Um00563 - 01 - 03 - A4 - Polimat® Evo 25 PDF

POLIMAT® EVO 25
Operation and maintenance manual
Created by: MOM-IT

Approved by: MAP-IT
FLSmidth Ventomatic, 10th June 2014 UM00563G03
POLIMAT® EVO 25
MD00365G03
Page 2 of 114
We thank you for choosing a FLSmidth Ventomatic S.p.A. product.
This machine has been designed and manufactured using the most modern processes
and best technologies available, in order to grant its reliability during its lifetime while
ensuring the utmost security to the operators.
The pictures and drawings in the manual are for indication purposes only, since they
only represent a general reference, and are not necessarily precise in every detail.
The dimensions and technical specifications of the machine indicated in the manual
are not binding, and can be changed without warning by FLSmidth Ventomatic S.p.A.
The drawings and all the other documents supplied together with the machine belong
to FLSmidth Ventomatic S.p.A. and cannot be handed over to any third party without
prior consent in writing by FLSmidth Ventomatic S.p.A.
Proper use
In order to ensure a proper and safe use of the machine, we recommend you to
carefully read and follow what is indicated in the manual. 
All the documents included in the supply of the machine, and in particular this manual,
shall be properly kept for any further reference.
The product described in this manual has been manufactured

using the operation processes and modes according to the Quality
System of FLSmidth Ventomatic S.p.A.
Since January 2001 the Quality System of the company has
been examined and certified by Bureau Veritas Italia S.p.A to be
complying to the requirements of the standard ISO 9001.
This ensures that every phase of the production process – from

the formulation of the order up to the technical service following
the supply – is monitored and always kept under control, in order
to ensure that the product complies with the requirements of the
customer and with its quality standards.
The information transmitted by this document is the proprietary and confidential property of FLSmidth
Ventomatic and may not be duplicated, disclosed or utilized without written consent from FLSmidth
Ventomatic.
POLIMAT® EVO 25
MD00365G03
Page 3 of 114
Table of contents
1.0 General information...................................................................................7
1.1 Purpose of the manual.........................................................................8
1.2 Manual’s addressees............................................................................9
1.3 General prescriptions......................................................................... 10
1.3.1 Warnings and precautions........................................................... 11
1.4 List of the enclosures......................................................................... 12
1.5 Warranty.......................................................................................... 12
1.6 Test................................................................................................. 12
1.7 Service personnel.............................................................................. 12
1.8 Contacts with the customer service and spare parts department.............. 13
1.9 Norms and reference documentation.................................................... 13
1.10 General notes upon delivery.............................................................. 13
2.0 Safety information.................................................................................. 15

2.1 General safety instructions.................................................................. 16
2.2 Safety systems................................................................................. 17
2.2.1 Protection of the electric system.................................................. 17
2.2.2 Mechanical protections............................................................... 17
2.2.3 Safety devices.......................................................................... 18
2.3 Interventions on the machine.............................................................. 20
2.4 Improper use of the machine.............................................................. 22
2.5 Operators’ clothing............................................................................ 22
2.6 Safety signals and information plates................................................... 23
2.7 Demolition and disposal...................................................................... 24
3.0 Technical information............................................................................... 25

3.1 Description of the machine................................................................. 26
3.2 Composition of the machine................................................................ 26
3.2.1 Bags-rotating group................................................................... 28
3.2.2 Accumulation/transfer belt.......................................................... 29
3.2.3 Half-layer formation belt............................................................ 30
3.2.4 Layer formation plate................................................................. 31
3.2.5 Layer-shifting module................................................................ 32
3.2.6 Lifting table and openable plates................................................. 33
3.3 Layer formation cycle......................................................................... 34
3.4 Photocells and proximity switches........................................................ 36
3.5 Identification of the manufacturer and the machine................................ 37
3.6 Overall dimensions............................................................................ 38
3.7 Technical data................................................................................... 39
3.8 Position of the operators..................................................................... 40
Ventomatic.
POLIMAT® EVO 25
MD00365G03
Page 4 of 114
4.0 Handling and installation information......................................................... 41

4.1 Addressees of the document............................................................... 42
4.1.1 Responsabilities........................................................................ 42
4.2 Packing and unpacking....................................................................... 42
4.3 Checking of the installation requirements.............................................. 43
4.4 Lifting and transport.......................................................................... 44
4.4.1 Equipment required................................................................... 44
4.4.2 Marking of the points of support.................................................. 45
4.4.3 Lifting and transport.................................................................. 45
4.4.4 Positioning and assembling......................................................... 47
4.4.4.1 Lifting table and openable plates...................................... 47
4.4.4.2 Half formation plate........................................................ 48
4.4.4.3 Half-layer formation belt, accumulation/transfer belt and bags-
rotating group........................................................................... 49
4.4.4.4 Layer-shifting module..................................................... 50
4.5 Electric connection............................................................................. 51
5.0 Adjustment information........................................................................... 53

5.2 Warnings.......................................................................................... 54
5.3 Tension of the bags-rotating belt......................................................... 55
5.4 Tension of the accumulation/transfer belt.............................................. 56
5.5 Tension of the half-layer formation belt................................................. 57
6.0 Maintenance information.......................................................................... 59

6.2 Routine maintenance......................................................................... 60
6.2.1 General rules............................................................................ 61
6.2.2 Cleaning and checking at the end of production............................. 61
6.2.3 Monthly checkout (400 hours)..................................................... 61
6.2.4 Maintenance of the bags-rotating group....................................... 62
6.2.5 Maintenance of the accumulation/transfer belt.............................. 64
6.2.6 Maintenance of the half-layer formation belt................................. 66
6.2.7 Maintenance of the layer formation plate...................................... 68
6.2.8 Maintenance of the layer-shifting module...................................... 69
6.2.9 Maintenace of the palletizing module............................................ 70
6.2.10 Maintenance of the lifting modules with forks.............................. 71
6.2.11 Maintenance of the lifting module with motorized roller way and belt...72
6.3 Summary table of the maintenance operations...................................... 74
6.4 Table of lubricants............................................................................. 76
6.4.1 Table of lubricants for reduction gears.......................................... 76
6.4.2 Table of lubricants for supports, bearings, guides and chains........... 76
6.5 Lubrication of the supports with bearing............................................... 77
6.6 Lubrication of the reduction gears........................................................ 78
6.6.1 Check of the reduction gears....................................................... 78
6.7 Lubrication of the chains..................................................................... 79
6.7.1 Wear and replacement............................................................... 79
Ventomatic.
POLIMAT® EVO 25
MD00365G03
Page 5 of 114
7.0 Accessories information........................................................................... 81

7.1 Feeding roller way with idle rollers....................................................... 83
7.1.1 Installation............................................................................... 83
7.1.2 Pneumatic connection................................................................ 84
7.1.3 Maintenance............................................................................. 84
7.2 Pacing and pressing belt group............................................................ 85
7.2.1 Adjustment of the minimum distance between the pressing belts..... 86
7.2.2 Adjustment of the tension of the pressing belts............................. 87
7.2.3 Adjustment of the centering blades.............................................. 87
7.2.4 Maintenance............................................................................. 88
7.3 Pacing and pressing rollers group......................................................... 89
7.3.1 Adjustment of the pacing and pressing rollers............................... 90
7.3.2 Maintenance............................................................................. 91
7.4 Empty pallets roller way..................................................................... 92
7.4.1 Installation............................................................................... 93
7.4.2 Maintenance............................................................................. 93
7.4.3 Pallet-centering device............................................................... 94
7.4.3.1 Pneumatic connection..................................................... 95
7.4.3.2 Maintenance.................................................................. 95
7.5 Full pallets roller way......................................................................... 96
7.5.1 Installation............................................................................... 96
7.5.2 Maintenance............................................................................. 97
7.6 Belt roller way................................................................................... 98
7.6.1 Installation............................................................................... 98
7.6.2 Replacement and adjstment of the belt tension............................. 99
7.6.3 Maintenance........................................................................... 100
7.7 Pallet feeder................................................................................... 101
7.7.1 Operating cycle....................................................................... 101
7.7.2 Installation............................................................................. 102
7.7.3 Maintenance........................................................................... 102
7.8 Cardboard feeder............................................................................ 103
7.8.1 Operating cycle....................................................................... 103
7.8.2 Installation............................................................................. 104
7.8.3 Pneumatic connection.............................................................. 104
7.8.4 Maintenance........................................................................... 104
7.9 Full pallets translating roller way....................................................... 105
7.9.1 Installation............................................................................. 106
7.9.2 Maintenance........................................................................... 106
7.10 Rotating roller way......................................................................... 107
7.10.1 Installation........................................................................... 108
7.10.2 Maintenance......................................................................... 108
7.11 Rotating and translating roller way................................................... 109
7.11.1 Installation........................................................................... 110
7.11.2 Maintenance......................................................................... 110
7.12 Approaching roller way with idle rollers............................................. 111
7.12.1 Installation........................................................................... 111
7.12.2 Pneumatic connection............................................................ 112
7.12.3 Maintenance......................................................................... 112
Ventomatic.
POLIMAT® EVO 25
MD00365G03
Page 6 of 114
7.13 Approaching roller way with motorized rollers.................................... 113

7.13.1 Installation........................................................................... 114
7.13.3 Maintenance......................................................................... 114
Ventomatic.
POLIMAT® EVO 25
MD00047G11
Page 7 of 114
1.0 General information

Table of contents
1.0 General information...................................................................................7
1.1 Purpose of the manual.........................................................................8
1.2 Manual’s addressees............................................................................9
1.3 General prescriptions......................................................................... 10
1.3.1 Warnings and precautions........................................................... 11
1.4 List of the enclosures......................................................................... 12
1.5 Warranty.......................................................................................... 12
1.6 Test................................................................................................. 12
1.7 Service personnel.............................................................................. 12
1.8 Contacts with the customer service and spare parts department.............. 13
1.9 Norms and reference documentation.................................................... 13
1.10 General notes upon delivery.............................................................. 13
Ventomatic.
POLIMAT® EVO 25
MD00047G11
Page 8 of 114
1.1 Purpose of the manual

Please read this handbook carefully before doing any kind of intervention on the machine.
This manual, issued by the manufacturer, is an integral part of the machine equipment.
The information contained herein is headed to qualified and skilled people, with high
technical preparation, to people aware of the laws and regulations in force, who will
be able to recognise and avoid possible dangers during the transfer, installation, use
and maintenance of the machine.
The aim of this manual is to describe the operation modes of the machine, the use prescribed
by the manufacturer and the precautions to be taken to ensure a safe and proper handling,
installation, use, operation and maintenance of the machine.
Only if you observe the indications contained in this manual and in general of all the
documents included in the supply you can ensure the safety of the operators, the
economy of use, the proper operation of the machine as well as a longer lifetime of
the same.
It is necessary to carefully read and keep the whole documentation provided in the supply.
FLSmidth Ventomatic S.p.A. declines any responsibility for damages to people or

things caused by an incorrect use of the machine, not foreseen in this manual.
To ease the consultation and improve the reading of the manual, we have divided it
into chapters and paragraphs, which are listed in the general index.
Some parts of the texts have been highlighted in bold characters to underline their
importance, and they are preceded by the symbol shown below.
DANGER - ATTENTION
It’s absolutely necessary to be very careful in order to avoid consequences that could
cause physical damages to the user. 
CARE - CAUTION
It’s absolutely necessary to be very careful in order to avoid consequences that could
cause damages to tangible goods (resources and product). 
Any remark you would like to make for our guidance is of great interest to us, in
order to improve services that FLSmidth Ventomatic S.p.A. usually offers to its own
customers.
Ventomatic.
POLIMAT® EVO 25
MD00047G11
Page 9 of 114
1.2 Manual’s addressees

