Super Combi Manual C-3154 - SC4000 L1300 - Ago 19 - en

SUPER COMBI 4000 L1300
Instruction manual
SERIAL NO. C-3154
Drawn up according to Directives

- translation of the original instructions -
NORDMECCANICA S.p.A. - ITALIA - Strada dell’Orsina 16/A - 29122 Piacenza

Tel. +39 0523 596411 – Fax +39 0523 612051 – e-mail: nordmeccanica@nordmeccanica.com
BEFORE CARRYING OUT ANY OPERATION ON OR WITH THE MACHINE, ALL THE INSTRUCTIONS,
PROCEDURES AND WARNINGS DESCRIBED IN THIS INSTRUCTION MANUAL MUST BE READ AND
UNDERSTOOD.
THE IMAGES OF THE MACHINE ARE PURELY FOR INFORMATION AND THEY THEREFORE MAY NOT BE
EXACTLY REPRESENTATIVE OF THE FEATURES OF THE PRODUCT. THE COLOURS, DIMENSIONS AND
ACCESSORIES MAY VARY.
Manual code: C-3154

Edition: 08/2019
Copy of the translation of the EC Declaration of Conformity
- TO BE KEPT FOR FUTURE REFERENCE -
Table of contents
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................... 4
PURPOSE OF THIS MANUAL ...................................................................................................... 4
WHO SHOULD USE THIS MANUAL ............................................................................................ 4
SAFE KEEPING OF THIS MANUAL ............................................................................................. 5
SUPPLEMENTS AND REVISIONS ............................................................................................... 5
HOW TO USE THIS MANUAL....................................................................................................... 5
SYMBOLS USED IN THE TEXT.................................................................................................... 6
SYMBOLS USED IN TECHNICAL DRAWINGS............................................................................ 7
ENCLOSURES AND RELEVANT CODES .................................................................................... 8
Chapter 1 GENERAL INFORMATION......................................................................................................... 1.1

Table of contents.......................................................................................................................................................... 1.1
Chapter 2 TECHNICAL DESCRIPTION ...................................................................................................... 2.1

Chapter 3 SAFETY ...................................................................................................................................... 3.1

Chapter 4 TRANSPORT AND INSTALLATION .......................................................................................... 4.1

Chapter 5 USE ............................................................................................................................................. 5.1

Chapter 6 PROCESSING FLAWS AND TROUBLESHOOTING................................................................. 6.1

Chapter 7 CLEANING AND MAINTENANCE .............................................................................................. 7.1

Enclosures 1HS03154F - “Bearing points layout” ................................... folder “2S Schematics” on USB drive
1HS03154I - “Material flow path diagram” ............................ folder “2S Schematics” on USB drive
1HS03154P - “Layout diagram” ............................................ folder “2S Schematics” on USB drive
1HS03154X - “Water system diagram” ................................. folder “2S Schematics” on USB drive
C-3154_DW3619: ................................................................. folder “2S Schematics” on USB drive
- Wiring diagram DW3619 E
- Pneumatic diagram DW3619 P
Suppliers documentation ............................................ folder “3D Third parties doc.” on USB drive
ID code: SUPER COMBI 4000 – C-3154 – 08/2019 4

Table of contents
INTRODUCTION
The lifespan and smooth running of the machine will depend on the rigorous and reasonable compliance with the
guidelines and instructions provided in this manual.
The data contained in this manual are owned by NORDMECCANICA S.p.a. They may not be reproduced, in whole
or in part, without written permission from NORDMECCANICA S.p.a.
NORDMECCANICA S.p.a. reserves the right to make changes without notice with respect to the features of the
machine described in this document.
PURPOSE OF THIS MANUAL

The purpose of this manual is to specify the expected use of the machine as intended in the design, and to provide
the necessary instructions as regards transport, handling, installation, adjustment and use, staff training, accident
prevention, maintenance and spare parts ordering. A description of the main technical features of the machine is
also included.
However, in terms of conditions of use, risk assessment and accident prevention, the content of the manual cannot
be a substitute for the users’ experience.
Before operating the machine, read carefully these instructions and strictly follow them.
It is mandatory for operators and maintenance personnel to read and understand all the instructions
contained within this manual.
WHO SHOULD USE THIS MANUAL

− the production or factory supervisor
− the safety supervisor
− the machine operator
− the maintenance technician
Information:
In this manual, the word “Purchaser” refers to the natural or juridical person that has possession of the
machine and/or has the power to take decisions with regard to its actual utilization.

Table of contents
SAFE KEEPING OF THIS MANUAL
Information:
This manual must be kept at the machine location at all times and for the entire life cycle, even in case
of conveyance or sale to third parties.
For a proper safekeeping, please keep the manual in a protected and dry place, sheltered from dust and
sunbeams. Near the machine there must be a suitable space where to keep the copy for the operator and the
maintenance technician.
Do not remove, add or modify any part of the manual: only the Manufacturer is entitled to make any changes.
SUPPLEMENTS AND REVISIONS

This manual reflects the state-of-the-art technology existing when the machine was marketed and cannot be
considered as inadequate due to subsequent revisions made on the basis of new knowledge.
The Manufacturer reserves the right to make changes to the production and relevant documentation, without being
bound to make changes to the previous production and documentation, except in exceptional cases relating to the
health and safety of persons and property.
HOW TO USE THIS MANUAL

This instruction manual consists of 7 chapters, each relating to a specific topic:
− Chapter 1 provides general information;
− Chapter 2 contains a technical description of the machine and of its operation;
− Chapter 3 explains the safety norms to be observed and the residual risks;
− Chapter 4 describes machine transport, handling and installation;
− Chapter 5 describes machine use and adjustment;
− Chapter 6 describes the main processing flaws of the wound reels;
− Chapter 7 contains a list of the maintenance interventions.
The pages and the figures are numbered according to the “Chapter-Page” and “Chapter-Figure” scheme. The
paragraphs are numbered according to the “Chapter. Section. Paragraph” scheme.
Warnings and pieces of information have each been inserted within the most appropriate section and are not
repeated elsewhere. For this reason, the manual must be read first entirely and in sequence, from beginning to
end, and all such information must be understood and kept in mind. Afterwards, only the required paragraphs can
be referred to.

Table of contents
SYMBOLS USED IN THE TEXT

The graphical symbols used in this manual to point out precautions or warnings that must be observed are:
OBLIGATION Sign
It is absolutely MANDATORY to carry out the actions indicated by this sign.
PROHIBITION Sign
It is absolutely PROHIBITED to carry out the actions indicated by this sign.
DANGER Sign
It indicates an action or behaviour likely to cause damage to property or persons.
INFORMATION Sign
It indicates a noteworthy piece of information that should be read very carefully.
Hereunder is a list of the graphic symbols used in this manual in order to make reading easier, and understanding
of certain significant parts of the text more immediate. Each symbol (ISO 7000) is identified by its related IMAGE,
CODE NUMBER AND MEANING.
0421 EXAMINE – CHECK
0717 CALL FOR MAINTENANCE
0981 DATA CARRIER

Table of contents
SYMBOLS USED IN TECHNICAL DRAWINGS

The drawing named “LAYOUT 1HS03154P” includes the following graphical symbols:
This symbol is shown on the layout in the positions of the connection points of the POWER
SUPPLY.
This symbol is shown on the layout in the positions of the connection points of the PNEUMATIC
SUPPLY.
This symbol is shown on the layout in the position of the connection point of the COOLING DRUM
HYDRAULIC SUPPLY
This symbol is shown on the layout in the position of the connection point of the WATER
CONDITIONING UNITS HYDRAULIC SUPPLY
TELESERVICE CONNECTION

Table of contents
ENCLOSURES AND RELEVANT CODES

The following enclosures are integral parts of the manual:
• Layout of the machine ...................................................................... layout code = “P”
• Material flow path diagram ............................................................... layout code = “I”
• Water system layout ......................................................................... layout code = “X”
• Oven heating system layout ............................................................. layout code = “V”
• Rest points and Weights layout ........................................................ layout code = “F”
• Rotoscanner (optional) monitoring areas layout .............................. layout code = “Y”
• Machine wiring diagram ................................................................... DW3619E
• Machine pneumatic diagram ............................................................ DW3619P
• documentation concerning the main trade parts
Example:
1. Nordmeccanica code
2. Machine serial number
3. Layout code
Information:
A detailed list of the documentation supplied with the machinery is enclosed with the consignment
letter. We recommend to sign the appropriate copy as a receipt of consignment and to send it as soon
as possible to Nordmeccanica S.p.a. - Documentation Department.

General Information
1 - GENERAL INFORMATION
Table of contents
1.1 Identification data of the Manufacturer ............................................................................................................................. 1.2
1.2 Instruction manual identification data ............................................................................................................................... 1.2
1.3 Identification data of the Machine ..................................................................................................................................... 1.3
1.4 Requesting technical assistance ...................................................................................................................................... 1.4
1.5 Spare parts ordering ......................................................................................................................................................... 1.4
1.6 Machine function .............................................................................................................................................................. 1.5
1.7 Intended use ..................................................................................................................................................................... 1.6
1.8 Misuses ............................................................................................................................................................................ 1.6
1.9 Reasonably foreseeable misuses ..................................................................................................................................... 1.6
1.10 Limitation of use ............................................................................................................................................................... 1.6
1.11 General safety provisions ................................................................................................................................................. 1.7
1.12 Limitation of liability .......................................................................................................................................................... 1.7
1.13 Machine testing ................................................................................................................................................................ 1.7
1.14 Warranty ........................................................................................................................................................................... 1.8
1.15 Demolition and disposal ................................................................................................................................................... 1.9
ID code: SUPER COMBI 4000 – C-3154 – 08/2019 1.1

General Information
1.1 Identification data of the Manufacturer

NORDMECCANICA S.p.a.
Strada dell’Orsina 16/A – 29122 PIACENZA (ITALY)
Phone +39 0523 596411

Fax +39 0523 612051
e-mail: nordmeccanica@nordmeccanica.com
1.2 Instruction manual identification data

The identification code of this manual is featured on the footer of each page: this code is required when purchasing
additional copies of the manual.

General Information
1.3 Identification data of the Machine

The CE Mark plate fixed to the machine features the following identification data.
MACHINE: ................................................LAMINATING MACHINE

TYPE: .................................................................. SUPER COMBI 4000
MODEL: ............................................................ L1300
SERIAL NUMBER: ................................. C-3154
YEAR OF CONSTRUCTION: ...... 2019
The CE mark, stamped on the identification plate in clear, visible, legible and indelible characters,
certifies the machine compliance with the Machinery Directive.
The Purchaser must make sure the plate is never removed from the machine and the featured data are
always clearly legible.

General Information
1.4 Requesting technical assistance

For any information regarding:
- use
- maintenance
- installation
you can contact Nordmeccanica S.p.a. After Sales Service:
After Sales Service
Phone +39 0523 596411

Fax +39 0523 612051
e-mail: service@nordmeccanica.com
Any inquiry or request for assistance submitted to the After Sales Service must indicate the machine data
featured on the identification plate.
1.5 Spare parts ordering

The parts subject to normal wear and tear require periodic replacement. Whenever ordering spare parts, make sure
they can be clearly identified by submitting the relevant info, such as: code number featured in the diagrams, ID
data featured on the physical label, any reference code mentioned in this instruction manual, etc.).
The request must be addressed to:
Spare Parts Department
Phone +39 0523 596411

Fax +39 0523 612051
e-mail: spareparts@nordmeccanica.com
Always use genuine spare parts to preserve the safety conditions provided by the Manufacturer.

General Information
1.6 Machine function

The “LAMINATING MACHINE SUPER COMBI 4000”, according to the job configuration and the fittings used, is
designed for the following basic typology of processing:
- lamination of two webs coming from two distinct reels, by coating specific adhesives/lacquers (solvent-based,
solventless and water-based) on one of the two, and rewinding of the resultant material on a third reel.
Thanks to the possibility of configuring the machine in different ways and to the compatibility with a wide range of
optional fittings, the machine offers a wide flexibility of use.

General Information
1.7 Intended use

The machine is designed for a PROFESSIONAL use only, to be carried out by technical personnel instructed and
trained for the specific processing and use of these machines.
The machine must only be used as intended by the Manufacturer, namely in accordance with the definition
given under the heading “Machine function”, with the relevant details regarding performance, features and
restrictions, listed in Chapter 2 – TECHNICAL DESCRIPTION, and with the procedures for use, adjustment,
maintenance and cleaning described in this manual.
In particular:
- the machine must be installed properly;
- the features regarding the electric, pneumatic and hydraulic supplies must remain constant through time;
- the environmental operating conditions must always be observed;
- the materials to be processed must be among those listed in Chapter 2 – TECHNICAL DESCRIPTION;
- the indicated specifications (speed, web width, load capacity, reel size, etc.) must always be observed;
- the procedures described in this manual as regards use, maintenance and cleaning must always be observed;
- all the provisions concerning the safety of persons and machine must be strictly observed.
Any exception to what so far stated must be decided upon during the contractual stage. Should that not be the
case, the Purchaser shall be charged with both civil and criminal liability in relation to any improper use whatsoever
of the machine.
Any other use not specifically indicated must be considered IMPROPER.
1.8 Misuses
Any use of the machine not described in this manual must be regarded as “not intended” by the Manufacturer.
In particular, the machine must not be used if the guards provided by the Manufacturer are not in place, or
if the safety devices are not installed, not adjusted, deliberately excluded, or otherwise inefficient.
1.9 Reasonably foreseeable misuses
See paragraph 3.6.8 – Reasonably foreseeable misuse
1.10 Limitation of use
The machine cannot be used in potentially explosive atmospheres nor can it be used outdoors.

General Information
1.11 General safety provisions

All general information concerning safety and accident prevention has been collected in Chapter 3 - HEALTH,
SAFETY AND ACCIDENT PREVENTION.
They refer to all the stages of machine use, from installation to operation and from cleaning to repair.
The general safety provisions are not repeated in any of the other chapters; therefore, before carrying out any
operations, make sure you fully understand them.
Please do not hesitate to read them again if you are in doubt.
1.12 Limitation of liability

NORDMECCANICA S.p.a. declines any liability arising from the misuse or not reasonably foreseeable use
of the machine, use of non-genuine spare parts and from any modification or tampering whatsoever
(circuits, components, software, additional fittings).
The Safety supervisor is responsible for the thorough and scrupulous enforcement of the safety provisions. The
Safety supervisor must also ascertain that the personnel entrusted with the use of the machine hold the
qualifications to carry out the required task, are knowledgeable about the instructions described in this manual and
about the general safety provisions applicable to the machine.
Failure to observe the safety rules may cause personal injury and may damage machine components.
1.13 Machine testing

The machine is assembled and tested for the first time at the manufacturing site.
After that, it is entirely or partially disassembled and forwarded to the Purchaser. At the end of the subsequent
installation and commissioning, carried out by the Manufacturer’s technicians, the machine is fully tested again in
the presence of the Purchaser, according to the following procedure:
- checking the smooth operation of the machine;
- lamination trial with materials supplied by the Purchaser of the machine;
- functional tests on the safety equipment.
The final test, performed in the presence of the Purchaser, shall constitute evidence of machine acceptance by the
Purchaser.

General Information
1.14 Warranty
Unless expressly agreed otherwise, NORDMECCANICA S.p.a. guarantees the machine herein free from any
material or manufacturing faults for a period of twelve months from date of installation and, in any case, for not over
fourteen months from date of delivery.
During the warranty period, NORDMECCANICA S.p.a. shall undertake to eliminate, within the required time, any
obvious defect and/or fault detected by the Purchaser.
This warranty will be valid only if the Purchaser adheres strictly to the contractual/administrative terms and
conditions, and if the installation and use of the machine is carried out in compliance with the instructions given in
this manual.
Under this warranty, NORDMECCANICA S.p.a. will repair or replace, free of charge, any parts that may prove
defective at source.
Any decision thereof made by NORDMECCANICA S.p.a. authorised technicians shall be considered irrevocable.
Unless expressly agreed otherwise, labour costs are not included in the warranty and will be charged accordingly.
Likewise, not included in the warranty, and therefore charged to the Purchaser, are any expenses relating to
transport, inspection, disassembly and reassembly due to the intervention of the Manufacturer’s technicians, in the
case where the faults are not ascribable to NORDMECCANICA S.p.a.
The warranty does not cover parts subject to normal wear and tear.
The warranty does not include any liability whatsoever for any direct or indirect damage to property and persons
resulting from improper use or insufficient maintenance, and is limited to manufacturing or processing defects only.
The materials used in the construction of this machine were selected at the sole discretion of NORDMECCANICA
S.p.a. as being the most appropriate in terms of type and quality (except for any specifications provided by the
Purchaser during the contractual stage). Even after installation, NORDMECCANICA S.p.a. can decide to make
changes aimed at improving the operating conditions.
The warranty and NORDMECCANICA S.p.a. liability shall lapse in case any modification or tampering
whatsoever is carried out on the machine.

General Information
1.15 Demolition and disposal

At the end of its lifespan, the machine must be dismantled and the various parts and components must be
disposed of correctly.
During this stage, strictly comply with all the relative regulations in force in the Country where the
machine was in use.
In addition to the above provision, the following must be regarded as special materials and must be disposed of
accordingly:
- lubricants and coolants;
- various filters;
- pressure vessels;
- batteries and accumulators;
- cathode tubes and liquid crystal screens;
- electronic components and cards.
The materials being recycled must be separated into:
- plastic and synthetic material (structural parts, components, systems);
- electric material (cables, motors, transformers etc.);
- metal material (machine frame, guards, rollers etc.).
The machine CE Mark plate must be definitely destroyed.
Before starting any dismantling operation, disconnect all the supply lines upstream from the machine
sectioning devices and exhaust any pressure vessel (pneumatic and hydraulic tanks etc.).
It is recommended to clean the machine from any residue of adhesive, solvent, or whatever other material that
could somehow hinder the disposal and recycling operations.
Disassembled parts must be adequately packed according to mass and features, and handled with utmost care. A
plate must be affixed to the packaging, indicating mass, contents and any other information useful for transport
operations.

Technical description
2 - TECHNICAL DESCRIPTION
Table of contents
2.1 General Information .......................................................................................................................................................... 2.3
2.2 Main units composing the machine .................................................................................................................................. 2.4
2.3 “Shaftless” unwinder ......................................................................................................................................................... 2.5

2.3.1 General description ............................................................................................................................................................... 2.5
2.4 Corona treatment.............................................................................................................................................................. 2.8

2.4.1 Pulling unit (optional) ............................................................................................................................................................. 2.8
2.5 “SHAFTLESS” unwinder B ............................................................................................................................................... 2.9
2.6 Automatic web guide system ............................................................................................................................................ 2.9
2.7 Shaftless winder ............................................................................................................................................................. 2.10
2.8 Coating column............................................................................................................................................................... 2.11
2.9 Inserting the trolleys in the machine ............................................................................................................................... 2.12
2.10 Laminating unit ............................................................................................................................................................... 2.14
2.11 Rotogravure trolley ......................................................................................................................................................... 2.15

2.11.1 Doctor blade ........................................................................................................................................................................ 2.17
2.11.2 Feed pans ........................................................................................................................................................................... 2.18
2.11.3 Adhesive tank with pneumatic pump.................................................................................................................................... 2.18
2.12 Solventless coating trolley .............................................................................................................................................. 2.19

2.12.1 General description ............................................................................................................................................................. 2.19
2.12.2 SL adhesive feed ................................................................................................................................................................. 2.20
2.12.3 System for SL adhesive feed ............................................................................................................................................... 2.22
2.12.4 Metering rollers .................................................................................................................................................................... 2.23
2.12.4.1 Checking performance of the sensor detecting the presence of the rubber-coated transfer roller...................................2.24
2.12.5 Lock and regulation brackets ............................................................................................................................................... 2.26
2.12.6 Rubber-coated transfer roller ............................................................................................................................................... 2.28
2.12.6.1 Transfer roller cutting ........................................................................................................................................................2.29
2.12.6.2 Transfer roller handling trolley...........................................................................................................................................2.30
2.12.6.3 Roller storage rack (for transfer rollers) .............................................................................................................................2.31
2.13 Rubber-coated coating impression roller ........................................................................................................................ 2.32

2.13.1 Interchangeable rubber-coated sleeve ................................................................................................................................. 2.33
2.14 Ionogenic bars ................................................................................................................................................................ 2.34
2.15 Horizontal drying oven (Standard) .................................................................................................................................. 2.35

2.15.1 Description .......................................................................................................................................................................... 2.35
2.15.2 Oven key features ............................................................................................................................................................... 2.35
2.16 Horizontal drying oven with removable blowers (optional).............................................................................................. 2.36

2.16.1 Description .......................................................................................................................................................................... 2.36
2.16.2 Oven key features ............................................................................................................................................................... 2.36
2.17 Information about air recirculation and heating in the drying ovens ................................................................................ 2.37
2.17.1 Automatic recirculation (optional) ......................................................................................................................................... 2.37
2.17.1.1 Manual recirculation (optional) .........................................................................................................................................2.37
2.17.2 Air heating with thermo-oil battery........................................................................................................................................ 2.37

2.18 Web tensioning control system: load cell and dancing roller .......................................................................................... 2.38
2.19 Systems .......................................................................................................................................................................... 2.40

2.19.1 Electric system .................................................................................................................................................................... 2.40
2.19.1.1 Electrical cabinet/Container ...............................................................................................................................................2.40
2.19.2 Pneumatic system ............................................................................................................................................................... 2.41
2.19.3 Vapour exhaust system ....................................................................................................................................................... 2.42
2.19.4 Heating system for the drying oven...................................................................................................................................... 2.42
2.19.5 System for controlling the solvent concentration (L.E.L.)...................................................................................................... 2.42
2.19.6 Explosion-proof pressurization system................................................................................................................................. 2.43
2.19.7 Roller thermoregulating system ........................................................................................................................................... 2.43
2.20 Adhesives, inks and lacquers ......................................................................................................................................... 2.44
2.21 Solvents .......................................................................................................................................................................... 2.44
2.22 Processable materials .................................................................................................................................................... 2.45
2.23 Technical characteristics of rubber-coated rollers .......................................................................................................... 2.46
2.24 Technical data ................................................................................................................................................................ 2.47
2.25 Thermoregulating units (diagram)................................................................................................................................... 2.50

2.1 General Information

The technical description of the main machine components has been set out in this chapter in a deliberately simple
form, in order to provide operators and maintenance technicians with the technical knowledge of those parts they
will have to interact with for a proper and safe use and maintenance.
The documentation provided by the suppliers of commercial parts has been attached to the present Instruction
Manual: in order to acquire a complete and overall view of the technical aspects of the machine, also said
documentation should be referred to and carefully read.
LEGEND:
Coating trolley ........................ interchangeable and movable coating unit, mounted on a chassis with wheels, which
fits inside the coating column.
RT ................................................. rotogravure trolley or type of working where coating is performed by means of the
rotogravure trolley.
SL ................................................. solventless trolley or type of working where coating is performed by means of the
solventless trolley.
Shaftless winder .................... type of winder without reel-holder shaft.
Shaftless unwinder............... type of unwinder without reel-holder shaft.
NUMERICAL CODES FOR CONTROL PANELS, SELECTOR SWITCHES AND PUSH-BUTTONS

In this Instruction Manual, all the numerical codes used for identifying the control panels, selector switches and
push-buttons are those featured in the Wiring Diagrams DW3619 corresponding to machine Super Combi 4000 C-
3154.
When describing the “front side”, “right side” and “left side” control panels located on the Local Control Panel
(LCP), their positions are referred to with respect to the person facing the LCP, namely: the panel in front of the
person, the one to his right or the one to his left.

2.2 Main units composing the machine

The main units composing the machine are listed in the following table:
T 2.1 – Machine main components

Position Description
1 Coating column with interchangeable trolleys
2 Shaftless unwinder “A” for the material to be coated (primary material)
3 Shaftless winder
4 Laminating column
5 Shaftless unwinder “B” for the material to be laminated (secondary material)
6 Drying oven

2.3 “Shaftless” unwinder

2.3.1 General description
The unwinder A is a “shaftless” unit: it supports the reel to be unwound by clamping its core at the ends, without
using a central shaft. The reel change is manual and must be carried out with unwinder still. The unit is motorized
and can unwind both clockwise (CW) and counterclockwise (CCW).
From a mechanical point of view, the unwinder consists of two independent reel-holder arms sliding on two round
guiding bars by means of sliding ball sleeves: the two arms get closer to clamp the reel and move away to release
it. Two interchangeable metal cones, which are assembled on the unwinding pins, support the reel; when the reel-
holder arms close, the cones slip and fix into the core allowing the transmission of the unwinding/braking torque.
The main arm accomplishes the functions of manual centring of the reel and of automatic web guide. The motion is
obtained by means of a gearmotor coupled to a ball screw.
F 2.1 – Unwinder: detail
1. Secondary arm
2. Motorized arm
3. Reel-holder cone
4. Unwinder motor
The secondary arm holds the drive system for unwinding: the electric motor, driven by an electronic inverter with
vectorial control, is coupled to an epicyclic reduction gear assembled in axis.
The motion of the secondary arm for opening and closing is controlled by a double-acting pneumatic cylinder.
At the end of the closing, the cylinder remains under pressure and constantly keeps the core clamped.

To load the reel to be unwound and unload the empty core, autonomous handling means (e.g. reel-lifting trolley)
are to be used.
The motion of the two arms for opening/closing is co-ordinated and takes place under the control of the operator.
When opening, the secondary arm covers the whole travel of the pneumatic cylinder. To shorten the time required
for the reel change, the main arm, on the contrary, covers a reduced travel: this travel, necessary to release the
core, is delimited by two proximity switches installed on a regulation trolley.
When closing, the main arm returns to the previous position while the pneumatic cylinder shuts the secondary arm
against the reel core.
A safety system, consisting of three other fixed proximity switches, controls the travel of the two arms so as to
prevent any damage.
F 2.2 – Proximity switches, release travel
The unit allows reels of various widths to be quickly loaded and to be precisely centred; the control of manual
alignment intervenes on the main arm, by operating the relevant gearmotor for shifting. Also the automatic web
guide system works in the same way, by driving the gearmotor in real time in order to correct any side skid of the
web.
The core clamping, obtained by means of the pneumatic cylinder, is of a floating type: the secondary arm follows
every movement of the main arm and constantly keeps the core properly clamped.
Cones of various types can be assembled, different in diameter (3” or 6”), length and material: aluminium for
cardboard/plastic cores, steel for metal cores. For the reels with metal core of 6”, rubber expanding chucks are also
available, with pneumatic inflation.
Reels with a minimum width below the standard value (L/2) can be loaded by means of extensions.

F 2.3 – Reel-holder cones
Otherwise, the unwinder can be supplied with pneumo-mechanical expanding chucks which need not be
disassembled every time; the chucks are suitable for cores of different materials and an adapter ring makes it
possible to pass from 3” to 6” and vice versa with ease.

2.4 Corona treatment

Flexible packaging materials are usually pre-treated at source; with time, however, the Corona treatment level
decays to the point of resulting, in many cases, insufficient. The machine can be thus equipped with an in-line
refreshing system to restore the required Corona treatment level.
Effects of the Corona treatment, according to the treated material:
increases the treated side surface improvement of the adhesive/ink

Mechanical effects
roughness anchorage
increases the surface tension, improvement of the adhesive/ink

Chemical effects
favouring the wettability anchorage
The system is composed of a generator and of a discharge station placed by the unwinder. The web passes onto a
roller inside the discharge station; a number of electrodes, placed as a semicircle around the roller, send the
electric discharges onto the web.
The Corona treatment components are subject to very high voltage during their operation.
The ozone produced in the discharge station is sucked by a suitable fan and must be properly exhausted.
Further information regarding the discharge:

Paragraph 4.1.4 – AERATION AND EXHAUST SYSTEM
2.4.1 Pulling unit (optional)

In order to improve the web pulling, the treatment station can be motorized: the discharge roller is mechanically
connected with an electric motor and the web pulling is guaranteed by a rubber nip roller. The nip roller is
pneumatically operated (opening/closing).
Information for the operator:

The motorization is very useful during the acceleration and braking phases to avoid breaking the more
delicate webs.
Further information about Corona treatment:

Supplier documentation.

