians or maintenance personnel that
may be involved on installing, operating or maintaining the system.
This publication does not in anyway replace adequate specific training prior to system
operation or maintenance for all involved personnel in similar systems supervised by already
trained and experienced personnel.

1.3.3 | Preservation

This publication weather distributed in digital and/or printed form is considered to be part of
the system and should be kept for future reference and until final system decommissioning.
If supplied in printed form, it should be carefully and safely kept, free from dust and in a
moisture-free environment. In case of damage or loss a new copy should be ordered from Motofil
Robotics, S.A. referring the respective system serial number as referred in its rating plate.

Fig. 1 – System rating plate

Notice
Motofil Robotics, S.A. declines any whatsoever responsibility on all
consequences that may arise from unfulfilment or misinterpretation of any
instructions or procedures detailed in this publication.

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1.3.4 | Glossary of adopted terms and definitions

Warning: Applied whenever there is danger of injury to the user or when there is danger of both
the user being injured and the equipment being damaged if the approved procedure is not
observed.

Notice: Applied to indicate supplementary information or specific aspects of a given procedure

Typical: information: As used on this manual “typical” or "typically" identify valid specifications or
operations when using basic default system configurations. These specifications may vary
according to systems configuration or function.

Operator: As used on this manual defines a person or persons authorised by the system’s safety
manager to execute system operations including risk assessment and avoidance of risk situation
that may inflict danger to him self or others exposed to system hazards.

Service operations: As used on this manual, defines simple operation tasks taking place
occasionally or in regular intervals but that do not require outstanding technical expertise or the
intervention of expertise personnel.

Technician: As used on this manual, defines expertise personnel

Expertise personnel: As used on this manual defines a person or persons with specific technical
competence in one or more than one specific fields and thus capable of executing maintenance
tasks other than those of normal machine operation. Expertise personnel can be manufacturer
dependent or its representative, internal or external.

Danger: As used on this manual defines a situation where one or more elements are associated in
a way personnel injuries may occur.

Risk: As used on this manual defines a possible hazardous condition witch may result on
personnel injuries.

Danger Area: As used on this manual defines but it is not limited to every machine operation area
or its surroundings where personnel presence may carry personal safety or health risks.

Exposed personnel: As used on this manual defines every person that for any reason may be
totally or partially, inside a danger area.

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1.4 | Safety information

1.4.1 | Generic aspects

System configuration and respective safety devices comply with all aspects of machinery
directive as determined by the European Community
Council (98/37/CE and subsequent amendments).

This publication details all safety devices,

measures and prescriptions regarding this system
installation, operation and maintenance.
Disregarding any of these prescriptions may
invalidate or make inadequate all safety measures taken
under consideration at system design stage.

All personnel involved in system operation should

be made fully aware of all safety risks and respective safety measures and available safety related
devices as well as all local normatives and directives concerning accident prevention.

Motofil Robotics, SA declines any whatsoever responsibility for any damage to the system
or any injuries inflicted to the operator or any other personnel resulting from disregarding any
safety normatives or good practices as detailed in this publication.

1.4.2 | Warnings and good practices

The system should only be operated accordingly to the instructions referred in this
operating manual.

A responsible and careful use of the system is critical for operator and other personnel safety.
When operating or maintaining the system the use of Personal Protective Equipment (PPE) is
strongly advised.
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in
moving machinery.

. Always keep the working areas clean and free from debris and obstacles

. Do not remove or attempt to remove any covers included in the system. If by any reason this
need arises, please remount all covers as soon as possible.

. It is strictly forbidden to remove or alter any safety mechanism. In case of system modifications,
the system manufacture declines any responsibility for any damages inflicted on personnel.

. Proper personnel qualification and specific training is required for machine operation.

. Clear definition of operation, installation, maintenance and repairing responsibilities is strongly

advised.

. All electrical related tasks should only be carried out by electrician personnel.

. Personnel performing maintenance or repair tasks must be trained in the procedures necessary
to perform the required tasks in a safe manner.

. Follow thoroughly all inspection and maintenance intervals as well any advises referred in this
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manual

. While carrying out maintenance operations turning off the machine and locking the power switch
so that no other person can turn it is advised.