The operators, depending on their tasks and different information requirements (UNI
10653), are divided into:
Addressee Information requirements

Homogeneous addressees
H a n d l i n g Pack the equipment, check its right position into the package, close
operators it appropriately. Unpack the equipment in accordance with the
instructions indicated in the package. If required, these operations
must be carried out by means of lifting devices and under safe
conditions for the people, the product and the environment.
Carriers Load the packed product on the means of transport by means
of lifting and containing devices, if required; stow and position it
adequately, transport it to its place of destination and then unload
it by carrying out the above-mentioned operations in reverse order,
always under safe conditions for the people, the product and the
environment.
Sellers Illustrate the characteristics of the available products, supplying
to potential customers all the indications required for their choice,
warning them about unsafe conditions for the people, the product
and the environment, and supplying the addresses to carry out
all the operations relating to the product, its installation, use,
maintenance, repair, disassembling and dismantling.
I n s t a l l a t i o n Install the equipment, by explicit and implicit authorisation of
operators the purchaser and with the cooperation of the dealer, under safe
conditions for people, the product and the environment, supplying
the user with the necessary instructions for its safe use and
maintenance.
M a i n t e n a n c e Carry out routine check, verification and adjustment operations and,
operators if required, small repairs, according to the maintenance schedule
supplied by the manufacturer, always under safe conditions for the
people, the product and the environment.
Repairers Carry out the troubleshooting and check any abnormal operation
of the machine by making use of the information supplied by the
user; carry out all necessary repairs, replacement and adjustment
operations, so that the product can work correctly under safe
D i s m a n t l i n g Understand when it is necessary to dismantle the machine,
operators disassemble it, eventually selecting the relevant materials,
disposing of the non-reusable materials and recycling the others
in safe conditions for the environment.
Heterogeneous addressees
Users Start the equipment under safe conditions for the people, the product
and the environment, interpret an elementary troubleshooting and
abnormal working conditions and carry out simple adjustment,
maintenance operations and repairs.
Ventomatic.
POLIMAT® EVO 25
MD00047G11
Page 10 of 114
1.3 General prescriptions

Always make sure that you have completely understood the content of this manual.
The inobservance of specific indications included herein exempts the manufacturer
from any responsibility for damages to people and/or things.
Before the installation, make sure that the safety rules and positioning instructions have
been complied with and that the machine works correctly; check the environmental
conditions (temperature, humidity, lighting, vibrations, suspension powders) and the
suitability of the installation place.
Delimit the operating areas and the user’s position and provide sufficient room for
operation and maintenance, in accordance with the safety prescriptions recommended
by the manufacturer and by the norms in force.
Always check that the environmental and production conditions close to the operating
area do not hinder the control operations of the machine.
For further information, directly contact the authorized technical service or the
manufacturer and give all the information listed in paragraph 1.8.
Before proceeding with the installation, check that the supporting surface of the
machine is suitable to bear the load foreseen in the layout drawings.
In case of incompatibilities, immediately inform the technical service.
Ventomatic.
POLIMAT® EVO 25
MD00047G11
Page 11 of 114
1.3.1 Warnings and precautions

Users, repairers and maintenance operators must possess specific skills as well as
psycho-physical requisites in order to carry out the above-mentioned operations.
Warnings and precautions

During the installation always check first the proper operation, mounting and efficiency
of commands and safety systems of the machine.
In case of anomalies in the machine, immediately stop the work cycle and contact
the technical service.
It is absolutely forbidden to operate on the machine wearing unsuitable clothing
(large or unbuttoned clothes, etc.) or personal objects (bracelets, watches, rings,
etc.).
Before starting a work cycle, make sure that neither the machine nor its auxiliary
components may cause dangerous situations to people and/or things.
Preliminary startup, checks, starting of control units and any other operation to be
set by means of electric controls require competence, awareness and prudence of
the operator. In any case, it’s important to pay attention during the control phases,
operating carefully on the control devices, without handling tools or bulky objects at
the same time. Adhere to the manufacturer’s recommendations and the instructions
listed herebelow.
It is absolutely forbidden to place and/or abandon on the machine and on its auxiliary
parts any tool, object and/or anything that may be potentially dangerous for people’s
health or damage parts of the machine.
To safely access the machine parts, stop the machine and disconnect the external
power supply according to the indications and procedures described in chapter 2.
It is forbidden to modify or tamper with the machine. FLSmidth Ventomatic S.p.A.
declines any responsibility in the event of any change to equipment, control
components and/or safety devices. 
Ventomatic.
POLIMAT® EVO 25
MD00047G11
Page 12 of 114
1.4 List of the enclosures

Attached to this manual you will find the following documents:
Electrical diagrams: necessary to advanced operators for interventions in the electric

system.
Spare parts catalogue: to order original spare parts.
Documents of commercial devices: they include the information of the commercial
devices installed on the machine.
Layout drawings: necessary for the installer to position the machine.
1.5 Warranty
The machine is covered by a warranty for manufacturing defects.
Refer to the purchase contract for any information about the duration of the warranty
period.
The warranty is only valid if the machine has been used in accordance with the
manufacturer’s instructions and has not been tampered with.
The warranty does not cover any part subject to wear and tear.
The warranty includes the replacement of faulty parts (ex-works FLSmidth Ventomatic
S.p.A.).
1.6 Test
The positive test of the machine is carried out at FLSmidth Ventomatic S.p.A.’s
premises before the machine is dispatched.
1.7 Service personnel

All extraordinary repair and maintenance operations of the machine must only be
carried out by qualified personnel, that is by FLSmidth Ventomatic S.p.A. or by
personnel duly authorised by the company itself.
For information about the personnel please directly revert to FLSmidth Ventomatic
S.p.A. and contact the customer service department.
Ventomatic.
POLIMAT® EVO 25
MD00047G11
Page 13 of 114
1.8 Contacts with the customer service and spare parts department
Please revert to the leaflet “Field service & spare parts contacts” delivered as
attachment and follow the indications stated for each specific contact.
1.9 Norms and reference documentation

The machine complies with the prescriptions included in the following documents:
1. 2006/42/CE directive (“machine directive”);

2. UNI EN ISO 12100:2010: Safety of machinery – General principles for design –
Risk assessment and risk reduction;
3. all specific technical prescriptions pertaining to this field that regulate the
design, development, production, installation and service of the machine.
1.10 General notes upon delivery

When receiving the machine make sure that:
• the supply corresponds to the order specifications;
• all the components stated in the packing list are present;
• the machine has underwent no damages due to the transport or other.
In case of damages or missing parts please immediately inform FLSmidth Ventomatic

S.p.A.
Ventomatic.
POLIMAT® EVO 25
MD00047G11
Page 14 of 114
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 15 of 114
2.0 Safety information

Table of contents
2.0 Safety information.................................................................................. 15
2.1 General safety instructions.................................................................. 16
2.2 Safety systems................................................................................. 17
2.2.1 Protection of the electric system.................................................. 17
2.2.2 Mechanical protections............................................................... 17
2.2.3 Safety devices.......................................................................... 18
2.3 Interventions on the machine.............................................................. 20
2.4 Improper use of the machine.............................................................. 22
2.5 Operators’ clothing............................................................................ 22
2.6 Safety signals and information plates................................................... 23
2.7 Demolition and disposal...................................................................... 24
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 16 of 114
2.1 General safety instructions

The safety instructions listed herebelow shall be absolutely observed; this list however
is not exhaustive, and does not relieve the user from strictly knowing and applying
the regulations in force in the country of use of the machine pertaining to the accident
prevention and the working safety.
Safety instructions
In order to safely use the machine it is absolutely necessary to strictly follow the
working safety instructions ruled out by the laws in force in every country. 
All the operations on the machine shall only be carried out by high-qualified technicians.
Never carry out any operation while the machine is operating.
When the plant is operating, never put any object and tool into it.
Always disconnect the electric and pneumatic supply before carrying out any operation
on the machine.
The area around the machine must be clean, clear and well-lit.
Safety devices
Before starting the machine, always ensure that the safety devices have been
activated and are operating properly. 
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 17 of 114
2.2 Safety systems

The machine is supplied with active and passive safety systems: all these systems
allow to avoid dangers to the people working on the machine or staying nearby.
Violation, change or elusion of the safety systems

It is absolutely forbidden to tamper with, change or try to elude in any way the safety
systems of the machine. 
Safety and soundness of the machine

The presence of safety systems does not relieve the operators from working with
the utmost care, avoiding behaviours that could endanger their own safety or the
soundness of the machine. 
2.2.1 Protection of the electric system

The electric system has been designed and manufactured so as to protect the
operators from electric shocks and to protect the machine from overheating or any
other dangerous condition.
All the accessible metallic parts of the machine are connected to the unipotential
protection circuit, in order to avoid dangers deriving from faults of the insulation.
Moreover, all the electric devices with which the operators come into contact
(pushbuttons, indicators etc.) are fed with a low voltage deriving from a transformer
(that galvanically separates them from the high voltage section); they are liquid-
proof and vapour-proof, in order to avoid short-circuits or any deterioration of the
insulation.
There are also protections against overcurrent, so as to avoid that possible faults may
cause overheating or dangerous conditions.
2.2.2 Mechanical protections

The machine is equipped with fixed guards protecting the moving parts and the
driving gears.
When designing the protection devices, the regulations included in the UNI EN 294,
UNI EN 349 and UNI EN 811 standards have been taken into consideration: such
norms refer to the safety distances preventing the user from reaching the hazardous
zones with his/her upper and lower limbs and to the minimal spaces to avoid the
crushing of parts of the body.
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 18 of 114
2.2.3 Safety devices

The picture shows the safety devices installed on the palletizing plant mod. POLIMAT®
EVO 25.
The safety devices installed shall be evaluated according to the specific configuration
of a plant; therefore all the safety aspects and relevant reference norms shall be
taken into consideration when evaluating the characteristics of each palletizing plant.
3 8
6
7
2.1
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 19 of 114
List of the safety devices:
Main switch with padlock, placed on each main electric control

board (Pos. 1 Fig. 2.1).
Mushroom-head button with key, placed on the main operator

panel (Pos. 2 Fig. 2.1) and on the secondary operator panel (Pos.
3 Fig. 2.1).
Lamp signaling the machine start and alarm status; it is placed

on the lifting table.
Protection barriers, 2-meter high, placed on the floor: they are

equipped with doors with safety microswitch (Pos. 4 Fig. 2.1).
Protection barriers placed in the higher section of the palletizer:
they are equipped with kick-strip profile and access gate with
safety microswitch (Pos. 5 Fig. 2.1).
Barriers with safety photocells to prevent the operators from

entering the bags take-up area (Pos. 6 Fig. 2.1).
The floor of the bags take-up area is foreseen with a mass-

detection probe (Pos. 7 Fig. 2.1) connected to a device which
decodes the signal in the presence of the forklift truck. This device
allows only forklift trucks being properly positioned to enter the
take-up area.
Safety pin of the lifting table (Pos. 8 Fig. 2.1).