2.5 “SHAFTLESS” unwinder B

The unwinder B is constructed like the unwinder A and operates in the same way; they are both equipped with an
automatic web guide system.
2.6 Automatic web guide system

The web guide system keeps the web coming from the unwinder centred. It corrects any side skidding of the web
by shifting the entire unwinder towards the opposite direction; in fact, the unwinder can shift in crosswise direction.
The web skidding detection is entrusted to an edge-reading sensor while correction is obtained by making the
unwinder slide. The fork-shaped web guide sensor must be manually positioned onto the edge of the web before
starting the system; when it is operative, the system keeps the web in the middle of the sensor reading area.
F 2.4 – Web guide system
1. Fork-shaped sensor
Further information:

2.7 Shaftless winder

The winder is a shaftless unit: it supports the reel in winding by clamping its core at the ends, without using a
central shaft. The unit is motorized and can wind both clockwise (CW) and counterclockwise (CCW). It is equipped
with a lay-on roller, which is an idle roller whose function is to press against the reel during winding, and make it
compact by preventing the film web from accumulating air between the coils.
F 2.5 – Winder
1. Secondary arm
2. Motorized arm
3. Winder motor
4. Safety bar on lay-on roller
5. Safety bar on dancing roller
The tension of the winding web is controlled by means of a dancing roller. The winder can wind either with a
constant tension or with a decreasing tension, i.e. progressively reducing the winding tension as the diameter of the
wound reel increases.

2.8 Coating column

The machine is fitted with a coating column characterized by the coating trolley interchangeability. This column
houses the pipes for exhausting both the vapours released by the solvent present in the adhesive (RT coating) and
the vapours released by the adhesive (SL coating); above it there is a fan for extracting the vapours and it is
provided of a door having a double function:
- protective element preventing operators from entering into contact with the internal moving parts;
- contributes to creating a depression in the room that facilitates the vapours extraction.
F 2.6 – Coating column
1. Vertical sliding door

2. Vapour exhaust hood
3. Operator panel LCP21 (left side)
4. Safety microswitch
5. Operator panel LCP21 (front side)
6. Foot pedal for the rollers counter-rotation, to use in the cleaning phase
In the coating column, the smoothing bar is optional and it is supplied at the Purchaser’s request.
Coating trolleys description:

Section 2.11 – ROTOGRAVURE TROLLEY;
Section 2.12 – SOLVENTLESS TROLLEY.

2.9 Inserting the trolleys in the machine

The machine can use various coating techniques, depending on the type of adhesive and on the performances
desired for the final product. This is possible thanks to interchangeable coating units, assembled on trolleys with
swivel wheels, to be inserted in coating column.
The machine referred to in this Instructions Manual is fitted with the following coating trolleys:
- RT trolley (rotogravure);
- SL trolley (solventless);
The operations for inserting and extracting the coating trolleys are to be done manually: a special handle, to
remove after use, allows rotating the pinion fixed to the side of the trolley that engages with the rack fixed onto the
coating column shoulder. This mechanism facilitates the sliding of the trolley.
F 2.7 – Detail: belt tensioning
1. Cam tensioner
2. Driven pulley of the chromed coating roller
3. Automatic belt tensioning with trolley inserted

Once inserted in the coating space, the trolley is firmly locked. Two brackets, hinged on the side frames of the
coating column, hook some pins arranged on the trolley; by acting on the two handles, the brackets put the trolley
in traction and lock it in the working position.
F 2.8 – Detail: trolley locking
1. Pin on the coating column

2. Lock bracket
3. Spindle on which to insert the removable handle
4. Pinion fixed on the trolley
5. Locking knob
6. Rack fixed to the coating column

2.10 Laminating unit

In the machine there is a laminating column whose task is to achieve the lamination of the two entering webs.
Inside the column there is the laminating unit, namely the group physically accomplishing the lamination of the two
webs by exerting a strong pressure on them. This unit is basically composed of three rollers which, by exerting a
strong pressure on the webs passing between them, allow the adhesive to grip and to glue the webs together. The
working principle is summarized in the following picture.
F 2.9 – Laminating unit
1. Chromed laminating roller (heated)

2. Rubber-coated laminating nip roller
3. Counter-roller
4. Counter-roller actuating cylinders
The chromed laminating roller is assembled on bearings lubricated with grease. It is operated by a motor fixed on
the side frame of the laminating column and the transmission is by means of a toothed belt. The same belt also
provides for the motorization of the post-laminating drum/s. A disk brake, pneumatically operated, keeps the
laminating roller locked when it is necessary to avoid undesirable motion (e.g. for the web tensioning).
The laminating roller is hollow inside (double-walled, with spiral jacket) and connected to a heating unit by means
of rotary joints.
The rubber-coated nip roller is assembled, with greased bearings, on a couple of hinged arms on the machine side
frames. Below the rubber-coated nip roller, there is a third roller (counter-roller) with the task of preventing the
deformation of the rubber-coated nip roller caused by the intense pressure exerted during lamination. The counter-
roller is mounted on two arms driven by two double-action pneumatic cylinders (nip roller opening/closing).

Procedure for replacing the laminating roller: section 7.25
When the nip roller is closed, the independent adjustment of the two cylinders (operator side and transmission
side) allows the operator to control the laminating pressure with precision.
Elimination of the crushing risk:

A safety guard is installed on the web entry line, between the laminating roller and the nip roller.

2.11 Rotogravure trolley
F 2.10 – RT trolley: main components
1. Engraved coating roller

2. Adhesive inlet
3. Adhesive discharge
4. Internal pan (adhesive fountain pan)
5. External pan (adhesive collecting pan)
6. Doctor blade unit
7. Web under coating
8. Rubber-coated coating impression roller
Key features:
- medium/high grammage coating of solvent-based or water-based adhesive or lacquer;
- engraved coating roller;
- very high precision coating.
Description:
The Rotogravure coating unit is outlined in the above picture: the coating roller A rotates dipped into the adhesive;
a thin blade, called “doctor blade”, levels the quantity of adhesive carried by the coating roller, before the web in
transit is coated.
The web speed is imposed by the laminating unit, according to the operator setting. The coating roller rotates at the
same speed, keeping the web tension at the set value.
The feed system is a closed-circuit type: a pneumatic pump keeps the adhesive continuously circulating between a
tank, placed on the ground, and the coating unit. Two feed pans, assembled inside each other, make it possible to
keep the adhesive level constant. This is a system of overflowing type: the pump feeds the internal pan and keeps
it always full; the overflowing adhesive drops into the pan below and from there it returns to the tank through a
discharge hose with properly dimensioned section. Thanks to these solutions, the coating roller always remains
dipped into fresh adhesive.
The surface of the coating roller is thickly engraved, following a regular screen; the engraving section normally has
the shape of a truncated pyramid. The coating roller is interchangeable and several engraving pitches are available

(expressed in number of lines per centimetre). Moreover, the engraved coating roller is chrome-plated to ensure
maximum resistance to wear.
The adhesive evenly wets the surface of the engraved roller and settles on the engravings.
The doctor blade works in contact with the engraved roller, pressed by two pneumatic cylinders.
It fulfils two functions:
- it ensures the complete filling of the cells of the engraved roller;
- it wipes off the exceeding adhesive.
Coating is carried out by means of the rubber-coated coating impression roller that, operated by a couple of
pneumatic cylinders, presses the web onto the coating roller A in rotation. The adhesive contained in the
engravings of the coating roller is totally transferred onto the web.
The quantity of coated adhesive is constant with speed changing and it only depends on the engraving of the
coating roller used: the more the lines are, the less the weight is.
The coated band depends on the coating impression roller: the rubber must properly be cut at the sides, according
to the desired width of coating. For each coating width, a different rubber cutting is required: the coating impression
roller is therefore with interchangeable sleeve.

The machine automatically enables the necessary functions for the specific processing and disables
the non-compatible and/or dangerous equipment.

2.11.1 Doctor blade

The doctor blade is a sharp thin sheet of metal, fitted for rotogravure processing: it is housed in a rigid doctor blade
holder (which is locked by means of several screws) and is coupled to a thicker sheet called “counter doctor blade”.
The doctor blade holder is assembled on an articulated unit by means of a fast lock/unlock system.
F 2.11 – Doctor blade
1. Doctor blade lock

2. Doctor blade holder
3. Regulators for controlling the doctor blade parallelism with the coating roller
The doctor blade articulated unit ensures all the necessary regulation movements for the doctor blade orientation
and for the maintenance.
The incidence angle of the coating roller can be adjusted in the best possible way, according to the type of
processing and to the development of the coating roller used. The two front regulators allow to adjust the
parallelism with respect to the coating roller. The entire unit can quickly be overturned backwards for maintenance
and cleaning.
The doctor blade is pressed against the coating roller by two pneumatic cylinders (the pressure can be regulated
by the operator). Furthermore, the doctor blade is lowered into contact with the roller and it moves away from it
thanks to the pneumatic cylinders.
To improve the uniformity of wiping, a cam sets the doctor blade in alternating crosswise motion; the motion is
derived from the coating roller by means of a worm screw and a helical spur gear.

Due to the friction against the coating roller, the doctor blade wears out and needs to be replaced
frequently.

2.11.2 Feed pans

The feed pans have the function of keeping the adhesive/lacquer, where the coating roller is dipped, at a constant
level.
To limit the emission of vapours, they are closed on the upper side by a cover with an opening by the coating
impression roller. To position the cover, hold it by the side handles and lay it on the edges of the pans.
The pans can be lowered and slid out, after having removed the cover, for being emptied and cleaned. The crank
for lifting/lowering the pans is fitted with a locking pin with spring return to lock the pans in the working position.
F 2.12 – Pan crank
2.11.3 Adhesive tank with pneumatic pump

The adhesive tank is a sheet-steel container, assembled on swivel wheels to be moved with ease; it is closed by a
cover that can be opened and removed for cleaning.
The tank is equipped with a pneumatically operated diaphragm type delivery pump, with suction system at the
bottom of the tank itself.
The pump is connected to a specific connector, in the pneumatic system of the machine, by means of a spiral
hose.
Documentation of the diaphragm pump Supplier.

2.12 Solventless coating trolley

2.12.1 General description
F 2.13 – SL coating unit
1. Rubber-coated coating impression roller

2. Chromed coating roller (heated)
3. Rubber-coated transfer roller
4. Motorized chromed metering roller (heated)
5. Fixed chromed metering roller (heated)
Key features:
- coating of Solventless adhesives, both monocomponent and bicomponent, with medium/low grammage;
- even coating on the entire web;
- adhesives heated and coated at a controlled temperature to obtain the required viscosity for coating.
Description:
The adhesive is poured between the two metering rollers C and D, both chrome-plated; the rubber-coated transfer
roller B conveys the adhesive onto the chromed coating roller A; by the latter, the adhesive is coated onto the web
in transit.
The web speed is imposed by the laminating unit, according to the operator setting. The coating roller rotates at the
same speed, keeping the web tension at the set value.
The adhesive is supplied by a dedicated preparation system, by means of a direct feed: a sensor checks the
adhesive quantity between the two C and D metering rollers and keeps it to a minimum level so as to limit the time
spent between the rollers; this ensures that in the coating unit there is always fresh adhesive.
The metering roller C rotates at low speed; the metering roller D is instead fixed but it can be manually rotated for
cleaning needs. The two metering rollers do not operate in contact with each other but are kept at a calibrated
distance (about 0.08÷0.1 mm) to control the quantity of adhesive collected by the C roller: in this way it is carried
out the first regulation of the quantity of adhesive to be coated.
The rubber-coated transfer roller B is mechanically connected to the same motor of the metering roller, but with a
different gear ratio: in fact, it rotates at a speed that is 10 times higher; during coating, it is kept in contact with the

two chromed rollers A and C, whereas it remains lifted when it is not working. The working pressure can be
regulated by the operator.
The speed of the transfer roller B is kept proportional to the speed of the coating roller A, to ensure a proper supply
of adhesive. The ratio between the two speeds is the second factor determining the coated adhesive metering: the
operator can set the speed of the metering/transfer motor in percentage.
Coating is carried out by means of the rubber-coated coating impression roller that, operated by a couple of
pneumatic cylinders, presses the web onto the coating roller A in rotation. The adhesive that is present on the
surface of the coating roller is totally transferred onto the web.
The coated band depends on the transfer roller: the rubber must properly be cut at the sides, according to the
desired width of coating. For each coating width, a different rubber cutting is required: the transfer roller is therefore
easily interchangeable.
The three chromed rollers are equipped with rotary joints and connected to a heating unit by means of hoses.
During coating, they are heated at a carefully controlled temperature to keep the adhesive in the best conditions;
the system also allows a fast cooling for the cleaning operations.
2.12.2 SL adhesive feed

The adhesive, supplied by an external system that provides for its heating/mixing, is poured between the two
metering rollers; two properly shaped Teflon walls contain it sideways. The distance between the walls represents
the width of the metering chamber.
The capacitive sensor checking the adhesive level between the two rollers can be regulated in height; if necessary,
it is possible to modify its sensitivity too.
F 2.14 – SL coating unit: sensor
1. Teflon wall
2. Capacitive level sensor
The SL coating unit is equipped with a conveying device (slide), pneumatically operated, to distribute the fresh
adhesive evenly along the metering rollers.
The nozzle delivering the adhesive is fixed on a pulling trolley, operated by a pneumatic cylinder; during the
adhesive supply, the slide pulls the nozzle from one end to the other of the metering chamber, with a continuous
alternating motion.
The slide can be removed from the trolley and the pneumatic connections are carried out by means of two quick
couplings.

F 2.15 – SL coating unit: adhesive slide
1. Adhesive feed nozzle

2. Adhesive slide
Coating band adjustment

The two Teflon walls must be positioned according to the coating width; likewise, it is possible to adjust the slide
travel so that the adhesive can be poured onto the usable area only.
The pneumatic cylinder travel is set, on both sides, by inserting a limit stop pin in one of the arranged holes: when
the trolley arrives at the limit stop, it automatically reverses the movement direction.
The limit stop pins must be positioned near the Teflon walls to ensure the presence of fresh adhesive on the entire
coating band.
F 2.16 – SL coating unit: travel adjustment
1. Capacitive level sensor

2. Limit stop pin

2.12.3 System for SL adhesive feed

The mixing and metering unit for solventless adhesives, where present, must be connected to supply lines
differentiated from those of the machine.

For the relevant technical data, refer to the specific documentation.

2.12.4 Metering rollers

The first metering of the adhesive is carried out by the two metering rollers and exclusively depends on their
distance (about 0.08÷0.1 mm); it is therefore essential that the regulation of such a distance, manually carried out
at the beginning of each processing, should be very accurate.
Due to thermal expansion, the distance between the rollers is also influenced by their working temperature.
The regulation handwheels are equipped with reading scale and zero-setting ring nut; the ring nut can be locked
with a dowel, after carrying out the regulation.
The fixed metering roller can be rotated by hand, for cleaning or maintenance, by means of a handwheel placed on
the same axis.
A locking pin with spring return allows the roller to be locked in various positions.
F 2.17 – SL coating unit: detail
1. Adjustment handwheel
2. Zero-setting ring nut
3. Manual rotation handwheel
4. Lock pin with spring return

2.12.4.1 Checking performance of the sensor detecting the presence of the rubber-coated transfer roller
A sensor installed on the SL trolley detects the transfer roller presence (green roller) (1, F 2.18). The sensor is
installed on a drilled plate near the right-hand end of the rubber-coated roller.
F 2.18 – Rubber-coated transfer roller
1. Rubber-coated transfer roller

2. Right-hand end of the shaft of the rubber-coated transfer roller
3. Sensor detecting the roller presence
After replacing the roller, it is necessary to proceed as follows in order to make sure that the distance
between the sensor and the end of the shaft of the rubber-coated transfer roller is correct.
Any incorrect adjusting of the distance between the sensor and the rubber-coated transfer
roller may result in a malfunctioning of the sensor detecting the roller presence; consequently,
it may cause injuries to people or damages to property.

Procedure:
- Fit the rubber-coated transfer roller on the SL trolley.
- Loosen the ring nut (5, F 2.19).
- Rotate the ring of the sensor (2, F 2.19) until the sensor (3, F 2.19) touches the shaft (4, F 2.19) of the rubber-
coated transfer roller.
- Rotate the ring through 1.5 revolutions, so that the sensor moves away from the end of the shaft of the rubber-
coated transfer roller up to 1.5 mm.
- Lock the sensor in this position by bringing the ring nut (5, F 2.19) into contact with the adjusting ring (2, F 2.19).
F 2.19 – Adjusting the sensor detecting the rubber-coated transfer roller presence
1. Threaded support of the sensor detecting the presence of the roller

2. Adjusting ring of the sensor
3. Sensor
4. Right-hand end of the shaft of the rubber-coated transfer roller
5. Ring nut of the sensor

2.12.5 Lock and regulation brackets

Description:
The two brackets locking the transfer roller are articulated parts consisting of a lever equipped with three screws
with knobs.
Function:
The main function of the brackets is to allow the transfer roller to be quickly locked and unlocked on its supports, by
means of the locking knob.
F 2.20 – Lock/unlock bracket for the transfer roller
1. Lifting knob
2. Locking knob
3. Regulation knob
4. Lock nut
5. Regulation fulcrum
Transfer roller adjustment:

The brackets operate in different ways depending on the situation:
- Stand-by;
- During coating;
- Machine idle for a long time.

F 2.21 – Action of the transfer roller locking/unlocking brackets
a) Stand-by The two pneumatic cylinders keep the transfer roller up, with a fixed
pressure. The brackets remain completely free, without leaning on the side
frames of the coating unit.
b) During coating The two pneumatic cylinders keep the transfer roller in traction, pressed
between the metering roller and the coating roller, with a pressure that can
be regulated by the operator. The regulation may become necessary at a
high speed because the transfer roller, especially with very dense adhesive,
tends to wedge itself between the two rollers below; this brings about an
overstress of the coating roller motor (a specific display shows the motor
current).
The regulation screw, laid on the side of the coating unit, limits the transfer
roller travel and prevents it from keeping going down. The regulation is
carried out when starting the working, before increasing the speed, and it
can be locked by the lock nut.
The lifting screw is released and the bracket directly leans on the regulation
fulcrum.
c) Machine idle for a long time The pneumatic cylinders of the transfer roller are equipped with stop valves
that keep it up even in absence of pneumatic supply. Even if the machine
does not work for a long time, the transfer roller can however go down
(though quite slowly)
To prevent rubber deformation when the roller is motionless, it is advisable
to lock the roller down travel mechanically, by screwing the lifting screw.
The regulation screw must not be touched: to go back to the working
regulation, it is enough to loosen the lifting screw and let the bracket lean on
the regulation fulcrum again.

2.12.6 Rubber-coated transfer roller

The transfer roller is an interchangeable rubber-coated roller, equipped with bearings already assembled on pins,
assembled on two sliding supports, which are operated by two pneumatic cylinders and lubricated with grease. A
rack-and-pinion system ensures the synchronization between the two slides. The roller is fixed by means of two
lock and regulation brackets; the two brackets, clamping the roller bearings on the respective slides, allow fast
operations of lock/unlock.
The transfer roller is motorized; it can rotate both when it is in working position and when it is lifted, thanks to a
special articulated joint that manages to follow the roller travel and to transmit the motor rotation.
A chuck that can be opened, and is fixed to the joint, allows the connection/disconnection of the transfer roller at
the time of replacement. The chuck is opened by unscrewing a nut by means of the spanner supplied with the
machine; once the chuck is closed again, it transmits the motor torque thanks to a tongue that is engaged with a
key-way on the pin of the roller.
F 2.22 – SL coating unit: openable articulated joint
1. Nut for opening the chuck

2. Spanner purposely supplied
Information for the mechanical maintenance technician:

The reduction gear of the motorized metering roller “C” is lubricated for life.
Other maintenance interventions: see Chapter 7 – CLEANING AND MAINTENANCE

2.12.6.1 Transfer roller cutting

The rubber cutting is useful for defining the coating width of the transfer roller. It is carried out by means of a
mechanical machining on a lathe or grinding machine, by using specific tools.
On both sides of the roller, a portion of the rubber covering must be taken off for a thickness of 1.5÷2 mm on the
radius (see paragraph 3.7.9) leaving an intact central band equal to the desired coating width.
Risk of damages to the transfer roller!

Pay attention to the machining direction: the rubber must be taken off starting from the edge of cutting
and proceeding towards the end of the roller.
F 2.23 – Cutting of the transfer roller rubber
1. Coating band (centred)

2. Cut area
3. Edge of cutting
The roller can be cut more than once, to obtain different sizes of the central band (less wide). It can also be grinded
completely, to correct possible roundness deformation.
FORBIDDEN OPERATION
The diameter of the rubber-coated roller must never be less than the minimum diameter indicated in
Section 2.23 – TECHNICAL CHARACTERISTICS OF RUBBER-COATED ROLLERS.

2.12.6.2 Transfer roller handling trolley

Considering the weight of the transfer rollers, a specific handling trolley is provided to remove them
from the machine and replace them in an easy and safe way.
The trolley has two hooks, with manual chain motion operated by a handwheel.
F 2.24 – Trolley for handling the transfer rollers
1. Hook
2. Chain handling the hook
3. Handwheel for manually operating the chains

2.12.6.3 Roller storage rack (for transfer rollers)

For the solventless processes, it is necessary to have several transfer rollers available: one for each coating width
and some more still to be cut.
A roller storage rack is therefore included in the supply. It is a sturdy metal structure that can safely hold the
transfer rollers. The loading/unloading of the rollers is manual.
The rollers rest on the pins only, so as to avoid deformation of the rubber.
The roller storage rack is not equipped with an automatic roller loading/unloading system. Therefore,
these operations must be carried out in manual mode by means of mechanical lifting/handling
equipment. Use lifting/handling equipment with a suitable capacity for the transfer roller weight: use
190 kg as a reference.
F 2.25 - Transfer rollers storage rack
The table below shows the information for a correct use of the roller storage rack:
T 2.2 – Max. admitted load on the roller storage rack
Max. no. of rollers on the Max. weight of each roller Max. total loadable weight
rack
18 190 kg 3420 kg
• Do not load rollers with a weight different from that indicated in the table.
• Do not load any other objects except the transfer rollers used on the laminating machine identified by
serial number C-3154.

2.13 Rubber-coated coating impression roller

The rubber-coated coating impression roller, located inside the coating column, has the task of keeping the web
into contact with the chromed coating roller of the underneath coating unit. It consists of an idle roller, with
interchangeable rubber-coated sleeve, mounted on two mobile slides that glide on high precision mobile guides
due to ball type sliding shoes, lubricated with grease. A rack and pinion synchronization system ensures the two
slides coordinated movement.
Two double-action pneumatic cylinders control the motion/adjustment of the impression roller:
impression roller lowered onto the coating roller, with operator adjustable
Coating conditions:
pressure.
Idle conditions: impression roller raised (with anti-fall safety valve).
For opening and closing the rubber-coated coating impression roller, use the lighted “COATING IMPRESSION
ROLLER” selector switch.
To close the rubber-coated coating impression roller it is necessary to activate the “COATING IMPRESSION
ROLLER” selector switch for a few seconds until the selector switch light is fully on. If the switch is released
beforehand, for safety reasons, the impression roller opens again.

The impression roller can only be closed when the machine is running and the oven ventilation is
working.
At every replacement of the impression roller, always check that the rubber layer is
ANTISTATIC and CONDUCTIVE.

2.13.1 Interchangeable rubber-coated sleeve

The coating impression roller has an interchangeable rubber-coated sleeve:
Solventless process: Completely smooth sleeve without any cutting
Other processes: Sleeve with cutting

For each coating width it is necessary a different rubber cutting, and hence a different sleeve.
Rubber cutting is achieved by means of mechanical machining on a lathe or grinding machine by using specific
tools: part of the rubber layer must be removed on both sleeve sides up to a depth of 1.5÷2 mm on the radius (see
paragraph 3.7.9), while leaving intact a central band equal to the desired coating width. Pay attention to the
machining direction: the rubber must be removed by starting from the edge of cutting and proceed towards the end
of the sleeve.
An additional sleeve-holder spindle is supplied, to be used for cutting.
F 2.26 – Rubber sleeve cutting
1. Coating band (centred)

2. Cut area
3. Edge of cutting
Whenever the rubber sleeve is replaced, always make sure it is ANTISTATIC and CONDUCTIVE.

For sleeve change procedure see section 5.15 .

2.14 Ionogenic bars

During processing, due to the friction, webs may accumulate static electricity. The machine is equipped with an
active device for the reduction of static electricity on the webs.
Elimination of the risk of fire caused by electrostatic charges:

The active antistatic bars are assembled upstream from the coating area, to reduce the fire risk for the
solvent due to possible sparks.
The device consists of a series of metal electrodes, arranged on crosswise bars installed at a distance of few
centimetres from the web in transit. The electrodes are supplied at high voltage by the special unit and are
protected against accidental contact.
The antistatic bars only operate when the machine is running and they ionize the surrounding air. The ions
produced, both the cations and the anions, neutralize the opposite electrostatic charges present on the web
surface.

2.15 Horizontal drying oven (Standard)

2.15.1 Description
Drying chambers  each chamber, of 2.85 metres long, has its own temperature control system
and a fan controlled via inverter. The hot air is blown onto the coated web
side and the particular blowing nozzles arrangement:
a) optimizes the hot air distribution, improving the overall oven efficiency
b) generates a controlled turbulence that creates a downward directed

force; this force keeps the web into contact with the dragging rollers.
2.15.2 Oven key features

- The rollers on which the web runs inside the oven, are idle rollers.
- The rollers surface is transversely engraved to avoid the formation of creases on the web;
- The web tension is controlled via the digital reading carried out by a load cell;
- The dragging chain for web threading is manually operated;
- The oven ventilation is entrusted to two independent fans, sized to obtain the required flow rate even while
making them rotate at low speed: in this way the emission noise level is limited. The exhaust flow rate is greater
than the inlet flow rate: the depression created in the oven prevents the solvent vapours from out-flowing
through the web entry and exit slots.

The operator can separately adjust the speed of the two fans, to set the air pressure of the two
blowers and the depression inside the oven.

2.16 Horizontal drying oven with removable blowers (optional)

2.16.1 Description
Drying chambers  each chamber, of 2.85 metres long, has its own temperature control system
and a fan controlled via inverter. The hot air is blown onto the coated web
side and the particular blowing nozzles arrangement:
a) optimizes the hot air distribution, improving the overall oven efficiency
b) generates a controlled turbulence that creates a downward directed

force; this force keeps the web into contact with the dragging rollers.
2.16.2 Oven key features

- The oven is equipped with sliding doors on the operator side to gain access to the removable blowers. These
doors must be kept closed during normal machine operation. They must only be opened for cleaning purposes,
as shown in Section 7.17.
- The rollers on which the web runs inside the oven, are idle rollers.
- The rollers surface is transversely engraved to avoid the formation of creases on the web;
- The web tension is controlled via the digital reading carried out by a load cell;
- The dragging chain for web threading is manually operated;
- The oven ventilation is entrusted to two independent fans, sized to obtain the required flow rate even while
making them rotate at low speed: in this way the emission noise level is limited. The exhaust flow rate is greater
than the inlet flow rate: the depression created in the oven prevents the solvent vapours from out-flowing
through the web entry and exit slots.

The operator can separately adjust the speed of the two fans, to set the air pressure of the two
blowers and the depression inside the oven.

