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- Page 1 EXPRESS USE AND MAINTENANCE MANUAL HOT ROLLER LAMINATOR MODEL : CWTLAM-160 YEAR OF CONSTRUCTION : 2018 MANUAL CODE : 771027010 REVISION : DATE : 29/11/2018 Copy in original language Read carefully before use...
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Page 3: Table Of Contents
EXPRESS USE AND MAINTENANCE MANUAL Contents 1 General information: scope of this manual 1.1 Intended audience 1.2 Professionals involved 1.3 Manual use and storage 1.4 How to consult the manual 1.4.1 Description of the symbols/pictograms in the manual 1.4.2 Descriptions of the symbols used in the maintenance chapter 1.5 Manufacturer identification 1.6 Ownership of information 1.7 Marking date 1.8 Directives and reference standards 1.9 Declaration of conformity 1.10 Warranty 1.11 Assistance 2 Machine presentation 2.1 Machine parts 2.1.1 Rear panel 2.2 Operating principle 2.3 Intended and improper use 2.4 Technical data 3 Safety 3.1 General warnings 3.2 Machine safety devices 3.2.1 Arrangement of fixed guards and safety photocells MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... - Page 4 EXPRESS USE AND MAINTENANCE MANUAL 3.2.2 Arrangement of emergency stop devices and the main electrical switch 3.3 Safety signs 3.4 Personal protective equipment 3.5 Residual risks 4 Transportation and handling 4.1 General warnings 4.2 Lifting and transporting the machine - packaged components 4.2.1 Lifting the machine with packaging 5 Installation instructions 5.1 Environmental conditions and preparation for installation 5.2 Checks before installation 5.3 Unpacking 5.3.1 Disposing of packaging 5.4 Assembly 5.5 Handling 5.6 Positioning, levelling and fixing 5.7 Connections 5.7.1 Electrical connections 5.7.2 Pneumatic connection 5.8 Checks before putting into service 6 Control, adjustment and signalling devices 6.1 Positioning/Layout of the control devices 6.2 Main switch 6.3 Control panel 6.3.1 Using the control panel 6.4 Foot pedal control MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation...
- Page 5 EXPRESS USE AND MAINTENANCE MANUAL 6.5 Emergency buttons 6.6 RESET button 6.7 Manual upper roller movement lever 6.8 Roller clutch adjustment knobs 7 Use 7.1 Putting into service 7.2 Starting processing 7.3 Manual controls 7.4 Cycle stop 7.5 Emergency stop 7.6 Restart after an emergency stop 7.7 Re-start after a black-out 7.8 Shut-down 7.9 Machine in safe conditions for various operations 7.9.1 Safely restarting the machine 7.10 Path diagrams of the material and the finished product 7.10.1 Spindle shaft definitions 7.10.2 Cold protective film lamination on sheets or rolls 8 Maintenance 8.1 General warnings 8.2 Descriptions of the symbols used in the maintenance chapter 8.3 Routine maintenance 8.3.1 Routine maintenance summary table 8.3.2 General cleaning 8.4 Special maintenance 8.5 Oils and lubricants MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation...
- Page 6 EXPRESS USE AND MAINTENANCE MANUAL 9 Dismantling and disposal 10 Attachments MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018...