Before entering the working area of the lifting table, the operator
shall put the safety pin in its proper seat so to prevent any
movement.
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 20 of 114
2.3 Interventions on the machine

To carry out all the routine maintenance operations (cleaning of the photocells,
adjustments for the change of size, removal or arrangement of the bags) or other
maintenance interventions under safety conditions the operator shall always:
• disconnect the machine from the power supply by means of

the main switch with padlock placed on the electric control board
(Fig. 2.2).
2.2
All the maintenance operations can only be carried out after opening the door of the
safety barriers (Fig. 2.3); the door is equipped with an electric interlock system which
allows to carry out these operations safely.
2.3
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 21 of 114
Access to the machine

In order to enter the machine only use the doors of the safety barriers; any other
access is forbidden. 
To open the door of the safety barriers pull the handle (Pos. 1 Fig. 2.4) in the direction
shown in the picture; the safety microswitch cuts off the power supply of the machine.
2.4
To prevent the door from accidentally closing, use a safety padlock (Pos. 1 Fig. 2.5):
when the door is open, pull the handle in the direction shown in the picture and insert
the mechanical ring of the padlock in the slot of the bolt (Pos. 2 Fig. 2.5).
2.5
Once the routine maintenance operations have been carried out, leave the protected
area, remove the safety padlock, close the door and the handle so to trip the safety
microswitch.
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 22 of 114
2.4 Improper use of the machine

The machine shall not be used for purposes different from those it has been destined
to (see chapter 3). Each time the machine is used for any other purpose it could
cause dangers, since the safety foreseen at a design level cannot be fully guaranteed.
2.5 Operators’ clothing

All personnel working with the machine shall be properly trained on the correct
working methods, and shall be informed about the type and the operation of the
safety devices.
All the operators shall read this manual carefully.
Operators shall not wear large and fluttering clothes that could get caught in the
moving parts of the machine.
Moving elements
Do not get your clothes near the moving elements. 
Operators shall wear the accident prevention clothing foreseen in the working area,
such as protective glasses, gloves, shoes and headsets, according to the laws in force
in the country where the machine is installed.
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 23 of 114
2.6 Safety signals and information plates

All safety signals and information plates shall always be complete and perfectly
readable; if necessary, clean them using only water or soap detergents. Do not use
solvents or any other product that could damage the signals.
Replace the damaged plates with new ones, placing them always in the same place.
Safety procedures and indications

Follow the safety procedures and indications described on the plates, decals and/or
pictograms foreseen on the machine. 
DANGER OF ELECTRIC SHOCK: it is forbidden to enter the area when the machine is
energized.
On the gates of the protection barriers the following safety signals and information
plates are mounted:
VI ETATO SALI RE SULLE RULLI ERE

GET ON DRAWING FRAME ROLLER
IS NOT ALLOWED
IL EST INTERDIT DE MONTER SUR LES
CONVEYEURS A’ ROULEAUX
PROHIBIDO SUBIR SOBRE LOS
TRANSPORTADORES A RODILLOS
ES IST VERBOTEN, AUF DIE
ROLLENFORDERER ZU STEIGEN
SKIDDING DANGER: it is forbidden to mount onto the roller ways.
MACCHINA AD AVVIAMENTO AUTOMATICO

SELF-STARTING ENGINE
MACHINE À DÈMERRAGE AUTOMATIQUE
MÁQUINA A ENCENDIDO AUTOMÁTICO
MASCHINE MIT AUTOMATISCHEM START
MÁQUINA DE ARRANQUE AUTOMÁTICO
МАШИНА С АВТОМАТИЧЕСКИМ ЗАПУСКОМ
ATTENTION: self-starting machine.
Ventomatic.
POLIMAT® EVO 25
MD00366G02
Page 24 of 114
Crush danger signs are mounted on the lifting table uprights (Pos. 1 Fig. 2.6).
2.6
ATTENTION: crush danger area.
2.7 Demolition and disposal

Useful information for the disposal of the machine and its components.
The demolition operations shall be carried out by skilled personnel, equipped with
personal and general protection devices, according to the accident prevention laws
and the environment protection regulations.
Construction material:
• steel, aluminium, cast iron;
• copper and silver for the electric components;
• rubber, nylon, PVC, resins and fibers.
To our knowledge no component is harmful or toxic.
Be extremely careful when disposing of the gearmotors, since they contain oil.
Do not abandon them in the environment, and do not dispose of them as waste.
Disposal
After exceeding their useful lifetime, all the machines and components shall be
disposed of according to the laws in force in the countries of use.
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 25 of 114
3.0 Technical information

Table of contents
3.0 Technical information............................................................................... 25
3.1 Description of the machine................................................................. 26
3.2 Composition of the machine................................................................ 26
3.2.1 Bags-rotating group................................................................... 28
3.2.2 Accumulation/transfer belt.......................................................... 29
3.2.3 Half-layer formation belt............................................................ 30
3.2.4 Layer formation plate................................................................. 31
3.2.5 Layer-shifting module................................................................ 32
3.2.6 Lifting table and openable plates................................................. 33
3.3 Layer formation cycle......................................................................... 34
3.4 Photocells and proximity switches........................................................ 36
3.5 Identification of the manufacturer and the machine................................ 37
3.6 Overall dimensions............................................................................ 38
3.7 Technical data................................................................................... 39
3.8 Position of the operators..................................................................... 40
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 26 of 114
3.1 Description of the machine

The palletizer mod. POLIMAT® EVO 25 is an automatic machine designed to arrange
the bags onto pallets. The bags size can vary according to their capacity, while the
bags arrangement can have various configurations according to the loading program
selected.
The processing operations are the following:

• rotation of the bags;
• formation of the half-layer;
• translation of the half-layer;
• translation of the layer;
• deposit of the layer;
• formation of the pallet or the pile of bags;
• evacuation of the pallet or the pile of bags.
A characteristic of the palletizer mod. POLIMAT® EVO 25 is its modular composition,

each module having a specific function; the modules may vary according to the
product to be palletized.
3.2 Composition of the machine

The palletizer mod. POLIMAT® EVO 25 can have the following configurations:
Bags-rotating group (Pos. 1 Fig. 3.1).

Half-layer formation belt (Pos. 2 Fig. 3.1):
• fixed bottom blade (Pos. 3 Fig. 3.1);
• multi-position bottom blade (Pos. 4 Fig. 3.1).
Layer-shifting module (Pos. 5 Fig. 3.1).
Layer formation plate:
• layer formation standard plate (Pos. 6 Fig. 3.1);
• layer formation plate with motorized roller (Pos. 7 Fig. 3.1).
Openable plates (Pos. 8 Fig. 3.1):
• fixed bags-compaction blades (Pos. 9 Fig. 3.1);
• multi-position bags-compaction blades (Pos. 10 Fig. 3.1).
Lifting module:
• lifting module with motorized roller way and belt (Pos. 11 Fig. 3.1);
• lifting module with forks for pallets (Pos. 12 Fig. 3.1);
• lifting module with forks for slip sheets (Pos. 13 Fig. 3.1).
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 27 of 114
5
7
2
8
10
6 1
11
12
13
3.1
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 28 of 114
3.2.1 Bags-rotating group

The bags-rotating group conveys the incoming bags up to the accumulation/transfer
belt and turns the bags by 90° according to the layer being formed.
The group is composed of a belt conveyor (Pos. 1 Fig. 3.2) driven by a gearmotor
(Pos. 2 Fig. 3.2). On the frame of the belt a bags-rotating group is installed, which is
composed of a side board (Pos. 3 Fig. 3.2) and of a bags-rotating blade (Pos. 4 Fig.
3.4) driven by a gearmotor (Pos. 5 Fig. 3.2).
On request a bags-rotating group is available (Pos. 6 Fig. 3.2) with electric adjustment
for the change of bag size.
When the bag currently passing is not to be turned, the bags-rotating blade (Pos. 4
Fig. 3.2) is inside and the bag passes keeping its incoming position.
When the bag is to be turned by 90°, the bags-rotating blade (Pos. 7 Fig. 3.2)
moves outside and tilts it by about 30°. During its passage onto the belt, the inclined
bag meets on its path the bags-turning roller (Pos. 8 Fig. 3.2) which completes its
90°-rotation.
5
2 6 6
3 6
8
3
3.2
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 29 of 114
3.2.2 Accumulation/transfer belt

The accumulation/transfer belt forms the rows of bags composing the half-layer.
The group is placed between the bags-rotating group and the half-layer formation
belt, and is composed of a belt conveyor (Pos. 1 Fig. 3.3) driven by a gearmotor with
inverter (Pos. 2 Fig. 3.3) and of a photocell (Pos. 3 Fig. 3.3).
The bag arrives on the belt turned or straight, according to the position it will take
in the half-layer. The photocell of the bags-rotating group sends the signal that the
first bag is approaching the belt; after a preset time has elapsed, this stops to form
the row of bags.
3.3
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 30 of 114
3.2.3 Half-layer formation belt

The half-layer formation belt receives the bags coming from the accumulation/
transfer belt.
This group is composed of a belt conveyor (Pos. 1 Fig. 3.4) driven by a gearmotor
(Pos. 2 Fig. 3.4).
On the half-layer formation belt the bags pile up against the bottom blade.
When the half-layer has been completed, the belt conveyor stops to allow the
translation of the bags by means of the layer-shifting module.
The bottom blade can be fixed (Pos. 3 Fig. 3.4) or equipped with gearmotor with a
rod/handle mechanism (Pos. 4 Fig. 3.4) that positions the blade according to the bag
size being processed.
3.4
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 31 of 114
3.2.4 Layer formation plate

On this plate (Pos. 1 Fig. 3.5) two half-layers coming from the half-layer formation
belt form the layer of bags. Once the layer has been completed, it is conveyed onto
the openable plates, so to be deposited on the pallet.
This plate is also available with a motorized capstan (Pos. 2 Fig. 3.5) (optional).
3.5
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 32 of 114
3.2.5 Layer-shifting module

The layer-shifting module is composed of a supporting framework inside which a
trolley (Pos. 1 Fig. 3.6) slides; the trolley is driven by a gear motor (Pos. 2 Fig. 3.6)
and a toothed belt.
The trolley (Pos. 3 Fig. 3.6) is foreseen with:
• two blades (Pos. 4/5 Fig. 3.6) driven by a couple of reduction gears (Pos. 6/7
Fig. 3.6) that lowers behind the bags and moves them;
• two chimney-formation blades (Pos. 8 Fig. 3.6) driven by a couple of reduction
gears (Pos. 9/10 Fig. 3.6) that move to form the layer.
The blade (Pos. 4 Fig. 3.6) conveys the bags from the half-layer formation belt (Pos.
11 Fig. 3.6) to the layer formation plate (Pos. 12 Fig. 3.6).
The blade (Pos. 5 Fig. 3.6) conveys the bags from the layer formation plate (Pos. 12
Fig. 3.6) to the openable plates (Pos. 13 Fig. 3.6).
The carriage stroke can be adjusted according to the size of the layer.
8
6
9
7
10 4
5
2 11
4
1 12
13
3.6
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 33 of 114
3.2.6 Lifting table and openable plates

Once the layer of bags has been completed, it is conveyed onto the openable plates
(Pos. 1 Fig. 3.7) where a set of blades compact it on its four sides: two lateral blades
(Pos. 2 Fig. 3.7), one bottom blade (Pos. 3 Fig. 3.7) and one layer-shifting blade.
The openable plates (Pos. 1 Fig. 3.7) are composed of two plates sliding along guides.
Their motion is driven by a gearmotor.
When the plates (Pos. 1 Fig. 3.7) open, the layer is placed onto the lifting platform
(Pos. 6 Fig. 3.7), that is already positioned below the openable plate.
The lifting table is composed of a vertical guide (Pos. 4 Fig. 3.7) and a lifting platform
(Pos. 5 Fig. 3.7) driven by a gearmotor with encoder (Pos. 7 Fig. 3.7).
The lifting platform (Pos. 5 Fig. 3.7) can be foreseen with:
• motorized roller way with belt (Pos. 6 Fig. 3.7);
• forks (Pos. 8 Fig. 3.7);
• forks for slip sheets (Pos. 9 Fig. 3.7).
After the layer of bags has been deposited, the lifting platform (Pos. 6 Fig. 3.7) moves
down so that the openable plates (Pos. 1 Fig. 3.7) can close; then lifting platform
(Pos. 6 Fig. 3.7) moves up again to press the layer under the plates and finally moves
back to its position for a new deposit phase.
After all the layers forming the pile of bags have been deposited, the lifting platform
moves down again at a rapid speed to convey it to the next processing phases.
7
8
1
3
2
3.7
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 34 of 114
3.3 Layer formation cycle

Herebelow you will find the sequences carried out by the machine to form a layer of
bags.
3.8
3.9
3.10
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 35 of 114
3.11
3.12
3.13
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 36 of 114
3.4 Photocells and proximity switches

The machine is equipped with photocells (see fig. 3.14) and proximity switches having
the following functions:
1. Photocell, bags-rotating belt inlet.
2. Photocell, accumulation/transfer belt inlet.
3. Photocell, half-layer formation belt inlet.
4. Proximity switch, layer-shifting group backward.
5. Proximity switch, blade 1 of layer-shifting group high.
6. Proximity switch, blade 2 of layer-shifting group high.
7. Photocells, below mobile plates frame plate levelling.
8. Proximity switch, compacting blades.
9. Proximity switches, mobile plates.
10. Proximity switch, lifting forks low.
11. Limit switch, lifting forks.
12. Proximity switch, pallet feeler.
13. Photocell, full pallet onto roller way.
4
3
5
7
2
8 7
11
12 13
10
3.14
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 37 of 114
3.5 Identification of the manufacturer and the machine

On the frame of the palletizing module you will find an identification plate of the
machine.
The plate shows all the marking data (Fig. 3.15):

A. identification and address of the manufacturer;
B. job number;
C. position in the legend;
D. year of manufacture;
E. serial number;
F. type of machine;
G. model of the machine.
B Job: Ref.n°: Year: D

E Serial n°:
Designation:
F
G Type:
FLSmidth Ventomatic S.p.A.