2.17 Information about air recirculation and heating in the drying ovens
2.17.1 Automatic recirculation (optional)
To get optimum energy efficiency, the oven is equipped with a recirculation system: part of the exhausting hot air is
conveyed again to the inlet, thus reducing the power requirement for heating. The dampers on the recirculation
duct are servocontrolled by the L.E.L. system, which controls the recirculation percentage to maintain the solvent
concentration in the oven constant.
FORBIDDEN OPERATION
The calibration is set during the machine installation and must not be modified.
2.17.1.1 Manual recirculation (optional)

To get optimum energy efficiency, the oven is equipped with a recirculation system: part of the exhausting hot air is
conveyed again to the inlet, thus reducing the power requirement for heating. The dampers on the recirculation
duct are manually controlled, so as to maintain the solvent concentration in the oven within the safety limits.
FORBIDDEN OPERATION
2.17.2 Air heating with thermo-oil battery

The drying air is heated by passing through a fluid/air heat exchanger (battery), fed with thermo oil (at constant
temperature and flow rate) coming from an external heating unit.
Modulating the flow of warm oil in the battery regulates the air temperature in the blower. Upstream from the
battery, there is a by-pass valve (3-way valve) operated by a pneumatic actuator with proportional control. A digital
thermoregulator pilots the actuator, according to the signal coming from a temperature probe installed in the
concerned blower, to maintain the temperature set by the operator.
Temperature and flow rate:

Section 2.24 – TECHNICAL DATA
Supplier documentation

2.18 Web tensioning control system: load cell and dancing roller
The webs pass through various processing units (unwinding, pulling, coating, lamination, and final winding) at the
speed set by the operator; all units are motorized with electric motors for the web pulling. The fragility of webs
requires a special care when handling them, to prevent them from straining or breaking: for this reason, the web
tension is carefully controlled in every section of the travel and the various units operate in a co-ordinated way. The
measuring of the tension is performed by means of:
- dancing roller;
- load cell.
The regulation of the tension, in the various points of the machine, is obtained by changing the speed of the various
motors.
DANCING ROLLER
P = Pressure exerted by the pneumatic cylinder

T = Web tension
The dancing roller is a device that effects an indirect

measuring of the web tension. It is coupled with an electric
motor and the machine electronic system regulates the web
tension, in the section under control, by changing the motor
speed. The dancing roller is a dynamic device: it can damp
strong variations of the tension, thus limiting the risk of a
web break.
The side picture merely shows the working principle and it
does not reproduce the exact device shape.
LOAD CELL
T = Web tension
The load cells are electronic transducers giving an electric

signal that is proportional to a force. Inserted in the supports
of an idle roller, they can perform a direct tension measuring
of the web on the roller. The load cell is coupled to an
electric motor and the machine electronic system regulates
the web tension, in the section under control, by changing
the motor speed.
The functional diagram beside shows the positions of the

sensor and of the red circle to be used as reference for
orienting the load cell.

The following image shows, by way of example, the photo of a load cell with the red circle used as reference. This
circle shows the orientation of the sensor to be turned towards the resulting T of the tensions acting on the web that
wraps the roller on which the load cell is mounted, as shown in the functional diagram on the previous page.
Photo, by way of example, of a load cell with the red circle, used as reference, oriented towards the direction of the resulting T of the tensions
acting on the web.

2.19 Systems
2.19.1 Electric system
The machine electric system is thoroughly described in the Wiring diagram supplied with the machine
documentation.
FORBIDDEN OPERATION
It is absolutely forbidden to modify the machine electric system, in any way, without the prior written
consent from NORDMECCANICA S.p.a.
The Wiring diagram is specific for the single machine; it contains the technical data and all the information of
electric, electronic and structural nature than can be useful for maintenance operations.
In order to guarantee the safety of the machine and the success of the technical interventions, it is essential that
the Wiring diagram is not changed, rectified or altered in any way.
FORBIDDEN OPERATION
Any modification in the diagrams must exclusively be carried out by NORDMECCANICA S.p.a., which
guarantees its proper updating and subsequent distribution.
The Wiring diagram is organized in a series of numbered drawings, methodically describing the entire system:
construction maps, supply distribution, power components (transformers, power supply units, filters, motors), circuit
of the machine emergencies, inverters for the electric motors, electrical and operation safety, devices for control,
signalling and visualization.
At the beginning, the instructions for reading and consulting the Wiring diagram are given. Each leaf is marked with
the identification data (machine and serial number, code, updating, title, leaf number, number of the following leaf).
Moreover, the Directives followed for the fulfilment of the entire electric system of the machine are indicated.
Information for the electrical maintenance technician:

Each component is codified and labelled in the machine to ensure its identification on the diagram and
to simplify maintenance interventions.
The operation of the entire machine is managed by an on-board Computer (PC), which performs the PLC functions
thanks to several I/O digital and analogue channels. For each input or output, the relevant circuit is illustrated,
including the wiring, up to the sensor or the actuator.
For further details on the commercial components of the electric system, refer to the specific
documentation.
2.19.1.1 Electrical cabinet/Container

All the machine circuits converge in a metal cabinet/container with doors and key locks. For the optimal operation
of the electric/electronic equipment, the cabinet/container is provided with air conditioning.

2.19.2 Pneumatic system

The machine pneumatic system is thoroughly described in the Pneumatic diagram, fully enclosed with the
documentation.
FORBIDDEN OPERATION
It is absolutely forbidden to modify the machine pneumatic system, in any way, without written consent
from NORDMECCANICA S.p.a.
The Pneumatic diagram is specific for the single machine; it contains the technical data and all the information than
can be useful for maintenance operations.
In order to guarantee the safety of the machine and the success of the technical interventions, it is essential that
the Pneumatic diagram is not changed, rectified or altered in any way.
FORBIDDEN OPERATION
Any modification in the diagrams must exclusively be carried out by NORDMECCANICA S.p.a., who
guarantees its proper updating and subsequent distribution.
The Pneumatic diagram is carried out like the Wiring diagram; the same considerations regarding reading and use
are therefore valid. The diagram moreover indicates the codified colours used in the machine for the pneumatic
hoses.

Each component is codified and labelled in the machine to ensure its identification on the diagram and
to simplify maintenance interventions.
On the line of pneumatic supply of the machine, the main shut-off valve, a filtering unit with automatic discharge of
the condensate, and a pressure regulator are installed. All the service lines are controlled by means of pneumatic
valves or solenoid valves at low voltage and all the exhausts are silenced.
F 2.27 – Pneumatic supply inlet
1. Air supply shut-off valve

2. Condensate tank
3. Pressure regulator and gauge
4. Filter
Specific documentation.

2.19.3 Vapour exhaust system

To ensure the utmost health conditions for the operator, the machine is equipped with a system for exhausting the
vapours/odours produced during processing. A specific fan, installed above the coating area, sucks any vapours or
odours and conveys them outside the machine; a pressure switch constantly checks the system efficiency.
F 2.28 – Vapour exhaust hood
The exhaust duct must be arranged by the Purchaser, in the room of installation.
The Layout drawing, enclosed with the manual, gives the necessary technical indications.
Exhausting takes place in the coating area, by means of an exhaust hood and some lateral intake openings
equipped with filter. The transparent door, kept closed during processing, helps in the system effectiveness.
2.19.4 Heating system for the drying oven

The system is described in Chapter 2 - Drying oven.
For further information, refer to the specific documentation.
2.19.5 System for controlling the solvent concentration (L.E.L.)

The system is described in Chapter 3 - Control of solvent vapour concentration.

2.19.6 Explosion-proof pressurization system

The motor of the coating roller, the electric cabinets of the coating column and those of the middle column are
served by a pressurization system, with explosion-proof function.
A specific fan, placed in a suitable area, sucks the air from the outside and conveys it through hoses towards the
arranged points; a pressure switch constantly checks the system efficiency.
2.19.7 Roller thermoregulating system

Some rollers require to be heated/cooled with a careful control of their temperature, both for the thermal treatment
of the webs under processing and to ensure the best performances of the adhesives used.
The roller thermoregulation is obtained through a forced circulation of water and concerns both the processing
rollers (e.g. laminating roller) and some rollers specially arranged, called heating or cooling “drums”.
The processing rollers requiring thermoregulation are double-walled rollers, with spiral jacket; the heating or cooling
drums are double-walled rollers, coupled with one of the main motors of the machine by means of a toothed belt
(e.g. the post-lamination drum is motorized by the laminating unit).
Heating
Heating is carried out by an electric closed-circuit heating unit, connected to the roller/drum by means of rotary
joints and hoses.
The heating unit heats the water thanks to an electric resistance and maintains it at the temperature set by the
operator. The unit can quickly decrease the water temperature in its own circuit thanks to a heat exchanger
(indirect cooling).
The heat exchanger of the unit is connected to an external cooling circuit that, according to Purchaser
requirements, can be:
− the hydraulic system (open circuit, with water consumption during the cooling phase);
− a cooling tank with circulation pump, at Purchaser’s care (closed circuit);
− a specific chiller, optional (closed circuit).
Cooling
The roller/drum is connected, by means of rotary joints and hoses, to an external cooling circuit that, according to
Purchaser requirements, can be:
− the hydraulic system (open circuit, with water consumption during whole processing);
− a cooling tank with circulation pump, at Purchaser’s care (closed circuit);
− a specific chiller, optional (closed circuit).
The cooling circuit is usually the same one used by the heating units.

2.20 Adhesives, inks and lacquers

The utmost flexibility of the machine makes it possible, thanks to the different coating units, to use various types of
adhesives, inks and lacquers. Carefully follow the supplier’s indications concerning the fields of use, the
instructions for preparation and coating, the accident prevention measures.
Risk of damages to the machine and to the processed material!

The Purchaser has the responsibility of making sure that the materials used are explicitly suitable for
the processing to be carried out.
Solvent-based processes
The adhesives/inks/lacquers are dissolved in a solvent to achieve the necessary coating viscosity. The solution
percentage is usually advised by the supplier.
The solvent added for the solution must totally evaporate, during the passage in the drying oven, so that the final
product will be free of solvent residues.
Water-based processes
Water is actually a solvent, but it does not create any trouble in terms of injuriousness and safety.
It is possible to use specific adhesives/inks/lacquers that dissolve in water, preparing them according to the
supplier’s instructions. The coated web must accurately be dried, even if no concern exists for any dangerous
residual in the final product.
2.21 Solvents
Information:
Section 7.9 – SOLVENTS INFORMATION

2.22 Processable materials

The laminating machine can process materials that are of various origins, of different qualities, virgin or not, already
printed or laminated, often with pre-existent defects of various kind that cannot be eliminated and condition the final
result. Considering the wide range of combinations of materials, adhesives, lacquers, etc., the experience and
training of the personnel are decisive for the quality of the final product: case by case, the operator must carefully
look over the possibility of carrying out the desired process and the necessary regulations of the machine.
The greatest troubles occur with the coating for the first lamination (DUPLEX product): an already laminated
substrate can easily be coated and laminated a second time.
The materials that can be processed and the suggested thickness are listed hereunder: the data are to be regarded
just as an indication and, besides depending on the operator’s skill, they depend on the width of the webs under
processing and on the unwinding and winding tensions.
Unwinding and winding tensions:

T 2.3 – Processable materials
PRIMARY MATERIALS SECONDARY MATERIALS

(substrates to be coated) (substrates to be laminated)
Material Thickness (µm) Material Thickness (µm)
BOPP 12÷80 BOPP 12÷80
PETP 10÷30 PETP 8÷30
LDPE, LLDPE 30÷200 LDPE, LLDPE 20÷200
OPA 12÷18 OPA 12÷18
NYLON CAST 30÷80 NYLON CAST 20÷80
ALU 6.3÷40 ALU 6.3÷40
PP CAST 60÷150 PP CAST 20÷150
PAPER 40÷150 g/m2 PAPER 40÷150 g/m2
--- --- COEX FILM 25÷200
All substrates intended to have a level of surface treatment of 38 dyne/cm when processed. With lower
values the final quality of lamination is not guaranteed.

2.23 Technical characteristics of rubber-coated rollers

In the table are given the rubber-coated rollers technical characteristics. Said information must be used for:
- checking the rubber for wear - the nominal diameter and the minimum diameter are
indicated: the roller must be replaced when the rubber has
reached the minimum diameter.
- identifying the rubber type - for purchasing the spare part, please contact
NORDMECCANICA S.p.a. Spare Parts Service and indicate
the rubber-coated roller model name, rubber type and
colour, diameters.
Information:
Section 1.5 – SPARE PARTS ORDERING.
T 2.4 – Rubber-coated rollers
Hardness of
Model Code Type Colour ∅ max. ∅ min.
rubber
Sleeve of the coating CARBOSLEEVE

CE1059L BLACK 80÷85 Sh 165 mm 155 mm
impression roller NPS
Transfer roller (SL unit) 12109L POLYCOAT “18F” GREEN 85 Sh 165 mm 155 mm
Rubber-coated
laminating nip roller (70 38558L NEOPRESS “B” RED 80÷85 Sh 120 mm 110 mm
kg)
The rubber-coated rollers are only to be cleaned by using the products indicated in § 7.4.2: different
products could irreversibly damage the rubber-coated surfaces

2.24 Technical data

Description Measure Unit of measurem.
GENERAL DATA
Nominal web width, “L” 1300 mm
Coated web width 1315 mm
Max. web width 1330 mm
Maximum core width (using expanding chucks) 1300 mm
Maximum core width (using the cones) 1340 mm
Min. web width 650 mm
Production speed (1) 450 m/min

(1) Maximum production speed is influenced by quality and nature of the material and adhesive used.
UNWINDER A
Core diameter (internal Ø) 3 or 6 ”
Max. reel diameter 1000 mm
Maximum weight of reel 1000 kg
Unwinding web minimum tension 20 N
Unwinding web maximum tension 400 N
UNWINDER B
Core diameter (internal Ø) 3 or 6 ”
Unwinding web minimum tension 20 N
Unwinding web maximum tension 400 N
WINDER
Core diameter (internal Ø) 6 ”
Winding web minimum tension 40 N
Winding web maximum tension 550 N
Max. % of taper tension 60 %

DRYING OVEN with DIATHERMIC OIL
Capacity 311 + 311 kW
Nominal inlet temperature 240 °C
∅ Thermo-oil circuit 2 “
Feed flow rate 19363 l/h
Oven air inlet – section 1 7000 m3/h
Oven air inlet – section 2 7000 m3/h
Oven air exhaust – section 1 8000 m3/h
Oven air exhaust – section 2 8000 m3/h
Oven exhaust depression – section 1 -2 ÷ -5 mm H2O
Oven exhaust depression – section 2 -2 ÷ -5 mm H2O
VAPOUR EXHAUSTING SYSTEM ON COATING COLUMN
Flow rate of exhaust fan 3000 m3/h
ELECTRIC SUPPLY
Nominal voltage 380 ±10% V
Frequency 50 ±1% Hz
Phases 3/PE ---
Full load current 120 A
Main switch: rated breaking (Icu) 36 kA
Main switch: rated current 250 A
Magnetic setting 2750 A
Protection against direct contact IP20 ---
PNEUMATIC SUPPLY (NON-LUBRICATED DRY AIR)

Max. consumption 80 l/min
Inlet pressure 7÷10 bar
Diameter of the inlet hose 3/8 “
HYDRAULIC SUPPLY (Thermoregulating units)
Water hardness 7÷15 °f

MOTORS and speed CONTROL DEVICES

Controlled unit Motor ID code Load cell Dancing roller
Unwinder A M1 --- B1
Unwinder B M9 --- B5
Winder M31 --- B20
Laminating unit M5 MASTER motor
Coating unit M4 LC3 ---
Corona treater for unwinder A --- --- ---
Corona treater for unwinder B --- --- ---
LAMINATING NIP ROLLER
Operating pressure range 1,5÷4 bar
ENVIRONMENTAL CONDITIONS
Temperature for transport and storage 1÷50 °C
Operating temperature 10÷40 °C
Average temperature over 24 hours ≤ 35 °C
Humidity for transport and storage (without condensation) 30÷95 %
Operating humidity range (without condensation) 30÷95 %
TELESERVICE CONNECTION
Virtual private network Ethernet with RJ45 connector
NOISE
The level of maximum noise produced by the machine during processing has
been measured according to the directive ISO 11202 (level measured on the < 85 dB(A)
operator side, with the deduction of the room reverberation)
VIBRATIONS
The level of vibrations produced by the machine, in normal conditions, is not

dangerous to the operator’s health.
--- ---
Excessive vibrations may be caused by a mechanical fault
only; they must immediately be reported and eliminated, so as
not to undermine the safety of machine and operator.
COLOURS
Machine (white) 9001 RAL
Electrical cabinet 7035 RAL
Control panels 7035 RAL

2.25 Thermoregulating units (diagram)

Safety
3 - SAFETY
Table of contents
3.1 Introduction ....................................................................................................................................................................... 3.2
3.2 Duties of the Safety Officer ............................................................................................................................................... 3.3
3.3 Duties of the staff interacting with the machine ................................................................................................................ 3.3
3.4 Hazards associated with this type of machine .................................................................................................................. 3.4
3.5 Logic for safe machine interaction .................................................................................................................................... 3.6
3.6 Potential dangers and risks .............................................................................................................................................. 3.7

3.6.1 Mechanical hazards............................................................................................................................................................... 3.7
3.6.2 Hazards of electrical nature ................................................................................................................................................... 3.8
3.6.3 Hazards due to thermal energy.............................................................................................................................................. 3.9
3.6.4 Hazards of fire and explosion .............................................................................................................................................. 3.10
3.6.5 Hazards due to bad ergonomics .......................................................................................................................................... 3.11
3.6.6 Hazards due to malfunction of command and control systems............................................................................................. 3.12
3.6.7 Emergency stop category 1 ................................................................................................................................................. 3.12
3.6.8 Reasonably foreseeable misuse .......................................................................................................................................... 3.13
3.7 Implemented safety-related solutions ............................................................................................................................. 3.14

3.7.1 Lay-on roller on the “shaftless” winder ................................................................................................................................. 3.15
3.7.2 Reel-holder arms of “shaftless” unwinders and winder ......................................................................................................... 3.16
3.7.3 Opening/closing of rubber-coated coating impression rollers ............................................................................................... 3.17
3.7.4 Dancing roller guard ............................................................................................................................................................ 3.18
3.7.5 Dispersion in the environment of adhesive or solvent vapours ............................................................................................. 3.19
3.7.6 Control of solvent vapour concentration ............................................................................................................................... 3.20
3.7.7 Coating column: side guards ............................................................................................................................................... 3.21
3.7.8 Coating column: transparent doors ...................................................................................................................................... 3.22
3.7.9 SL unit (If fitted): safety bar .................................................................................................................................................. 3.23
3.7.10 SL unit (If fitted): transfer roller drive system ........................................................................................................................ 3.25
3.7.11 Metering roller reverse rotation ............................................................................................................................................ 3.26
3.7.12 Hold-to-run control device.................................................................................................................................................... 3.27
3.7.13 Laminating unit .................................................................................................................................................................... 3.28
3.7.14 Sectioning the pneumatic power supply ............................................................................................................................... 3.29
3.7.15 Sectioning the electric power supply .................................................................................................................................... 3.30
3.7.16 Corona Treatment ............................................................................................................................................................... 3.31
3.7.17 General electrical panels ..................................................................................................................................................... 3.32
3.7.18 Safety microswitches ........................................................................................................................................................... 3.34
3.7.19 Positions of emergency stop mushroom-head push buttons ................................................................................................ 3.35
3.7.20 Position of emergency stop cords ........................................................................................................................................ 3.36
3.8 Residual risks ................................................................................................................................................................. 3.37
3.9 Safety signs .................................................................................................................................................................... 3.41

Safety
3.1 Introduction
Notwithstanding the fact that:
1. the machine described in this manual has been designed using the latest technologies, so that it can be
operated by trained and qualified personnel under conditions of utmost safety;
2. the personnel should be trained in aspects of general safety provisions, as regards those in force in the Country
where the machine is installed and those valid within the factory;
all staff members must be aware that distraction, overconfidence in performing operating and maintenance
procedures, non-observance of safety provisions and inexperience can result in severe accidents, causing damage
to persons and property.
Therefore, operators and maintenance technicians interacting with the machine should:
- first of all read and understand the contents of the entire “Instruction Manual” and of the enclosed
documentation;
- be always aware that paying attention is essential to preventing damage to both staff and machine: no safety
system or code of practice can guarantee absolute safety, unless staff members interact with the machine in a
professional, accurate and scrupulous manner.
Information for the Purchaser:

Nordmeccanica S.p.a. shall in no way be liable for any damages or accidents to persons or
property resulting from failure to comply with:
• the contents of this Instruction Manual;
• the code of practice as regards the use of the machine specified by NORDMECCANICA S.p.a.;
• the code of practice as regards the use of the machine indicated by the RSPP(1) (Italy) or by an
equivalent professional role provided by the law in the Country where the machine is installed;
• the current health and safety regulations;
• the instructions provided by the suppliers of materials, adhesives, solvents and commercial
parts.
1 RSPP stands for Head of the Prevention and Protection Service: it refers to the health and safety professional (safety officer) appointed
by the Employer to manage and coordinate the prevention and protection service (SPP), which consists in the people, the systems and the
equipment inside or outside the company, all having the purpose of preventing and protecting the workers against risks in the workplace
(art. 2 lett. l of D.Lgs. 81/2008 - Italian law)

Safety
3.2 Duties of the Safety Officer

The duties of the safety officer are basically the following:
Circulation of safety information • machine transport and handling;

 • installation and commissioning;
the information included in this manual • adjustment, operation and cleaning;
must be disclosed to all personnel in • machine maintenance;
charge of: • final dismantling and disposal.
• staff members accessing the machine must be skilled and trained;

• access to “danger zones” must be permitted to authorized personnel
Monitoring and supervision
only;

• all staff members interacting with the machine must be considered
all information and code of practice
“exposed person”;
provisions must be observed by the staff
• operators must be especially knowledgeable on the machine
interacting with the machine:
intended use, misuses, limitation of use, process materials and
performance limits.
The definitions of danger zone and exposed person are laid down in Annex 1 of Machinery Directive 2006/42/EC,
Chapter 1 – “ESSENTIAL HEALTH AND SAFETY REQUIREMENTS”, section 1.1.1 – “Definitions”. These
definitions are reported in full hereunder:
«Danger zone»: “any zone within and/or around machinery in which an exposed person is subject to a risk to his
health or safety”;
«Exposed person»: “any person wholly or partially in a danger zone”.
3.3 Duties of the staff interacting with the machine
Operators - they must promptly inform their immediate superior of any fault detected on the
machine, so that the situation can be resolved in good time and any potential future
danger avoided.
Maintenance technicians - they must perform adequate preventative maintenance on the machine, assign repairs
to skilled technicians and always use genuine spare parts.
The instructions contained in this manual and in the enclosed documentation,
as regards the required competence for carrying out maintenance activities,
must be closely observed at all times.

Safety
3.4 Hazards associated with this type of machine

Owing to the nature of the production process being carried out, some intrinsic risks still remain; if assessed, these
risks can be minimized by correct installation/setting of the machine and by appropriate behaviour of the personnel
involved.
Hazard Situation
Electrocution hazard a) Electrical hazards can occur in the event of direct or indirect contact with
energized components or parts.
b) During the production process, plastic film webs can accumulate

dangerous tensions due to static charge.
Fire and explosion hazard a) Flammable solvents release vapours, which are easily ignited. Vapours
can accumulate to form explosive concentrations.
Moreover, the materials processed by the machine are inherently
flammable.
Burn and scald hazard a) The production process requires some of the rollers to be heated.
Temperatures depend on the features of the materials being used (film
webs and adhesives). Burn and scald risks exist on the involved rollers and
relevant rotary joints, on the heating units and on the pipes.
b) For production processes requiring solvent evaporation or film web drying,

burn and scald risks exist in the drying ovens and the associated heating
systems (batteries, pipes, valves, burners, etc.).
Dragging hazard a) The presence of rotary parts and components (rollers, gears, reels and
other) brings risk of trapping and dragging during the production process
and during cleaning and maintenance operations.

Safety
Hazard Situation
Limb crushing or severing hazard a) The presence of mechanical moving parts brings about risks of collision,
crushing and severing. Crushing can affect various parts of the human
body (head, limbs, hands, feet, etc.) and can occur between two relatively
moving components or between a moving part and the environment (e.g.
floor).
b) This type of risk also exists during the normal stages of machine
preparation/use, namely in all those operations where interchangeable
parts are handled (roller replacement, reel loading/unloading etc.).
Injury, abrasion and cutting a) Friction against moving film webs, rotating reels and rollers may cause
hazard abrasions. The film web edge may cause cuts.
Inhalation, poisoning, irritation, a) The use of adhesives, chemical compounds, solvents, lubricants, coolants
allergy and pollution hazards and detergents brings about risks of:
• poisoning and irritation;

(inhalation or contact with skin, eyes and mucous membranes)
• allergy;
(to the materials or their components)
• environment pollution
(during preparation or cleaning operations, in case of leakage or
spillage)

Safety
3.5 Logic for safe machine interaction

A risk assessment was made by NORDMECCANICA S.p.a. during the design stage as regards potential risks, and
solutions were then implemented to safeguard the health and safety of exposed persons and at the same time
ensure the required performance and productivity.
To this end, the logic developed by NORDMECCANICA S.p.a. for a safe man-machine-environment interaction is
featured in the diagram below in which the strategy adopted for the risk assessment and reduction is summed up
according to the three-step sequence provided for in UNI EN ISO 12100-2010 standard:
- determination of the limits of the machinery
- hazard identification
- risk estimation and subsequent risk elimination or reduction. The risk reduction is conducted by means of
inherently safe design measures and implementation of safeguarding and complementary protective measures,
taking into account the state of the art at the time of drawing up the present document. When it is not practicable
to reduce risk for technical reasons, the residual risks shall be identified in the information for use.
F 3.1 – Logic for safe machine interaction
Mechanical, electrical,
functional machinery guarding, + Procedures and code of
practice = Safety of personnel and
machinery
etc.
Two types of machinery guarding have been used on this machine, “fixed” and “movable”.
FORBIDDEN OPERATION
It is absolutely forbidden to remove, disconnect or tamper with the guards and the safety devices in
any way whatsoever, except for the time strictly necessary to carry out specific maintenance/repair
interventions by observing the safety procedures associated with the ongoing intervention. In case of
removal of the protection bars, do not activate the rollers rotation (neither automatically nor manually)
for any reason.
All guards and safety devices must be kept in perfect working order, to ensure such operating
efficiency as provided by NORDMECCANICA S.p.a. Regularly check that the guards are in place and
verify the smooth operation of all safety-related systems, devices and services (emergency push-
buttons, microswitches, filters etc.).
In the event of any failure, repair or replace at once.

Safety
3.6 Potential dangers and risks

Due to the nature of its working, the laminating machine shows potential risks that were eliminated by means of
design and construction features.
Various types of potential risks and the situations, in which these risks can arise are provided in the following
paragraphs.
3.6.1 Mechanical hazards

Mechanical risks are essentially due to two conditions that are inevitably present on the machines: presence of
moving parts and of bodies subject to falling by gravity.
Potential risk:
Risk of dragging, abrasion, cutting, crushing, severing.
a) The presence of rotary parts and components (rollers, gears, reels and other) brings risk of
trapping and dragging during the production process and during cleaning and maintenance
operations.
b) The presence of mechanical moving parts brings about risks of collision, crushing and severing.
Crushing can affect various parts of the human body (head, limbs, hands, feet, etc.) and can
occur between two relatively moving components or between a moving part and the environment
(e.g. floor).
c) This type of risk also exists during the normal stages of machine preparation/use, namely in all
those operations where interchangeable parts are handled (roller replacement, reel
loading/unloading etc.).
Elimination of the potential risk:

A risk assessment was performed according to the safety and health requirements contained in the
following directives:
- Machinery Directive 2006/42/EC
- Low Voltage Directive 2014/35/EU
- EMC Directive 2014/30/EU.
Section 3.7 – IMPLEMENTED SAFETY-RELATED SOLUTIONS
Section 3.8 – RESIDUAL RISKS

Safety
3.6.2 Hazards of electrical nature
Potential risk:
Risk of electrical shock, burns.
a) Electrical hazards can occur in the event of direct or indirect contact with energized components
or parts.
b) During the production process, plastic film webs can accumulate dangerous tensions due to
electrostatic charges. The presence of insulating teflon-coated idle rollers can accentuate the
build-up of static electricity. Accumulated electrostatic charges can produce discharges and
voltaic arcs, thus posing the risk of electrical shock, burns or, at worst, can be a source of ignition
for solvent-charged atmosphere in the coating areas.