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Page 7: Contents
EXPRESS USE AND MAINTENANCE MANUAL 1 General information: scope of this manual This manual is provided as an aid and a guide during the machine work phases. It contains information regarding use, maintenance and troubleshooting, providing indications for the most suitable conduct for correct use and correct operation of the machine as required by the Manufacturer. This manual is an essential safety requirement and must accompany the machine throughout its life cycle. It is essential to preserve and make this manual available to all persons involved in use and maintenance of the machine. This document and/or its parts cannot be reproduced or transmitted to third parties without prior authorisation from FLEXA S.r.l. Warning The company FLEXA S.r.l. is not responsible for any damage to persons or property resulting from improper use not indicated in this manual and in contrast to the information specified in the technical characteristics table related to each model. 1.1 Intended audience The manual in question is addressed to qualified, adequately trained personnel for operation of the machine described in this manual. -
Page 8: Professionals Involved
EXPRESS USE AND MAINTENANCE MANUAL 1.2 Professionals involved Below is a description of the professionals who can work on the machine, depending on the type of activities to be carried out. Operator Qualified personnel able to operate the machine, carry out loading and unloading of the product to be machined/processed, carry out adjustment, cleaning, start-up operations or restore processing following an emergency stop. The operator is not authorised to perform maintenance. -
Page 9: Manual Use And Storage
EXPRESS USE AND MAINTENANCE MANUAL 1.3 Manual use and storage Warning Read this manual carefully before operating the machine or taking any action on it. If you do not read it first, you may not be able to recognise dangerous situations that can cause death or serious injury to yourself and others. This manual is intended to provide all the information necessary for correct use of the machine and its management as autonomously and safely as possible. Users and maintenance technicians must carefully read the instructions contained in this manual and any attachments before performing any operations on the machine. If any doubts arise regarding correct interpretation of the information in the documentation, contact the manufacturer for necessary clarifications. It is the competence and responsibility of the end user to study and optimise the machining process for which the machine was purchased. Caution Keep this manual and all attached documentation in good conditions, legible and complete in all its parts. Store documentation near the machine in an accessible location known to all operators and maintenance personnel and, more generally, to all those who for various reasons may come into contact with the machine. Warning Store the manual in its original state. Do not rewrite, modify or delete manual pages or their contents. The manufacturer declines all responsibility for any damage to people, animals and property caused by failure to comply with the warnings and operating procedures described in this manual. This manual is an integral part of the machine and must be kept for future reference. Caution This manual must be delivered together with the machine if it is transferred/sold to another user. Caution In case of loss or deterioration of the manual, request a copy from the Manufacturer, specifying the document identification data: document name, code, revision and date of preparation. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 10: How To Consult The Manual
EXPRESS USE AND MAINTENANCE MANUAL 1.4 How to consult the manual The manual is divided into chapters, paragraphs and sub-paragraphs, listed in the index: an easy way to find any topic of interest. The symbols used provide direct information on the type of information expressed by the symbol itself. For example, the symbol: Signals the presence of a Note. 1.4.1 Description of the symbols/pictograms in the manual Below are the various symbols used in the manual to highlight especially important information or the recipients of the information itself. Danger The risks described in this way indicate a HIGH LEVEL of hazard which, if not avoided, could result in serious injury or death. Warning The risks described in this way indicate a MEDIUM LEVEL of hazard which, if not avoided, could result in serious injury or death. Caution The risks described in this way indicate a LOW LEVEL of hazard which, if not avoided, may result in minor or moderate injury. This symbol indicates a NOTE: especially important information or in-depth analysis. This symbol indicates a REMINDER: the presence of a form, a drawing or an attached document which should be read and, if required, filled in. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 11: Descriptions Of The Symbols Used In The Maintenance Chapter
EXPRESS USE AND MAINTENANCE MANUAL 1.4.2 Descriptions of the symbols used in the maintenance chapter This paragraph describes the symbols used in the maintenance chapter. Icon used Description Mechanical type intervention Electrical type intervention Specifies the frequency of interventions 1.5 Manufacturer identification FLEXA S.r.l. Via dell'Industria, 11 31014 Colle Umberto (TV) Italy e-mail: flexa@flexa.it web: www.flexa.it Tel.: 0438 38565 - Fax: 0438 38767 1.6 Ownership of information This document and/or its parts cannot be reproduced or transmitted to third parties without prior authorisation from FLEXA S.r.l. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 12: Marking Date
EXPRESS USE AND MAINTENANCE MANUAL 1.7 Marking date Manufacturer's logo. CE marking. Manufacturer's name. Machine model. Serial number. Supply voltage. Nominal power. Frequency. Year of manufacture. Mass. Caution Request a new identification plate whenever the one applied on the machine becomes illegible. The identification plate is applied on the machine in the position shown in the figure. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 13: Directives And Reference Standards
EXPRESS USE AND MAINTENANCE MANUAL 1.8 Directives and reference standards List of directives and reference standards used for the design and construction of the machine. Directives 2006/42/EC Machinery directive. 2014/35/EU Low voltage directive 2014/30/UE EMC Directive (electromagnetic compatibility). Harmonised standards UNI EN ISO 12100: 2010 Safety of machinery - General principles of design - Risk assessment and risk reduction. UNI ISO/TR 14121-2: 2013 Safety of machinery - Risk assessment - Part 2: Practical guide and examples of methods. UNI EN ISO 3744, 3745, 3746 and 11200-11204 Determination of sound power levels and sound energy levels of noise sources using sound pressure. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 14: Declaration Of Conformity
EXPRESS USE AND MAINTENANCE MANUAL 1.9 Declaration of conformity The original document is supplied separately to this manual. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 15: Warranty
EXPRESS USE AND MAINTENANCE MANUAL 1.10 Warranty The warranty is supplied separately or with the contract. 1.11 Assistance The purchaser must contact the Manufacturer directly (or the service centre if present) for any need related to the use, maintenance or request for spare parts, specifying the machine identification data indicated on the identification plate. The Customer can make use of the technical sales support of local agents or importers who are in direct contact with the company FLEXA S.r.l. In the event of failure or inconvenience that cannot be overcome, the Customer must directly contact the manufacturer whose contacts are as follows: TELEPHONE: +46 554 33390 EMAIL: info@cwtworktools.se ASSISTANCE DEPARTMENT: info@cwtworktools.se WEBSITE: www.cwtworktools.com Årstidsvägen 8 MAILING ADDRESS: 665 35 Kil Sweden In the event of a change of ownership or company movement of the machine, it is always necessary to inform the manufacturer or the reference service centre, even after the warranty period. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... - Page 16 EXPRESS USE AND MAINTENANCE MANUAL MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018...