. Never operate the machine under the influence of drugs, alcohol or any kind of medical products
than may influence physical or psychological condition

Prior to start operating the system all involved personnel

should be fully aware of all system specifications, operator
panels switches and control units location and operation modes.

The system should only be operated by personnel that

have taken part in Motofil Robotics, S.A. sponsored training
events (if applicable, at system installation premises or Motofil
robotics, S.A. facilities) and that have received and understood
all instructions, recommendations, advises as well as any
general rules or good practices referred in the supplied user manuals, maintenance manuals and
all related diagrams, drawings and charts.
All instructions, recommendations, advises as well as any general rules or good practices
on accident prevention referred on all system manuals, warning labels or plates should be strictly
respected and followed.

Non-authorised modifications or replacing of any machine parts as well as the use of

accessories, tools or any kind of materials other than those recommended by the manufacturer
may cause hazardous situations and are disapproved by the manufacturer who is hereby isent of
any civil responsibility or legal liability.

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2 | System description

2.1 | Generic aspects

Equipment used to horizontally position circular structures, in order to paint the inner and
outer surfaces without significant contact from positioning equipments.
The system is composed of two synchronized moveable welded steel structures on
rail system. Each of the structures is fitted with an elevation cart which allows for propor
height adjustment of the circular structures to be painted. The positioning of the elevator
cart is guaranteed by means of two AC motorizations with variable speed.
The equipment model determines the overall minimal and maximum diameters which can
be correctly positioned, overall weight, length and rotational capacity.

Domain | The use of this system in order to achieve results other than those specified is
considered as improper use and thus any responsibility is firmly declined by the manufacture for
any damage imposed on personnel and/or goods.
Moreover the manufacturer reserves the right to consider extinct any form of manufacturing
warranty.

Applications | Wind towers, tank and pipe welding.

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2.2 | Painting rotational positioner

2.2.1 | System overview

Fig. 4 – Painting rotational positioner

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Base Structure

Motorized cart with adjustable speed

selection and steel wheels adjustable to rail
systems.

Elevator cart

Motorized cart with adjustable speed

selection and two sets of rollers used to
rotate circular structure to be painted.

Motorization of the rollers allows for the

rotation of variable circular structure
diameters.

Platform

Steel structure used to access the interior of

the circular structure.

Vertical columns

Columns that support the elevator cart and

elevation system.

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2.3 | System layout

Fig. 10 – System layout

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2.3.1 | General dimensions

Fig. 12 – General dimensions

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3 | Technical data

Model

Units
Technical data D 4300 D 5200
(SI)
Max Weight Ton 60
Diameter Max. e
mm 4300 / 1500 5200 / 1500
Min.
Height Max.(A)
(structure + mm 5700 6550
wheel)
Distance between
mm 3500
axles (B)
Total length (C) mm 4893
Total width (D) mm 238
Distance between
mm 2020
rails (E)
Elevator cart
height intervals mm 500
(F)
Hook dimensions mm 1009x620x150
Elevator cart
mm 2000 3000
distance (H)
Translation speed m/mim Adjustable
Rotational Speed m/mim Adjustable
Elevator Speed m/mim Adjustable
Elevator Power Kw 2x1,1
Rotational Power Kw 0,75
Translation Power Kw 2x0,25
Weight Kg

Nota: Technical data may vary without notice.

Notice
All specifications are approximate and subject to change without prior
notice

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4 | Transportation

4.1 | Load handling and crane operation rules and preventive measures

- Always keep paths free from obstacles

- Always use adequate Personal Protective Equipment (PPE) such as safety shoes and protective
gloves.

- Always uphold preventive maintenance as it is the correct way ensure proper working order and
safe operation conditions.

. Use protective gloves and adequate tools when handling materials.

. Never wear watches, rings, neckties, scarves, loose clothing or hair that could get caught in
moving machinery.

. Never turn your back to a manoeuvring fork-lift. Keep a safe distance, make a safe exit and keep
attentive until the manoeuvre is completed.

. It is strictly forbidden to endure on any maintenance tasks inside an electrical cabinet except for
authorised personnel (maintenance personnel)

. It is mandatory to keep all electrical cabinets doors closed and any fault must be immediately
informed.

. Do not operate cranes or any other related equipment beyond the rated payload.