The elimination of the electrical risks was carried out in accordance with standard EN 60204-1 with
particular reference to prevention of accidental contacts, locking devices and signalling devices
located on the switchboards.
A risk reduction connected with the accumulation of electrostatic charges is obtained by ensuring the
continuity of the equipotential bonding circuit at any point of the laminating machine along with the
installation of antistatic bars which are active at the points where the energy build-up is foreseen and,
in particular, inside the coating columns.
Section 2.14 – IONOGENIC BARS
Paragraph 2.19.1 – ELECTRICAL SYSTEM
Paragraph 2.19.1.1 – ELECTRICAL CABINET/CONTAINER

Safety
3.6.3 Hazards due to thermal energy
Potential risk:
Burn and scald hazard.
a) The production process requires some of the rollers to be heated:
Roller Operating temperature*
Coating roller 40/45 ° C ÷ 90 °C
Metering roller 40/45 ° C ÷ 90 °C
Laminating roller about 60 °C
Pre-heating drums 40/45 ° C ÷ 90 °C
Temperature-controlled < 28 °C
cooling drums (depending on the working process)
* These temperatures do not pose a danger according to standard EN 13732-1, as long as they stay under the threshold of
burning of:
< 43 °C, set for metals for periods of exposure longer than a minute
or
< 65 °C for accidental contact not exceeding 4 s.
Temperatures depend on the features of the materials being used (film webs and adhesives). Burn
and scald risks exist on the involved rollers and relevant rotary joints, on the heating units and on
the pipes.
b) For production processes requiring solvent evaporation or film web drying, burn and scald risks
exist in the drying ovens and the associated heating systems (batteries, pipes, valves, burners,
etc.).

Interlocking movable guards are used to prevent accidental contact with the rollers.
The outer surfaces of the ovens reach a temperature of about 53 °C during the working cycle in ovens
with maximum power (300 kW). This temperature does not pose a hazard, since it is under the
threshold of burning (equal to the minimum of 57 °C for bare metal and about 62° for painted metal)
assessed for accidental contact for a period not exceeding 4 seconds.
Further information: see section 3.8 “RESIDUAL RISKS”

Safety
3.6.4 Hazards of fire and explosion
Potential risk:
Fire and explosion risk.
a) Flammable solvents release vapours, which are easily ignited. Vapours can accumulate to form
explosive concentrations. The lower threshold for explosion is identified as the “Lower Explosive
Limit” (L.E.L.).
Moreover, the materials processed by the laminating machine are inherently flammable.
b) High concentrations of solvent can be toxic for the exposed personnel.

For a proper identification of the risk reduction measures, the areas surrounding the laminating
machine were classified in accordance with standard EN 60079-10-1 [Ref.: MAP OF THE DANGER
ZONES].
Below are listed the measures taken for risk reduction:
1) elimination of ignition sources by installing equipment suitable for use in explosive atmospheres
(Zone 1, EX II 2 GD)
2) areas with explosive atmospheres are enclosed with movable guards and ventilation systems are
installed, in order to:
- confine the solvent-charged atmosphere inside the laminating machine, by creating
depressurization
- ensure evacuation of the solvent-charged atmosphere from the laminating machine
3) installation of a monitoring system to analyse the concentration of solvent vapours in the air in real
time
4) installation of a flame regulator interlock with airflow monitoring for burner heating systems (only
for machines with gas burner)
5) installation of an airflow monitoring system in the oven blowers, in the inlet and exhaust ventilation
ducts and in the depression system of the oven unit.
6) Purging at every switching-on of the machine, after every ventilation stop.

Safety
3.6.5 Hazards due to bad ergonomics
Potential risk:
Poor visibility of the operational areas.
The laminating machine poses hazards due to ergonomics which are concentrated in the poor visibility
of all operational areas, resulting from the big size of the plant and the accessibility that must be
guaranteed to the areas subject to ordinary operations or maintenance.

- Use of conventional visual and acoustic signals for laminating machine start.
- All operating modes requiring the operations to be performed by accessing the danger zones with
excluded safety devices, can be controlled only locally in an area where maximum visibility for the
operator is ensured.
- Areas for the transit of personnel and accessories for maintenance were sized according to the
values laid down in harmonized standard EN 349 – Safety of machinery. Minimum gaps to avoid
crushing of parts of the human body.

Safety
3.6.6 Hazards due to malfunction of command and control systems

The malfunction of command and control systems can expose to the risks above mentioned. Below are listed the
measures relevant to the control circuits of the safety functions to reduce the risk occurrence:
- Emergency stop category 1

Pressing any of the emergency stop mushroom-head push buttons or activating the emergency stop cords (in
the coating booth) causes a Category 1 controlled stop.
Paragraph 3.7.19 POSITIONS OF EMERGENCY STOP MUSHROOM-HEAD PUSH BUTTONS
- Category 1 controlled stop when L.E.L limit is exceeded.

When the limit of 25% L.E.L. (or 50% booth) is reached and/or an alarm condition coming from the control
system of solvent vapour concentrations occurs, this causes a category 1 controlled stop of the plant. Upon
reaching the threshold, the stop time (power supply and pneumatic supply cutting off) is 1 second per 100
m/min of maximum speed, in order to allow the coated material to leave the drying ovens.
Example:
max. speed = 400 m/s → time = 4 seconds
Paragraph 3.7.6 CONTROL OF THE SOLVENT CONCENTRATION
- Monitoring of the interlocking movable guards of the power transmission systems.

When the movable guards protecting the transmission elements, equipped with interlocking limit switches, open,
a category 1 controlled stop of the whole laminating machine is triggered.
- Monitoring of the interlocking movable guards and/or safety light curtains of the coating areas,
unwinder and winder in automatic production mode and without local exclusion.
- Monitoring of the operating mode selector switches (main and local).
- Monitoring of the hold-to-run devices in local mode for exclusion of guards and/or washing.
- Monitoring of the reduced-speed control.
- Monitoring of the hold-to-run device for closing the reel-holder arms (triangles) on unwinders and
winders.
- Monitoring of the hold-to-run control for closing the lay-on roller.
- Monitoring of the system controlling the oven depression, the coating booth, the purging and enabling
of burner switching-on and coating.
3.6.7 Emergency stop category 1

Pressing any of the emergency stop mushroom-head push buttons or activating the emergency stop cords (in
the coating booth) causes a Category 1 controlled stop.
Paragraph 3.7.19 POSITIONS OF EMERGENCY STOP MUSHROOM-HEAD PUSH BUTTONS

Safety
3.6.8 Reasonably foreseeable misuse

"Reasonably foreseeable misuse" means the use of machinery in a way not intended in the instructions for use, but
which may result from readily predictable human behaviour, as defined in Annex I of Machinery Directive
2006/42/EC.
Through the assessment made on the laminating machine the following behaviour was identified:
- simultaneous presence of several operators in danger zones, one of whom operates the hold-to-run devices
while the other performs the dangerous operations
- use of devices for operations off the ground (stairways, lift trucks, reel lift trucks) to gain access to danger zones
from above for monitoring purposes and/or attempts to carry out cleaning and maintenance operations when the
machine is running
- deliberate use of the machine with solvent-based mixtures in water-based mode
- attempts to spread the folds of the film, by smoothing the winding reel with the hand
- removal of anti-dragging safety bars, without restoring them, during maintenance operations to reduce
downtime
- installation of not permanently fitted scrapers on the doctor blade side on the RT trolley: for adjustement need,
when the rear access is impeded, the operator may be tempted to adjust the scrapers from the opposite side
with machine at 100 m/min and open guards, with consequent risk of finger and hand crushing.
FORBIDDEN OPERATION
This behaviour undermines the effectiveness of the safety measures and/or infringes the requirements
indicated as necessary in the instruction manual to avoid residual risks: it must be expressly forbidden.
MALICIOUS TAMPERING
Removing or disabling the interlocking systems of the movable guards is considered as malicious
tampering, performed with the only purpose of reducing the adjustment/maintenance time for the
benefit of productivity of the plant and/or of reduction of scraps resulting from this period of operation at
reduced speed.

Safety
3.7 Implemented safety-related solutions

Information on the main technical solutions implemented for eliminating the potential risks are provided in this
section.
The most important solutions to accident prevention are described hereunder.

Safety
3.7.1 Lay-on roller on the “shaftless” winder

Information on the main technical solutions implemented for eliminating the potential risks are provided in this
section.
The most important solutions to accident prevention are described hereunder.
Potential risk:
The lay-on roller presents a potential risk of dragging, crushing and trapping between film web and lay-
on roller.
Elimination of potential risk – Mechanical solution:

The above-mentioned risks have been eliminated by installing a mechanical protective device on the
lay-on roller; however, there is still a residual risk of crushing and dragging in the event of side access
from above because it is necessary to make the area involved in the visual inspection and web
centering operations accessible.
F 3.2 – Elimination of potential trapping hazard on lay-on roller of “shaftless” winder
1. Lay-on roller on the winder

2. Mechanical device for the protection against crushing and dragging hazards
Make sure that the guards, if removed for maintenance interventions, are installed again and properly
regulated.
FORBIDDEN OPERATION
for any reason.

Safety
3.7.2 Reel-holder arms of “shaftless” unwinders and winder
Potential risk #1:

Crushing of lower limbs or of parts of the human body due to reel fall as a result of lack of cone
clamping force.
Reduction of potential risk – Functional solution:

• Installation of stop valves.
• Pneumatic pressure hold also when the machine is off.
In case of pneumatic feed lack for a long time, the inevitable pressure loss of the system may reduce the clamping
force of the cylinder: the particular structure of the clamping cones, however, keeps the reel hanging and prevents
it from falling down.
FORBIDDEN OPERATION
In case of long stops, unload all the reels from unwinders/winder.

Safety
3.7.3 Opening/closing of rubber-coated coating impression rollers
Potential risk:
Closing of rubber-coated coating impression roller by gravity.

The pneumatic cylinders of the rollers are fitted with stop valves on the closing circuit: when the
machine is off or not powered (no pressure), the valves prevent the rubber-coated rollers from closing
by gravity.

Safety
3.7.4 Dancing roller guard
Potential risk:
The dancing roller presents a potential risk of impact in case of web break.

To prevent the risk of collision, a fixed guard (bar) is installed in front of the dancing roller to block the
incidental access to the danger zone.
F 3.3 – Elimination of potential trapping hazard on dancing roller
FORBIDDEN OPERATION
for any reason.

Safety
3.7.5 Dispersion in the environment of adhesive or solvent vapours
Potential risk:
Dispersion of vapours released by adhesives or solvents, which can result in a poisoning hazard for
the personnel assigned to the machine, and in a fire.
Elimination of potential risk – Functional solution:

To ensure the utmost health conditions for the operator, the machine is equipped with a system for
exhausting the vapours/odours produced during processing. A specific fan, installed above the coating
area, sucks any vapours or odours and conveys them outside the machine; a pressure switch
constantly checks the system efficiency.
The suction flow passes through hoods fitted with a filter. All transparent doors must be kept closed
during the production process so that, by creating a slight depression inside the coating chamber,
suction power is increased.
F 3.4 – Access doors and centrifugal fan
1. Vertical sliding door on coating column

2. Centrifugal fan on coating column
The exhaust ducting must be arranged by the Purchaser at the installation site. The technical data as
regards the exhaust system will be supplied to the Purchaser on the layout forwarded by
NORDMECCANICA S.p.a. prior to machine installation.

Safety
3.7.6 Control of solvent vapour concentration
Potential risk:
Explosion caused by excessive concentration of solvent vapour.

Accumulated solvent vapour can reach such concentration in air to ignite an explosion. The
concentration level differs according to the type of solvent, and it is identified as the “Lower Explosive
Limit” (L.E.L.).
The machine is equipped with a control system that, by analysing vapour concentration in air in real
time, prevents hazardous situations from occurring. The system operation is based on three channels
on each oven:
• channel 1  sample taking within the coating area;
• channel 2  sample taking within drying oven 1;
• channel 3  sample taking within drying oven 2.
In order to prevent damage and contamination, the measurement sensors are installed inside a
dedicated cabinet, far from where samples are taken.
Operating principle:
Air being analysed is sucked up by a pneumatic system, conveyed to the sensors and finally discharged; sample
taking is inhibited when solvent is not required in the production process.
The sensors are connected to an electronic monitoring unit which, in case any of the three concentration thresholds
is exceeded, will signal the occurrence and implement adequate countermeasures:
A1 (20% L.E.L.) • the machine emits an acoustic signal;
• The machine shuts down, only the discharge fans keep operating to reduce
A2 (25% L.E.L.)
concentration levels;
Blowers:
A3 (30% L.E.L.)
• The monitoring unit cuts off power supply to the machine (main switch hardware-
operated delayed tripping)
Coating area:
A3 (50% L.E.L.)

Upon reaching level A1, reduce the speed of the machine so as to reduce the amount of vapour
being produced and, if the alarm persists, check the suction system performance.
Acoustic signal acknowledgement:

Refer to the Supervision Software documentation

Safety
3.7.7 Coating column: side guards
Potential risk:
High risk of crushing, trapping and dragging exists in some areas, both on the operator side and on the
transmission side, owing to the presence of several mechanical moving parts (drive belts, reduction
gears, etc.).

On the operator side, the coating column is closed by a movable guard (door). The decision to use
movable guards rather than fixed ones, is based on the frequency of access by the operator during a
normal production process. The doors have handles. A safety microswitch stops the entire machine in
the event one of the doors should open while the machine is running.
F 3.5 – Movable side guards (doors) on the coating column
1. Door opening handle

2. Movable guard with safety microswitch on coating column (operator side)

Safety
3.7.8 Coating column: transparent doors
Potential risk:
Accidental contact with film web or mechanical moving parts while the machine is running at a high
speed.
Two protective doors, fitted with transparent panels and safety microswitches, have been installed in
front of the coating unit, one on the coating side and the other on the doctor blade side: the machine
cannot run at a high speed unless both doors are fully closed. Each door has a twofold function:
• prevent accidental contact with the materials being processed and with moving machinery;
• prevent leakage of toxic vapours, in that way improving the efficiency of the exhaust system.
T 3.1 – Behaviour with open guards, hold-to-run control actuated

TROLLEY GUARDS EXCLUSION MODE MANUAL WASHING MODE
--- COATING SIDE DOCTOR BLADE SIDE COATING SIDE DOCTOR BLADE SIDE
Allowed speed: Allowed speed:

Rotogravure
100 m/min 1 m/min MET
(with closed doctor --- ---
Control device: Control device: pedal, 2-
blade too)
2-position pedal position type too
Allowed speed: Allowed speed:

25 m/min COAT 1 m/min MET
Solventless 1 m/min DOS --- without transfer roller, ---
Control device: with reversal of metering
2-position pedal. rollers
MET = METERING ROLLER - COAT = COATING ROLLER

Safety
3.7.9 SL unit (If fitted): safety bar
Potential risk:
Risk of upper limbs crushing in the contact zone between the transfer roller and the coating roller,
owing to the rollers rotation direction, which can cause dragging towards the contact zone. The risk
level is increased by the fact that, being the transfer roller rubbed-coated and therefore featuring a
friction coefficient greater than that of metal, adherence between hand and roller surface is stronger.

The implemented mechanical solution is a metal safety bar with rounded corners, fixed at such
distance from the rollers as to prevent any accidental dragging of the hands.
F 3.6 – Safety bar adjustment on the SL coating unit
F 3.7 – Rotation of transfer and coating rollers: functional diagram
A) The rollers rotation direction shown in the figure can cause dragging of the hand towards the contact zone when approaching
from direction A.
B) The rollers rotation direction shown in the figure can make the hand move away from the contact zone when approaching from
direction B.

Safety

1. Make sure the bar is always in place. If removed for maintenance, it must be reinstalled by
accurately adjusting position and orientation. Follow the indications shown in the figure below.
2. The specified measurement (4 mm) refers to new transfer rollers: it will be necessary to check the
safety bar adjustment when using ground rubber-coated rollers. In this case the roller diameter
decreases and, therefore, if the bar adjustment is not modified, the safety distance would be greater
than 4 mm.
Every time a transfer roller is mounted on the machine, make sure the safety bar is properly
adjusted.
To avoid exceeding a distance of 4+2 mm from the safety bar in the cutting zone, it is forbidden
to remove a part of rubber (cutting) of a thickness of more than 2 mm.

Safety
3.7.10 SL unit (If fitted): transfer roller drive system
Potential risk:
The transfer roller drive components, the articulated connecting joint in particular, [Paragraph 2.12.6 –
RUBBED-COATED TRANSFER ROLLER], bring about a high risk of crushing and trapping.

Considering the frequency of the transfer roller assembly/disassembly operations, a movable guard
(lid) is installed in front of the articulated joint.
- When the lid is open, a safety microswitch prevents the motor of the chromed metering roller from
running.
- When the lid is opened while running, the safety microswitch stops the motor of the chromed
metering roller and, consequently, the entire machine stops.

Safety
3.7.11 Metering roller reverse rotation
Potential risk:
Risk of dragging in the contact zone between the two metering rollers. This risk is higher during
washing operations, as they must be carried out while the metering roller is rotating.

To prevent the rag from being trapped between the two metering rollers, and consequently putting the
maintenance technician at risk, during cleaning operations the metering roller rotates in the opposite
direction.
Slow rotation can be controlled using the pedal located at the base of the coating unit.
F 3.8 – Coating column
1. Pedal for metering roller slow rotation
WARNING: The reverse rotation is automatically enabled only when the transfer roller is not in the
machine; its presence is detected by a dedicated microswitch (presence sensor).
If it is necessary to replace the pedal-switch for controlling the rollers of the coating unit, it is
compulsory to use a genuine spare part to be requested from Nordmeccanica S.p.a.

Safety
3.7.12 Hold-to-run control device

The rollers rotation during cleaning procedures shall be obtained exclusively by using the hold-to-
run control devices (slow run).
The laminating machine is fitted with the following hold-to-run control devices:
- ON-OFF two-position control foot switch.
F 3.9 – Control foot switch for rollers low rotation
Two-position foot control switch operation
Pos. 1 – Released = Quick stop*

Pos. 2 – Pressed down = Slow run
* The machine stops within 5 seconds and the unit controlled by

the foot switch is disconnected.
Stopping the rollers rotation without triggering the machine stop and the unit disconnection:
1) Hold the foot control switch in Pos. 2.

2) Close the column door.
3) Release the foot control switch.
If it is necessary to replace the foot control switch controlling the rollers of the coating unit, it is
compulsory to use a genuine spare part, of the same type, to be requested from Nordmeccanica
S.p.A.

Safety
3.7.13 Laminating unit
Potential risk:
Risk of crushing and trapping produced by the film web movement, by the rotation direction of the
rollers and by the fact that one of the rollers is rubber-coated.

A movable metal bar is installed on the entry line, between the laminating roller and the rubber-coated
nip roller. The bar can be opened for web threading or cleaning operations by means of the two
handles. A safety microswitch checks the position of the metal safety bar:
• if the metal bar is in “open” position, the nip roller is inhibited from closing;
• if the metal bar is opened while the machine is running, the safety microswitch immediately
stops the entire machine.
Moreover, a manual hold-to-run control enables the linear movement of the laminating nip roller which
is active only when the guards are closed.

Safety
3.7.14 Sectioning the pneumatic power supply
Potential risk:
Ejection of highly pressurized fluid during maintenance interventions.

The compressed air inlet unit is fitted with a shut-off valve, whereby pneumatic power supply to the
machine can be interrupted. The valve can be padlocked in ‘closed’ position.
Information for the maintenance technician:

Before proceeding with any maintenance intervention, close the shut-off valve of the compressed air
inlet unit and padlock it.
F 3.10 – Compressed air inlet unit

2. Condensate tank
4. Filter

Safety
3.7.15 Sectioning the electric power supply
Potential risk:
Electrocution or damage to persons or property in the event any moving motor-driven element should
be accidentally started during maintenance interventions.

The main I/O switch can be padlocked in “O” position.

Before proceeding with any maintenance intervention, make sure the main I/O switch is padlocked in
“O” position.
F 3.11 – Main switch
1. Main switch

Safety
3.7.16 Corona Treatment
Potential risk:
Electrocution. Electrical shock.

The whole system is adequately closed to prevent any accidental contact with live parts.
Potential risk:
Upper limb crushing in the electrode closing zone.
Reduction of the potential risk:

The movement of the electrode closing hood is manually operated, there is however a residual risk of
crushing because of the position of the hood (position depending on the need to stay close to the
manual control and visually check the movement zone).
See residual risks: section 3.8

Safety
3.7.17 General electrical panels

These electrical panels are all situated inside a 3-door cabinet, which is located at the rear of the machine
(transmission side).
Potential risk:
Electrocution or damage to persons or property in the event of unauthorized access.

A key lock is fitted on the electrical cabinet to keep it closed. The key must not be available to the
operator, but must be kept by the Head of Maintenance.
Moreover, the doors of the electrical cabinet are interlocked and can be opened only after having
opened the door where the main I/O switch is located.
F 3.12 – Electrical cabinet door
1. Key lock
The machine main switch is installed inside the cabinet; it is operated from the outside, with the cabinet closed, by
means of a handle that can be locked, in position “O” (OFF), to ensure the maximum safety during maintenance
operations.
The main switch breaks the power supply of the entire machine, except for the safety systems (e.g. control of the
solvent concentration), which must always remain live and have a specific breaking switch. Also the optional
systems (e.g. adhesive mixer, Corona treatment) can be supplied apart.
The electrical cabinet/container is designed to ensure the best safety conditions against accidental contacts: the
dangerous components are protected either intrinsically or by means of non-conductive panels, indicated with
suitable symbols. Nonetheless, the utmost precautions must be taken against the various risks connected with
electricity.

Safety
FORBIDDEN OPERATION
It is absolutely forbidden to carry out operations on live electric equipment. Do not remove the guard
panels and the safety devices.
Information for the electrical maintenance technician:

In case of repair or troubleshooting, make sure to maintain the safety standards provided for by the
Manufacturer and, in particular, avoid leaving parts of wiring or components exposed. Do not force the
cables and be extremely careful when removing/installing the connectors.
Some electronic equipment is sensitive to electrostatic charges (EGB): just before touching it, you must
discharge your own body. When necessary, use the antistatic bracelet too (consult the specific
equipment documentation).
The overall dimensions of the 3-door electrical cabinet are indicated in the drawing hereunder; please note the
dimensions of the doors, so as to keep the areas around them clear and facilitate access to the electrical panels.
F 3.13 – Overall dimensions of electrical cabinet

Safety
3.7.18 Safety microswitches

Where fitted, the doors giving access to the coating and laminating units, as well as the movable guards (e.g.:
column protective side panels), are all equipped with safety microswitches.
If a door or guard is opened during a normal production cycle, an emergency shut-down of the machine is
immediately triggered; the machine will not automatically restart upon closing the involved element.
The operator has to return the machine to normal conditions and then restart it.
The figure below features, by way of example, one of the microswitches fitted on the machine.
F 3.14 – Microswitch installed on the vertical sliding door of the coating column
1. Safety microswitch

Safety
3.7.19 Positions of emergency stop mushroom-head push buttons
The machine is equipped with several emergency stop mushroom-head push buttons, located as detailed in the
table hereunder.
T 3.2 – Positions of emergency stop mushroom-head push buttons

Local control
Position of local control panel Quantity
panel
LCP1 Unwinder A, operator side 2
LCP12 Unwinder A, transmission side 2
LCP11 Unwinder A, right-hand side 1
LCP21 Coating column, operator side 2
LCP22 Coating column, transmission side 2
LCP23 Laminating column, transmission side 2
LCP24 Laminating column, operator side 2
LCP31 Unwinder B 1
LCP91 Winder 1
When an emergency push-button is pressed, the machine immediately stops. The push-button can be released by
turning the red mushroom-head in the direction indicated by the arrows. The machine will not automatically restart
upon releasing the push-button so, firstly, troubleshoot the cause that triggered the emergency stop, then restore
normal operating conditions and, lastly, restart the machine.
Code of practice for operators:

In the event of fault conditions or potentially hazardous situations, immediately press one of the
emergency stop mushroom-head push buttons and inform the corporate safety supervisor and the
head of maintenance.
Section 5.22 – QUICK START GUIDE: HOW TO USE THE PUSH-BUTTON PANELS.

Safety
3.7.20 Position of emergency stop cords

The health and safety of all staff members interacting with the machine is safeguarded by two cords which, if
needed, can be pulled or pushed to trigger an emergency stop. One cord is over the coating trolley and the other is
over the doctor blade.
F 3.15 – Coating column (front view): emergency stop cord protecting against dragging hazard
1. Emergency stop cord
F 3.16 – Coating column (rear view): emergency stop cord protecting against dragging hazard
1. Emergency stop cord
FORBIDDEN OPERATION
interventions by observing the safety procedures associated with the ongoing intervention.

Safety
3.8 Residual risks

In accordance with the Machinery Directive, where risks remain despite the inherent safe design measures,
safeguarding and complementary protective measures adopted – these risks are called "residual risks" – the
necessary warnings, including warning devices, must be provided.
This section contains the information about the residual risks relating to the laminating machine:
AREA: Unwinder/winder
WARNING: Rotation of the material reel
RESIDUAL RISK: Dragging and impact/laceration upwards, if rotation is clockwise, ONLY IF the operator
deliberately lays down on the reel (reasonably foreseeable misuse).
Dragging, crushing between reel and floor, ONLY IF the operator deliberately slips
under the machine (reasonably foreseeable misuse).
CODE OF PRACTICE:
Since it is necessary to access the area for reel loading/unloading, the operator MUST NOT lean on the reel, nor
slip under it.
AREA: Unwinders/winder
WARNING: Linear motion of the pneumatic cylinder for reel clamping
RESIDUAL RISK: - Crushing between cone and reel during the reel clamping phase.
- Crushing between triangle and frame during the reel releasing phase.
CODE OF PRACTICE:
Since there is the need to gain access to the reel load/unload area, the unit can only be moved by means of a
hold-to-run device.
WARNING: Linear motion of the recirculating-ball screw for reel clamping
RESIDUAL RISK: - Crushing between cone and reel during the reel clamping phase.
- Crushing between triangle and frame during the reel releasing phase.
CODE OF PRACTICE:
Since there is the need to gain access to the reel load/unload area, the unit can only be moved by means of a
hold-to-run device.

Safety
WARNING: Bruising of head, upper limb crushing
RESIDUAL RISK: 1) Bruising after impact/collision against the safety bar on the dancing roller.
2) Hand or arm crushing between the safety bar and the dancing roller
CODE OF PRACTICE:
1) During adjustment and maintenance operations there is a risk of collision/impact against the safety bar,
therefore the operator must approach with caution and, if needed, wear a protective helmet.
2) Do not rest your hand on the safety bar side facing the dancing roller: in the event of web break, the roller
could move rapidly towards the bar with consequent hand or arm crushing. Place your hands only on the
control panel of the safety bar for as long as necessary to carry out the required settings.
WARNING: Reel falling as a result of lack of reel-holder cone clamping force
RESIDUAL RISK: Crushing of lower limbs/body
CODE OF PRACTICE:
Unwinders and winder are equipped with stop valves that maintain the pneumatic pressure also when the
machine is off. The operator must make sure that the reels are balanced and do not have defects (related to the
loading, the core or the winding). Highly unbalanced reels could generate forcing in resonance so as to exceed
the clamping cylinder constraints. Under such conditions, it is mandatory for the operator to stop the machine and
to replace the core/reel. Do not leave reels mounted on the unwinders/winder, if there is lack of pressure.
AREA: Coating column
WARNING: Sharp edges of the doctor blade
RESIDUAL RISK: Cutting/laceration of upper limbs
CODE OF PRACTICE:
Installation of interlocking movable guard.