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Page 17: 2 Machine Presentation
EXPRESS USE AND MAINTENANCE MANUAL 2 Machine presentation 2.1 Machine parts Control panel Manual upper roller movement lever Printed material unwinding shaft High temperature upper roller Liner recovery shaft Lamination film unwinding shaft Counter bar Material trimming blades (optional) Foot pedal control Pneumatic connection For the detailed arrangement of the shafts see par. 7.10.1. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 18: Rear Panel
EXPRESS USE AND MAINTENANCE MANUAL 2.1.1 Rear panel Main switch Control circuit safety fuse Resistance safety fuse Connector for pedal connection Electric socket for machine power supply connection Air supply for upper roller UP/DOWN movement MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 19: Operating Principle
EXPRESS USE AND MAINTENANCE MANUAL 2.2 Operating principle The HOT ROLLER LAMINATOR performs mounting, laminating and laying of tape and double-sided adhesive application on various types of materials. The machinable materials are indicated in the technical data tables. Machining is carried out by passing the material on a pair of rollers. The upper rubber roller is equipped with temperature adjustment. The machine is equipped with a control panel with a display through which the operator can set and view all functions, like for example upper roller temperature adjustment and speed. For the material passage diagrams see par. 7.10. 2.3 Intended and improper use The HOT ROLLER LAMINATOR has been designed solely to mount, laminate, apply application tape and double-sided adhesive. Danger The machine has not been designed to operate in potentially explosive areas. Warning The machine must only be used for the purposes for which it was designed and built and as established in the contract. In case of malfunction, failure, breakage etc., always consult this manual before working on the machine. Contact FLEXA S.r.l. when necessary. Do not use the machine with products that are of a size or raw material differing from those for which it has been built and defined in the contract. The dimensions, material and weight of the machinable products are reported in the technical data. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 20: Technical Data
EXPRESS USE AND MAINTENANCE MANUAL 2.4 Technical data General technical characteristics of the machine Machinable materials Description U.M. Data Description Useful working width 1620 Printed flexible materials Maximum distance between Rigid panels the rollers Cardboard (packaging) Roller diameter Car wrapping Pneumatic system Floor graphics Description U.M. Data Backlit displays Working pressure Graphics for exhibitions, events Banner roll-up & Display pop-up Table displays MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 21: 3 Safety
EXPRESS USE AND MAINTENANCE MANUAL 3 Safety 3.1 General warnings The machine can only be used by trained. authorised operators and for the sole purpose for which it was designed and built. Danger Use the machine only after having read and understood all parts of this manual. Danger Do not use the machine under the influence of drugs or other substances that can alter your capacity for attention and reaction. Danger Authorised operators must perform only operations or interventions that they are responsible for or assigned to according to their role and qualification. Warning Do not make any changes to the machine in order to obtain performance other than that for which it was designed and built unless authorised to do so by the manufacturer. Warning Do not neutralise, remove, modify or otherwise render the safety, protection and/or control devices of the machine inefficient. Warning Always keep the work areas and access to the machine free from materials and/or components that can impede movements or be a source of accidents for the operator. Caution The work area must always be properly lit. Danger Do not place hands, arms or any part of the body in areas where there are moving parts. ... - Page 22 EXPRESS USE AND MAINTENANCE MANUAL Warning At the end of any operation that involved the removal of guards, provide for their restoration and make sure that they are put back in their correct position and original effectiveness. Danger Keep flammable substances away from the machine. The machine has been built in compliance with the technical safety standards in force at the time of its design. The instructions and safety warnings in this manual have been written taking into account the requirements and application of the directive implementing measures to promote the improvement of the safety and health of workers in the workplace and the directives (concerning safety in the workplace). For reference to the directive see par. 1.8. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018...