. Check all hoisting cables proper working condition

- Check all hooks safety locks

- Do not operate equipment under dubious safety conditions

- Check all safety and signalling devices regular working condition prior to operation

- Before hoisting loads check for interlaced cables or chains and check for crane’s neutral
operation status.

- Before hoisting check for clearance from personnel or obstacles that may obstruct the intended
operation.

- Never lay limbs under loads.

- Never attempt to transport personnel.

- Avoid sudden manoeuvres so cables or chains do not stress.

- Never attempt to handle wrongly conditioned loads

- Never leave suspended loads unattended

- Never hoist unbalanced loads

- All hoisting hooks should be equipped with safety locks

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- Always monitor the load being handled. Call for help if in poor visibility conditions.

- When moving a crane empty from loads, ensure that the hoisting hook is above the minimum
safety height in order to avoid collisions.

Notice
When transporting, moving or unloading any machine parts using a
crane, cranes payload rating should be higher than the heaviest machine part to
handle.
All elevations devices or accessories should be made available in good
operating conditions and should only be used by properly authorised and trained
personnel on load manoeuvring.

4.2 | Equipment and devices

For adequate machine parts handling the use of the following equipments and devices
should be considered.

. Crane
. Steel cables
. Eyebolts / slings ( not included )

Notice

Do not use fork lifts

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4.4 | Painting Rotational Positioners

Fig. 15 – Transportation method

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5 | Operating instructions

5.1 | System installation

Machine should be positioned and floor mounted according to guidelines and installation
specifications as detailed in the annexed layout.
The system should only be used for the sole purpose it was designed and intended for.
Please provide appropriate stability conditions by ensuring correct levelling.
As machine parts handling should attend to all safety regulations, all personnel that may be
required to operate this system and/or to handle machine parts should receive adequate training
witch should take in consideration risk assessment related to machine danger areas.

5.2 | System commissioning

5.3 | System operation and maintenance areas

Machine may be moved, operated and maintained without any peripheral limitations or
requisites.

5.4 | Environmental operating requirements (temperature, moisture, work

environment and lighting)

This system is designed to operate between 15

e 35° Celsius temperatures and 20% to 60% relative
humidity.
In order to avoid electrical discharge hazards
system should never operate over 90% relative humidity
or temperatures over 45º Celsius (113ºF).

As this system is intended for indoor industrial use

only, premises should be kept free from atmospheric
agents such as rain, gravel, snow, etc.

The system is not intended to be used under any type of explosive or partially explosive
conditions and environments and thus its use under these conditions is strictly forbidden according
to ATEX directives.

All installation, operation, maintenance, and adjusting tasks should only be made by
properly qualified, trained and authorised personnel.

Appropriate lightning conditions should be made available in order to easily identify all
command switches including all emergency stop switches and related devices.

Under normal operating conditions vibration is at controlled levels for safe operation. If any
abnormal vibration arises specially at machine surroundings immediately stop operating the
machine and contact service representatives.

Under normal operating conditions acoustic noise level is less than 80 dB (A) complying
with all applicable noise normatives.

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 Warning
If the system is to be used under corrosive conditions, maintenance
intervals should be shorten.

5.5 | Mains supply connection instructions

All machines must be fitted with a device for putting all power plants out of circuit. Such a
device should be clearly identified and possible to lock in its disconnected position.
If reconnection may involve danger to exposed personnel locking the disconnection device
should be possible. When the power supply is cut out it must be possible in a normal way to
discharge any energy remaining or stored in the circuits of the machine without risk to personnel.

After reconnection, active action from the operator is required by proper validating system
start up.
For mains connection extra-flexible 16mm2 section for phases supply and 10mm² for neutral
and earth grounding cable should be used.
All cables should be electrically grounded and mechanically safeguarded up to the respective
electrical cabinet. Mains supply voltage must supplied with 460 VAC phase-to-phase and 115 VAC
phase-to-neutral potentials.

5.6 | Waste control and environmental contamination

Compliance with all local normatives and directives should be

observed when disposing of machine fluids and lubricants. The
forwarding of used lubricants to specialized recycling facilities is
advised.
In case of spilling make sure to absorb all spilled fluids using
absorbent materials and to correctly dispose those using proper
contaminated waste containers as these resulting materials should be
dealt as dangerous residues.