Safety
AREA: Rotogravure trolley
WARNING: Relative movement of the roller and adhesive collecting pans
RESIDUAL RISK: Bruising and abrasions
CODE OF PRACTICE:
Despite the presence of an interlocking movable guard and, with open guards, of an emergency stop cord, this
risk is pointed out by warning the staff assigned to proceed with the utmost caution when intervening in this
area.
AREA: Solventless trolley
WARNING: Relative motion of the adhesive feed slide unit with respect to the fixed guard
RESIDUAL RISK: Crushing of upper limbs/body
CODE OF PRACTICE:
Although the slide operates at a low travel speed, do not go near the slide with the hands for any reason.
AREA: Winder/Lay-on roller
WARNING: Tilting movement of the lay-on roller
RESIDUAL RISK: Crushing of upper limbs between the reel and the lay-on roller when lowering of the lay-
on roller is operated.
CODE OF PRACTICE:
Movement by means of manual hold-to-run control, with stationary reel or reel rotating at a low speed: 5 m/min

Safety
AREA: Winder/Lay-on roller
WARNING: Relative movement reel/lay-on roller
RESIDUAL RISK: Crushing and dragging.
CODE OF PRACTICE:
Although the presence of fixed guards, this residual risk is pointed out because of a potential side access during
the visual inspection and web centering operations. This residual risk is pointed out by warning the staff assigned
to proceed with the utmost caution when intervening in this area.
AREA: Corona Treatment
WARNING: Movement of the electrode closing hood
RESIDUAL RISK: Crushing
CODE OF PRACTICE:
Only manual operation.

Safety
3.9 Safety signs

This section deals with the safety signs that have been fixed to the machine to facilitate the conveyance of
information concerning behaviour in terms of accident prevention.
T 3.3 – Meaning and position of safety signs
Sign Position Meaning

- Coating column Caution sign
- Laminating column
Moving machinery
- Winder
- Corona Treatment
- Laminating column
Upper limb crushing hazard
- Winder
- Corona Treatment
- Laminating column
Scalding or burn hazard
- Electrical cabinet doors Caution sign
Live parts
- Coating column Prohibition sign
- Laminating column
No smoking
- Laminating column
Do not wear
unsuitable clothing or accessories
Do not remove rollers guards

Safety
- Protective lid of transfer roller articulated Prohibition sign

joint
Mechanical moving parts:
- Protective covers for the mechanical
do not remove the guards
moving parts of winder and unwinders
- Electrical cabinet door Prohibition sign
Do not extinguish fires with water
- Electrical cabinet door Prohibition sign
Do not touch internal parts
- Coating column Obligation sign
Safety gloves must be worn
Verify the anti-crushing bar position

Safety
F 3.17 – Safety signs on coating column

Every 6 months, check that the signs are still perfectly readable and properly fixed.
In case of replacement, please contact NORDMECCANICA After Sales Service.

Safety
F 3.18 – Safety signs on coating column (solventless)
The plate indicates the distance of the anti-crushing bar from the coating roller (A) and from the rubber-coated
transfer roller (B).


Safety
F 3.19 – Safety signs on laminating column - left side

F 3.20 – Safety signs on laminating column - right side


Safety
F 3.21 – Safety signs on winder and unwinders

F 3.22 – Safety signs on winder and unwinder motors


Safety
F 3.23 – Safety signs on the electrical cabinet door where the main I/O switch is located

F 3.24 – Safety signs on the electrical cabinet doors


Safety
The roller storage rack (for transfer rollers) is equipped with a plate showing the maximum number of rollers which
can be stored, the maximum weight of each roller and the maximum total weight that can be loaded on the roller
storage rack.
F 3.25 – Plate on roller storage rack

Transport and installation
4 - TRANSPORT AND INSTALLATION

Table of contents
4.1 To be provided by the Purchaser...................................................................................................................................... 4.2

4.1.1 Site building ........................................................................................................................................................................... 4.2
4.1.2 Foundations or supporting structures ..................................................................................................................................... 4.2
4.1.3 Connections to energy sources ............................................................................................................................................. 4.2
4.1.4 Aeration and exhaust system................................................................................................................................................. 4.3
4.1.5 Fire suppression system ........................................................................................................................................................ 4.3
4.1.6 Lighting.................................................................................................................................................................................. 4.4
4.1.7 Teleservice remote connection V.P.N. ................................................................................................................................... 4.5
4.1.8 Equipment and personnel ...................................................................................................................................................... 4.6
4.2 Transport of the machine.................................................................................................................................................. 4.7
4.3 Receipt and check ............................................................................................................................................................ 4.8
4.4 Handling of the machine ................................................................................................................................................... 4.9

4.4.1 General handling guidelines .................................................................................................................................................. 4.9
4.4.2 Symbols used for handling operations ................................................................................................................................. 4.11
4.4.3 Weights and lifting points ..................................................................................................................................................... 4.12
4.5 Possible storage ............................................................................................................................................................. 4.14
4.6 Installation ...................................................................................................................................................................... 4.15

4.6.1 Positioning and levelling ...................................................................................................................................................... 4.15
4.6.2 Assembly............................................................................................................................................................................. 4.15
4.6.3 Connection to the supply lines ............................................................................................................................................. 4.15
4.6.4 Connection to the exhaust systems ..................................................................................................................................... 4.16
4.6.5 Connection to the auxiliary systems ..................................................................................................................................... 4.16
4.7 Commissioning ............................................................................................................................................................... 4.17

4.1 To be provided by the Purchaser

4.1.1 Site building

The Purchaser is primarily responsible for setting up the room for the installation of the machinery in
compliance with the current local safety regulations.
The Purchaser shall arrange a sufficiently large room to allow the equipment and the processing materials to
remain outside the area taken up by the machine. The perimeter shall be marked by a yellow line on the floor.
The overall machine dimensions and the positioning of the various units are shown in the layout drawing
previously supplied to the Purchaser and annexed to this manual.
4.1.2 Foundations or supporting structures

To the Purchaser is supplied, well in advance, a drawing showing how the machine must be rested on the floor and
its related loads distribution (a good industrial floor is required):
- Foundation drawing: when civil foundation works are foreseen (to be carried out by the Purchaser);
- Bearing points drawing: when the machine is directly resting on the floor.
Additionally, it is necessary that the floor is level and sufficiently smooth so as not to hinder the handling of the
units/mobile accessories (trolleys, tanks, mixer, etc.).
Purchaser’s obligation:
The costs for any foundation are to be borne by the Purchaser.
4.1.3 Connections to energy sources

The room must have provisions for connections to the power line, water supply (inlet, outlet and emergency
drainage without backpressure), compressed air etc., necessary for correct machine operation.
On the machine layout drawing are indicated the connection points for the energy sources, together with the main
technical characteristics.

The supplies technical characteristics are specified in Section 2.24 – TECHNICAL DATA.
NORDMECCANICA S.p.a. is not liable for any malfunction if the power, water and air supplies do not
correspond to the given specifications.
The mains line must be of the correct size to withstand the machine power consumption and have a grounding
conductor. The Purchaser is responsible for the grounding system suitability and efficiency. The cables and supply
pipes must be protected by the way of fixed conduits.

The circuit breaker protecting the power supply line, which the Purchaser must have installed upstream
of the machine main switch, must be of type B.

The Purchaser is responsible for the grounding system suitability and efficiency.
4.1.4 Aeration and exhaust system
Potential risk:
Release of vapours into the environment.
Elimination of potential risk - Functional solution to adopt during installation:

The Purchaser must ensure a good room aeration and the correct connection of all the exhaust
systems discharging into the environment, for the elimination or recovery foreseen in the supplied
layout drawing (vapour exhaust, etc.), in compliance with current local regulations.
On the machine layout drawing are shown the flanges for connecting the emissions exhaust ducts; keep to the
dimensions indicated.
If the exhaust duct is very long or with many bends, in order to ensure that the discharge flows shown in the layout
drawing are met, it may be necessary to increase the ducts size or to install auxiliary exhaust systems.
Forbidden operation:
If the layout drawing foresees diverging exhaust ducts, it is absolutely forbidden to join them together to
prevent emissions cross back flow. It is also strictly forbidden to join the exhaust ducts with those from
other machines.
Special attention must be given to the possible presence of dampers or valves on the air and exhaust ducts
independent from the machine. Their failure can have very dangerous effects.
4.1.5 Fire suppression system

The room where the machine is installed must have a suitable fire suppression system.

4.1.6 Lighting
The room must be properly lit to prevent hazardous situations.
In case of additional installation of devices, parts or components, always ensure that the lighting remains adequate.
Information for safe installation:

The place where the machine is installed should have no shadowy areas, glaring or annoying lights or
stroboscopic effects due to the type of lighting.

4.1.7 Teleservice remote connection V.P.N.

This function allows to control the laminating machine by means of a remote connection with Virtual Private
Network. Nordmeccanica can perform the connection to the machine through the internet, drives or HMI panel
(Human Machine Interface). Connection is established through a Siemens’ Industrial Router which is installed in
the main cabinet. It will be possible to perform real-time diagnosis/troubleshooting on anomalies detected in the
machine, as well as perform software modifications and upgrades.
In order to ensure maximum safety of the communication towards the machine, V.P.N. connection is established
through Siemens’ Sinema Internet Server, physically installed and totally controlled by Nordmeccanica’s main site.
In order to allow the setup of this system, the customer will make available an Ethernet connection to the Internet.
Industrial router will appear as a common office PC in customer’s LAN.
F 4.1 – Ethernet - V.P.N. connection diagram
In order to ensure the proper V.P.N. connection between the Nordmeccanica’s server and the
machine, the ports, hereunder listed, at the customer’s firewall must be open:
TCP 443
UDP 1194
TCP 5443
TCP 6220

4.1.8 Equipment and personnel

Save for different and specific contractual arrangements, to unload and start assembling the machine, the
Purchaser must provide:
- suitable handling and lifting equipment
- the availability of trained and authorized personnel
- any necessary equipment and consumable materials

4.2 Transport of the machine

The machine is prepared and transported by NORDMECCANICA S.p.a.
The machine is divided and crated into several units according to its mass and dimensions; the moving parts are
locked or disassembled. The smaller components are packed in wooden boxes or on pallets for forklift handling.
The machine is suitably prepared for being transported to the installation site; the kind of crating and protection
depends on the type of shipping (by sea, air, road, etc.) and on the foreseen period for any storage.
Some unpainted metal parts are covered with oil or other protective means. The rollers are protected by cardboard
or packing tape.
For the packaging are used heat shrinkable tapes or moisture-proof heat-sealed bags. For sea shipments,
desiccants packets are placed inside the barrier bags.
Information for those assigned to the transport:

The provided lifting and handling points are left uncovered for ease of loading/unloading operations.
All parts are suitably secured to prevent moving or shifting during transport.

4.3 Receipt and check

- Upon receiving the machine, the Purchaser must verify that all the material stated in the Transport Document is
present;
a) Upon arrival the Purchaser must very carefully check the conditions of all the material received
and report immediately any damage to the carrier. It is advisable to produce photographic proof
of any damage found. Contact NORDMECCANICA S.p.a. as soon as possible. (Section 1.1 -
MANUFACTURER IDENTIFICATION DATA).
b) To ease the subsequent handling operations, unpack the various machine parts. This will also
allow ascertaining their actual dimensions.
- Thoroughly clean all machine parts using only rags and non-aggressive detergents. Do not use solvents;
- Dispose of all packaging materials in accordance with current regulations.
Obligation for the assigned personnel:

During these operations wear gloves, protective overall, safety shoes and helmets.

4.4 Handling of the machine

Ascertain in advance that the path ahead is clear and verify the presence of any potential obstacles (narrow or low
passageways, machinery or plants, uneven floors, bulky material).

All machine handling operations must be exclusively entrusted to trained personnel (harness, truck
and crane operators, etc.).
4.4.1 General handling guidelines

The Manufacturer has arranged lifting and hooking points for each unit in which the machine is divided.
Normally lifting is expected to be from above by means of mobile or gantry cranes. For the smaller components or
packages on pallets, forklift is required.
Code of practice:
Strictly follow all handling procedures foreseen by the Manufacturer, both with regard to the hooking
points, and to the means to use.
Always comply with the current safety rules applicable in the country of installation.
The following are general guidelines and cannot in any way substitute the experience and competence of
the assigned personnel.
- Wear protective clothing (helmet, gloves, overall, safety shoes, etc.).
- Use lifting equipment having suitable load capacity.
- For lifting unbalanced loads, use ropes of different lengths or chains with adjustable length.
- Check each time the conditions of all equipment used and discard it if not in perfect working order.
- Do not knot or twist the ropes or harnesses so as not to reduce the lifting capacity or produce torsional effects
on the load being lifted.
- Use the utmost caution and remain at a safe distance from lifted loads unless absolutely necessary; do not
stand or pass under suspended loads.
- Pay attention in putting under tension the ropes or chains to prevent the load shifting sideways in an
uncontrolled manner.
- Avoid the excessive swinging of suspended loads and maintain a low travel speed.
It is advisable to have the assistance of a person on the ground capable of indicating the various
movements when the load does not allow sufficient visibility to the operator.

The following figure illustrates a load being lifted from above, hooked up with 2 eyebolts and chains, which result
balanced (case a) and unbalanced (case b). To prevent uncontrolled lateral movement the lifting point must be
kept on the vertical centre of gravity.
F 4.2 – Example of lifting from above
Use sufficiently long chains so that the angles are going to be as close as possible (αMAX < 45°).
Information for the lifting operator:

It must be taken into account that as angle α increases, the pull exerted on the chains increases too. It
is thus necessary to use chains with greater nominal load capacity.
If the load is highly unbalanced, to keep the load horizontal it is necessary to use chains having different lengths (L1
≠ L2). Please note how the angles produced by the chains change (α1 ≠ α2). In the case of highly unbalanced
loads, the pulls exerted on the two chains are very different. For this reason it is necessary to allow ample
safety margins.
The same considerations are valid for lifting by means of ropes or harnesses.
Potential risk:
Chains breaking (ropes or harnesses)
Elimination of the potential risk – Code of practice:

Always ascertain that the lifting capacity of the ropes, harnesses, eyebolts and chains used is
adequate for the load and for the way it is harnessed. Allow for ample safety margins on the given
nominal load values also in consideration of any equipment wear and tear.

4.4.2 Symbols used for handling operations

The following table describes the symbols used in the manual to show the ways of lifting the machine.
T 4.1 – Meaning of the symbols used for identifying the lifting points
Symbol Meaning Notes
Vertical lifting line • The symbol is used in case of unbalanced loads and it shows
the vertical line passing through the centre of gravity of the
load; the lifting hook should be kept in that position.
Eyebolt with chain • To comply with their foreseen lifting capacity, the eyebolts must
be fully tightened.
• Always use hooks with safety lock.
Rope or harness • Protect painted parts by interposing some packaging

cardboard.
• Securely tighten the knot before starting to lift.
Push-through bar • The round lifting bar must be fully inserted into the specified
hole.
• Use ropes or harnesses, keeping them as near as possible to
the load.
Forklift truck • Fully insert the lift truck forks.

• Only the driver and no one else must be on the truck.

4.4.3 Weights and lifting points

The following figure shows the weights of the main parts of the machine.
F 4.3 – Weights of the main components

In the table below are shown the lifting points (type and number) and the weight of the main components
constituting the machine.
T 4.2 – Lifting points and weight of the main machine components

Component Weight in kg Lifting points Qty and position
Rotogravure trolley 500 - x2
Solventless trolley 1200 - x2
- x4
Coating column(1) 2100
- On the top part of the column.
- x4
Middle column 1800
- x4
Laminating column 4000
Drying oven(2) 5500 ---
Exhauster (each) 200 ---
- In the case of handling the control units together

with the supporting structure, interpose some
Thermoregulating units (each) 60
packaging material and securely tie them to the
structure.
300 kg x 3 - x 4 for each module

Electrical cabinet
doors - On the top of each module.
Corona treatment see Supplier documentation
(1) For transport requirements, the coating column can be handled with a coating trolley inserted. In this case, the trolley weight must be
added.
(2) Use ropes or belts of proper length, in order to prevent mechanical stress to upper parts (fans and ventilation ducts).

4.5 Possible storage

If it is not possible to install the machine immediately, its various parts must be properly stored in a dry well-aired
place. To prevent corrosion and deterioration, all the pieces must be unpacked and cleaned carefully, with cloths
and non-aggressive detergents.

Especially in sea shipping, the temperature variations can cause a build-up of moisture inside the
barrier bags.
Place the pieces of the machine on a dry flat floor, suitable to support their weight; make sure they are well steady
and cannot fall down; do not pile them on each other. Use special precautions for the paper documentation.

The environment conditions for storage are described in Section 2.24 - TECHNICAL DATA.
If the machine must remain stored for a long period, some precautions should be taken to prevent oxidation and
deterioration:
- keep the machine sheltered from atmospheric agents, in a closed well-aired room;
- spread antioxidant oil on all unpainted steel parts (carefully avoiding smearing it on the rubber or plastic
components);
- cover the push-button panels and the control devices with plastic films;
- protect the machine with canvas covers or something of the sort.
Avoid places where temperature can drop below 0 °C, because the water contained in the roller thermoregulating
system could freeze, causing heavy damage to the system.
In case of doubt, fill the circuit with antifreeze liquid and water.

4.6 Installation
The assembly and installation of the machine are carried out by Manufacturer’s technicians (with the co-operation
of personnel put at disposal by the Purchaser): the sequence of the operations is therefore described just as an
indication.
Code of practice:
It is forbidden to start assembling and connecting the machine without the supervision of the
Manufacturer’s technicians.
4.6.1 Positioning and levelling

The machine units are positioned according to the Layout drawing and aligned (both lengthwise and in height).
Each one is then carefully levelled (both lengthwise and crosswise) by means of a centesimal-precision level.
At the end of the installation, the machine can be fixed to the floor (as indicated in the Foundation drawing or
Bearing points drawing).

The civil works (e.g. drillings) and the material (e.g. anchor means, chemical resins) required to fix the
machine to the ground are at Purchaser’s charge.
4.6.2 Assembly
The machine is completely reassembled from a mechanical point of view and all the connections among the
various components (mechanical, electric, pneumatic, hydraulic, etc.) are restored.
4.6.3 Connection to the supply lines

Obligation for the maintenance personnel:
Before connecting any energy source, it is necessary to ascertain that any locking device used for the
transport has been removed.
The machine is connected to the supply lines shown in the Layout drawing. Ensure that all pipes and cables are
adequately protected by the way of floor or overheads conduits.
Potential risk:
Supplies having different characteristics than those required may cause unpredictable reactions,
damage or hazards to the personnel.
Elimination of the potential risk – Code of practice:

Ascertain that all the characteristics of the supply lines comply with the specifications given in the
Machine Layout.

4.6.4 Connection to the exhaust systems

The outlets indicated in the Layout drawing are connected to the exhaust systems set up by the Purchaser.
The Purchaser is responsible for the efficiency of the exhaust lines and ducts.
4.6.5 Connection to the auxiliary systems

The machine is connected to all the auxiliary systems or components included in the consignment.

For the specific characteristics of the supplies and installation of the systems or auxiliary components,
refer to the specific documentation.

4.7 Commissioning
The commissioning is carried out by the Manufacturer’s technicians and thus is not described in this manual.
The commissioning technicians have electrical/electronic skills; by following a preset operating procedure, the
technicians verify the functionality of all systems and prepare the machine for start-up.
In particular, checks are made on all safety devices and protective safeguards and the efficiency of the
signals and emergency stop verified.
Once the machine has been started, correct execution of all foreseen functions is verified, to which then follow the
working tests on materials supplied by the Purchaser and the training of Purchaser’s personnel.

After the commissioning has been completed, the final testing is carried out with a machine trial
process previously agreed with the Purchaser.

Use
5 - USE
Table of contents
5.1 General Information .......................................................................................................................................................... 5.3
5.2 Functioning principle......................................................................................................................................................... 5.3
5.3 Push-buttons and selector switches ................................................................................................................................. 5.3
5.4 Codes of practice to be adopted before starting work ...................................................................................................... 5.4
5.5 Operator work station ....................................................................................................................................................... 5.5
5.6 Foreseen operating modes ............................................................................................................................................... 5.6

5.6.1 Running modes ..................................................................................................................................................................... 5.6
5.6.2 Operating modes ................................................................................................................................................................... 5.6
5.6.3 Automatic mode for normal solvent-based production............................................................................................................ 5.7
5.6.4 Automatic mode for normal solventless production ................................................................................................................ 5.7
5.6.5 Automatic mode for normal water-based production .............................................................................................................. 5.8
5.7 Operating modes for local operation................................................................................................................................. 5.9

5.7.1 Local mode with guards excluded: ......................................................................................................................................... 5.9
5.7.2 Normal local mode (coating area): ....................................................................................................................................... 5.10
5.7.3 Local mode for washing/manual cleaning: ........................................................................................................................... 5.10
5.7.4 Local mode for automatic washing/cleaning (only for machines equipped with automatic washing): .................................... 5.10
5.8 Inserting the trolleys in the machine ............................................................................................................................... 5.11
5.9 Loading the reels on the unwinders ................................................................................................................................ 5.13

5.9.1 Arranging the reels on the unwinders .................................................................................................................................. 5.13
5.9.2 Procedure for loading the reel on the unwinder .................................................................................................................... 5.14
5.9.3 Sensors detecting the position of shaftless unwinder arms .................................................................................................. 5.16
5.9.4 Adjusting the disengagement travel ..................................................................................................................................... 5.18
5.9.5 Setting the unwinding direction ............................................................................................................................................ 5.19
5.10 Loading the core on the winder ...................................................................................................................................... 5.20

5.10.1 Lay-on roller ........................................................................................................................................................................ 5.22
5.11 Web threading ................................................................................................................................................................ 5.23

5.11.1 General Information ............................................................................................................................................................. 5.23
5.11.2 Threading chains ................................................................................................................................................................. 5.24
5.11.3 Duplex lamination and winding of the laminated web on the winder ..................................................................................... 5.25
5.12 Slow rotation of the coating unit rollers ........................................................................................................................... 5.27
5.13 Preparing the machine for the ROTOGRAVURE process .............................................................................................. 5.29
5.13.1 Inserting the rotogravure trolley in the machine (if not already present) ............................................................................... 5.29
5.13.2 General information (RT process) ........................................................................................................................................ 5.30
5.13.3 Replacing the coating roller (RT process) ............................................................................................................................ 5.31
5.13.4 Doctor blade unit: positioning and adjustment devices (RT process).................................................................................... 5.33
5.13.5 Fitting/removing the doctor blade holder and the splash guard (RT process) ....................................................................... 5.34
5.13.6 Assembling the doctor blade and the counter-doctor blade (RT process) ............................................................................ 5.36
5.13.7 Doctor blade adjustment: return to the working position (RT process).................................................................................. 5.37
5.13.8 Doctor blade adjustment: adapting to the coating roller development (RT process) ............................................................. 5.38
5.13.9 Doctor blade adjustment: incidence angle (RT process) ...................................................................................................... 5.39
5.13.10 Doctor blade adjustment: parallelism (RT process) ........................................................................................................... 5.40
5.13.11 Fitting the lower pans and the trolley cover (RT process) .................................................................................................. 5.41
5.13.12 Preparing the adhesive feed (RT process) ........................................................................................................................ 5.43
5.13.13 Webs tensioning (RT process) .......................................................................................................................................... 5.45
5.13.14 Checking web breakage (RT process) .............................................................................................................................. 5.46
5.13.15 Webs tension adjustment (RT process)............................................................................................................................. 5.47

Use
5.13.16 Taper tension mode adjustment (RT process)................................................................................................................... 5.48

5.13.17 Misaligning idle roller adjustment (RT process) ................................................................................................................. 5.49
5.13.18 Starting the rotogravure process ....................................................................................................................................... 5.50
5.13.19 Adjusting the coating material quantity (RT process)......................................................................................................... 5.51
5.14 Preparing the machine for the SOLVENTLESS process ................................................................................................ 5.52
5.14.1 Inserting the solventless trolley in the machine (if not already present) ................................................................................ 5.52
5.14.2 General information (SL process) ........................................................................................................................................ 5.54
5.14.3 Removing and fitting the transfer roller (SL process)............................................................................................................ 5.55
5.14.4 Heating the metering rollers (SL process) ............................................................................................................................ 5.56
5.14.5 Adjusting the metering rollers distance (SL process) ........................................................................................................... 5.57
5.14.6 Preparing the SL adhesive feed (SL process) ...................................................................................................................... 5.58
5.14.7 Webs tensioning (SL process) ............................................................................................................................................. 5.60
5.14.8 Checking web breakage (SL process) ................................................................................................................................. 5.61
5.14.9 Webs tension adjustment (SL process)................................................................................................................................ 5.62
5.14.10 Winder taper tension mode adjustment (SL process) ........................................................................................................ 5.63
5.14.11 Misaligning idle roller adjustment (SL process) ................................................................................................................. 5.64
5.14.12 Starting the SL process ..................................................................................................................................................... 5.65
5.14.13 Adjusting the coating material quantity (SL process) ......................................................................................................... 5.67
5.14.14 Transfer roller adjustment (SL process) ............................................................................................................................ 5.67
5.15 Sleeve change procedure ............................................................................................................................................... 5.68

5.15.1 Procedure for removing the sleeve ...................................................................................................................................... 5.68
5.15.2 Procedure for fitting the sleeve ............................................................................................................................................ 5.72
5.16 Adjustments and description of single specific operations.............................................................................................. 5.75

5.16.1 Opening/closing the rubber-coated coating impression roller ............................................................................................... 5.75
5.16.2 Coating pressure adjustment ............................................................................................................................................... 5.77
5.16.3 Opening/closing the rubber-coated laminating nip roller....................................................................................................... 5.78
5.16.4 Lamination pressure adjustment .......................................................................................................................................... 5.79
5.17 Checking the winding reel .............................................................................................................................................. 5.80
5.18 Checking the unwinding reel........................................................................................................................................... 5.82
5.19 Reel unloading................................................................................................................................................................ 5.83

5.19.1 Unloading the unwinders ..................................................................................................................................................... 5.83
5.19.2 Unloading the winder ........................................................................................................................................................... 5.83
5.20 Multifunction Panel ......................................................................................................................................................... 5.84
5.21 Syntesis supervision ....................................................................................................................................................... 5.84

5.21.1 Presetting functions (optional) ............................................................................................................................................. 5.84
5.22 Quick start guide: how to use the push-button panels .................................................................................................... 5.85

Use
5.1 General Information

This chapter provides the instructions on the main procedures that the operator must follow for the safe use of the
laminating machine.
Please note, however, that the instructions relating to the working processes cannot be considered a replacement
for the professional and technical knowledge that the operator must have acquired through the experience gained
in the field of laminating machines.
5.2 Functioning principle

The machine is designed to laminate webs of different materials, in accordance with the indicated stages:
Lamination
The reel with the primary material (material to be coated) is mounted on unwinder A, while the reel with the
secondary material (material to be laminated) is mounted on unwinder B. The web coming from unwinder A enters
the coating column where inside it a special unit lays the adhesive on one side of the material (coating). After
exiting this column, the coated web goes through the drying oven; next, the web enters the laminating column and
goes through the laminating unit in which at the same time also passes the web coming from unwinder B. The final
web thus obtained is made up by the lamination of two different webs and reeled on the winder.
These stages will be described in greater detail in the subsequent sections within which are described the various
units composing the machine.
5.3 Push-buttons and selector switches

For clearer and immediately understood indications, next to the description of some operational stages, the
inherent topographical drawings showing the positions of the push-buttons and selector switches to use have been
added. In these drawings, the push-buttons and the selectors are indicated with an alphanumeric code made up of
4 or 5 digits and a letter: said code is the one appearing on the DW3619 wiring diagrams.

Use
5.4 Codes of practice to be adopted before starting work
Before starting the work cycle, it is mandatory to follow the procedure for ascertaining the machine
status.
1. The entire area around the machine must be free from any object, tools and materials not related to production
that could represent a hazard for the personnel safety (falls, slipping, tripping, etc.). Operators and
maintenance personnel must be able to move freely around the whole machine without meeting any
obstruction.
2. The whole area around the machine must be clean and free from any traces of oil, grease or other substances
that could make the floor slippery.
3. Ascertain that all the safety personal equipment specified as necessary by the Manager of Safety and Health
at Work is available.
4. Verify that the machine is not in emergency status (emergency status = lighted columns off).
5. Check that the fume extraction system is working.
6. Check that the reels to be loaded on the unwinders do not show any apparent anomaly.
7. Positively identify the reel with the primary material and that with the secondary material in order to not swap
them during the loading operation on the unwinders.
8. Check that you have available the “MATERIAL FLOW PATH” diagram for correctly carrying out the web
threading.
9. Read and understand the procedures laid out in this Instruction Manual and if in doubt contact Nordmeccanica
Customers Service.
10. Keep away from the machine surrounding area anyone not involved in the ongoing operations.
11. Verify that the lifting capacity of the reels hoisting equipment is suitable for the weight to be handled.
Reel weight:
Chapter 3 – HEALTH, SAFETY AND ACCIDENT PREVENTION

Use
5.5 Operator work station

The following picture shows the position in which the operator must be during normal machine operation and during
loading/unloading of the reels.
A person is needed to manage the laminating machine:

- 1 operator

Any other position different than that indicated is forbidden.
Obligation for the assigned personnel:

Wear suitable P.P.E. when performing these operations.
F 5.1 – Operator places
Operator (machine operator) position during normal machine working cycle.
Operator (machine operator) position during reel change.