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Page 23: Machine Safety Devices
EXPRESS USE AND MAINTENANCE MANUAL 3.2 Machine safety devices Caution Safety component replacement is an operation that affects the safety of the machine. This operation must be carried out in compliance with the machine manufacturing specifications. Safety devices must be maintained in efficient conditions. Use original spare parts only for the replacement of any safety components. The machine safety devices include all technical means put in place to allow use of the machine in safe conditions in compliance with the regulations in force at the time of design of the machine itself. The machine is equipped with fixed barriers, electromechanical locking, disconnecting and signalling devices and warning signs specifically designed for the safety of operators and the processes themselves. Fixed guards (see par. 3.2.1). They are fixed to the machine structure with screws. You will need to unscrew the screws to remove the guards. Safety photocells (see par. 3.2.1). Reset Button (see par. 3.2.1). Emergency buttons (see par. 3.2.2). Main electrical switch (see par. 3.2.2). Safety signs (see par. 3.3). MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 24: Arrangement Of Fixed Guards And Safety Photocells
EXPRESS USE AND MAINTENANCE MANUAL 3.2.1 Arrangement of fixed guards and safety photocells The following figure shows the location of the guards and various protections on the machine. Fixed guards: These are mounted with screws on the machine structure. Safety photocell composed of emitter and receiver. Reset Button. To restore normal safety photosensitive device operation, free the area and reset the circuit using the Reset button. NOTE FOR MAINTENANCE PERSONNEL Emergency buttons and the control panel are installed on the fixed guards. The emergency buttons and the control panel are connected with electrical wires to the electrical system of the machine. Take care when removing the guards. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 25: Flexa S.r.l. - Partial Or Whole Reproduction Prohibited Without Authorisation
EXPRESS USE AND MAINTENANCE MANUAL 3.2.2 Arrangement of emergency stop devices and the main electrical switch A. Emergency buttons The machine is equipped with emergency stop buttons that can immediately stop the operating cycle. Emergency buttons must not be used as ordinary stop commands. B. Main electrical switch When they are hot, the high temperature rollers can deform if left stationary for prolonged periods of time. They must always be kept in rotation for cooling. If they need to be stopped, for example for an emergency stop, restart them as soon as possible. When they are hot, the high temperature rollers can deform if stopped and left in contact with one another. If they need to be stopped, move them away from one another. When heated to a temperature exceeding 60°C, the high temperature rollers must always be in motion. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 26: Safety Signs
EXPRESS USE AND MAINTENANCE MANUAL 3.3 Safety signs The following safety signs are provided on the machine. Caution Labels must be replaced if worn or illegible. Danger: the surface of the upper roller is hot. Keep hands away from the upper roller, risk of burns. Danger of crushing. Keep hands away from rollers. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 27: Personal Protective Equipment
EXPRESS USE AND MAINTENANCE MANUAL 3.4 Personal protective equipment Caution Personnel working on the machine must wear the personal protective equipment (PPE) indicated in the following table. Operation Always wear Caution The operator must comply with the accident prevention regulations in force in the country where the machine is used. Caution The assigned PPE cannot be changed. The manufacturer declines all responsibility for any damage to persons caused by failure to use the PPE. Caution Operators and maintenance personnel must not wear clothing or accessories that could get caught in machines, such as: loose clothing, ties, belts, necklaces, bracelets, watches, earrings, rings, etc. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0... -
Page 28: Residual Risks
EXPRESS USE AND MAINTENANCE MANUAL 3.5 Residual risks The following zones, defined at residual risks, are present on the machine: During machine maintenance, personnel is subjected to some residual risks which, due to the nature of the various operations to be carried out, cannot be completely eliminated. Zone A: rubber rollers Warning Keep hands away from the upper roller, use suitable Burn hazard. means of hand protection. Zone B: trimming blades Warning Risk of cutting when positioning the material trimming Handle blades with care and wear gloves. blades. Handling of rolls Warning Coils with weight less than 50 kg must be handled by two operators. Coils with weight exceeding 50 kg must be handled using lifting equipment. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 29: 4 Transportation And Handling
EXPRESS USE AND MAINTENANCE MANUAL 4 Transportation and handling The packaging type and method is chosen according to the means of transport used and the place of destination of the goods. Packaging is always accompanied by a packing list. Transport of the packaging to the place of installation is the responsibility of the customer. 4.1 General warnings Warning The instructions provided in this chapter are intended only for handling the packaging at the customer's site. Warning Lift the machine following the instructions provided in this chapter. Warning Use appropriate, tested and certified lifting equipment. Warning Lifting and transport must be carried out by personnel who has been instructed and trained for this purpose. Always check the suitability and conditions of the packaging lifting devices and means. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 30: Lifting And Transporting The Machine - Packaged Components