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6 | System operation risks and warnings

6.1 | Risk assessment and preventive measures

Procedur
Danger e / Risc Dangerous situation Preventive measures Solution description
zone
Operation

Personnel in the area surrounding

the painting positioners while
Surrounding
mounting circular structure to be Correct operator training in large structure
area where Circular
painted;
circular structure Mechanical handling and correct operator training of Regular inspection of the elevation devices.
structures are mounting Falling shell during positioning equipment.
positioned Always keep clear of the danger zone.
operation of circular structure on
positioners

Access to the Passage by Risk of falling while passing to the Adjust the access platform as good as
Instructions on how to safely access the
interior of the means of the interior of the shell if the shell is no possible.
Mechanical interior of the shell through the access way
circular center of the totally adjusted to the equipment
structure equipment rolls Signs and related instructions on risk of fall. platform.

Areas os Translation All protections and barriers correctly applied.

equipment and rotation of Access to moveable parts of the Physical protections or barriers to access
Mechanical
maneuverabili circular machines. the danger zones. Signs and instructions of the correct
ty structures manageability.

Signs and instructions where moveable Instructions on how to safely access the
Shell Objects or equipments in the work pieces exist.
Area Mechanical interior of the shell through the access way
movements surrounding area.
surrounding platform.
Security information in the access area.
equipment

Work zone Rotation Noise Personnel close to noise source Information on aerial noise emissions Auricular protection is advised

Use of adequate auricular protection Specification of adequate auricular protection

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6.2 | Personal Protective Equipment (PPE)

The use of adequate clothing for personnel operating

or maintaining any machine organs is strongly
advised. Moreover all safety equipment should be in
conformity with local normatives or directives.
Generally, all personnel enduring operation or
maintenance tasks should use safety shoes bearing
falling objects protection and anti-skid sole as well as
adequate auricular protection. When handling parts
the use of protective gloves against cutting or thermal
hazards is advised.
When operating or maintaining the machine
never wear watches, rings, neckties, scarves, or
loose clothing that could get caught in moving
machinery.
Extreme care should be taken when operating on machine surroundings.
Welders must use appropriate GMAW welding masks as well as heat resistant non-
flammable clothes and gloves.

7 | System related instructions

7.1 | Machine and safety related devices description

All electrical devices including connections prior to transformers or power supplies and
excluding the 0 Volt wire connected to the equipotential protection circuit are protected from over-
current failures by circuit breakers or fuses.
Protection against unwanted and unscheduled operation triggered by deficient ground
connections is accomplished by means of connecting one of the transformer secondary coil poles
or one the power supply poles to the equipotential protection circuit, as well as all ground
connections.

7.2 | Safety functions description

7.2.1. Safety functions operating instructions

The use of a key for PO3 (SS30) or PO2 (SS110) enabling is mandatory and thus for
machine operation. Being this the same key for both operator panels, only one of the operator
panels can be enabled at a time, otherwise none will work.

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7.2.2. Lock-out / Tag-out

The lock-out / tag-out procedures refer to OSHA normatives for personnel protection when
servicing and maintaining machines or equipments in which the unexpected energization or start
up of machines or equipments being serviced as well as the release of stored energy could cause
injury.
Lock-out refers to the placement of a lock on an energy isolating device ensuring that the
energy isolating device and the equipment being controlled cannot be operated until the lock-out
device is removed,
A lock-out device is one that utilizes a positive mean such as a lock to hold an energy
isolating device in the safe position and prevent the energizing of a machine or equipment. Such a
device must possess an unique unlocking key or combination.
Tag-out refers to the placement of a warning tag or sign on the locked energy isolating
device to indicate that the device and the equipment being controlled is locked and may not be
operated until the lockout device is removed. These tags or signs must be securely fastened to the
energy isolating device.

Fig. 16 – Lock-out / tag-out tags

Lock-out / Tag-out procedure

Maintenance |

Using the respective locking device key lock the energy isolating device, switch off all
power supplies and place the respective warning tag or sign.
After maintenance task completion, remove all tags or signs and return the locking device
key to its respective safeguarded place under the supervision of the person responsible for the
production site.