Use
5.6 Foreseen operating modes

5.6.1 Running modes
In this section, reference is made to two different running modes: “NORMAL RUN” and “SLOW RUN” as defined
herein:
Machine operating in automatic mode with passage of the web through the unwinders, the
Normal run
coating unit, the laminating unit, the cooling drum and the winder.
Rotation/counter-rotation of only the metering devices for adhesive application to delay the
drying process.
The slow run, at reduced speed, is automatically activated after a normal machine stop.
Slow run
The operator can stop the slow run with a second stop command and resume the inking
process by means of the relevant push-button “SLOW RUN”.
The web can also be moved by means of a manual jog control.
5.6.2 Operating modes

The laminating machine can perform its function according to the operating modes described below, which can be
selected by means of the following selector switch:
T 5.1 – Selector switch for the laminator function:
Laminating column
Selector switch 123S1 on LCP24 and MCB
1 - S.B. PRODUCTION
2 - S.L. PRODUCTION 3 - W.B. PRODUCTION

Use
5.6.3 Automatic mode for normal solvent-based production
SELECTOR SWITCH 123S1 in position 1
When the selector switch is in this position, tha machine operates in normal production mode: the web goes
through the coating, drying, laminating, cooling and rewinding units with all interlocking movable guards closed.
The drying oven and the L.E.L. solvent monitoring system are active.
This operating mode can be associated with two different running modes: (ref.: § 5.6.1):
- normal run
- slow run
The operator can stop the slow run with a second stop command and resume the inking process by means of the
relevant command.
5.6.4 Automatic mode for normal solventless production
The drying oven and the L.E.L. solvent monitoring system are not active.
- normal run
- slow run
relevant command.

Use
5.6.5 Automatic mode for normal water-based production
- The oven is active;

- The L.E.L. monitoring is deactivated.
- normal run
- slow run
relevant command.

Use
5.7 Operating modes for local operation

The laminating machine can perform its function according to the operating modes described below, which can be
selected by means of the following selector switch:
T 5.2 – Selector switch for the laminating machine function:
Coating column
Selector switch 323S1 on LCP21
1 - PROTECTION OFF 2 - NORMAL
3 – CLEANING 4 – AUTO CLEANING
5.7.1 Local mode with guards excluded:
Winding area:
Restricted to the winding area, the mode disables the monitoring of the electro-sensitive device, thus making it
possible to get near the reel, and inhibits the machine running while maintaining the tension condition before
switching over.
Coating area:
Restricted to the coating area, the mode enables the operation of the machine with removed interlocking movable
guards (and/or light curtains) in manual feed with hold-to-run control device and at reduced speed for web
threading, adjusting and/or visual check of the product quality. The monitoring of the interlocking guards is
bypassed to allow for monitoring of the hold-to-run and reduced-speed controls. The exclusion of the guards
combined with activation of a hold-to-run control device in several zones at the same time is not mutually exclusive.
The switching-over of the selector switch causes immediate reduction of the speed of the line. Opening of the
guards (and/or triggering of the light curtains) with the machine in motion and without pressing the hold-to-run
control device causes a controlled stop of the line, whereas the inking for the rotogravure trolley is maintained.
Opening of the guards (and/or triggering of the light curtains) with the machine in motion and without pressing the
hold-to-run control device causes a controlled stop of the line.

Use
5.7.2 Normal local mode (coating area):

the machine operates depending on how the selector switch for general operating mode was set, with complete
monitoring of the guards. Opening of the interlocking guards causes the machine to stop.
5.7.3 Local mode for washing/manual cleaning:
The mode enables the operation of some machine parts in the coating area with removed interlocking movable
guards, in manual feed, with hold-to-run control device and at reduced speed for cleaning operations. Selecting this
operating mode implies controlled stop of the line (if running), start of the inking process and detachment of the
coating impression rollers.
5.7.4 Local mode for automatic washing/cleaning (only for machines equipped with automatic washing):
Within the area controlled by the selector switch, this mode allows selective operation of some laminating machine
parts in the coating area with interlocking movable guards closed.
Selecting this operating mode implies controlled stop of the line (if running), start of the inking process and
detachment of the coating impression rollers. It is foreseen for the assembly of the automatic washing system of
the solventless trolley to enable only the coating areas.

Use
5.8 Inserting the trolleys in the machine

The machine can use various coating techniques, depending on the type of adhesive and on the performances
desired for the final product. This is possible thanks to interchangeable coating units, assembled on trolleys with
swivel wheels, to be inserted in coating column.
The machine referred to in this Instructions Manual is fitted with the following coating trolleys:
- RT trolley (rotogravure);
- SL trolley (solventless).
The operations for inserting and extracting the coating trolleys are to be done manually: a special handle, to
remove after use, allows to rotate the pinion fixed to the side of the trolley that engages with the rack fixed onto the
coating column shoulder. This mechanism facilitates the sliding of the trolley.
F 5.2 – Detail: belt tensioning
1. Cam tensioner
2. Driven pulley of the chromed coating roller
3. Automatic belt tensioning with trolley inserted

Use
Once inserted in the coating space, the trolley is firmly locked. Two brackets, hinged on the side frames of the
coating column, hook some pins arranged on the trolley; by acting on the two handles, the brackets put the trolley
in traction and lock it in the working position.
F 5.3 – Detail: trolley locking
1. Pin on the trolley

2. Lock bracket
3. Rack fixed to the coating column
4. Spindle on which to insert the removable handle
5. Pinion fixed on the trolley
6. Locking knob

Use
5.9 Loading the reels on the unwinders
Before starting the below described operations for preparing the machine, check that in the coating
column is present the trolley needed for the type of coating foreseen for the material to be laminated.
Section 2.9 – INSERTING THE TROLLEYS IN THE MACHINE.
5.9.1 Arranging the reels on the unwinders

The loading of the reels on the unwinders depends on the type of lamination to be carried out; the following
diagram provides the indications for the “Type of lamination” – “Material” – “Unwinder to use”.
T 5.3 – Unwinders use diagram
Primary material on unwinder A
Type of lamination DUPLEX
Secondary material on unwinder B
FORBIDDEN OPERATION
Any combination of reels loaded on the unwinders different from that shown is forbidden.
Nordmeccanica S.p.a. declines any responsibility for injuries to people or damages to property ensuing
from the non-compliance with the above T 5.3 diagram.

Use
5.9.2 Procedure for loading the reel on the unwinder
Personnel assigned to the operation:

1 operator
Do not make the reels roll on the floor, to avoid risks of squashing and damage to the material.
1. Before loading the reel to unwind, it is necessary to measure the outside diameter of the core and input it (in
mm) in the machine by the way of the Multifunction Panel: during the process the machine calculates the
diameter of the reel and automatically stops when the minimum set diameter has been reached.
2. The way in which the reel is loaded on the unwinder determines the web face, inner or outer, that will be
processed: choose how to turn the reel in accordance with the web face that has to be processed by referring
to the Material flow path drawing. The unwinding direction (clockwise or counter-clockwise) will have to be set
accordingly.
Risk of damages to the machine!

The unwinding direction must be exclusively set with the unwinder stopped.
T 5.4 – Selector switch for clockwise/counter-clockwise unwinding
Unwinder A Unwinder B
Selector switch 216S5 on local control panel LCP1 Selector switch 416S5 on local control panel LCP24
UNWINDING UNWINDING
(CCW-CW) (CCW-CW)
3. Transport the new reel near the unwinder by means of a forklift truck with suitable lifting capacity for the reel
weight (Section 2.24 – TECHNICAL DATA).
Predictable conduct to be avoided:

Do not move the reels by rotating them. This kind of conduct could damage the reel or cause
harm to people or property.
4. Open the reel-holder arms, by acting on the “REEL CLAMPING“ selector switch (the main arm carries out the
release travel while the secondary arm moves away completely).

Use
T 5.5 – Selector for reel clamping
REEL CLAMPING REEL CLAMPING
5. Lift the reel with the forklift until the core is at the same height of the locking safety chucks.
Be careful not to put the hands between the clamping devices and the reel.
6. Close the reel-holder arms, by acting on the “REEL CLAMPING” selector switch until the selector lamp lights
up (if the selector is released before time, the two arms open again).
7. Make sure that both clamping devices are slipped in the core.
8. Inflate both expanding chucks (if used), by using the supplied gun.
9. Lower and move the reel-lifting trolley away.
10. Align the unwinder again with the centre of the machine, by using the “MANUAL ALIGNMENT” selector switch.
T 5.6 – Selector for manual alignment
MANUAL ALIGNMENT MANUAL ALIGNMENT
12. If needed, adjust the release travel (as described in the following pages).
13. Manually unwind a few metres of web and thread it along the machine. During processing, with the machine
already threaded, join the web to the tail of the previous reel (use adhesive tape).

Use
5.9.3 Sensors detecting the position of shaftless unwinder arms
The unwinders are fitted each with 5 coded sensors, as indicated in the tables below:
T 5.7 – Sensor coding and function for unwinder A
(Operator side) Unwinder A (Transmission side)
214B1 214B2 214B3 214B4 214B5

Maximum arm open Reel left displacement limit Reel right displacement Maximum arm closed Maximum arm open position
position for non- (web guide limit switch) limit position for non-powered for powered chuck
powered chuck (web guide limit switch) chuck
 With the reel mounted, the unwinder can translate  

by ± 2.5 cm with respect to the centre position
2.5 cm 2.5 cm
Meaning of symbols used in the table:

 = Moving left
 = Moving right
M = Chuck motor
F 5.4 – Sensor 214B2 and 214B3

After the reel has been mounted and aligned at the centre of the unwinder,
photocells 214B2 and 214B3, kept together by a spacer, must be moved on
the horizontal guide so that the arm of the non-powered chuck is located
between them (position 2, F 5.4).
Use the special knob to lock/release the photocells.
1. Arm of non-powered chuck

2. Centre position for the arm of the non-powered chuck during reel normal unwinding conditions
3. Spacer
4. Lock/release knob for photocell displacement

Use
T 5.8 – Sensor coding and function for unwinder B
(Operator side) Unwinder B (Transmission side)
414B1 414B2 414B3 414B4 414B5

Maximum arm open Reel left displacement limit Reel right displacement Maximum arm closed Maximum arm open position
position for non- (web guide limit switch) limit position for non-powered for powered chuck
powered chuck (web guide limit switch) chuck
 With the reel mounted, the unwinder can translate  

by ± 2.5 cm with respect to the centre position
2.5 cm 2.5 cm
Meaning of symbols used in the table:

 = Moving left
 = Moving right
M = Chuck motor
F 5.5 – Sensor 414B2 and 414B3

After the reel has been mounted and aligned at the centre of the unwinder,
photocells 414B2 and 414B3, kept together by a spacer, must be moved on
the horizontal guide so that the arm of the non-powered chuck is located
between them (position 2, F 5.5).
Use the special knob to lock/release the photocells.
1. Arm of non-powered chuck

2. Centre position for the arm of the non-powered chuck during reel normal unwinding conditions
3. Spacer
4. Lock/release knob for photocell displacement

Use
5.9.4 Adjusting the disengagement travel

If the width of the mounted reel is different from the previous one, after centering the unwinder the disengagement
travel of the main arm must be adjusted:
1. Loosen the locking knob;

2. Move the carriage so as to position proximity sensor 1 level with the reel holder arm;
3. Tighten the locking knob.
F 5.6 – Adjusting the disengagement travel
1. Locking knob
2. Proximity sensor 1
3. Proximity sensor 2
When the carriage is properly positioned, the travel of the reel holder arm is limited by the two proximity sensors:
while opening  the arm will stop under proximity sensor 2, which acts as a travel limit reference;
while closing  the arm will return and stop under proximity sensor 1, which acts as a working position
reference.

The led fitted on the casing of the proximity sensors signals the status of the sensor, namely it lights up
when the arm is detected by the sensor.

Use
5.9.5 Setting the unwinding direction

Set the required unwinding direction (clockwise or counterclockwise) by means of the “UNWINDING CCW CW”
selector switch.
The unwinding direction can be modified only when the unwinder is still.
T 5.9 – Selector switch for clockwise/counter-clockwise unwinding
UNWINDING UNWINDING
(CCW-CW) (CCW-CW)

Use
5.10 Loading the core on the winder

1 operator
1. make sure that the lay-on roller is lifted;
2. Open the reel-holder arms, by acting on the “REEL CLAMPING“ selector switch (the main arm carries out the
release travel while the secondary arm moves away completely).
Winder
Selector switch 918S11 on local control panel LCP91
REEL CLAMPING
4. by moving the reel-lifting trolley, position the core between the two winder arms, aligned with the clamping
devices (it is advisable to keep the core near the arm controlled by the screw);
F 5.7 – Electric reel-lifting trolley
5. close the reel-holder arms, by acting on the “REEL CLAMPING” selector switch until the selector lamp lights
up (if the selector is released before time, the two arms open again).
Be careful not to put the hands between the clamping devices and the core.
6. make sure that both clamping devices are slipped in the core;
7. inflate both expanding chucks (if used), by using the supplied gun;

Use
8. lower and move the reel-lifting trolley away;
9. align the winder again with the centre of the machine, by using the “MANUAL ALIGNMENT” selector switch.
T 5.11 – Selector for manual alignment
Winder
MANUAL ALIGNMENT
10. if needed, adjust the release travel.
Paragraph 5.9.4 - Adjusting the disengagement travel
The web threaded along the machine must be properly fixed on the winding core, according to the side of the web
to be external in respect to the wound reel. The winding direction (clockwise or counterclockwise) must be set
accordingly.

Use
5.10.1 Lay-on roller

During processing, the lay-on roller must remain closed, pressed on the reel in winding. Open the lay-on roller, with
the machine not running, to allow the winder load/unload.
To open and close the lay-on roller, use the “LAY-ON ROLLER” light selector, staying at the winder side.
Pay attention to the lay-on roller motion. Beware the risks of collision and squashing.
T 5.12 – Selector switch for opening/closing the LAY-ON ROLLER

Winder
LAY-ON ROLLER
To close the lay-on roller, it is necessary to act on the “LAY-ON ROLLER” selector switch for a few seconds, till the
selector lamp completely lights up. If the switch is released beforehand, for safety reasons, the impression roller
opens again.
The lay-on roller is driven by two pneumatic cylinders that can be regulated separately; it is therefore possible to
regulate the lay-on roller thrust on the two sides of the reel in an independent way. Use the LAY-ON PRESSURE
OPERATOR SIDE and LAY-ON PRESSURE TRANSMISSION SIDE regulators and check the pressure on the
respective pressure gauges.
Winder
Selector switch 8093B4 on local control panel LCP24 Selector switch 8093B9 on local control panel LCP24
LAY-ON LAY-ON
PRESSURE PRESSURE
OPERATOR SIDE TRANSMISSION SIDE

Use
5.11 Web threading

5.11.1 General Information

2 operators
The webs path depends upon the type of process decided by the Purchaser and the following chart summarizes
the possible combinations available to the Purchaser. Combinations which differ from those specified must be
considered forbidden. The webs paths must be those indicated in the “Material Flow Path” diagram which is an
integral part of the machine technical documentation.
F 5.8 – Possible material flow paths
Lamination Winding of the laminated web on the winder
Process
Lacquering Winding of the lacquered web on the winder

Use
5.11.2 Threading chains

To facilitate the web threading operation, inside the machine runs a chain to which must be hooked
the free end of each web coming from the unwinders.
The chains, manually operated by means of a crank, pull a crosswise bar to which the head of the web is fastened.
With the chains revolving by means of the crank, the web is therefore pulled till the end of the threading path.
F 5.9 – Threading crank
The crank must be slipped on the relevant shaft, on the transmission side.
Remove it after use.

Use
5.11.3 Duplex lamination and winding of the laminated web on the winder
F 5.10 – Material flow path
Web
Chain
Procedure:
1. Visually check that the reels are correctly fitted:
- primary material (to coat) on unwinder A;
- secondary material (to laminate) on unwinder B.
2. Disable the safety systems, open the doors and the interlocking guard of the laminating roller.
Coating column
Push-button 323S1 on local control panel LCP21
PROTECTION OFF
3. Open the coating impression roller and the laminating nip roller
Coating impression roller Laminating nip roller

Push-button 319S5 on local control panel LCP21 Push-button 389S5 on local control panel LCP24
COATING LAMINATING
IMPRESSION ROLLER NIP ROLLER
↑ 0 ↓ ↑ 0 ↓
↓ ↑ ↓ ↑
4. Manually unwind some web from the reel mounted on unwinder A.

Use
5. Thread the web through the unwinder A rollers by following the path indicated in the “Material Flow Path”
diagram until point (1, F 5.10 – Material flow path) is reached.
6. Thread the web through the coating unit until point (2, F 5.10 – Material flow path) is reached.
7. Hook the web to the chain until the web has reached point (3, F 5.10 – Material flow path) by using the
threading crank.
8. Unhook the web.
9. Manually unwind some web from the reel fitted on unwinder B, make it pass through the unwinder B rollers
and the Corona treater (in accordance with the indications given in the “Material Flow Path” diagram) and take
it as far as the laminating unit area.
10. Make the two webs, coming neatly arranged from unwinder A and unwinder B, pass in the laminating unit.
11. Make the laminated webs pass on the cooling drum and on the winder rollers, by following the path indicated
in the “Material Flow Path” diagram.
12. Fix the webs onto the core by using common adhesive tape.
13. Close the coating impression roller and the laminating nip roller.
14. Close the interlocking guard of the laminating roller, the doors and enable the safety systems.
Coating column
NORMAL
15. Select the operating mode according to the type of processing to be carried out.
Laminating column
1 - S.B. PRODUCTION
2 - S.L. PRODUCTION 3 - W.B. PRODUCTION

Use
5.12 Slow rotation of the coating unit rollers

If the coating trolley is already inserted in the coating column, activate the rollers slow running mode: a mode which
sets in motion the SOLE coating unit and consists in a very low speed continuous rotation of the rollers indicated
below, so as not to allow the adhesive to dry.
According to the coating unit used, the slow running mode affects different rollers:
Rotogravure unit Coating roller
Metering roller and transfer roller

Solventless unit
(both in the reverse direction)
The slow running mode is started by pressing the “SLOW RUN” push-button: the push-button lights up indicating
the operating mode.
T 5.13 – Push-button for starting the slow running mode
Coating unit
SLOW RUN
To stop the slow running mode press the “COATING STOP” push-button.
T 5.14 – Push-button for stopping the slow running mode
Coating unit
COATING STOP

Use

The next operation is split into two since dependent upon the type of coating that must be
carried out:
Preparing the machine
ROTOGRAVURE SOLVENTLESS
coating coating
Section 5.13 Section 5.14

Use
5.13 Preparing the machine for the ROTOGRAVURE process

5.13.1 Inserting the rotogravure trolley in the machine (if not already present)
Information for the operators:

For inserting the trolley in the machine it is required the presence of two operators.
For a better understanding of the below indicated procedure, please read first Chapter 2 –
TECHNICAL DESCRIPTION.
Procedure for inserting the trolley in the coating column:

1. Open the coating column lateral casings
2. Make sure that the doctor blade holder is not on the way (if necessary overturn it backward by using the
crank).
3. Push the trolley in front of the coating area in order to bring the two insertion shaft pinions to correspond with
the respective racks on the shoulders of the machine. To insert the trolley in the proper way, the two operators
must coordinate their movements, namely: one will push the trolley against the machine, while the other will
turn the double handle crank, previously fitted on the associated shaft.

When inserting the trolley, make sure it is parallel with the machine sides (if the trolley is not
straight, it must be pulled out and inserted again).
4. Turn the crank to insert the trolley, stopping some cm from the mechanical reference stop inside the coating
compartment.
5. Fit the toothed drive belt on the pulley of the trolley coating roller; be careful to the fingers: risk of crushing.
6. To complete the trolley insertion, make sure the drive belt has been properly tightened by the eccentric
adjuster.
7. Hook the two lock brackets to the sides of the trolley and tighten the handles.
8. Remove the trolley insertion crank.
9. Connect the three doctor blade air hoses to the quick couplings marked with the label “DOCTOR
BLADE/TRANSFER”. Observe the colours: green, black and white.
10. Close the casings and the lateral protections.

Use
5.13.2 General information (RT process)

For the rotogravure process (hereinafter also referred to as RT process) the machine must be prearranged and
used as indicated in the table below:
T 5.15 – Machine configuration for rotogravure coating
Component: Usage condition:
Coating trolley Rotogravure trolley + doctor blade unit
Coating roller with engraving suitable for the desired adhesive quantity
Rubber sleeve with cutting suitable for the necessary coating band
Adhesive or lacquer at the necessary percentage solution
Heating units laminating unit
Cooling drum as appropriate (materials and adhesives)

Exhaust hood must always be ON
Drying oven ON

1) The quantity of adhesive coated with the Rotogravure technique depends on the engraving of the
coating roller and by the solution percentage.
2) The coating band is determined by the cutting width of the rubber sleeve that is fitted. It is not
possible to coat the adhesive along the entire web width: it is instead opportune leaving a few mm on
each edge to avoid undesirable gluing on the reel once the web has been laminated and rewound.
The coating width must be at least 3÷6 mm narrower than the film web being used.
3) Type of pump for the adhesive tank:
Adhesive/lacquer Feed unit
Solvent-based Tank with diaphragm pump
Water-based Tank with peristaltic pump
4) The rollers temperature and the use of the cooling drums must be chosen in accordance with the
adhesive manufacturer's indications, the materials being processed and the own technical experience
in coating/laminating procedures. Open the relevant water lines stopcocks.
Switching-on and adjusting the thermoregulating units:

5) When the Rotogravure trolley is inserted in the machine, the drying oven is automatically rendered
operative. The operator must however adjust the air temperature and the pressure both to the
blowers and to the oven exhaust.

Use
5.13.3 Replacing the coating roller (RT process)
Personnel assigned:
1 mechanical maintenance technician

The coating roller must be fitted before inserting the trolley in the machine.
Procedure for removing the coating roller:
1. Loosen and take off the screws on the top of the trolley sides and remove the two shaped brackets for locking
the coating roller bearings.
F 5.11 – Bracket locking the coating roller bearing
2. Remove from the coating roller the drive pulley by loosening the relative taper bush (use a screw as extractor
by screwing it into one of the free holes).
3. Remove the casing covering the worm screw at the end of the coating roller (unit for the doctor blade
alternating movement).
4. Place slings at both ends of the coating roller and extract it from the trolley while lifting it with ropes and
suitable hoisting equipment.
5. Take off from the coating roller the worm screw for the doctor blade alternating movement by removing the
lock washer.
6. Move away the roller and place it in a suitable place, taking care to interpose some packaging material before
resting it down.

Absolutely avoid any damage to the roller engraved surface.

Use
Procedure for fitting the coating roller:
Repeat the steps followed for the removal but in the reverse order.

If only one pulley and one worm screw are available, it is necessary to move them each time from
roller to roller.

Use
5.13.4 Doctor blade unit: positioning and adjustment devices (RT process)
Personnel assigned:
1 operator
The doctor blade unit has available several movements concurring to the final doctor blade positioning on the
coating roller.

For correct doctor blade positioning, it is essential to respect the function of each device and the order
shown for the operations to be carried out.
F 5.12 – Devices for regulating the doctor blade
1. Crank for overturning the unit

2. Levers for adapting to the coating roller development
3. Pneumatic cylinders for contact/distance and pressure adjustment
4. Handwheels for adjusting the incidence angle and the parallelism

All adjustment devices are provided of a scale index to allow positioning repeatability.
The doctor blade working pressure, once the working position has been adjusted, must exclusively be changed via
the “DOCTOR BLADE/TRANSFER PRESSURE” pressure regulator.
T 5.16 – Doctor blade working pressure adjustment
Coating unit
Regulator 8022B6 on local control panel LCP21
DOCTOR BLADE/TRANSFER PRESSURE

Use
5.13.5 Fitting/removing the doctor blade holder and the splash guard (RT process)

Before overturning the doctor blade holder backwards, it is necessary to make sure that the lower pans
of the coating trolley, if they are assembled, are lowered.
Procedure for removing the doctor blade holder:
1. Insert the crank (1 F 5.13) into the hole on the rear casing and rotate it so as to overturn backward the doctor
blade unit;
F 5.13 – Overturning the doctor blade unit
2. Loosen the three handles locking the doctor blade holder on the two feed slides;
3. Grab the doctor blade holder by the two middle handles, slide it out and remove it;
4. Remove the splash guard strip by sliding it from its housing;
5. Slide out and remove the crank.

Use
F 5.14 – Overturning the doctor blade unit
1. Doctor blade locking handles

2. Middle handles
Risk of cuts to the upper limbs!

Cover the doctor blade edge with the protective plastic profile.
Procedure for fitting the doctor blade holder:
For fitting the doctor blade holder, operate in the reverse order than that described for removing it.

Remember to fit the splash guard strip.
Ensure that the housing of the doctor blade holder is thoroughly clean. Remove any possible deposits.

Use
5.13.6 Assembling the doctor blade and the counter-doctor blade (RT process)

The doctor blade holder is designed for doctor blades of 40 mm and counter-doctor blades of 35 mm
wide.
The doctor blade and the counter-doctor blade can be easily assembled on the bench after having removed the
doctor blade holder from the machine; follow the procedure indicated below:
1. Loosen all the lock screws without removing them (the inner springs keep the two parts of the doctor blade
holder open).
2. Thoroughly clean the counter-doctor blade (replace it only if damaged).
3. Roll out the new doctor blade on the flat and cut a piece of it long exactly as the doctor blade holder.
4. Slide the doctor blade and the counter-doctor blade into the slot of the doctor blade holder (it is advisable to
smear some grease on them to keep them firmly in position).
5. Check that the two foils are well aligned with each other and rested against the arranged limit stop.
6. To reclose the doctor blade holder, evenly tighten all the top screws starting from the middle ones.

The doctor blade length must be precise: it must arrive to the edge of the lateral splash guards of
the doctor blade holder, but without touching them.
F 5.15 – Doctor blade assembly diagram
Residual risk: cuts to the upper limbs

During the assembly operations cover the doctor blade edge with the protective plastic profile.

Use
5.13.7 Doctor blade adjustment: return to the working position (RT process)
Insert the overturning crank into the pre-arranged hole found on the rear casing and rotate it counter-clockwise
while reading on the graduated reference scale the position obtained. The working position, denoted by the doctor
blade unit in vertical position, is indicated by the position 0 on the relative scale.
Mandatory code of practice:

The crank must always be taken out and removed to prevent accidental changes to the setting made.
F 5.16 – Doctor blade adjustment: graduated scale
1. Graduated scale for reading the doctor blade rotation (overturning)

Use
5.13.8 Doctor blade adjustment: adapting to the coating roller development (RT process)
The doctor blade unit is designed to allow the correct positioning of the doctor blade on the printing roller of any
size (provided that it is within the range permitted by the machine construction limits). Through an eccentrically
adjusted shaft, the operator must adapt the geometry of the doctor blade unit to the development of the printing
roller fitted. The working position, with a standard coating roller, is indicated on the relative scale by the position 2
(halfway). By always using standard rotogravure rollers (same development) it is never necessary to
change the eccentric setting.
If it is necessary to change the setting:

1. loosen the two locking knobs (1)
2. rotate the two levers (2)
3. retighten the knobs (1)
F 5.17 – Doctor blade adjustment
1. Locking knobs
2. Levers for adjusting the doctor blade position
In general, the positions of the adjustment levers, depending on the type of coating roller fitted on the coating unit
RT 2 or RT SV-VAR 3 are those indicated in the following table:
T 5.17 – Doctor blade position
Development of the standard coating roller: Pos.:
Standard (628.3 mm  Ø 200 mm) 2

Development of the variable development coating Pos.:
roller:
Minimum (500 mm) 1
Maximum (800 mm) 3
2 RT = Rotogravure
3 RT SV-VAR = Variable development rotogravure

Use
5.13.9 Doctor blade adjustment: incidence angle (RT process)

The incidence angle must be exclusively adjusted through the two feed handwheels.
F 5.18 – Doctor blade adjustment: incidence angle
1. Locking handles
2. Feed handwheels
To change the setting:
1. Release the three locking handles
2. Act on the two feed handwheels
3. Retighten the locking handles

Act simultaneously on both handwheels to prevent jamming on the slides.