A Via G. Marconi, 20 - 24030 Valbrembo (BG) - Italy
3.15
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 38 of 114
3.6 Overall dimensions

NOTE: The dimensions have not been indicated, since each plant is characterized by
specific sizes; for the installation please refer to the detailed layout drawings supplied
separately.
3.16
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 39 of 114
3.7 Technical data

The standard version of the machine can handle bags having the following
characteristics:
Characteristics of the pile of bags
Material of the bag paper/polyethylene

Dimensions in mm. length 400/700 width 300/450
Type of bag glued with valve, sewn
Bags number/layer 5 with bags of 50 kg
8 with bags of 25 kg
Capacity
Bags/hour 2400 with bags of 50 kg
2800 with bags of 25 kg
Power
Installed power see electric diagram
Noise level
Noise level equivalent to the weighed acoustic pressure A lower than 65 dBA.
at 1 meter
Max. instantaneous weighed acoustic pressure C in the lower than 70 dB/20mPa
working places
Working temperatures
Max. relative humidity allowed 80%

Min. ambient temperature allowed (storage) -20° C
Max. ambient temperature allowed (storage) +50° C
Min. ambient temperature allowed (operation) +5° C
Max. ambient temperature allowed (operation) +40° C
Max. production time allowed (without pauses) 23,5 hrs.
Operators
Number of operators in 1 with supervisory tasks 1 with unloading tasks

automatic mode
Ventomatic.
POLIMAT® EVO 25
MD00367G03
Page 40 of 114
3.8 Position of the operators

Two operators are required for the operation of the POLIMAT® EVO 25: one operator
has supervisory tasks, and shall control the whole working process, while the task of
the other operator is to unload.
3.17
Working station of the operator (Pos. 1 Fig. 3.17) with supervisory tasks.
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 41 of 114
4.0 Handling and installation information

Table of contents
4.0 Handling and installation information......................................................... 41
4.1.1 Responsabilities........................................................................ 42
4.2 Packing and unpacking....................................................................... 42
4.3 Checking of the installation requirements.............................................. 43
4.4 Lifting and transport.......................................................................... 44
4.4.1 Equipment required................................................................... 44
4.4.2 Marking of the points of support.................................................. 45
4.4.3 Lifting and transport.................................................................. 45
4.4.4 Positioning and assembling......................................................... 47
4.4.4.1 Lifting table and openable plates...................................... 47
4.4.4.2 Half formation plate........................................................ 48
rotating group........................................................................... 49
4.4.4.4 Layer-shifting module..................................................... 50
4.5 Electric connection............................................................................. 51
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 42 of 114
4.1 Addressees of the document

The operations described in this chapter are addressed to the following skilled
operators whose functions are the following:
Addressees Information requirements

H a n d l i n g Pack the equipment, check its right position into the package, close
operators it appropriately. Unpack the equipment in accordance with the
instructions indicated in the package. If required, these operations
must be carried out by means of lifting devices and under safe
Carriers Load the packed product on the means of transport by means
of lifting and containing devices, if required; stow and position it
adequately, transport it to its place of destination and then unload
it by carrying out the above-mentioned operations in reverse order,
always under safe conditions for the people, the product and the
environment.
I n s t a l l a t i o n Install the equipment, by explicit and implicit authorisation of
operators the purchaser and with the cooperation of the seller, under safe
conditions for people, the product and the environment, supplying
the user with the necessary instructions for its safe use and
maintenance.
(abstract of UNI 10653 standard)
4.1.1 Responsabilities
Given the complexity of the machine installation, the responsibilities of those in charge
of the machine handling and installation operations are defined in the contract.
4.2 Packing and unpacking

The machine can be packed:
• with wooden cases;
• in containers.
The machine is shipped partially assembled, some components have been disassembled
to ease their transport; all components have been properly packed and protected.
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 43 of 114
Once the packings have been correctly positioned, proceed with the unpacking as
follows:
A. make sure that the content of the packings complies with what is indicated in
the shipment documents;
B. visually check the soundness of all the electric components;
C. should any component/part be missing, immediately stop the unpacking
operations and inform FLSmidth Ventomatic S.p.A.;
D. if the plant has been damaged during its transport, immediately inform the
insurance company and stop the unpacking operations until you are authorized by
the company itself to proceed.
Responsability
The manufacturer declines any responsibility for damages to the machines due to
incorrect handling operations carried out by unqualified personnel or with the help of
unsuitable means. 
Disposal
The packing material shall be properly disposed of according to the laws in force. 
4.3 Checking of the installation requirements

Except for specific layout indications, the foundations of the plant must be arranged
according to the drawings supplied by the manufacturer.
The area required for the assembling depends on the lifting and handling means
provided by the purchaser.
The room shall be foreseen with the connections for power supply and compressed
air.
Setting of the connections

The position and size of the connections are set out by the manufacturer and are
shown in the layout enclosed. 
Positioning of the machine

The surface of the area housing the machine shall be perfectly leveled and suitable to
bear the specific load of the anchorages (see layout enclosed). 
Arranging the area

The purchaser is responsible for arranging the area of the plant according to the
safety norms and requisites in force. 
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 44 of 114
4.4 Lifting and transport

Before lifting and transporting the machine, check its overall dimensions and weights,
and use suitable means. To have a correct view of the weight of the machine and of
its groups please refer to the packing list.
Lifting
The capacity of the lifting devices shall correspond to the weight of the different parts
to be handled (including the safety margins) and to the capacity increase foreseen
by the safety norms. 
Pay particular attention to the capacity of the lifting equipment (steel cables, chains,
fiber ropes) in respect to the inclination of the two section composing the sling. The
force acting on each of them strongly varies; the picture below illustrates the acting
loads.
30°
500 Kg
60°
g
7K
51
90°
Kg
7
57
g 120° 75°
K 60°
7 07 45°
Kg 150° 30°
0 0
10
15°
Kg
1932
1000 Kg
4.1
4.4.1 Equipment required

For the installation the following equipment is required:
• lifting devices with hook;
• lifting chains or cables;
• eyebolts with threaded shaft;
• workshop keys;
• level.
For the screws use a standard torque (if nothing else is indicated).
Use a torque wrench if required.
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 45 of 114
4.4.2 Marking of the points of support

Mark the points of supports of the modules of the palletizer according to the layout
enclosed.
Position the log bolts (Pos. 1 Fig. 4.2) and check the availability of base shims (h
=35 mm.) (Pos. 2 Fig. 4.2) and leveling shims (h=0,5-1 mm.) (Pos. 3 Fig. 4.2) to be
interposed between the fastening plate (Pos. 4 Fig. 4.2) and the floor (Pos. 5 Fig. 4.2)
as well as of sealing material.
Points of support
Check that the points of support of the palletizer are aligned with the equipment
placed upstream and downstream the palletizer itself. 
5 2
4.2
4.4.3 Lifting and transport

The machine shall be lifted and handled by means of hemp ropes; apply the ropes on
the supporting framework as shown in the figure (Pos. 1 Fig. 4.3) and check that no
part may be damaged during the lifting phase.
The ropes shall be in good conditions, with the protections prescribed by the
regulations in force in the country where the machine is installed. The ropes or the
cables shall be long enough to ensure a top angle equal to or lower than 90°.
4.3
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 46 of 114
The fig. 4.4 shows the weight for lifting and transporting the modules.
The palletizer shall be installed and mounted by skilled technicians, appointed or
defined by the manufacturer, under the supervision of a person in charge duly
appointed by FLSmidth Ventomatic S.p.A.
Safety devices
The barriers and all the safety devices shall be installed according to the relevant
layout drawings. 
2350 Kg.
150 Kg.
1800 Kg.
2200 Kg.
1000 Kg.
2200 Kg. 2250 Kg.
4.4
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 47 of 114
4.4.4 Positioning and assembling

The positioning and assembling of the various modules composing the palletizer are
described in the following paragraphs.
4.4.4.1 Lifting table and openable plates
There are three possible alternatives for the lifting module:
• lifting module with motorized roller way and belt (Pos. 1 Fig. 4.5);
• lifting module with forks for pallets (Pos. 2 Fig. 4.5);
• lifting module with forks for slip sheets (Pos. 3 Fig. 4.5).
Position the lifting module (Pos. 4 Fig. 4.5) in its preset point and mount the openable
plates group (Pos. 5 Fig. 4.5).
If necessary, insert leveling shims between the fastening plates and the base shims,
in order to ensure the perfect levelness of the openable plates.
Geometrical verification
Check the levelness of the openable plates by means of a spirit level. 
Check that the height from the floor of the openable plates is equal to the height of
the transport plates (belts) of the other modules. 
Mount the lifting module (Pos. 4 Fig. 4.5) fixing it to the openable plates group (Pos.
5 Fig. 4.5).
If necessary, insert leveling shims between the fastening plates and the base shims,
in order to ensure the perfect levelness of the lifting module.
3
2
4.5
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 48 of 114
4.4.4.2 Half formation plate

Fasten the half formation plate (Pos. 1 Fig. 4.6) to the lifting module (Pos. 2 Fig. 4.6)
with the bolts included in the supply.
Check the flatness of the lifting module and of the half formation plate with the help
of a spirit level. 
4.6
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 49 of 114

rotating group
Position the legs of the framework supporting the half-layer formation belt (Pos. 1
Fig. 4.7), the accumulation/transfer belt (Pos. 2 Fig. 4.7) and the bags-rotating group
(Pos. 3 Fig. 4.7) in the properly defined points.
Mount the structure on the supporting legs and lock it with the bolts included in the
supply.
Mount the bracings (Pos. 5 Fig. 4.7) between the supporting legs and the structures,
locking them with the bolts included in the supply.
Fasten the module to the layer formation plate (Pos. 4 Fig. 4.7).
Check the flatness of the half-layer formation belt, of the accumulation/transfer belt
and of the bags-rotating group with the help of a spirit level.
2
3
4
5
4.7
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 50 of 114
4.4.4.4 Layer-shifting module

Mount the layer-shifting trolley group (Pos. 1 Fig. 4.8) and fasten it with the bolts
included in the supply.
Check the flatness of the layer-shifting module with the help of a spirit level. 
4.8
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 51 of 114
4.5 Electric connection