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8 | System operating instructions

8.1 | Control units and operating devices

8.1.1. Wireless control (PO1)

Red - Emergency stop

+ - Go up, rotate CW, or move + the translation
- - Go down, rotate CCW, or move - the translation
TM - Select master translation
TS - Select slave translation
TMS - Select master and slave translation
EM - Select master elevation
ES - Select slave elevation
RMS - Select master and slave rotation
2ºVE - Select second speed
Green- Reset wireless control
RST - Reset the machine

Explanation:
Each time you turn on the machine, or after an emergency,
you must press the green button to reset the wireless control,
then press 'RST' during 2s to reset the machine.
Then, to move the machine, you must always press two
buttons at the same time. One button corresponding to the
movement you need, and the other should be the desired
direction (+ or -).
To stop the machine, just press the button corresponding to
the movement you want to stop.

Note:
CW – clockwise
CCW – counter-clockwise

Fig. 17 – Operator panel 1 (PO1)

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 8.2| Operating mode

1-Position the motorized carts according to the diameter of the circular structure to be painted.
(Check if the motorized carts are interlocked, if not, the buzzer should be ON).

2-Place the postioners apart from each other, until the distance between them be larger than the
length of the tower.

3-With two cranes, align the tower section with the rails where the positioners are located.

4-Lower one flange of the tower in the rollers of one of the positioners, then, on the other side,
adjust the position of the positioner and place the other top.

5-By pressing 'TMS' and '+' or '-' at the same time, move the positioners with the tower, to the
desired place (this movement only work, if both piece detectors, SQ030 and SQ054, are detecting
the tower)

6-You can now, start the rotation (this movement also needs the condition described above) to
paint the tower.

7-At the end, stop the rotation, and move back the positioners with the tower.

8-With a crane, go up with one top of the tower and move away the corresponding positioner.

9-Do the same on the other side, to completely remove the tower.

10-Repeat the steps to paint another tower.

8.3 | System adjustments

All system adjustments should only be made by properly authorised and trained personnel.

8.4 | Emergency stop modes

An emergency stop condition can be triggered by a PLC failure or by acting on the

emergency stop switch available on the wireless control(PO1), on the master electrical cabinet(L1),
and on the slave electrical cabinet(L2).
Such a condition may be reset by resetting the emergency switch and restart the machine.

8.5 | Troubleshooting

Notice
In case of system malfunction, maintenance personnel should be
immediately contacted.

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8.6 | Restricted space

Personnel must not be allowed in the safeguarded machine work areas / restricted spaces.
Designated restricted space floor area marking is strongly advised.

Zone A + B – High danger

Fig. 18 – Restricted space

Danger
It is strictly forbidden for personnel to access all machine work areas /
restricted spaces during machine operation.

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9 | Maintenance

9.1 | System commissioning and basic maintenance instructions and procedures

1 | Prior to start any maintenance or repair task, the system must be brought to a stop,
disconnected and isolated from all external power sources, as well as be freed of any residual
currents.

2 | A “machine at maintenance” sign must be clearly visible and the main breaker should be key-
locked preventing powering on during maintenance working by mistake.

3 | During maintenance operations specially when operating with open safeguards or disabled
safety mechanisms ( allowed to properly authorised and trained personnel only ) special care must
be used preventing personnel not directly connected to the current maintenance activities entering
restricted spaces.

4 | As soon as all maintenance operations are completed correct reconnection of all safety
mechanisms is required.

5 | All machine devices and mechanisms should be kept at good operating conditions and subject
to careful periodic maintenance operations as well as additional periodic inspections if any
modifications were imposed as described in this manual in order to attain the specified
performance levels.

6 | Whenever full disconnection from mains is not possible, additional safety precautions should be
observed according to the situation at hand. Incorrect or inexistent maintenance procedures can
lead to machine damages and result in severe personnel injuries.

Note | CASTROL ® SPHEEROL APT2 is a registered trademark for Castrol Limited.