Use
5.13.10 Doctor blade adjustment: parallelism (RT process)

The parallelism of the doctor blade edge in relation to the coating roller is preset in dry run mode.
Procedure:
1. Rotate the overturning crank (1  F 5.21) and slowly bring the doctor blade edge near to the coating roller
surface.
2. Turn one of the two feed handwheels up to the point of making the entire doctor blade edge evenly rest on the
coating roller.
3. Secure the adjustment made (by tightening the locking handles) and reset to zero the reading scale of the two
handwheels (by acting on the outer ring nut) to ease subsequent repositioning.
4. Rotate the overturning crank (1  F 5.21) clockwise and bring back the doctor blade unit in the default
working position.
5. Slide out and remove the overturning crank (1  F 5.21).

The fine adjustment of the parallelism must be made with the adhesive, at the start of the
working process, while keeping the coating unit in slow running mode.
F 5.19 – Crank for overturning

Use
5.13.11 Fitting the lower pans and the trolley cover (RT process)
Procedure:
1. The (internal) adhesive pan must be installed inside the (external) collecting pan. Both are suitably shaped
according to the mechanical parts dimensions: carefully observe their shape.
2. The internal pan is adjustable in height at different positions: in the case of using a coating roller with standard
development, it should be positioned at mid-height, while in the case of a coating roller with variable
development, also the other two positions can be used:
T 5.18 – Intermediate internal pan positioning in the case of using a standard coating roller
Coating roller development: Internal pan position:
MINIMUM (variable development coating roller – 500 cm) 1
STANDARD (standard development coating roller – 628.3 cm) 2
MAXIMUM (variable development coating roller – 800 cm) 3
F 5.20 – Intermediate internal pan positioning in the case of using a standard coating roller
3. Fit the pans in the coating trolley by slipping them under the coating roller. The pans slide on the guides up to
a stopping position (a locking pin slides into a hole predisposed on the guides).

Use
4. At the time of starting the adhesive feed, the pans must be raised in the working position: use the crank at the
side of the trolley. It is necessary to ensure that the doctor blade unit is already in the working position in order
to avoid mechanical interferences.

When lifting the pans, ensure that the splash guard strip of the doctor blade slips into the pan,
but without touching the coating roller.
5. The top cover has seals fitted inside it that clean the ends of the coating roller: check the conditions of the
seals. Replace them if necessary.
Risk of damages to the coating roller!

Take care not to damage the roller surface while fitting the cover.

Use
5.13.12 Preparing the adhesive feed (RT process)

Use personal protective equipment (gloves, mask and suitable clothing).
The solvent adhesive must be kept into the tank with DIAPHRAGM PUMP. It is forbidden to use tanks,
pumps or accessories different from those supplied.
FORBIDDEN OPERATIONS:
It is forbidden to smoke either during the preparation or during the handling of the adhesive. In any
case the smoking ban is extended to entire area in which the machine operates.
It is forbidden any activity that could generate sparks.
It is forbidden to light naked flames.
Procedure for preparing the adhesive:
1. Pour the adhesive into the tank at the set concentration.
2. Place the adhesive tank to the side of the Rotogravure trolley, which must be closed with its own lid
3. Slide the air pump into its housing in the adhesive tank.
4. Connect the pump feed pipe to the adhesive inlet connector on the trolley.
5. Connect the tank return pipe to the lateral drain connector of the pan of the trolley.
6. Turn on the exhaust hood by turning the “HOOD EXHAUST FAN” selector switch on position 1.
T 5.19 – Selector switch for the exhaust hood operating mode
Coating unit
HOOD EXHAUST FAN

1 AUT

Use
7. Make sure that the “123S1 – 1SB 2SL 3WB” key selector switch is on position 1;.
8. Connect the air pump spiral hose to its coupling indicated with the label “SOLVENT-BASED ADHESIVE
CONTROL” (the pump starts working and must not be stopped).
9. Start the slow running mode by pressing the “SLOW RUN” push-button.
Coating unit
SLOW RUN
10. The air pump, in starting to work, puts the adhesive in circle between the trolley and the tank. The coating
roller must remain constantly rotating to prevent the adhesive from drying-up in the engravings.

When using water-based products, turn selector switch “123S1” to position 3.
Risk of damages to the coating unit!

In case of stops during processing, even temporary stops, the coating unit must always be
restarted in slow running mode.
Risk of fire and explosion!

With the “123S1” selector switch in position 3, all the safety systems relating to the presence of
solvent are disabled. Never use solvent-based products while leaving the selector switch in this
position.

Use
5.13.13 Webs tensioning (RT process)

The webs are put in tension, with the machine stopped, by activating the unwinders and the winder motors; the
machine controls the motors so as to obtain, at the various web path points, the tensions set by the operator. Each
unwinder rewinds its own web end and puts it in tension. When the webs are taut, the motors remain in tension; the
laminating units, fitted with a stationing brake, prevent the webs from moving. It is necessary that the laminating
nip rollers be closed.
Unwinders:
- to start the unwinding motor and put the web in tension press the corresponding “UNWINDER ON” push-button
- to turn off the motor and release the web press the corresponding “UNWINDER OFF” push-button
T 5.21 – Push-buttons for unwinders start/stop
UNWINDER ON UNWINDER ON
UNWINDER OFF UNWINDER OFF
Winder:
- to start the winding motor and put the web in tension press the corresponding “WINDER ON” push-button
- to turn off the motor and release the web press the corresponding “WINDER OFF” push-button
T 5.22 – Push-buttons for winder start/stop
Winder
WINDER ON

Use
5.13.14 Checking web breakage (RT process)

It is possible to set a control check on the possible breakage of the web itself: the machine stops automatically in
order to reduce production waste.
The web tension is checked in each section by a dancing roller or by a load cell; when the web breaks, the tension
in that section is totally zeroed out.
The control check is enabled via the two-position “FILM BREAK” selector switch:
T 5.23 – ”FILM BREAK” selector switch functions
Position Function
0 in case of breakage the machine does not stop

1 in case of breakage the machine stops immediately
The following table shows the control panel on which is located the “FILM BREAK” selector switch relative to each
dancing roller or each load cell:
T 5.24 – “FILM BREAK” selector switches list
Control device Selector switch code – Control panel Unit

Dancing roller B1 Unwinder A
Load cell LC3 Unwinder A
Dancing roller B5 123S7 on control panel MCB Unwinder B
Dancing roller B20 Winder

Use
5.13.15 Webs tension adjustment (RT process)

The tension adjustment must be made according to the materials elasticity: the greater the elasticity and the lesser
the tension that must be set to avoid stretches that would affect the quality of the finished product.
It is possible to independently adjust the web tension for the various machine points and check its reading on the
special “FILM TENSION” displays.
T 5.25 – List and positions of "FILM TENSION” displays
Display code Display position

Control device
for reading the tension on the machine
Dancing roller B1 209P1 on local control panel LCP1 Unwinder A
Load cell LC3 313P12 on local control panel LCP21 Coating column
Dancing roller B5 409P1 on local control panel LCP24 Unwinder B
Dancing roller B20 909P1 on local control panel LCP24 Winder

For correct machine operation, a tension different from zero must always be set at each point.

Use
5.13.16 Taper tension mode adjustment (RT process)

The winder is characterised by the possibility of winding the reel with different tension settings:
Constant tension: • the reel is wound with a constant tension, set by the operator.
• the winding web tension decreases with the increase of the reel
Taper tension:
diameter.
The taper tension web winding technique limits the internal pressure between each web turn and prevents the reel
from sliding sideways (“telescope” effect).
Selector switch 918S8 on local control Position Function

panel LCP24
0 Constant tension winding

“TAPER TENSION”
1 Taper tension winding
In taper tension mode, the tension reduction increases proportionally with the increase in diameter. Via the
Multifunction Panel, the operator can set the final reduction, expressed as a percentage of the starting tension
(from 0% to -60%); the final reduction is referred to the maximum winding diameter set. It is possible to select via
Supervision the tension reduction trend according to linear, parabolic or hyperbolic function.
Examples:
- if a maximum diameter of 500 mm and a tension reduction of -30% are set, winding will start with 100% of the
set tension and will end (at 500 mm diameter) with 70% of the set tension;
- if the reduction is set to 0%, the winder will keep the tension constant with the set value.

Use
5.13.17 Misaligning idle roller adjustment (RT process)

Use only if effectively needed and verify every time its adjustment prior to start processing.
The type of adjustment (vertical or eccentric) is optional.

Fitted on the machine Misaligning roller
Eccentrically adjustable misaligning roller
The adjustment, on both web sides, is accomplished by acting on the respective
X
adjustment ring nuts: loosen the locking knob, turn the ring nut while reading on the
graduated scale the adjustment made, then tighten the knob.
Vertically adjustable misaligning roller
 adjustment knobs: loosen the locking knob, turn the adjustment knob while reading
on the graduated scale the adjustment made, then tighten the knob.
 = used on this machine
X = not used on this machine

Use
5.13.18 Starting the rotogravure process

FORBIDDEN OPERATIONS:
It is forbidden to smoke in the entire area in which the machine operates.
It is forbidden any activity that could generate sparks.
It is forbidden to light naked flames.
Once the machine has been prepared, with the adhesive in circulation (machine in slow running mode) and the
centred and aligned webs in tension (the rubber-coated laminating nip roller must be closed), follow the indicated
procedure.
1. Enable the drying oven automatic function by turning the “OVEN” selector switch, located on the control desk
unit, to the AUT position and set the temperature, the blower pressure and the exhaust depression.
2. Make sure the rubber-coated coating impression roller is open and the selector switch “COATER LIFTING” is
set to position AUT.
Coating unit
COATER LIFTING
0 AUT
3. Make sure that the trolley top cover is fitted to maximize splashing avoidance once speed is increased.
4. Lower the doctor blade to the working position by turning the “DOCTOR BLADE” selector switch to position1.
Coating unit
DOCTOR BLADE
0 1

Use
5. By acting on the “DOCTOR BLADE/TRANSFER PRESSURE” regulator, set the doctor blade working
pressure at about 3 bar.
6. Visually check the adhesive uniformity on the surface of the coating roller in rotation.
7. Set the machine in motion by using one of the “MACHINE START” push-buttons: the speed reached at this
stage is of 10 m/min.
8. Close the rubber-coated coating impression roller by turning the “COATING IMPRESSION ROLLER” selector
switch on the symbol:


9. Recheck the webs alignment and the functioning of the oven (temperatures and pressures).
10. Increase the machine speed up to a value of 60÷80 m/min (use one of the “SPEED +” push-buttons) while
checking the coater motor absorption.
11. Enable the exhaust hood automatic function by turning the “HOOD EXHAUST FAN” selector switch to the
AUT position.
T 5.26 – Selector switch for the exhaust hood operating mode
Coating unit
HOOD EXHAUST FAN

1 AUT
12. After a short working process at the above indicated speed, stop the machine. Carry out the necessary checks
on the finished product and make any other adjustments (pressures, speeds, temperatures, etc.). To stop the
process, press any of the “MACHINE STOP” push-buttons.

With the adhesive in the machine, the slow running mode must always be re-started. Resume
processing as quickly as possible or proceed with the cleaning operations.
5.13.19 Adjusting the coating material quantity (RT process)

To alter the adhesive quantity, in rotogravure coating, it is necessary to vary the solution percentage or use a
coating roller with different engraving.

Use
5.14 Preparing the machine for the SOLVENTLESS process

5.14.1 Inserting the solventless trolley in the machine (if not already present)
Information for the operators:

For inserting the trolley in the machine it is required the presence of two operators.
For a better understanding of the below indicated procedure, please read first Chapter 2 –
TECHNICAL DESCRIPTION.
Procedure for inserting the trolley in the coating column:
1. Open the coating column lateral casings.
2. Push the trolley in front of the coating area in order to bring the two insertion shaft pinions to correspond with
the respective racks on the shoulders of the machine.
3. For making the trolley enter correctly it is necessary a coordinated action by the two operators: while the first
pushes the trolley against the machine, the second acts on the two arms crank, previously inserted on the
pertinent shaft.

When inserting the trolley, make sure it is parallel with the machine sides (if the trolley is not
straight, it must be pulled out and inserted again).
4. Turn the crank to insert the trolley, stopping some cm from the mechanical reference stop inside the coating
compartment.
5. Fit the toothed drive belt on the pulley of the trolley coating roller; be careful to the fingers: risk of crushing.
6. To complete the trolley insertion, make sure the drive belt has been properly tightened by the eccentric
adjuster.
7. Hook the two lock brackets to the sides of the trolley and tighten the handles.
8. Remove the trolley insertion crank.
9. Connect the cable of the sensor for detecting the transfer roller presence to the connector marked with the
label “TRANSFER IN”.
10. Connect the three transfer roller air hoses to the quick couplings marked with the label “DOCTOR
BLADE/TRANSFER”. Observe the colours: green, black and white.

Use
11. Electrically connect the trolley motor by plugging the connectors into the sockets provided in the operator
panel.
12. Ascertain that in the trolley have been inserted the Teflon septa for retaining the adhesive and that the
adhesive level sensor is in position. Close the casings and the lateral protections.

Use
5.14.2 General information (SL process)

For the Solventless process (hereinafter also referred to as SL process) the machine must be prearranged and
used as indicated in the table below:
T 5.27 – Machine configuration for solventless coating
Component: Usage condition:
Coating trolley solventless trolley
Rubber-coated coating impression smooth, without cutting

roller
Transfer roller with cutting suitable for the necessary coating band
Adhesive exclusively without solvent, mono- or bi-component
Heating units laminating unit and SL coating unit
Cooling drum as appropriate (materials and adhesives)
Exhaust hood must always be ON
Drying oven OFF
1) The coating band is determined by the width of the rubber-coated transfer roller. It is not possible to
coat the adhesive along the entire web width: it is opportune to leave a few mm on each edge to
avoid undesirable gluing on the reel once the web has been laminated and rewound. The coating
width must be at least 3÷6 mm narrower than the film web being used.
2) The solventless adhesive must be prepared in a specially provided feed unit:
Adhesive Feed unit
Monocomponent Glue heater with independent delivery pump (optional)
Bicomponent Heated mixer with possible preheating glue heater
If necessary, activate the adhesive heating or preheating devices.
Supplier documentation for the adhesive preparation and feed units/systems.
3) The rollers temperature and the use of the cooling drums must be chosen in accordance with the
adhesive manufacturer's indications, the materials being processed and the own technical
experience in coating/laminating procedures. Open the relevant water lines stopcocks.
Switching-on and adjusting the thermoregulating units:


Use
5.14.3 Removing and fitting the transfer roller (SL process)
Personnel assigned:
2 operators
Risk of harm to people or property!

In consideration of the rollers weight, to safely carry out the operations it is necessary to use the
transfer rollers handling trolley.
Procedure for removing the transfer roller:
1. Ascertain that the machine is stopped.
2. Disconnect and remove, if installed:

- the adhesive level sensor,
- the adhesive feed slide
3. Loosen and remove the two lock and regulation brackets of the transfer roller.
4. Open the protective casing of the transfer roller articulated joint.
5. By turning the outer knob, make the articulated joint rotate in order to bring the lock nut in an accessible
position ( 2.12.6 - RUBBER-COATED TRANSFER ROLLER).
6. Loosen the lock nut, using the supplied key, and open the joint.
7. Fully lower the arms of the rollers handling trolley by acting on the handwheel.
8. Push the rollers handling trolley in front of the coating unit as far as to bring the two arms of the same trolley to
hook up to the transfer roller extremities.
9. Extract the transfer roller by acting on the handling trolley handwheel and remove it.

Absolutely avoid operating the machine in this condition, i.e. without the transfer roller: the opened
articulated joint could cause serious damage. When necessary for clearing operations, ALWAYS
install the purposely supplied substitute hub.
10. To install a new transfer roller, proceed in the reverse order as that described for its removal.
11. Verify that the anti-crushing bar position is correct.

Use
5.14.4 Heating the metering rollers (SL process)

Before starting to heat the metering rollers, move them away with the adjustment handwheels so that
the thermal expansion does not bring them into contact with each other causing serious damages to
the machine.
Procedure:
1. Start the coating unit in slow running mode via the push-button “SLOW RUN”.
Coating unit
Push-button 319S2
on local control panel LCP21
SLOW RUN
2. Switch on the relevant heating units, set the wanted temperature and wait for the rollers to reach working
temperature.

Use
5.14.5 Adjusting the metering rollers distance (SL process)

The metering rollers distance adjustment must be carried out in compliance with the specified conditions:
- Rollers stopped.
- Rollers perfectly clean.
- Rollers at working temperature to ensure coating the preset adhesive quantity and to avoid damages to the
machine.
Procedure:
1. Act alternatively on the right adjustment handwheel and on the left adjustment handwheel of the fixed metering
roller until adjustment is complete.
2. Slide the purposely supplied 0.08 mm feeler gauge between the metering rollers and adjust the distance
between the two rollers via the adjustment handwheel. The feeler gauge must be inserted at various points
along the entire roller development by vertically moving it up and down until slight drag is felt.

Do not slide the feeler gauge horizontally between the two rollers to avoid scratching and damaging
them.
3. Remove the feeler gauge.

To ensure accuracy, the adjustment must always be carried out in “close-up”, i.e. by bringing the
rollers near. If the feeler gauge gets stuck, it is necessary to move the rollers back and repeat the
adjustment from the beginning.
4. When adjustment is complete, after having loosened the grub screw of the zero-setting ring nut, reset to zero
the reading scale of the two adjustment handwheels; retighten the grub screw.
5. The reading scale of the adjustment handwheels allows bringing back the rollers to previously established
positions, at same temperature conditions.

The distance adjustment between the metering rollers must be again carried out at any processing
temperature change.

Use
5.14.6 Preparing the SL adhesive feed (SL process)

The adhesive is fed to the machine from an external preparation and/or mixing system. Consult the documentation
supplied with the system and prepare the adhesive in time for the start of the process.
Procedure:
1. Make sure that the “123S1 – 1SB 2SL 3WB” key selector switch is on position 2.
2. Position the two retaining Teflon walls and adjust their distance on the spacer bar (pay attention to the Teflon
walls fitting direction). The Teflon walls centreline must be in correspondence with the transfer roller
cutting.
3. Install the adhesive level sensor on its support and connect it to the 338X1 connector indicated with the label
“SL ADHESIVE LEVEL”.
Connector position:
Sheet 53.2 – Wiring diagram DW3619.
4. The adhesive level sensor is fixed by the way of an elastic ring with which it is possible to vary the sensor
height position: adjust it only if necessary (it is advisable to keep a low level of adhesive).
5. Install the feed slide device and carry out the pneumatic connection.
6. Insert the limit stop pins in the holes provided on the adhesive feed slide. Check the pins position: they must
be within the coating area of the rubber-coated coating roller (that is to say, in correspondence of the edges
for the roller cutting).
7. Turn the “ADHESIVE FEED” selector switch to position 0.
8. Turn the selector switch “ADHESIVE SLIDE” on the AUT position to enable the automatic mode (the adhesive
feed slide moves when the command for inletting new adhesive is given).
T 5.29 – Selector switches for adhesive feed and feed slide movement
Coating unit
ADHESIVE FEED
0 AUT 1
ADHESIVE SLIDE
0 AUT
9. Set on the “ADHESIVE QUANTITY” display the amount required for processing (use the relevant + and –
push-buttons).
10. Connect to the machine the adhesive preparation and/or mixing system, by fixing the nozzle or similar feed
device to the dragging block on the feed slide.

Use
11. Connect the hose for the adhesive feed command to the pre-arranged coupling (marked with the label
“SOLVENTLESS ADHESIVE CONTROL”).
The adhesive must be sent into the machine at the last minute while production must be promptly
started to avoid its aging.
With the above listed settings, the SL coating unit automatically recalls fresh adhesive as soon as the level sensor
detects that the adhesive is finished. For several reasons, not dependent upon the machine, it is possible that the
coating unit is not fed (e.g. adhesive finished, mixer or pump failure, etc.).
A control is available on the feed outcome: when demanding for new adhesive, if the level is not restored (within a
certain period), the operator is alerted via an audible beep and a message. The control is activated via the selector
switch “ADHESIVE LACK WARNING”.
T 5.30 – Selector switch to set the alarm for lack of adhesive
Coating unit
ADHESIVE LACK WARNING

0 1

Use
5.14.7 Webs tensioning (SL process)

The webs are put in tension, with the machine stopped, by activating the unwinders and the winder motors; the
machine controls the motors so as to obtain, at the various web path points, the tensions set by the operator. Each
unwinder rewinds its own web end and puts it in tension. When the webs are taut, the motors remain in tension; the
laminating units, fitted with a stationing brake, prevent the webs from moving. It is necessary that the laminating
nip rollers be closed.
Unwinders:
- to start the unwinding motor and put the web in tension:
• press the corresponding “UNWINDER ON” push-button
- to turn off the motor and release the web:

• press the corresponding “UNWINDER OFF” push-button
T 5.31 – Push-buttons for unwinders start/stop
UNWINDER ON UNWINDER ON
UNWINDER OFF UNWINDER OFF
Winder:
- to start the winding motor and put the web in tension:
• press the corresponding “WINDER ON” push-button
- to turn off the motor and release the web:

• press the corresponding “WINDER OFF” push-button
T 5.32 – Push-buttons for winder start/stop
Winder start Winder stop

WINDER ON WINDER OFF

Use
5.14.8 Checking web breakage (SL process)

It is possible to set a control check on the possible breakage of the web itself: the machine stops automatically in
order to reduce production waste.
The web tension is checked in each section by a dancing roller or by a load cell; when the web breaks, the tension
in that section is totally zeroed out.
The control check is enabled via the two-position “FILM BREAK” selector switch:
T 5.33 – ”FILM BREAK” selector switch functions
Position Function
0 in case of breakage the machine does not stop

1 in case of breakage the machine stops immediately
The following table shows the control panel on which is located the “FILM BREAK” selector switch relative to each
dancing roller or each load cell:
T 5.34 – “FILM BREAK” selector switches list
Control device Selector switch code – Control panel Unit

Load cell LC3 Unwinder A
Dancing roller B5 123S7 on control panel MCB Unwinder B
Dancing roller B20 Winder

Use
5.14.9 Webs tension adjustment (SL process)

The tension adjustment must be made according to the materials elasticity: the greater the elasticity and the lesser
the tension that must be set to avoid stretches that would affect the quality of the finished product.
It is possible to independently adjust the web tension for the various machine points and check its reading on the
special “FILM TENSION” displays.
T 5.35 – List and positions of "FILM TENSION” displays
Display code Display position

Control device
for reading the tension on the machine
Dancing roller B1 209P1 on local control panel LCP1 Unwinder A
Load cell LC3 313P12 on local control panel LCP21 Coating column
Dancing roller B5 409P1 on local control panel LCP24 Unwinder B
Dancing roller B20 909P1 on local control panel LCP24 Winder

For correct machine operation, a tension different from zero must always be set at each point.

Use
5.14.10 Winder taper tension mode adjustment (SL process)

The winder is characterised by the possibility of winding the reel with different tension settings:
Constant tension: • the reel is wound with a constant tension, set by the operator.
• the winding web tension decreases with the increase of the reel
Taper tension:
diameter.
The taper tension web winding technique limits the internal pressure between each web turn and prevents the reel
from sliding sideways (“telescope” effect).
Selector switch 918S8 on local control Position Function

panel LCP24
0 Constant tension winding

“TAPER TENSION”
1 Taper tension winding
In taper tension mode, the tension reduction increases proportionally with the increase in diameter. Via the
Multifunction Panel, the operator can set the final reduction, expressed as a percentage of the starting tension
(from 0% to -60%); the final reduction is referred to the maximum winding diameter set. It is possible to select via
Supervision the tension reduction trend according to linear, parabolic or hyperbolic function.
Examples:
- if a maximum diameter of 500 mm and a tension reduction of -30% are set, winding will start with 100% of the
set tension and will end (at 500 mm diameter) with 70% of the set tension;
- if the reduction is set to 0%, the winder will keep the tension constant with the set value.

Use
5.14.11 Misaligning idle roller adjustment (SL process)

Use only if effectively needed and verify every time its adjustment prior to start processing.
The type of adjustment (vertical or eccentric) is optional.

Fitted on the machine Misaligning roller
Eccentrically adjustable misaligning roller
 adjustment ring nuts: loosen the locking knob, turn the ring nut while reading on the
graduated scale the adjustment made, then tighten the knob.
Vertically adjustable misaligning roller
X
adjustment knobs: loosen the locking knob, turn the adjustment knob while reading
on the graduated scale the adjustment made, then tighten the knob.
 = used on this machine
X = not used on this machine

Use
5.14.12 Starting the SL process

Once the machine has been prepared, with the adhesive feed system ready, and the centred and aligned webs in
tension (the rubber-coated laminating nip roller must be closed), follow the indicated procedure.
1. Close the safety doors.
2. Verify that the rubber-coated coating impression roller is open and that the “COATER LIFTING” selector
switch is on the AUT position.
Coating unit
COATER LIFTING
0 AUT
3. Switch on the exhaust hood by turning the “HOOD EXHAUST FAN” selector switch on position 1 (always on,
even with the machine stopped) or to AUT position (the hood turns off when the machine is not working).
Coating unit
HOOD EXHAUST FAN

1 AUT
4. Start the slow running mode by pressing the “SLOW RUN” push-button.
Coating unit
SLOW RUN
5. Turn the “ADHESIVE FEED” selector switch on position 1 for the time necessary to let flow out a small amount
of adhesive (evenly spread).
Coating unit
ADHESIVE FEED
0 AUT 1
6. Turn the “ADHESIVE FEED” selector switch on the AUT position to enable the automatic inletting of new
adhesive as and when the level sensor indicates its shortage.

Use
7. Wait until the adhesive has evenly spread over the metering roller entire surface, then lower and raise several
times the transfer roller by alternatively turning the “TRANSFER” selector switch on position 1 and on position
0. When the adhesive on the transfer roller is evenly distributed, turn the selector switch on the AUT position.
Coating unit
TRANSFER
1 0 AUT
8. Loosen the adjustment knobs of the two transfer roller regulation brackets so that roller fully adheres to the
chromed rollers.
9. Press the “COATING JOG” push-button and make all rollers rotate for as long as necessary to evenly spread
the adhesive over their entire surface.
Coating unit
COATING JOG
10. Set the machine in motion by using one of the “MACHINE START” push-buttons: the speed reached at this
stage is of 10 m/min.
11. Close the rubber-coated coating impression roller by turning the "COATING ROLLER IMPRESSION" selector
switch on the symbol:


Automatically also the transfer roller is lowered.
12. Increase the machine speed up to a value of 60÷80 m/min (using one of the “SPEED +” push-buttons), while
checking the coater motor absorption or the arising of abnormal transfer roller vibrations (if necessary carry
out the transfer roller adjustment, as described in paragraph 5.14.14);
13. After a short working process at the above indicated speed, stop the machine. Carry out the necessary checks
on the finished product and make any eventual adjustments (pressures, speed, temperatures, etc.). To stop
the process, press any of the “MACHINE STOP” push-buttons.

With the adhesive in the machine, the slow running mode must always be re-started. Resume
processing as quickly as possible or proceed with the cleaning operations.
14. If the control carried out do not show any processing flaws, start the lamination by restarting the working cycle.