EXPRESS USE AND MAINTENANCE MANUAL 4.2 Lifting and transporting the machine - packaged components Danger Be careful during all transport and handling operations. Do not stand under suspended loads. Warning Verify the weight to be lifted and the pre-established hooking points on the packaging or on the documentation attached to it. Use suitable lifting equipment. 4.2.1 Lifting the machine with packaging Use a forklift truck as shown in the figure for lifting and handling. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 31: 5 Installation Instructions
EXPRESS USE AND MAINTENANCE MANUAL 5 Installation instructions Installation operations and the first machine start-up are carried out by FLEXA S.r.l. Caution The machine must not be installed if it shows obvious signs of damage. 5.1 Environmental conditions and preparation for installation The area where the machine is to be installed must allow for a good support base, good natural and/or artificial lighting (according to current regulations) that guarantees that the operator has good visibility over the work and can monitor the area surrounding the machine so as to prevent the approach of third parties. In the case of special provisions, layouts and characteristics are provided in the contract phase that must be complied with, as regards foundation, connections and environmental conditions. The machine has been designed and built to work in normal environmental conditions in industrial warehouses as required by current legislation. Consult the technical data and diagrams provided to determine the type, cross-section and position of the power supply cable and the supply lines of the various lines. Danger The machine must not be installed in partially or totally explosive atmospheres. See technical data par. 2.4 5.2 Checks before installation Prerequisites necessary for installation: Check that all agreed arrangements are respected. Check that the lighting system is adequate. Check that flooring meets the agreed specifications. Prior to delivery of the machine, FLEXA S.r.l. provides the Customer with the necessary information and specifications in order to prepare the areas where the machine will operate. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 32: Unpacking
EXPRESS USE AND MAINTENANCE MANUAL 5.3 Unpacking Make use of the following information to remove the packaging. Cut the straps holding the machine to the pallet. Caution: the straps are pulled taut; move to the side of them at an arm's distance and cut them. Remove the external packaging. Cut the internal straps holding the machine to the pallet. Remove the wooden sides. Carefully remove the packaging. 5.3.1 Disposing of packaging Dispose of the packaging in a differentiated manner. Keep in mind the different nature of the components (i.e.: Metals, plastic, rubber, etc.) and dispose of the various parts according to the local regulations in force. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 33: Assembly
EXPRESS USE AND MAINTENANCE MANUAL 5.4 Assembly Assemble components (A) with components (B). Assemble the machine with components (A). 5.5 Handling To move the machine: Release the locks (A) to release the wheels (B). MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 34: Positioning, Levelling And Fixing
EXPRESS USE AND MAINTENANCE MANUAL 5.6 Positioning, levelling and fixing Positioning The machine must be positioned in such a way as to allow access on all sides to carry out control and maintenance operations, ensuring adequate distance from walls and other machines. Locking the wheels After positioning the machine, press on the stops (A) to lock the wheels (B). MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 35: Connections
EXPRESS USE AND MAINTENANCE MANUAL 5.7 Connections 5.7.1 Electrical connections The following table defines the conditions for making connections. Machine/electrical panel conditions: Machine off with main switch set to indicator light off. (see par. 6.2). Authorised personnel: Operator. Personal protective equipment: See par. 3.4 or PPE IMAGES Necessary equipment: The electrical connection of the machine is the responsibility of the customer. The electrical connection must only be carried out when positioning/fixing has been completed and when all the parts making up the machine have been assembled. Check that the power supply corresponds to the data indicated on the machine plate. Connect the machine plug (B) to the power supply socket (A). MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0... -
Page 36: Pneumatic Connection
EXPRESS USE AND MAINTENANCE MANUAL 5.7.2 Pneumatic connection The pneumatic connection of the machine is the responsibility of the customer. The pneumatic connection must only be carried out when positioning/fixing has been completed and when all the parts making up the machine have been assembled. The following figure shows where to make the pneumatic connection. Pneumatic line connection point with quick coupling. Pressure regulator. Pressure gauge. Provide a manually operated interception valve on the supply line upstream of the connection point. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 37: Checks Before Putting Into Service
EXPRESS USE AND MAINTENANCE MANUAL 5.8 Checks before putting into service FLEXA S.r.l. is responsible for the first commissioning of the machine. Carry out the following checks before starting the machine: Verify that the connections are complete and have been executed properly. Verify complete and correct assembly of all parts. Verify correct and complete assembly of the fixed guards. Verify correct functioning of the safety devices. Verify that the machine is completely free of assembly equipment and materials. Verify that a general cleaning of the machine has been performed. Do not operate the machine if even only one of the points listed in this paragraph has not been successful. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... - Page 38 EXPRESS USE AND MAINTENANCE MANUAL MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018...