Danger
Elevator cart should be brought to the bottom position to prior to any
maintenance procedures

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9.1.1 | Machine layout

Fig. 19 – Painting roller positioners

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9.1.2 | Transfer cart

Necessary conditions
– Equipment power OFF

Maintenance level
– Level 1 – Operator

Procedure and periodicity

1 – Geared Motor

See suppliers documentation in

attchments

2 – Geared motor bearings

Remove protection of geared motor

Apply CASTROL SPHEEROL APT2
grease or equivalent, every 6 months
on existing grease inlets

3 – Bearing covers

Apply CASTROL SPHEEROL APT2

grease or equivalent, every 6 months
on existing grease inlets

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9.1.3 | Elevator cart

Necessary conditions
– Equipment power OFF

Maintenance level
– Level 1 – Operator

Procedure and periodicity

1 – Roller bearings

Apply SHELL Retinax EP2 grease, or

equivalent every 3 months on existing
grease inlets.

2 – Elevation cart guides

Apply SHELL Retinax EP2 grease, or

equivalent every month.

3 – Geared Motor

See suppliers documentation in

attachments

4 – Security pin

Apply SHELL Retinax EP2 grease, or

equivalent every month on existing
inlets.

5 – Chains

Remove protection.
Clean and grease withCASTROL
SPHEEROL APT2, or equivalent, on all
the chain length every 3 months.

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9.1.4 | Vertical column
Necessary conditions
– Equipment power OFF

Maintenance level
– Level 1 – Operator

Procedure and periodicity

1 – Guides

Apply SHELL Retinax EP2 grease, or

equivalent, monthly.

2 – Geared Motor

See suppliers documentation in

attachments.

3 – Chains

Remove protection.
Clean and grease withCASTROL
SPHEEROL APT2, or equivalent, on all
the chain length every 3 months.

Roller bearings

Remove protection.
Apply SHELL Retinax EP2 grease, or
equivalent, anually.

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9.1.5 | Grease lubrication intervals

Lubrication intervals vary on work load and other operating conditions. An overall 6 months
lubrication interval is recommended. However, if repetitive long travel movements are present, a 3
months interval is recommended.

9.1.6 | Grease lubrication procedures

Grease must be applied in lubrication inlets. The lubricated part must be moved while
greasing until grease comes to sight on the respective rolling guide. Grease excesses must be
removed before machine normal operation. Needed grease quantity varies from 1/3 to 1/2 of rolling
guides free interior space. When greasing for the first time loss of grease is expected at some
extent and should be taken under consideration. Immediately after grease lubrication procedures
an increase in friction is to be expected.
However this behaviour should be brought back to normal over the subsequent 10 to 20
long travel movements.
If low friction is required, less grease quantity should be applied; nevertheless a minimum
level should be ensured and maintained in order to ensure proper mechanisms lubrication

9.1.7 | Oil lubrication procedures

When using oil as a lubricant, a high viscosity fluid should be selected for low operating
speeds and a low viscosity fluid for high operating speeds.
Heavy duty linear rolling guides operating with large weights require a 65mm2 s-1 viscosity
lubricant as low linear rolling guides operating on low weight conditions but high travel speeds
require a 13mm2s-1 viscosity lubricant.

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9.2 | Spare parts

For replacement purposes, use only genuine spare parts. When ordering spare parts
please make sure to indicate system type as well as the respective serial number and part number
if applicable and available.

10 | System decommissioning instructions

For a safe system decommissioning, disconnection of all power sources and operation key
extraction is advised.
Drain all machine fluids and post “Out Of Service” signs.

11 | Warranty terms
Unauthorized interference with the system as well as unauthorized alteration are prohibited
and result in complete cancellation of any guarantee and liability claims.

12 | Declarations of Conformity
-

13 | Electrical diagrams
See Annex X

14 | Pneumatic diagrams
See Annex X

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15 | Publication revision

Publication Part Number Edition Date Valid for Revision content

PRP_EN/01 01 25/Mai/2010 PRP - Any version Initial edition

Figures

Fig. 1 – System rating plate..........................................................................................................................5

Fig. 4 – Painting rotational positioner...........................................................................................................10
Fig. 10 – System layout ...............................................................................................................................13
Fig. 12 – General dimensions......................................................................................................................14
Fig. 15 – Transportation method..................................................................................................................18
Fig. 16 – Lock-out / tag-out tags...................................................................................................................23
Fig. 17 – Operator panel 1 (PO1).................................................................................................................24
Fig. 18 – Restricted space............................................................................................................................25
Fig. 19 – Painting roller positioners..............................................................................................................27
 PRP | EN/01
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www.motofil.pt

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