Together with the documents of the plant FLSmidth Ventomatic S.p.A. supplies a
lay-out diagram, showing the position and the type of canals (if present) to host the
connection cables going from the control cubicle to the pull boxes.
Electric line
The electric line which the control cabinet will be connected to shall comply with the
norms in force and shall have a correct earthing. Do not use the earth cable to bypass
different voltages, since the electronic devices of the machines might be subject to
disturbances. 
Accident prevention regulations

The connection shall be carried out only by skilled technicians which are familiar with
the accident prevention laws. 
We suggest you to shunt the power from a main switch, a differential magnetothermal
switch, set on the wall, having a thermal protection with suitable amperage.
As for the minimum section of the supply cable, please refer to the voltage and the
power marked on the identification tag, according to the regulations in force in the
country where the machine is to be installed.
For the identification of the pull boxes and the numeration of the connection cables
please consult the specific electric diagram of the plant.
Ventomatic.
POLIMAT® EVO 25
MD00368G02
Page 52 of 114
Ventomatic.
POLIMAT® EVO 25
MD00369G02
Page 53 of 114
5.0 Adjustment information

Table of contents
5.0 Adjustment information........................................................................... 53
5.2 Warnings.......................................................................................... 54
5.3 Tension of the bags-rotating belt......................................................... 55
5.4 Tension of the accumulation/transfer belt.............................................. 56
5.5 Tension of the half-layer formation belt................................................. 57
Ventomatic.
POLIMAT® EVO 25
MD00369G02
Page 54 of 114

operators whose functions are the following:

M a i n t e n a n c e Carry out routine check, verification and adjustment operations
operators and, if required, small repairs, according to the maintenance
schedule supplied by the manufacturer, always under safe
user, if required; carry out all necessary repairs, replacement
and adjustment operations, so that the product can work
correctly under safe conditions for the people, the product and
the environment.
5.2 Warnings
The machine is equipped with a series of adjustments (mechanic or panel-operated
adjustments), which allow the operator to adapt the machine to the required
production, the type of product used or simply to set it up properly.
Adjustment operations
All the adjustment operations shall only be carried out by skilled technicians, having
proper skills to recognize and avoid any danger while carrying out their tasks. 
Ventomatic.
POLIMAT® EVO 25
MD00369G02
Page 55 of 114
5.3 Tension of the bags-rotating belt

To adjust the tension of the belt:
• loosen the fastening screws (Pos. 1 Fig. 5.1) of the contrast rollers of the belt
placed on the frame;
• act on the adjusting screws (Pos. 2 Fig. 5.1) until you achieve the tension
required to ensure the constant rotation of the belt;
• once you achieve the proper tension, tighten the clamping screws.
5.1
Ventomatic.
POLIMAT® EVO 25
MD00369G02
Page 56 of 114
5.4 Tension of the accumulation/transfer belt

5.2
Ventomatic.
POLIMAT® EVO 25
MD00369G02
Page 57 of 114
5.5 Tension of the half-layer formation belt

5.3
Ventomatic.
POLIMAT® EVO 25
MD00369G02
Page 58 of 114
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 59 of 114
6.0 Maintenance information

Table of contents
6.0 Maintenance information.......................................................................... 59
6.2 Routine maintenance......................................................................... 60
6.2.1 General rules............................................................................ 61
6.2.2 Cleaning and checking at the end of production............................. 61
6.2.3 Monthly checkout (400 hours)..................................................... 61
6.2.4 Maintenance of the bags-rotating group....................................... 62
6.2.5 Maintenance of the accumulation/transfer belt.............................. 64
6.2.6 Maintenance of the half-layer formation belt................................. 66
6.2.7 Maintenance of the layer formation plate...................................... 68
6.2.8 Maintenance of the layer-shifting module...................................... 69
6.2.9 Maintenace of the palletizing module............................................ 70
6.2.10 Maintenance of the lifting modules with forks.............................. 71
6.2.11 Maintenance of the lifting module with motorized roller way and belt...72
6.3 Summary table of the maintenance operations...................................... 74
6.4 Table of lubricants............................................................................. 76
6.4.1 Table of lubricants for reduction gears.......................................... 76
6.4.2 Table of lubricants for supports, bearings, guides and chains........... 76
6.5 Lubrication of the supports with bearing............................................... 77
6.6 Lubrication of the reduction gears........................................................ 78
6.6.1 Check of the reduction gears....................................................... 78
6.7 Lubrication of the chains..................................................................... 79
6.7.1 Wear and replacement............................................................... 79
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 60 of 114

operators, whose functions are the following:

Maintenance Carry out routine check, verification and adjustment operations and,
operators if required, small repairs, according to the maintenance schedule
supplied by the manufacturer, always under safe conditions for the
people, the product and the environment.
user, if required; carry out all necessary repairs, replacement and
adjustment operations, so that the product can work correctly under
safe conditions for the people, the product and the environment.
6.2 Routine maintenance

FLSmidth Ventomatic S.p.A. declines any responsibility if the maintenance cycles
indicated in this manual and in the documents enclosed are not properly followed, if
maintenance is assigned to unskilled personnel or if procedures or lubricants having
characteristics non compatible with those indicated by us are used.
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 61 of 114
6.2.1 General rules

The systematic control of the operation of some of the most important elements
of the machine can avoid operation faults in the future, and helps in keeping the
machine at its maximum operational levels.
Skilled technicians
The maintenance operations shall be carried out by operators skilled in their specific
sector, having proper experience, technical training and knowledge of the relevant
regulations. The maintenance operations shall be carried out with the machine
properly isolated at an electric level. 
ELECTRIC DISCONNECTION:
• press the emergency button;
• turn the main switch to OFF and lock it by means of a padlock.
Safety devices
Every day check the conditions and operation of the safety devices. 
6.2.2 Cleaning and checking at the end of production

Once the plant has been stopped, clean with a jet of compressed air all the components
of the plant and in particular:
• the linear guides;
• the kinematic motion groups;
• the instruments;
• the photocells and reflection units;
• the signals.
Do not use water jets.
6.2.3 Monthly checkout (400 hours)

Every month you shall check that:
• all the mechanical lifting equipment and relevant connections are properly
connected to one another and do not show parts partially unscrewed or having too
much clearance;
• dust, dirt or rust laying on the motion groups do not hinder their movement,
uselessly overloading the movers;
• no component shows clear wear signs;
• the bearings slide properly;
• the rolling supports are properly greased.
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 62 of 114
6.2.4 Maintenance of the bags-rotating group

The maintenance operations are the following:
• see par. 6.2.3 “Monthly checkout;

- 400 hours - • tighten and adjust the belt (Pos. 1 Fig. 6.1);
• check the proper alignment and fastening of the photocell;
• check the wear of the belt (Pos. 1 Fig. 6.1);
• check the wear of the wearproof plate (Pos. 2 Fig. 6.1);
• check the wear of the wear plate (Pos. 3 Fig. 6.1);
- 2400 hours -
• check the wear of the blade (Pos. 4 Fig. 6.1);
• check the oil of the reduction gears (Pos. 5 Fig. 6.1);
• grease the supports and the bearings;
- 12000 hours - • change the oil of the reduction gears (Pos. 5 Fig. 6.1).
1 5
5
6.1
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 63 of 114
To replace the belt (Pos. 1 Fig. 6.2) and/or the wearproof plate (Pos. 2 Fig. 6.2)
proceed as follows:
• disconnect the reduction gear (Pos. 3 Fig. 6.2) from the power supply and
remove it;
• disconnect the bags-rotating group (Pos. 4 Fig. 6.2) from the power supply and
remove it, the contrast blade (Pos. 5 Fig. 6.2) and the bags-rotating roller (Pos. 6
Fig. 6.2);
• remove the supports (Pos. 7 Fig. 6.2), extract the rollers (Pos. 8 Fig. 6.2) and
the belt (Pos. 1 Fig. 6.2);
• unscrew the fastening countersunk screws and remove the wearproof plate
(Pos. 2 Fig. 6.2) and replace it;
• unscrew the fastening countersunk screws and remove the wear plates (Pos. 9
Fig. 6.2) and replace them;
• replace the belt;
• reassemble again all the parts following the reverse sequence, then tighten the
belt.
8 7
9
4 9
1 7
8
3
7 5
6.2
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 64 of 114
6.2.5 Maintenance of the accumulation/transfer belt


• tighten and adjust the belt (Pos. 1 Fig. 6.3);
- 400 hours -
• check the proper alignment and fastening of the photocells
(Pos. 2 Fig. 6.3);
- 2400 hours -
• check the oil of the reduction gear (Pos. 4 Fig. 6.3);
- 12000 hours - • change the oil of the reduction gear (Pos. 4 Fig. 6.3).
4
2
1
2
6.3
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 65 of 114
proceed as follows:
remove it;
• remove the support of the wearproof plate (Pos. 4 Fig. 6.4)
belt.
6 5
5
3
5
2
2
6.4
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 66 of 114
6.2.6 Maintenance of the half-layer formation belt


• tighten and adjust the belt (Pos. 1 Fig. 6.5);
- 400 hours -
• check the proper alignment and fastening of the photocells
(Pos. 2 Fig. 6.5);
- 2400 hours -
1
2
3 2
6.5
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 67 of 114
proceed as follows:
remove it;
belt.
4
4
3 1
5
6.6
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 68 of 114
6.2.7 Maintenance of the layer formation plate


- 400 hours -
• check the proper alignment and fastening of the photocells;
- 2400 hours -
6.7
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 69 of 114
6.2.8 Maintenance of the layer-shifting module

- 400 hours - • see par. 6.2.3 “Monthly checkout;

- 2400 hours - • check the oil of the reduction gear (Pos. 1 Fig. 6.8);
- 9600 hours - • grease the bearings;
The reduction gears (Pos. 2/3 Fig. 6.8) are foreseen with long-life lubrication and do
not need any maintenance intervention.
2
3
2
3
6.8
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 70 of 114
6.2.9 Maintenace of the palletizing module


• check the operation of the driving belt of the openable
plates;
- 400 hours -
• check the wear of the sheets of the openable plates (Pos.
1 Fig. 6.9) and of the wear plates of the bags-compacting blades
(Pos. 2 Fig. 6.9);
• grease the lifting chains (Pos. 3 Fig. 6.9);
- 2400 hours - • check the oil of the reduction gears (Pos. 4/5/6/7/8/9 Fig.
6.9);
• grease the bearings;
- 9600 hours -
• change the lifting chains (Pos. 3 Fig. 6.9);
• change the oil of the reduction gears (Pos. 4/5/6/7/8/9 Fig.
- 12000 hours -
6.9).
5
4
2
1
5
2
3
7
6.9
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 71 of 114
6.2.10 Maintenance of the lifting modules with forks


- 2400 hours -
- 9600 hours -
6.10
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 72 of 114
6.2.11 Maintenance of the lifting module with motorized roller way and belt

- 2400 hours - • check the wear of the belt (Pos. 2 Fig. 6.11);
- 9600 hours -
6.11
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 73 of 114
To replace the belt proceed as follows:

• loosen the tension of the belt acting on the tensioning roller (Pos. 1 Fig. 6.12);
• cut the belt and extract it from the frame while rolling it up;
• remove the motorized drum (Pos. 2 Fig. 6.12), the idle drum (Pos. 3 Fig. 6.12),
the tensioning roller (Pos. 1 Fig. 6.12) and the idle rollers (Pos. 4 Fig. 6.12);
• insert the new belt on the frame;
• mount again the motorized drum (Pos. 2 Fig. 6.12), the idle drum (Pos. 3 Fig.
6.12), the tensioning roller (Pos. 1 Fig. 6.12) and the idle rollers (Pos. 4 Fig. 6.12);
• check that the fastening bolts of the mechanical components are properly
tightened;
• tension the belt acting on the tensioning roller (Pos. 1 Fig. 6.12).
6.12
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 74 of 114
6.3 Summary table of the maintenance operations