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Page 39: 6 Control, Adjustment And Signalling Devices
EXPRESS USE AND MAINTENANCE MANUAL 6 Control, adjustment and signalling devices 6.1 Positioning/Layout of the control devices The image below shows the location of the control devices on the machine. Main switch Par. 6.2 Control panel Par. 6.3 Foot pedal control Par. 6.4 Emergency buttons Par. 6.5 Reset button Par. 6.6 Manual upper roller movement lever Par. 6.7 Roller clutch adjustment knobs Par. 6.8 MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0... -
Page 40: Main Switch
EXPRESS USE AND MAINTENANCE MANUAL 6.2 Main switch Main switch Two-position switch: Indicator light off: the machine is not being powered. Indicator light on: the machine is being powered. 6.3 Control panel The control panel lets you set up and manage the various machine processing phases. Cold operation LED. Hot operation LED. Machine ready LED (activates temporarily during the machine start-up phase). Display. Cold or hot operation activation. Upper roller temperature setting. Upper roller temperature increase. Upper roller temperature decrease. Pedal operation activation/deactivation. Pedal operation LED. Roller backwards movement activation/deactivation. Roller backwards movement activation LED. Roller speed increase. Roller speed decrease. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 41: Using The Control Panel
EXPRESS USE AND MAINTENANCE MANUAL 6.3.1 Using the control panel Cold operation activation Press (E) to activate/deactivation upper roller temperature. Cold operation is activated when the LED is on (A). The display (D) shows COLD. Hot operation activation Press (E) to activate/deactivation upper roller temperature. Hot operation is activated when the LED is on (B). The display shows the set temperature (D1) of the roller. The display shows the current temperature (D2) of the roller. Upper roller temperature setting Press (F) to set the upper roller temperature. Press (G) to increase the temperature. Press (H) to decrease the temperature. The display (D) shows the temperature. MANUAL CODE: 771027010 FLEXA S.r.l. - Page 42 EXPRESS USE AND MAINTENANCE MANUAL Roller speed setting Press (M) to increase roller speed. Press (N) to decrease roller speed. The display (D) shows the roller speed. Pedal operation activation/deactivation Press (I) to activate/deactivate the pedal function. Pedal operation is active when the LED is on (J). The display (D) shows P. Press the pedal to start up rubber roller feeding. Release the pedal to stop the rotation of the two rubber rollers. Roller backwards movement activation/deactivation Press (K) to activate/deactivate roller backwards movement. Backwards movement is active when the LED is on (L).
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Page 43: Foot Pedal Control
EXPRESS USE AND MAINTENANCE MANUAL 6.4 Foot pedal control A. Foot pedal control. Press the start feeding of the two rubber heating rollers. Release the pedal to stop the rotation of the two rubber rollers. It is possible to activate/deactivate pedal operation from the control panel (see par. 6.3). Roller feeding speed is set on the control panel (see par. 6.3). 6.5 Emergency buttons Emergency button When pressed, causes deactivation of the functional processes (immediate stop of all machine movements and equipment dependent on it). To reset operation, turn it clockwise and the button automatically comes back up. The emergency button must not be used as an ordinary operating cycle stop command. When they are hot, the high temperature rollers can deform if left stationary for prolonged periods of time. -
Page 44: Reset Button
EXPRESS USE AND MAINTENANCE MANUAL 6.6 RESET button RESET button Press the reset button to restore normal safety photosensitive device operation. Free the area before pressing the Reset button. 6.7 Manual upper roller movement lever Manual upper roller movement lever Push the control upward to raise the upper roller. Push the control downward to lower the upper roller. 6.8 Roller clutch adjustment knobs Roller clutch adjustment knobs Turn clockwise to increase roller clutch. Turn counter-clockwise to decrease roller clutch. The material being processed must be kept slightly taut. Excessive braking force of the unwinding roller clutch can cause excessive drive system stress and rewinding of the material being processed. Excessive stress can trigger the motor thermal protection and... -
Page 45: 7 Use
EXPRESS USE AND MAINTENANCE MANUAL 7 Use 7.1 Putting into service Putting the machine into service is carried out upon completion of installation operations and in practice consists of the first start-up. Follow the procedure below for putting into service: Make the pneumatic connection (see par. 5.7.2). Set the air pressure on the pressure regulator to 2 bar. Make the electrical connection (see par. 5.7.1). Position the main electrical switch with its indicator light on. (see par. 6.2). Reset any emergency buttons activated. Press the RESET button. (see par. 6.6). Set the laminating speed using the control panel. (see par. 6.3). Set the various parameters required for processing from the control panel. (see par. 6.3). At this point, the machine is ready to start working or it can be switched off. To start working, see par. 7.2. Warning The presence of equipment or parts not belonging to the Remove any equipment, materials or objects used for machine can cause damage to people or to the machine installation or other from the machine. itself. 7.2 Starting processing Perform the following operations to start processing after putting the machine into service: Check that the air pressure on the pressure regulator is set to 2 bar; adjust if it does not correspond. Check the laminating speed set on the control panel. Verify that the parameters correspond exactly to the processing that must be performed. Load the material to be processed into the machine. 7.3 Manual controls To manage roller rotation manually: Verify that pedal function is active. (see par. 6.3). The command is press-and-hold. Keep the pedal pressed until the operation is complete (see par. 6.4). -
Page 46: Cycle Stop
EXPRESS USE AND MAINTENANCE MANUAL 7.4 Cycle stop Proceed as follows: Activate pedal function to stop the processing cycle. (see par. 6.3). The cycle stop only stops the rotation of the rubber rollers while the rest of the machine continues to be in the "start" conditions. 7.5 Emergency stop Press one of the emergency buttons on the machine to immediately stop all its functions. The emergency stop causes deactivation of the auxiliary circuits and consequently an immediate stop of all machine movements. When they are hot, the high temperature rollers can deform if left stationary for prolonged periods of time. They must always be kept in rotation for cooling. If they need to be stopped, for example for an emergency stop, restart them as soon as possible. When they are hot, the high temperature rollers can deform if stopped and left in contact with one another. If they need to be stopped, move them away from one another. When heated to a temperature exceeding 60°C, the high temperature rollers must always be in motion. 7.6 Restart after an emergency stop To restore the cycle after an emergency stop: Resolve the cause that led to the emergency stop. Deactivate the emergency button, turning the button counter-clockwise. Press the RESET button. Restart processing (see par. 7.2). 7.7 Re-start after a black-out To restart the machine after a black-out: Perform the operations described in par. 7.1 and 7.2. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 47: Shut-Down
EXPRESS USE AND MAINTENANCE MANUAL 7.8 Shut-down The machine is switched off by setting the main electrical switch with the indicator light off. (see par. 6.2). Machine shut-down can only occur after the upper roller has cooled down. Stopping rotation of the two rubber heating rollers while the upper roller is still hot may damage it, as it tends to become oval-shaped. 7.9 Machine in safe conditions for various operations Setting the machine in safe conditions means making it impossible to start or carry out any movement whenever it is necessary to intervene directly on it or on its parts, for example for cleaning, maintenance, etc. To set the machine in safe conditions: Machine shut-down (see par. 7.8). Disconnect the piping for feeding the pneumatic system from the pneumatic connection point of the pressure regulator unit (see par. 5.7.2). 7.9.1 Safely restarting the machine To restart the machine: Restore the pneumatic connection (see par. 5.7.2). Switch on the machine (see par. 7.1 and 7.2). MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 48: Path Diagrams Of The Material And The Finished Product
EXPRESS USE AND MAINTENANCE MANUAL 7.10 Path diagrams of the material and the finished product 7.10.1 Spindle shaft definitions M1-M2 Rewinding shafts with manual mechanical clutch. F1-F2 Unwinding shaft with manual mechanical brake. R1-R2 Upper and lower rubber rollers. Shedding roller. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... -
Page 49: Cold Protective Film Lamination On Sheets Or Rolls
EXPRESS USE AND MAINTENANCE MANUAL 7.10.2 Cold protective film lamination on sheets or rolls Liner rewinding. The direction of rotation is the same as shaft F1. Roll with lamination film with external/internal liner. Direction of rotation of the roll with external liner. Direction of rotation of the roll with internal liner. Liner. Roll with wound images. Rewinding the finished product. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0... - Page 50 EXPRESS USE AND MAINTENANCE MANUAL MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018...