The table below summarizes the maintenance operations that shall be carried out
on the plant. The meaning of the letters and of the indications used in the table are
listed here below:
A. Intervention: Reset of the level

B. Intervention: Lubrication
C. Intervention: Oil check
D. Intervention: Oil change
E. Intervention: Inspection of the operation
(*) For the type of lubricant, please refer to the paragraph indicated.
Frequency hours
Reference
Par. Lub.
Quantity
Section of the
Component
12000
2400
4800
9600
machine
400
800
(*)
16
Belt E E
Photocell E
Wearproof plate E
Wear plate E
Bags-rotating group 6.2.4
Blade E
Reduction gear - belt 6.4.1 1,1 l. C D
Reduction gear - blade 6.4.1 0,7 l. C D
Supports/bearings 6.4.2 Variable B
Belt E E
Photocells E
Accumulation/
Wearproof plate E 6.2.5
transfer belt
Reduction gear 6.4.1 1,7 l. C D
Belt E E
Photocells E
Half-layer formation
belt
Photocells E
Layer formation
plate
Layer-shifting Reduction gear (Pos. 1) 6.4.1 1,5 l. C D

6.2.8
module Bearings 6.4.2 Variable B
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 75 of 114
Frequency hours
Reference
Section of the Par. Lub.
Quantity
12000
Component
2400
4800
9600
machine
400
800
(*)
16
Driving belt of the open. plates E
Wearproof plates E
Wear plates E
Lifting chains 6.4.2 Variable B E
Reduction gear - lifting 6.4.1 10,8 l. C D
Palletizing module Red. g. - lateral blades (Pos.5) 6.4.1 0,7 l. C D 6.2.9
Red. gear - openable plates 6.4.1 3 l. C D
Reduction gear - roller way 6.4.1 1 l. C D
Red. g. - lateral blades (Pos.8) 6.4.1 1,5 l. C D
Red. gear - bottom blade 6.4.1 1 l. C D
Bearings 6.4.2 Variable B
Lifting module with
Reduction gear - lifting 6.4.1 18,5 l. C D 6.2.10
fork
Lifting module with Belt E
motorized roller way Reduction gear - lifting 6.4.1 18,5 l. C D 6.2.11
and belt Reduction gear - roller way 6.4.1 1 l. C D
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 76 of 114
6.4 Table of lubricants

The following tables show:
1. The lubricants for the reduction gears (see par. 6.4.1)
2. The lubricants (grease) for the following elements (see par. 6.4.2):
• supports;
• bearings;
• guides;
• chains.
The abbreviations, the meaning of the shading and the indications used in the table
are listed here below:
CLP = mineral oil.
CLP PG = polyglycol (reduction gear W approved USDA-H1).
CLP HC = synthetic hydrocarbons.
HLP = hydraulic oil.
= synthetic lubricant (= grease for lubricants with synthetic basis).
= mineral lubricant (= grease for lubricants with mineral basis).
1. ambient temperature;
2. type of lubricant as per DIN (ISO);
3. ISO viscosity class or NLGI class;
4. at low temperatures, critical behaviour at startup.
6.4.1 Table of lubricants for reduction gears

For reduction gears use the lubricants (type OIL) listed below:
1)
®
Oil .3) ISO,NLGI Mobil
°C -50 0 +50 +100 2)DIN (ISO)
Standard Mobilgear Shell Omala Klüberoil Aral Degol BP Energol Tribol Optigear Renolin Spartan
-10 +40 CLP(CC) VG 220 Meropa 220 EP 220
600 XP220 220 GEM 1-220 N BG 220 GR-XP 220 1100/220 BM 220 CLP 220
Mobil Shell Tivela Klübersynth Aral Degol BP Enersyn Tribol Synlube Optiflex A Renolin
-25 +80 CLP PG VG 220 SG-XP 220
Glygoyle 220 S 220 GH 6-220 GS 220 800/220 CLP 220 220 PG 220
Mobil Shell Omala Klübersynth Aral Degol Tribol Pinnacle Optigear Syn- Renolin Unisyn
-40 +80 VG 220 thetic X 220 CLP 220
SHC 630 HD 220 GEM 4-220 N PAS 220 1510/220 EP 220
CLP HC
4) -40 +40 Mobil Shell Omala Klübersynth Pinnacle Optigear Syn- Renolin Unisyn
VG 150
SHC 629 HD 150 GEM 4-150 N EP 150 thetic X 150 CLP 150
VG 150 Mobilgear Shell Omala Klüberoil Aral Degol BP Energol Tribol Optigear Renolin Spartan
-20 +25 CLP (CC) GR-XP 100 Meropa 150 EP 150
VG 100 600 XP100 100 GEM 1-150 N BG 100 1100/100 BM 100 CLP 150
-30 +10 VG 68-46 Mobil Shell Tellus Klüberoil Aral Degol Tribol Rando EP Optigear Renolin Esso Automatic
HLP (HM) VG 32 D.T.E. 13M T 32 GEM 1-68 N BG 46 1100/68 Ashless 46 32 B 46 HVI Trasmission Fluid
4) Mobil Klüber-Summit Cetus Optilieb Renolin Unisyn
-40 +10 CLP HC VG 32 HySyn FG-32
SHC 624 PAO 46 HY 32 OL 32
4) -40 -20 VG 22 Mobil Shell Tellus Isoflex BP Energol Rando Hyspin Renolin
HLP (HM) VG 15 T 15 MT 30 ROT HLP-HM 15 HDZ 15 AWS 22 MR 310
D.T.E. 11M
6.4.2 Table of lubricants for supports, bearings, guides and chains

For supports, bearings, guides and chains use the lubricants (type GREASE) listed
below:
1)
Oil 3) ISO,NLGI Mobil ®
°C -50 0 +50 +100 2) DIN (ISO)
Esso
-25 +80 3 Unirex N3
DIN 51 502
Centoplex 2 Multifak EP 2
-25 +60 2-3 Mobilux EP2 Alvania R2 Beacon 2
Centoplex 2 EP Grease L2
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 77 of 114
6.5 Lubrication of the supports with bearing

Under normal operation conditions the bearings of the supports operate without
lubrication. In case of high humidity and dirt it is necessary however to lubricate
the bearings.The supports are equipped with a greaser to lubricate them at regular
intervals, according to the speed, the load and the environmental conditions. For
normal operation conditions use grease complying with N.L.G.I. n.2.3 consistency,
free of any dirt.
6.13
The ball-type greaser (Pos. 1 Fig. 6.13) is placed on the outside of the support,
therefore proceed as follows:
• smoothly insert the grease while rotating the bearing;
• grease often and in small quantities, a large greasing is deleterious;
• never lubricate with oil, always lubricate with grease using the relevant greaser.
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 78 of 114
6.6 Lubrication of the reduction gears

The oil-lubricated reduction gears are provided with filling plug, oil level and drain
plugs.
Periodically check (when the reduction gear is not working) the level of lubricant, and
change the oil every 12000 hours after accurately washing the reduction gear with
fluid oil and mineral naphtha.
In case of synthetic oil lubrication, wash the inside of the reduction gear so as to remove
any trace of mineral running-in oil and avoid any risk of lubricant saponification.
Avoid filling too much the casing of the reduction gear.
This would cause energy dissipation, thus damaging the reduction gear.
6.6.1 Check of the reduction gears

Reduction gears may have many construction forms. The picture below illustrates
the assembling position of the reduction gear and the position of the air valve. As a
general rule the reduction gear is supplied with the air valve activated (Pos. 1 Fig.
6.14).
6.14
Otherwise remove the sealing band before starting up the reduction gear. To activate
the air valve (Fig. 6.15):
1. air valve with sealing band;
2. remove the sealing band;
3. the air valve has been activated.
6.15
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 79 of 114
6.7 Lubrication of the chains

It is extremely important to properly lubricate the chains, so to ensure the lifetime
and the regular operation of a chain drive. Lubricate with a brush or a oiler, as
indicated in the table of the lubrication intervals. The quantity of oil and the frequency
of application must be enough to keep the chain humid, allowing the infiltration of the
lubricant in the joints.
6.16
6.7.1 Wear and replacement

The chain shall be considered worn out, and shall therefore be changed, when the
elongation due to the wear of the contact surface “pivot – bush” becomes excessive
(that is it exceeds 3% of the original length) and prevents the chain from properly
coupling with the driving gears; when the elongation exceeds certain values, the
roller of the chain tends to move onto the top of the gear tooth, thus missing the
tooth itself.
Ventomatic.
POLIMAT® EVO 25
MD00370G03
Page 80 of 114
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 81 of 114
7.0 Accessories information

Table of contents
7.0 Accessories information........................................................................... 81
7.1 Feeding roller way with idle rollers....................................................... 83
7.1.1 Installation............................................................................... 83
7.1.2 Pneumatic connection................................................................ 84
7.1.3 Maintenance............................................................................. 84
7.2 Pacing and pressing belt group............................................................ 85
7.2.1 Adjustment of the minimum distance between the pressing belts..... 86
7.2.2 Adjustment of the tension of the pressing belts............................. 87
7.2.3 Adjustment of the centering blades.............................................. 87
7.2.4 Maintenance............................................................................. 88
7.3 Pacing and pressing rollers group......................................................... 89
7.3.1 Adjustment of the pacing and pressing rollers............................... 90
7.3.2 Maintenance............................................................................. 91
7.4 Empty pallets roller way..................................................................... 92
7.4.1 Installation............................................................................... 93
7.4.2 Maintenance............................................................................. 93
7.4.3 Pallet-centering device............................................................... 94
7.4.3.1 Pneumatic connection..................................................... 95
7.4.3.2 Maintenance.................................................................. 95
7.5 Full pallets roller way......................................................................... 96
7.5.1 Installation............................................................................... 96
7.5.2 Maintenance............................................................................. 97
7.6 Belt roller way................................................................................... 98
7.6.1 Installation............................................................................... 98
7.6.2 Replacement and adjstment of the belt tension............................. 99
7.6.3 Maintenance........................................................................... 100
7.7 Pallet feeder................................................................................... 101
7.7.1 Operating cycle....................................................................... 101
7.7.2 Installation............................................................................. 102
7.7.3 Maintenance........................................................................... 102
7.8 Cardboard feeder............................................................................ 103
7.8.1 Operating cycle....................................................................... 103
7.8.2 Installation............................................................................. 104
7.8.3 Pneumatic connection.............................................................. 104
7.8.4 Maintenance........................................................................... 104
7.9 Full pallets translating roller way....................................................... 105
7.9.1 Installation............................................................................. 106
7.9.2 Maintenance........................................................................... 106
7.10 Rotating roller way......................................................................... 107
7.10.1 Installation........................................................................... 108
7.10.2 Maintenance......................................................................... 108
7.11 Rotating and translating roller way................................................... 109
7.11.1 Installation........................................................................... 110
7.11.2 Maintenance......................................................................... 110
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 82 of 114
7.12 Approaching roller way with idle rollers............................................. 111

7.12.1 Installation........................................................................... 111
7.12.3 Maintenance......................................................................... 112
7.13 Approaching roller way with motorized rollers.................................... 113
7.13.1 Installation........................................................................... 114
7.13.3 Maintenance......................................................................... 114
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 83 of 114
7.1 Feeding roller way with idle rollers