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Page 51: 8 Maintenance
EXPRESS USE AND MAINTENANCE MANUAL 8 Maintenance 8.1 General warnings Warning The authorised operators must only perform those interventions that fall within their specific competence on the machine and must wear the necessary and appropriate PPE (personal protective equipment). Danger All maintenance, cleaning or repair operation carried out with the electrical system live can cause serious accidents to people, including death. Warning Always disconnect the machine from energy sources before carrying out maintenance and/or replacement operations. Danger The operations described in this chapter must be performed by a single operator in order to avoid accidental or involuntary activations. Warning All maintenance must be carried out only after putting in place the "machine safety procedure" (see par. 7.9). Maintenance personnel must be informed of the movements and functions of each component belonging to the part on which maintenance must be carried out. Maintenance personnel should keep a record of all operations performed. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 52: Descriptions Of The Symbols Used In The Maintenance Chapter
EXPRESS USE AND MAINTENANCE MANUAL 8.2 Descriptions of the symbols used in the maintenance chapter This paragraph describes the symbols used in the maintenance chapter. Icon used Description Mechanical type intervention Electrical type intervention Specifies the frequency of interventions 8.3 Routine maintenance Routine maintenance is the set of operations that must be performed at a defined frequency. They are intended to keep the machine in good operating condition. Caution Perform routine maintenance with precision and at the frequency indicated by the manufacturer. The table reported in the paragraph 8.3.1 "Routine maintenance summary table" indicates all the recommended interventions, indicates the frequency with which they will have to be performed and, in the last column, shows the paragraph describing the procedure to be performed for the operation. 8.3.1 Routine maintenance summary table Abbreviations for types of interventions: E = Electrical; M = Mechanical; S = Software Routine maintenance table Type Description Frequency Reference General cleaning Daily 8.3.2 MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 53: General Cleaning
EXPRESS USE AND MAINTENANCE MANUAL 8.3.2 General cleaning Type of intervention Performed by Frequency Daily PPE to be used Materials and equipment Cotton cloth. Neutral detergent. Industrial vacuum cleaner. Warning Set the machine in safe conditions (see par. 7.9). Caution If the machine operates in dusty environments, clean more frequently. Ventilate the room well during and after cleaning the machine. To clean the machine, use a cotton cloth dampened with water and neutral detergent or 80% isopropyl alcohol. The use of other more aggressive substances (i.e. toluene, acetone, etc.) can damage the machine. Use an industrial vacuum cleaner to remove residues. During cleaning, check the status and conditions of the various machine parts. Contact the maintenance technician for possible servicing in the case of anomalies or damage. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation... -
Page 54: Special Maintenance
EXPRESS USE AND MAINTENANCE MANUAL 8.4 Special maintenance Special maintenance is the set of maintenance operations that do not have the purpose of maintaining the machine, but are maintenance operations that can occur or are used for improvements. These maintenance operations are entrusted directly to the manufacturer's specialised technicians. 8.5 Oils and lubricants Quantity Brand Grease for chains Arexons GC300 MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018... - Page 55 EXPRESS USE AND MAINTENANCE MANUAL 9 Dismantling and disposal To scrap the machine or its parts, you need to dispose of it in a differentiated manner, keeping in mind the different nature of the components (i.e.: metals, plastic parts, rubber, oils, etc.). Hire specialised disposal companies and in any case observe the laws in force concerning waste disposal. MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018...
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- Page 57 EXPRESS USE AND MAINTENANCE MANUAL 10 Attachments Description Code Wiring diagram 711039030 MANUAL CODE: 771027010 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation REVISION: 0 DATE: 29/11/2018...
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- Page 60 FLEXA Sr.l. reserves the right to make technical changes to this manual without prior notice.
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