The feeding roller way with idle rollers is placed before the pacing and pressing belts
and rollers and ensures a constant feed of bags to the palletizer; its length allows a
proper stacking of the belts to compensate for those entering and leaving the roller
way.
Given its inclination and idle rollers, the roller way doesn’t need a motor drive system.
The idle roller way is provided with side boards (Pos. 1 Fig. 7.1) that keep the bags
going out in axis; the side boards can be adjusted manually or pneumatically (option)
(Pos. 2 Fig. 7.1) when the type or size of the bag have changed.
The roller way is also equipped with a photocell (Pos. 3 Fig. 7.1) in the inlet area that
stops the feeding of bags should a clogging occur.
7.1
7.1.1 Installation
To install the feeding roller way with idle rollers use the fastening plates mounted in
the lower part of the structure; please revert to the layout drawings for the dimensions
and inclination foreseen.
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 84 of 114
7.1.2 Pneumatic connection

Connect the pneumatic actuators of the adjustment side boards (option) as shown in
the pneumatic diagram below.
7.2
7.1.3 Maintenance
- 400 hours - • check the proper alignment and fastening of the photocell;
• check the operation of the pneumatic actuators;
- 4800 hours - Note: It is necessary to have a kit of seals available for each pneumatic
actuator (see the spare parts catalogue).
- 8000 hours - • check the wear of the rollers.
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 85 of 114
7.2 Pacing and pressing belt group

The pacing and pressing belt group is placed at the inlet of the palletizer. It receives the
bags from the feeding roller way with idle rollers and conveys them to the palletizer.
Its functions are the following:
• pacing of the bags entering the palletizer;
• pressing of the bags passing between the upper and lower belt, so to deaerate
them and compact the product packed.
The group is composed of a double pressing belt (Pos. 1/2 Fig. 7.3), a pair of centering
blades (Pos. 3 Fig. 7.3), a frame and a supporting framework.
The two pressing belts (Pos. 1/2 Fig. 7.3) are foreseen with an independent motor drive
system; the upper pressing belt (Pos. 1 Fig. 7.3) tilts and its oscillation determines
the pressing of the bags currently passing.
The centering blades (Pos. 3 Fig. 7.3) can be adjusted manually or by means of
pneumatic actuators (option); their function is to keep the bags leaving the group
centered.
At the end of the pressing belt an idle roller (Pos. 4 Fig. 7.3) conveys the bags to the
next group reducing the wear of the belt.
3
3
4
7.3
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 86 of 114
7.2.1 Adjustment of the minimum distance between the pressing belts

It is possible to adjust the minimum distance between the upper and lower belt, so
to determine the pressing action on the bag. Proceed as follows:
• act on the side supporting screws (Pos. 1 Fig. 7.4) until you achieve the minimum
distance required.
7.4
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 87 of 114
7.2.2 Adjustment of the tension of the pressing belts

To adjust the tension of the pressing belts proceed as follows:
• loosen the stop nuts of the supports of the lower/upper belt;
• act on the tie rods (Pos. 1/2 Fig. 7.5) until you achieve the required tension;
• once the proper tension has been achieved, tighten the stop nuts.
Geometrical check
Check the parallelism between the idle roller and the motorized roller. An improper
adjustment may compromise the function (misalignment) and the lifetime of the belt.

7.2.3 Adjustment of the centering blades

To adjust the centering blades (mechanical version) proceed as follows:
• loosen the stop nut (Pos. 3 Fig. 7.5) and turn the lock nut;
• once the required position has been achieved, tighten the lock nut.
As alternative to the mechanical version, the machine can be foreseen with a

pneumatic adjustment system (option) with pneumatic actuators (Pos. 4 Fig. 7.5).
7.5
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 88 of 114
7.2.4 Maintenance
• check the tension and the adjustment of the belts (Pos. 1/2
- 400 hours -
Fig. 7.6);
• check the oil of the reduction gears (Pos. 3 Fig. 7.6);
- 2400 hours -
• grease the supports;
• check the wear of belts (Pos. 1/2 Fig. 7.6);
• check the operation of the pneumatic actuators (Pos. 4 Fig.
- 4800 hours - 7.6);
Note: It is necessary to have a kit of seals available for each pneumatic
- 12000 hours - • change the oil of the reduction gears (Pos. 3 Fig. 7.6).
3
3
7.6
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 89 of 114
7.3 Pacing and pressing rollers group

The pacing and pressing belt group is placed at the inlet of the palletizer. It receives the
bags from the feeding roller way with idle rollers and conveys them to the palletizer.
Its functions are the following:
• pacing of the bags entering the palletizer;
• pressing of the bags passing between the rollers, so to deaerate them and
compact the product packed.
The group is composed of two rubberized rollers (Pos. 1/2 Fig. 7.7) with an independent
motor drive system, whose distance can be adjusted according to the bag and the
product being processed.
7.7
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 90 of 114
7.3.1 Adjustment of the pacing and pressing rollers

To adjust the distance and parallelism of the rubberized rollers proceed as follows:
• loosen the nut and the lock nut (Pos. 1/2 Fig. 7.8) and act on the tie rods (Pos.
3/4 Fig. 7.8) until you achieve the required position;
• once the proper adjustment has been achieved, tighten the nut and the lock nut
(Pos. 1/2 Fig. 7.8) locking the tie rods.
7.8
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 91 of 114
7.3.2 Maintenance
• check the oil of the reduction gears (Pos. 1/2 Fig. 7.9);
- 2400 hours - • grease the supports (Pos. 3 Fig. 7.9);
• check the wear of the rubberized rollers (Pos. 4/5 Fig. 7.9);
- 12000 hours - • change the oil of the reduction gears (Pos. 1/2 Fig. 7.9).
2
5
7.9
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 92 of 114
7.4 Empty pallets roller way

The function of the motorized roller way for empty pallets is to convey them to the
next working cycles. The roller way is composed of a framework (Pos. 1 Fig. 7.10)
housing the rollers (Pos. 2 Fig. 7.10) motorized by a chain drive driven by a gear
motor (Pos. 3 Fig. 7.10).
The roller way can be equipped with one of the following components, whose function
is to detect the presence of the pallets:
• detector with two elastic elements (Pos. 4 Fig. 7.10) lifting the square-holding
(Pos. 6 Fig. 7.10) frame (Pos. 5 Fig. 7.10). At the passage of the bag, the square
lowers activating a microswitch (Pos. 7 Fig. 7.10) which detects the presence of the
pallet;
• feeler with shaft (Pos. 8 Fig. 7.10) supporting the blade (Pos. 9 Fig. 7.10) lifted
by a counterweight (Pos. 10 Fig. 7.10). At the passage of the bag, the blade lowers
activating the microswitch (Pos. 11 Fig. 7.10) which detects the presence of the
pallet.
4
6
2
3 1
9
9
3
2
8
10
11
7.10
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 93 of 114
7.4.1 Installation
Mark the points of support of the roller way according to the layout of the plant.
Check the availability of leveling shims to be interposed between the fastening plate
and the floor and check the levelness of the roller way by means of a spirit level.
Installation area
The area set for the installation of the roller way shall have a perfectly smooth surface
suitable to bear the specific load of the supports.
7.4.2 Maintenance
• grease the chain;

- 400 hours - • check the operation of the microswitches (Pos. 7/11 Fig.
7.10);
- 8000 hours - • check the wear of the rollers;
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 94 of 114
7.4.3 Pallet-centering device

The function of the pallet-centering device, mounted on the framework of the roller
way (Pos. 1 Fig. 7.11), is to position the pallets.
The device can have the following configurations:
• Electromechanical centering
The centering operation is achieved by means of two blades (Pos. 2 Fig. 7.11) driven
by a rod/handle kinematic motion (Pos. 3 Fig. 7.11), driven in turn by a gearmotor
(Pos. 4 Fig. 7.11).
• Pneumatic centering
The centering operation is achieved by means of two blades (Pos. 5 Fig. 7.11) resting
on linear guides (Pos. 6 Fig. 7.11) driven by two pneumatic actuators (Pos. 7 Fig.
7.11).
• Pneumatic centering with fixed blade

The centering operation is achieved by means of a blade (Pos. 8 Fig. 7.11) resting
on linear guides (Pos. 9 Fig. 7.11) and driven by a pneumatic actuator (Pos. 10 Fig.
7.11), as well as a fixed blade (Pos. 11 Fig. 7.11) that can be adjusted manually.
2
1
2 4
1 7
1 11
5 8
6
7 6 10 9
7.11
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 95 of 114
7.4.3.1 Pneumatic connection

Connect the pallet-centering device with pneumatic centering as shown in the
pneumatic diagram below.
7.12
Connect the pallet-centering device with pneumatic centering and fixed blade as
shown in the pneumatic diagram below.
7.13
7.4.3.2 Maintenance
• check the operation of the pneumatic actuators (Pos. 7/10

Fig. 7.11).
- 4800 hours -
Note: It is necessary to have a kit of seals available for each pneumatic
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 96 of 114
7.5 Full pallets roller way

The function of the full pallets roller way is to convey the full pallets to the next
working cycles.
The roller way is composed of a framework (Pos. 1 Fig. 7.14) housing the rollers (Pos.
2 Fig. 7.14) motorized by chains driven by a gear motor (Pos. 3 Fig. 7.14).
The roller way is equipped with a feeler which detects the presence of pallets. The
feeler is composed of two elastic elements (Pos. 4 Fig. 7.14) lifting the frame (Pos.
5 Fig. 7.14) which holds the roller of the feeler (Pos. 6 Fig. 7.14). At the passage of
the bag, the roller of the feeler lowers, and rotates the frame (Pos. 5 Fig. 7.14); this
activates a microswitch (Pos. 7 Fig. 7.14) which detects the presence of the pallet.
2 1
6
7.14
7.5.1 Installation
Installation area
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 97 of 114
7.5.2 Maintenance
- 400 hours - • grease the chain;

- 8000 hours - • check the wear of the rollers;
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 98 of 114
7.6 Belt roller way

The belt roller way conveys and handles the bags with and without a pallet; its
implementation in palletizing plants allows the following operations:
• handling of pallets used as a bags support for their handling and stocking;
• handling of slip sheets, i.e. supporting sheets used to handle stacks of bags;
• handling of palletless systems, i.e. application of a thermoshrinking film around
the pack without the use of any pallet support.
The roller way is composed of a framework and a gear motor (Pos. 1/2 Fig. 7.15)
that transmits the motion to all the rollers by means of a pinion-chain drive. It is also
foreseen with a belt conveyor (Pos. 3/4 Fig. 7.15) with tensioning system. The roller
way is equipped with a photocell with projector and receiver (Pos. 5 Fig. 7.15), while
the rollers at the side are foreseen with a projector (Pos. 6 Fig. 7.15) only.
6
3 5 4
1 2
7.15
7.6.1 Installation
Installation area
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 99 of 114
7.6.2 Replacement and adjstment of the belt tension

To replace the belt proceed as follows:
• loosen the tension of the belt acting on the tensioning roller (Pos. 1 Fig. 7.16);
• cut the belt (Pos. 2 Fig. 7.16) and extract it from the frame while rolling it up;
• remove the motorized drum (Pos. 3 Fig. 7.16), the idle drum (Pos. 4 Fig. 7.16),
the tensioning roller (Pos. 1 Fig. 7.16) and the upper idle rollers (Pos. 5 Fig. 7.16);
• insert the new belt on the frame;
• mount again the motorized drum (Pos. 3 Fig. 7.16), the idle drum (Pos. 4 Fig.
7.16), the tensioning roller (Pos. 1 Fig. 7.16) and the upper idle rollers (Pos. 5 Fig.
7.16);
• check that the fastening bolts of the mechanical components are properly
tightened;
• tension the belt acting on the tensioning roller (Pos. 1 Fig. 7.16).
7.16
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 100 of 114
7.6.3 Maintenance
• check the tension and the adjustment of the belt (Pos. 3/4
Fig. 7.15);
- 400 hours -
• check the proper alignment and fastening of the photocell
(Pos. 5 Fig. 7.15);
• check the wear of belt (Pos. 3/4 Fig. 7.15);
- 2400 hours - • check the oil of the reduction gear (Pos. 1/2 Fig. 7.15);
- 12000 hours - • change the oil of the reduction gear (Pos. 1/2 Fig. 7.15).
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 101 of 114
7.7 Pallet feeder

The function of the pallet feeder is to convey to the working cycle one single pallet
extracted from a stack loaded onto a roller way.
The pallet feeder is composed of the following elements:

• fixed frame (Pos. 1 Fig. 7.17);
• lifting trolley with retractable forks (Pos. 2 Fig. 7.17).
7.7.1 Operating cycle

A stack of empty pallets (Pos. 3 Fig. 7.17) is deposited onto the motorized roller way
(Pos. 4 Fig. 7.17) while the forks (Pos. 2 Fig. 7.17) driven by a gear motor with belt
drive move forward towards the stack of pallets, placing themselves above the first
pallet of the stack.
The lifting trolley, driven by a gear motor with belt drive, lifts the stack of pallets (Pos.
3 Fig. 7.17) and releases the first pallet (Pos. 5 Fig. 7.17) that remains on the roller
way. The motion of the roller way conveys the released pallet towards the working
cycle.
3 2
5
7.17
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 102 of 114
7.7.2 Installation
Mark the points of support of the pallet feeder according to the layout of the plant.
and the floor and check the levelness of the pallet feeder by means of a spirit level.
Installation area
The area set for the installation of the pallet feeder shall have a perfectly smooth
surface suitable to bear the specific load of the supports.
7.7.3 Maintenance
• check the oil of the reduction gears;

- 2400 hours - • grease the supports;
• check the wear of the belts;
- 12000 hours - • change the oil of the reduction gears.
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 103 of 114
7.8 Cardboard feeder

The function of the cardboard feeder is to position cardboard sheets with definite
sizes onto the roller way or onto an empty pallet.
The cardboard feeder is composed of the following elements:

• cardboard magazine (Pos. 1 Fig. 7.18);
• trolley with suction cups (Pos. 2 Fig. 7.18);
• vacuum generator (Pos. 3 Fig. 7.18).
The trolley holding the suction cups can move horizontally or vertically.
The vertical motion is driven by a pneumatic actuator and by linear guides mounted
on the trolley, while the horizontal motion is driven by a pneumatic actuator (Pos. 4
Fig. 7.18) without stem.
The cardboard taking and depositing position can be adjusted by means of mechanical
locks (Pos. 5 Fig. 7.18), which set the horizontal stroke of the trolley.
7.8.1 Operating cycle

The trolley holding the suction cups (Pos. 2 Fig. 7.18) moves above the cardboard
magazine. During the downward motion the feeler (Pos. 6 Fig. 7.18) detects the
presence of the cardboard sheet and a microswitch activates the vacuum generated
by the pump, allowing the suction cups to take the cardboard sheet.
The upward motion lifts the cardboard sheet while the the horizontal motion positions
it above the pallet or the roller way, then the pallet is released.
5
4 3
2 5
7.18
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 104 of 114
7.8.2 Installation
Mark the points of support of the cardboard feeder according to the layout of the
plant.
and the floor and check the levelness of the cardboard feeder by means of a spirit
level.
Installation area
The area set for the installation of the cardboard feeder shall have a perfectly smooth
surface suitable to bear the specific load of the supports.

Connect the cardboard feeder as shown in the pneumatic diagram below.
7.19
7.8.4 Maintenance
• check the operation of the pneumatic actuators.

Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 105 of 114
7.9 Full pallets translating roller way

The function of the full pallets translating roller way is to convey the pallets between
parallel transport lines. The roller way consists of a runway (Pos. 1 Fig. 7.20) supporting
a translating trolley equipped with wheels (Pos. 2 Fig. 7.20) housing the motorized
rollers (Pos. 3 Fig. 7.20). The trolley (Pos. 2 Fig. 7.20) and the motorized rollers
(Pos. 3 Fig. 7.20) are driven by two gear motors with chain drive. Two microswitches
(Pos. 4 Fig. 7.20) mounted on the frame define the positions of the roller way. The
presence of the pallet on the roller way is detected by a roller feeler that gives the
consent to the translation motion.
4
1
7.20
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 106 of 114
7.9.1 Installation
Installation area
7.9.2 Maintenance
- 400 hours - • grease the chains;

- 2400 hours - • check the oil of the reduction gears;
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 107 of 114
7.10 Rotating roller way

The rotating roller way receives the full pallets coming from a transport line, turns
them by 90° and transfers them onto another transport line placed at right angles.
The rotating roller way is composed of the following elements:

• basement (Pos. 1 Fig. 7.21) supporting the rotation group (fifth wheel) motorized
by means of pinion and gear wheel driven by a gear motor (Pos. 2 Fig. 7.21);
• rotating frame (Pos. 3 Fig. 7.21) housing the rollers motorized (Pos. 4 Fig. 7.21)
by a chain drive and driven by a gear motor (Pos. 5 Fig. 7.21).
Two microswitches (Pos. 6 Fig. 7.21) mounted on the basement define the positions
of the roller way.
The presence of the pallet on the roller group is detected by a roller feeler (Pos. 7 Fig.
7.21), that gives the consent to the rotation motion.
3
6
5 7
2
1
7.21
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 108 of 114
7.10.1 Installation
Installation area
7.10.2 Maintenance
- 400 hours - • grease the chains and the fifth wheel;

- 2400 hours - • check the oil of the reduction gears (Pos. 2/5 Fig. 7.21);
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 109 of 114
7.11 Rotating and translating roller way

The function of the rotating and translating roller way is to rotate and transfer the
empty pallets to the next working cycles.
The rotating and translating roller way is composed of the following elements:
• translating trolley (Pos. 1 Fig. 7.22) supporting the rotation group (fifth wheel)
motorized by pinion-gear wheel and driven by a gearmotor (Pos. 2 Fig. 7.22);
• rotating frame housing the rollers (Pos. 3 Fig. 7.22) motorized by a chain drive
driven by a gear motor (Pos. 4 Fig. 7.22).
The rotating roller way receives the pallets coming from a transport line, rotates and
translates them, transferring them onto another transport line.
7.22
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 110 of 114
7.11.1 Installation
Installation area
7.11.2 Maintenance
• grease the chain, the toothed pinion-wheel and the fifth

- 400 hours -
wheel;
- 2400 hours - • check the oil of the reduction gears (Pos. 2/4 Fig. 7.22);
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 111 of 114
7.12 Approaching roller way with idle rollers

The function of the approaching roller way with idle rollers is to put two full pallets
coming from parallel transport lines next to one another, so as to pick them up at the
same time by means of a lifting truck with long blades.
The approaching roller way is composed of the following elements:

• fixed frame (Pos. 1 Fig. 7.23) supporting the idle rollers (Pos. 2 Fig. 7.23);
• runway (Pos. 3 Fig. 7.23) supporting a translating trolley with wheels housing
the idle rollers (Pos. 4 Fig. 7.23);
• approaching actuator (Pos. 5 Fig. 7.23).
The presence of the pallets on the roller way is detected by microswitches (Pos. 6 Fig.
7.23) operated by a lever feeler.
1
6
7.23
7.12.1 Installation
Installation area
The determined area for the installation of the roller way must have a perfectly
smooth surface suitable to bear the specific load of the supports.
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 112 of 114

Connect the approaching roller way as shown in the pneumatic diagram below.
7.24
7.12.3 Maintenance
The maintenance operation is the following:
• check the operation of the pneumatic actuator.

Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 113 of 114
7.13 Approaching roller way with motorized rollers

The function of the approaching roller way with motorized rollers is to put two full
pallets coming from two parallel transport lines next to one another, so as to pick
them up at the same time by means of a lifting truck with long blades.
The approaching roller way is composed of the following elements:

• fixed frame (Pos. 1 Fig. 7.25) supporting the rollers that are motorized by
means of a chain drive driven by a gear motor (Pos. 2 Fig. 7.25);
• runway (Pos. 3 Fig. 7.25) supporting a translating trolley with wheels housing
the rollers motorized by means of a chain drive driven by a gear motor (Pos. 4 Fig.
7.25);
• approaching actuator (Pos. 5 Fig. 7.25).
One roller is foreseen with a feeler which detects the presence of the pallet, positioned
at the opposite side of the chain drive. The feeler consists of an elastic element (Pos.
6 Fig. 7.25) that lifts the end of the roller fastened to a guide plate (Pos. 7 Fig. 7.25).
At the passage of the bag, the roller lowers turning the lever (Pos. 8 Fig. 7.25); this
activates a microswitch (Pos. 9 Fig. 7.25) which detects the presence of the pallet.
2
4
3
7.25
Ventomatic.
POLIMAT® EVO 25
MD00645G00
Page 114 of 114
7.13.1 Installation
Installation area

Connect the approaching roller way as shown in the pneumatic diagram below.
7.26
7.13.3 Maintenance
- 400 hours - • grease the chain;

- 2400 hours - • check the oil of the reduction gears;
• check the operation of the pneumatic actuator;
Ventomatic.

Um00563 - 01 - 03 - A4 - Polimat® Evo 25 PDF

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Um00563 - 01 - 03 - A4 - Polimat® Evo 25 PDF

Caricato da

Copyright:

Formati disponibili

POLIMAT® EVO 25

Operation and maintenance manual

Created by: MOM-IT

We thank you for choosing a FLSmidth Ventomatic S.p.A. product.

The product described in this manual has been manufactured

This ensures that every phase of the production process – from

2.0 Safety information.................................................................................. 15

3.0 Technical information............................................................................... 25

4.0 Handling and installation information......................................................... 41

5.0 Adjustment information........................................................................... 53

6.0 Maintenance information.......................................................................... 59

7.0 Accessories information........................................................................... 81

7.13 Approaching roller way with motorized rollers.................................... 113

1.0 General information

1.1 Purpose of the manual

FLSmidth Ventomatic S.p.A. declines any responsibility for damages to people or

1.2 Manual’s addressees

Addressee Information requirements

1.3 General prescriptions

1.3.1 Warnings and precautions

Warnings and precautions

1.4 List of the enclosures

Electrical diagrams: necessary to advanced operators for interventions in the electric

1.7 Service personnel

1.9 Norms and reference documentation

1. 2006/42/CE directive (“machine directive”);

1.10 General notes upon delivery

In case of damages or missing parts please immediately inform FLSmidth Ventomatic

2.0 Safety information

2.1 General safety instructions

Never carry out any operation while the machine is operating.

2.2 Safety systems

Violation, change or elusion of the safety systems

Safety and soundness of the machine

2.2.1 Protection of the electric system

2.2.2 Mechanical protections

2.2.3 Safety devices

List of the safety devices:

Main switch with padlock, placed on each main electric control

Mushroom-head button with key, placed on the main operator

Lamp signaling the machine start and alarm status; it is placed

Protection barriers, 2-meter high, placed on the floor: they are

Barriers with safety photocells to prevent the operators from

The floor of the bags take-up area is foreseen with a mass-

Safety pin of the lifting table (Pos. 8 Fig. 2.1).

2.3 Interventions on the machine

• disconnect the machine from the power supply by means of

Access to the machine

2.4 Improper use of the machine

2.5 Operators’ clothing

2.6 Safety signals and information plates

Safety procedures and indications

VI ETATO SALI RE SULLE RULLI ERE

SKIDDING DANGER: it is forbidden to mount onto the roller ways.

MACCHINA AD AVVIAMENTO AUTOMATICO

ATTENTION: self-starting machine.

ATTENTION: crush danger area.

2.7 Demolition and disposal

To our knowledge no component is harmful or toxic.

3.0 Technical information

3.1 Description of the machine

The processing operations are the following:

A characteristic of the palletizer mod. POLIMAT® EVO 25 is its modular composition,