Use
5.14.13 Adjusting the coating material quantity (SL process)

To vary the amount of adhesive, in SL coating, the operator has available the “ADHESIVE QUANTITY” commands
(push-buttons and display, percentage adjustment from 40% to 100%).
If for some processes the amount of adhesive spread was to be anyhow insufficient, during the adjustment of the
distance between the metering rollers it is necessary to use the supplied feeler gauge of 0.1 mm.
5.14.14 Transfer roller adjustment (SL process)

Check the coater motor absorption via its “COATER CURRENT” display: the current drawn by the motor does not
normally exceed 50% of the end-scale value (indicated on the display plate).
In case of high absorption or in the presence of vibrations on the transfer roller, it is necessary to make an
adjustment through the lock and regulation brackets:
1. Leave in the working position:
- the coating impression roller,
- the laminating nip roller,
- the transfer roller.
2. By acting on the adjustment knobs, tighten the adjustment screws of the two transfer roller brackets up to
completely remove the play.
Technical description:
Paragraph 2.12.5 - LOCK AND REGULATION BRACKETS
3. Tighten the regulation brackets lock nuts.
This adjustment allows avoiding that, at higher speeds, the coating turns out uneven (acoustic effect: “beats” can
be heard, i.e. noises similar to those generated by the cyclical impact between two bodies).

To make the transfer roller regulation brackets work properly, only intervene on the adjustment
knobs; the lifting screws must be free and the brackets must rest on the regulation pivots.

Use
5.15 Sleeve change procedure
Before carrying out any operation on the machine, stop it according to the procedure for stop under
normal conditions, as described in the instruction manual.
5.15.1 Procedure for removing the sleeve

1) Open the vertical sliding door (1, F 5.21).
F 5.21 – Front view of the column
2) Take the terminal end (3, F 5.22) of the spiral hose of the sleeve change compressor from the housing (2, F
5.22).
3) Remove the fitting (1, F 5.22) from the terminal end of the spiral hose.
F 5.22 – Terminal end of the compressor hose: detail
1. Fitting screwed on the spiral hose of the compressor for sleeve change
2. Housing for the spiral hose of the compressor for sleeve change
3. Terminal end of the spiral hose of the compressor for sleeve change
4. Shut-off valve of the air supply closed

Use
4) Screw the fitting tightly onto the end of the sleeve-holder spindle (1, F 5.23)
F 5.23 – Sleeve-holder spindle: detail
1. Fitting screwed on the sleeve-holder spindle
5) Open the shut-off valve of the air supply (1, F 5.24) and fit the terminal end of the spiral hose into the fitting (1,
F 5.25).
F 5.24 – Terminal end of the spiral hose: detail
1. Shut-off valve of the air supply open

Use
F 5.25 – Connection between terminal end and sleeve-holder spindle: detail
1. Terminal end of compressor spiral hose inserted into the fitting
6) Open the protective casing (2, F 5.26) of the coating column (operator side).
F 5.26 – Protective casing open: detail
1. Sleeve completely ejected

2. Protective casing of coating column, open

Use
7) Turn the “SLEEVE CHANGE” selector to position 1 to lower the locking bracket that holds the end of the
sleeve-holder spindle (1, F 5.27).

The sleeve lowering is ONLY possible with front and side guards closed.
F 5.27 – Circular sleeve ejection compartment
1. Supporting bracket for end of sleeve-holder spindle, in position for sleeve change
8) Press the “SLEEVE AIR” button to eject the sleeve.
9) Slide completely off the sleeve from the sleeve-holder spindle (1, F 5.26).

Use
5.15.2 Procedure for fitting the sleeve
1) Make sure the sleeve-holder spindle supporting bracket is in the lowered position (Ref.: F 5.28). If needed,
lower it by turning the “SLEEVE CHANGE” selector switch on position 1.
1. Supporting bracket for end of sleeve-holder spindle, in position for sleeve change
2) Slide the sleeve onto the sleeve-holder spindle by keeping the “SLEEVE AIR” push-button pressed.
3) Release the “SLEEVE AIR” push-button.
4) Put the support bracket for the sleeve-holder spindle (1, F 5.29) back in place by turning the “SLEEVE
CHANGE” selector switch on position 0.
1. Supporting bracket for sleeve-holder spindle, in working position

Use
5) Close the coating column protective casing (2, F 5.30).
F 5.30 – Protective casing open: detail
1. Sleeve completely ejected

2. Protective casing of coating column, open
6) Pull the spiral hose terminal end out of the fitting (1, F 5.31) and close the shut-off valve of the air supply (4, F
5.32).
F 5.31 – Connection between terminal end and sleeve-holder spindle: detail
1. Terminal end of compressor spiral hose inserted into the fitting

Use
F 5.32 – Terminal end of the compressor hose: detail
1. Fitting inserted into the spiral hose of the compressor for sleeve change
2. Housing for the spiral hose of the compressor for sleeve change
3. Terminal end of the spiral hose of the compressor for sleeve change
4. Shut-off valve of the air supply closed
7) Unscrew the fitting from the end of sleeve-holder spindle and connect it to the terminal end of spiral hose (1, F
5.32).
8) Put the terminal end of spiral hose back into its own housing (2, F 5.32).
9) Close the vertical sliding door (1, F 5.33).
F 5.33 – Front view of the column

Use
5.16 Adjustments and description of single specific operations

5.16.1 Opening/closing the rubber-coated coating impression roller
For opening and closing the rubber-coated coating impression roller, use the lighted “COATING IMPRESSION
ROLLER” selector switch.
T 5.36 – Selector switch for opening/closing the rubber-coated coating impression roller
Rubber-coated coating impression roller

COATING IMPRESSION ROLLER

 

0 
The operation of the three-position “COATING IMPRESSION ROLLER” selector switch is summarized in the
following table:
T 5.37 – Operation of “COATING IMPRESSION ROLLER” selector switch
Position Function

Opening of the rubber-coated coating impression roller

O Selector switch return position


Closing of the rubber-coated coating impression roller

Use the “COATER LIFTING” selector switch for setting the function of the rubber-coated coating impression roller
when the machine stops:
Coating column
COATER LIFTING
0 AUT
T 5.38 – “COATER LIFTING” selector switch operation
Position Function
0 When the machine stops, the impression roller remains in the position in which it is
AUT When the machine stops, the impression roller opens automatically

The impression roller can only be closed when the machine is running and the oven ventilation is
working.

Use
To close the rubber-coated coating impression roller it is necessary to activate the “COATING IMPRESSION
ROLLER” selector switch for a few seconds until the selector switch light is fully on. If the selector is released
before time, for safety reasons the impression roller opens again.
Use the “COATER LIFTING” selector switch for setting the function of the rubber-coated coating impression roller
when the machine stops:
Position Action:
0 when the machine stops, the impression roller remains in the position in which it is
AUT when the machine stops, the impression roller opens automatically
T 5.39 – Selector switch for opening/closing the rubber-coated coating impression roller
Rubber-coated coating impression roller

COATER LIFTING
0 AUT

The manual control of the rubber-coated coating impression roller allows keeping it closed even when
the machine is not working to permit carrying out operations such as changing the reel without leaving
parts of the web unglued.

Use
5.16.2 Coating pressure adjustment

The rubber-coated coating impression roller is activated by two separately regulated pneumatic cylinders and it is
thus possible to independently adjust the pressure in the two cylinders for controlling the impression roller thrust on
the two sides of the web. Coherently with the impression roller position on the machine, the back side is defined as
“transmission side” and the front side as “operator side”.

The pressure is normally calibrated at the same value for both sides. Differing calibrations may be
necessary to compensate for possible web “flapping”.
For the control of the coating pressure, the regulators indicated in the following table are used:
T 5.40 – Regulators for the pressure of the rubber-coated coating impression roller
Coating unit
Regulator 8021A6 on local control panel LCP21
COATING PRESSURE
OPERATOR SIDE
COATING PRESSURE
TRANSMISSION SIDE
Section 2.12 – RUBBER-COATED COATING IMPRESSION ROLLER

Use
5.16.3 Opening/closing the rubber-coated laminating nip roller

For opening and closing the rubber-coated laminating nip roller, use the selector switch “LAMINATING NIP
ROLLER” shown in the table.
T 5.41 – Selector switch for opening/closing the rubber-coated laminating nip roller
Rubber-coated laminating nip roller

LAMINATING NIP ROLLER

 

0 
To close the rubber-coated laminating nip roller, it is necessary to act on the “LAMINATING NIP ROLLER” selector
for a few seconds, until the selector lamp completely lights up. If the selector is released before time, for safety
reasons the impression roller opens again.

With the machine running, if the rubber-coated laminating nip roller is left open, the pilot light of
the “MACHINE START” push-button flashes.

Use
5.16.4 Lamination pressure adjustment

The rubber-coated laminating nip roller is activated by two separately regulated pneumatic cylinders and it is thus
possible to independently adjust the pressure in the two cylinders for controlling the nip roller thrust on the two
sides of the web. Coherently with the nip roller position on the machine, the back side is defined as “transmission
side” and the front side as “operator side”.

The pressure is normally calibrated at the same value for both sides (1.5÷4 bar). Differing calibrations
may be necessary to compensate for possible web “flapping”.
For the control of the laminating pressure, the regulators indicated in the following table are used:
T 5.42 – Regulators for the pressure of the rubber-coated laminating nip roller
Laminating unit
LAMINATING PRESSURE
OPERATOR SIDE
LAMINATING PRESSURE
TRANSMISSION SIDE

In laminating soft materials such as polyethylene, the pressure must be especially low to avoid
crushing them: the final product may have a tendency to curl.
Section 2.10 – LAMINATING COLUMN.

Use
5.17 Checking the winding reel

For checking the winding reel, two geometrical parameters are monitored, as shown in the chart below:
The machine stops when the diameter

DIAMETER set by the operator is reached
Winding reel control
The machine does not stop when the

WOUND WEB
set length is reached: it only stops if
LENGTH the set diameter is reached.
DIAMETER CONTROL:
The machine checks and indicates the winding reel diameter: upon reaching the maximum diameter, the machine
emits a beep sound and stops.
Maximum diameter allowed:

Via the Multifunction Panel the operator can set a lesser diameter value than the maximum allowed; upon reaching
the maximum set value, the machine emits a beep sound and stops. To stop the beep sound, press the “MACHINE
RESET” push-button located on the control desk unit.
The setting of a threshold value lesser than the foreseen maximum can be used for:
1. Winding reels having a lesser diameter than the maximum (operation without automatic stop);
2. Setting a “forewarning” threshold signalling the nearing of the maximum diameter to the operator.
“SYNTESIS supervision – Operator’s Manual”

Use
LENGTH CONTROL:
The machine checks and indicates the wound web length: upon reaching the length set by the operator, the
machine emits a beep sound but does not stop. To stop the beep sound, press the “MACHINE RESET” push-
button located on the control desk unit.
This control allows the operator to produce reels according to the amount of web wound.
The machine makes two separate computations:
partial  computation of the web length on the winding reel; at each reel change the computation
restarts from zero.
total  computation of the overall web wound during processing.
Via the Multifunction Panel it is possible to:
- visualize the wound web length (partial computation and total computation);
- reset to zero the two partial and total computations independently from each other;
- set the desired web length.

The controls on the reel diameter are anyhow active: if the maximum diameter is reached the machine
stops.

Use
5.18 Checking the unwinding reel

For checking the unwinding reel, only one geometrical parameter is monitored, as shown in the chart below:
The machine stops when the

Unwinding reel control: MINIMUM DIAMETER minimum diameter set by the
operator is reached
DIAMETER CONTROL:
The machine checks and indicates the unwinding reel diameter: upon reaching the minimum diameter, the machine
emits a beep sound and stops.
Minimum diameter allowed:

Via the Multifunction Panel the operator can set a greater diameter value (change point diameter) than the
minimum allowed; upon reaching said value, the machine emits a beep sound. To stop the beep sound, press the
“MACHINE RESET” push-button located on the control desk unit.
The setting of a threshold value greater than the foreseen minimum can be used for:
1. Setting a “forewarning” threshold signalling the nearing of the minimum diameter to the operator.

Use
5.19 Reel unloading

5.19.1 Unloading the unwinders
The normal operation provides for the unloading of the empty core but it may be necessary to unload a reel
partially unwound. Carry out the following steps:
1. arrange the reel-lifting trolley under the reel, in a well-centred position, and lift the cradle until the reel lies on it
(do not force further upward, in order not to damage the unwinder);
2. deflate both expanding chucks (if used), by keeping the inflation valve pressed;
3. open the reel-holder arms, by acting on the “REEL CLAMPING” selector switch until the selector lamp turns off
(if the selector switch is released before time, the two arms do not open);
REEL CLAMPING REEL CLAMPING
4. lower the trolley cradle to the floor and move the reel away.
5.19.2 Unloading the winder

Carry out the following steps:
1. arrange the reel-lifting trolley under the reel, in a well-centred position, and lift the cradle until the reel lies on it
(do not force further upward, in order not to damage the unwinder);
2. deflate both expanding chucks (if used), by keeping the inflation valve pressed;
3. open the reel-holder arms, by acting on the “REEL CLAMPING” selector switch until the selector lamp turns off
(if the selector switch is released before time, the two arms do not open);
Winder
REEL CLAMPING
4. lower the trolley cradle to the floor and move the reel away.

Use
5.20 Multifunction Panel

The machine is equipped with an Operator Multifunction Panel, provided with a colour Liquid Crystal Display (LCD)
that uses "Touch screen" technology.
The Multifunction Panel is the interface between the operator and the industrial PC controlling the entire machine.
The industrial PC is installed in the electric cabinet, in stable environment conditions, properly sheltered from
machine vibrations and supplied by means of an uninterrupted power supply unit (UPS).
FORBIDDEN OPERATION
To ensure the continuous and reliable operation of the machine, it is absolutely forbidden to
install/remove/modify any software or to use the machine PC/PLC for other purposes than those
provided for by the Manufacturer.
5.21 Syntesis supervision

The machine is provided with a sophisticated supervision software, specifically designed for Nordmeccanica
laminating machines, called "SYNTESIS". The supervision software allows a centralized control of the entire
machine operation:
- displaying of the machine state;
- management of signals and alarms;
- management of the processing parameters through “recipes”;
- management of production orders and work shifts;
- production statistics;
- management of planned maintenance.
Program usage:
“SYNTESIS supervision– Operator’s Manual” or consult the online Help.
5.21.1 Presetting functions (optional)

The presetting functions, combined with the supervising SYNTESIS software, allow maximum control on the
processing parameters. The main settings (tensions, temperatures, pressures) can be memorized and stored by
the supervising software and automatically retrieved when needed.
After having established the best settings for a particular process, the operator can store the value settings in an
information block called “recipe”; when the need to carry out the same working process arises, it is sufficient to
recall the “recipe”: the machine automatically sets the tensions, the temperatures, the pressures, etc., in
accordance with the stored value settings.
The supervising software is also able to memorize all the changes, at variance with the recipe settings, intervening
during processing.
For having available the presetting functions, the machine pneumatic and electric systems are suitably
prearranged. In any case, all the settings can be manually entered via the various devices (operator interface).

Use
5.22 Quick start guide: how to use the push-button panels

• MCB
Code EN Name Function
LIGHTING Lighting of work areas

120S8
0 1
AUXILIARY Warning the auxiliary power supply is live

124H1
POWER ON
Machine working in case of film break:

FILM BREAK
123S7 0 = it doesn't stop;
0 1
1 = it stops

Use
• UNWINDER “A” – LCP1
MACHINE Machine complete stop

215S2
STOP
SPEED Film speed increase

215S3
+
SPEED Film speed decrease

215S4
-
MACHINE Machine running start

215S5
START

Use
• UNWINDER “A” – LCP1, side A
215S11 EMERGENCY Emergency stop mushroom-head push button

Use
• UNWINDER “A” – LCP1, side B
WEB GUIDE Selecting the web guide sensor to use

201S11 O. SIDE T. SIDE (guide on the most regular edge)
[PREARRANG.]
Displaying of the film tension in the area controlled by the

209P1 B1 FILM TENSION
dancing roller indicated
216S2 UNWINDER ON Unwinder motor on
216S3 UNWINDER OFF Unwinder motor off
UNWINDING Choice of unwinding direction

216S5
(CCW-CW)
WEB GUIDE Automatic web guide system starting

216S8 AUTOMATIC 0 = Off
0 1 1 = On

Use
• UNWINDER “A” – LCP12, side A

Use
• UNWINDER “A” – LCP12, side B

Use
• UNWINDER “A” – LCP11
REEL CLAMPING Reel clamping

218S11
→← 0 ←→
MANUAL Manual regulation of reel cross alignment

218S13 ALIGNMENT
←0→
MACHINE Manual control of machine running (slow speed range,

218S15
JOG enabled motors only)

Use
• COATER – LCP21
COATER CURRENT Displaying of coater motor current

313P1
MAX 29 A
Exhaust system operation:

HOOD EXHAUST FAN
319S14 1 = On
1 AUT
AUT = automatic
Unlocking the sleeve-holder spindle, to replace the rubber-

SLEEVE CHANGE coated sleeve
319S16
0 1 0: off
1: on
319S17 SLEEVE AIR Activating the air blow for sleeve change
Behaviour of coating impression roller when machine stops:

COATER LIFTING
319S8 0 = stays closed
0 AUT
AUT = opens
COATER SPEED Displaying the percentage speed of coating roller (PVDC or

(PVDC/SEMIFLEXO) Semiflexo unit)
333P31
-40% - +40%
[PREARRANG.]
Enabling the film coating in contrarotation mode (Semiflexo

CONTRAROTATION
unit)
333S35 0 1
0: off
[PREARRANG.]
1: on
Operation of transfer roller

TRANSFER 1 = lowered
338S25
1 0 AUT 0 = lifted
AUT = automatic
1 PROTECTION OFF Selecting the operating mode, local operation.

2 NORMAL
323S1
3 WASHING
4 AUTOMATIC WASHING

Use
Displaying of film speed

140P1 FILM SPEED M/MIN

317S4
STOP

317S5
+

317S7
-

317S9
START
Position of doctor blade:

DOCTOR BLADE
319S15 0 = lifted
0 1
1 = working position
Smoothing bar working position

SMOOTHING BAR
319S18 0 = lifted
0 1
1 = working position
Manual control of machine running

319S9 MACHINE JOG
(slow speed range, enabled motors only)

Use
• COATER – LCP21, side A
Machine working in case of film break:

LC3 FILM BREAK
313P12 0 = it doesn't stop
0 1
1 = it stops
COATING Stop of the slow running mode of coating unit

319S1
STOP
SLOW Coating unit slow running, to avoid the adhesive drying

319S2
RUN
COATING Manual control of coating unit running (slow speed range)

319S4
JOG
COATING Opening/closing of coating impression roller

IMPRESSION ROLLER
319S5
↑ 0 ↓
↓ ↑
338S8 METERING ROLLER: ADHESIVE REMOVAL Removes dried adhesive residue from the metering roller
Adhesive level sensor in SL unit

338X1 SL ADHESIVE LEVEL
ADHESIVE PAN Adhesive pan upward or downward movement

339S7 [FORESEEN]
↓ 0 ↑

Use
• COATER – LCP21, side B

Use
• COATER – LCP21, external arrangement
COATING Displaying the pressure on the indicated side of the coating

8021A6 IMPRESSION ROLLER impression roller
OPERATOR SIDE
COATING Displaying the pressure on the indicated side of the coating

8021A8 IMPRESSION ROLLER impression roller
TRANSMISSION SIDE
DOCTOR BLADE/TRANSFER Regulation of doctor blade (rotogravure) or transfer roller

8022B6
PRESSURE (SL) working pressure

Use
• COATER – LCP22
ADHESIVE QUANTITY Displaying the percentage of the coated adhesive quantity

333P11
40-100% (SL or Semiflexo unit)
TRANSFER Sensor detecting the transfer roller presence

338X2
IN
Adhesive lack alarm:

ADHESIVE LACK WARNING
338S3 0 = Off
0 1
1 = On
Adhesive feed:
ADHESIVE FEED 0 = Off
339S1
0 AUT 1 AUT = Automatic
1 = On
Working of adhesive feed slide:

ADHESIVE SLIDE
339S2 0 = Off
AUT
AUT = automatic

Use
• COATER – LCP22, side A

Use
• COATER – LCP22, side B

Use
• LAMINATOR – LCP23, side A
Manual control of laminating roller rotation (slow speed

389S4 LAMINATOR JOG
range)

Use
• LAMINATOR – LCP23, side B

Use
• LAMINATOR – LCP24
Selecting the operating mode, general operation:

1 SB PRODUCTION
- solvent-based production
123S1 2 SL PRODUCTION
- solventless production
3 WB PRODUCTION
- water-based production
MACHINE Machine and alarm resetting

128S1
RESET
Oven ventilation:
OVEN 0 = Off
347S1
0 1 AUT 1 = always ON
AUT = Automatic

387S4
STOP

387S5
+

387S6
-

387S7
START

389S3
LAMINATING Opening/closing of laminating nip roller

NIP ROLLER
389S5
↑ ↓
↓ 0 ↑

Use
• LAMINATOR – LCP24, side A

909P1 B20 FILM TENSION dancing roller indicated
916S2 WINDER ON Winder motor on
916S3 WINDER STOP Winder motor off
WINDING Choice of winding direction

916S5
(CCW-CW)
Opening/closing of the lay-on roller on the winder

918S5 LAY-ON ROLLER
Winding at decreasing tension when increasing the rewound

TAPER TENSION
918S8 reel diameter
0 1

Use
• LAMINATOR – LCP24, side B
WEB GUIDE Selecting the web guide sensor to use (guide on the most
401S11 O. SIDE T. SIDE regular edge)
[PREARRANG.]

409P1 B5 FILM TENSION dancing roller indicated
416S2 UNWINDER ON Unwinder motor on
416S3 UNWINDER STOP Unwinder motor off
UNWINDING Choice of unwinding direction

416S5
CCW ORARIO
Automatic web guide system starting

WEB GUIDE AUTOMATIC
416S8 0 = Off
0 1
1 = On

Use
• LAMINATOR – external arrangement
LAY-ON PRESSURE Displaying the pressure on the indicated side of the lay-on
8093B4
OPERATOR SIDE roller
LAY-ON PRESSURE Displaying the pressure on the indicated side of the lay-on
8093B9
TRANSMISSION SIDE roller
LAMINATING PRESSURE Displaying the pressure on the indicated side of the

8029A9
OPERATOR SIDE laminating nip roller
LAMINATING PRESSURE Displaying the pressure on the indicated side of the

8029A10
TRANSMISSION SIDE laminating nip roller

Use
• UNWINDER B – LCP31

418S11
→← 0 ←→
MANUAL ALIGNMENT Manual regulation of reel cross alignment

418S13
←0→
Manual control of machine running (slow speed range,

418S15 MACHINE JOG
enabled motors only)

Use
• WINDER – LCP91

918S11
→← 0 ←→
MANUAL ALIGNMENT Manual regulation of reel cross alignment

918S13
←0→

918S15

Processing flaws and troubleshooting
6 - PROCESING FLAWS AND TROUBLESHOOTING

Table of contents
6.1 Finished product checks ................................................................................................................................................... 6.2

6.1.1 Adhesive grammage measurement ....................................................................................................................................... 6.2
6.1.2 Residual solvent measurement .............................................................................................................................................. 6.3
6.1.3 Laminated web curling test .................................................................................................................................................... 6.4
6.2 Anomalies during processing............................................................................................................................................ 6.5

6.2.1 Anomalies not related to the type of coating .......................................................................................................................... 6.5
6.2.2 Rotogravure process specific anomalies................................................................................................................................ 6.6
6.2.3 SL process specific anomalies............................................................................................................................................... 6.7
6.3 Messages and alarms ...................................................................................................................................................... 6.9

6.3.1 General Information ............................................................................................................................................................... 6.9

6.1 Finished product checks

According to the processing carried out, different types of checks on the finished product may be necessary.
It is therefore advisable to carry out a short working process at production speed and then decrease the speed and
stop the machine for checking samples of the finished product taken prior to rewinding.
6.1.1 Adhesive grammage measurement

It is necessary to check:
- the quantity of adhesive coated,
- the coating uniformity.
The adhesive quantity is ascertained by calculating the difference between the weight of a sample with adhesive
and the weight of the same after the adhesive has been removed.
Procedure for ascertaining the adhesive coated:

1. Cut a just coated and laminated web square sample, e.g. 10 x 10 cm.
2. Weigh the sample by using a digital high-precision scale (0.001-g resolution).
3. Gently separate the two sample layers and thoroughly clean them with suitable solvent.
4. Weigh again the two web layers and calculate the difference in weight with the previously taken one.
The adhesive grammage, usually expressed in g/m2, is calculated on the basis of the used sample area.
The taken sample area must be precisely known. Usually fixed area cutting instruments (die-cutters and
similar) are used.
For measuring the coating uniformity it is necessary to compare the values of the samples taken in diverse
laminated web areas (middle, sides, etc.).

To better separate the two layers of the sample taken, a sheet of silicone paper is usually interposed to
prevent the solvent-based adhesive from adhering (rotogravure process).

6.1.2 Residual solvent measurement

The residual solvent in the laminated film is measured by means of gas chromatography analysis.
If the residual solvent is too high, it is necessary to modify the processing parameters regarding coating, production
speed and oven drying (air temperature, blowers pressure).

6.1.3 Laminated web curling test

The lamination technique allows obtaining a product that does not naturally tend to curl.

The main cause for curling is the different tension of the two webs before lamination, due to a not
adequately correct mechanical or thermal treatment.
Procedure for the test:

1. Make two “X” shaped cross cuts of approximately 10 cm length in the laminated web.
2. Note the shape created at the tip-edges.
3. The web is un-taut if the longitudinal edges do not tend to curl. In contrast, if the tensions of the two start-off
webs are unbalanced, the edges curl towards the more tensioned web face.
F 6.1 – Checking the curl on the laminated web
4. Adjust the two webs tensions before lamination. Repeat the process trial run at working speed and carry out a
new test at different web points.

It is more effective adjusting the tension of the more elastic web.

6.2 Anomalies during processing

It is possible that during the various processes some anomalies may arise, the most common of which are
indicated below together with their possible causes.
Anomalies not
related to the type
of coating
Laminated web
anomalies
Typical Typical
rotogravure Solventless
process process
anomalies anomalies
6.2.1 Anomalies not related to the type of coating
Anomaly Possible causes and actions to undertake
a) Excessive adhesive quantity.

b) Excessive adhesive quantity on one web side.
The winding reel slides sideways
c) Lay-on roller on the winder not perfectly adjusted.
(“telescope” effect).
d) Unsuitable winding tension.
e) Constant tension winding instead of taper tension winding.
The laminated web appears less a) Rubber-coated nip rollers worn in the middle.
transparent in the centre than on the
sides. Check and, if necessary, grind or replace.
a) Webs tension not correctly balanced.

The laminated web tends to naturally
curl.
Carry out a curling test and adjust the webs tensions.
a) Rubber-coated laminating nip roller worn in the middle.

Formation of longitudinal wrinkles on
the web before lamination.
Check. If necessary, grind or replace.

6.2.2 Rotogravure process specific anomalies

Web sliding on the coating roller.
It could be caused by:

Web tension increase between the
rotogravure coating unit and the
a) Excessive web tension before the coating unit.
laminating unit.
b) Coating roller worn (engraved roller).
c) Wrong doctor blade positioning.
d) Doctor blade insufficient working pressure.

6.2.3 SL process specific anomalies

a) Aging of the adhesive near the retaining Teflon walls because the
Scarcity of adhesive on the two sides
new adhesive replaces it too slowly.
of the web.
Manually mix the adhesive in the metering pan and rotate backwards
the fixed metering roller.

a) Transfer roller insufficient pressure.
b) Wrong positioning of one of the transfer roller regulation brackets.
Lack of adhesive on only one web
c) Transfer roller lock bracket: not correctly positioned, fitted the
side.
wrong way round, not tightened.
d) One of the transfer roller sliding supports blocked due to adhesive
seepage or lack of lubricant.
Rubber-coated coating impression roller worn: with usage the

Lack of adhesive in the middle of the
diameter in the middle decreases.
web
Check and, if necessary, grind or replace.
a) Transfer roller insufficient pressure.
Lack of adhesive on the entire web
b) Wrong transfer roller adjustment (regulation brackets).
width
c) Working temperature increase with consequent reduction of the
distance between the metering rollers.
This occurs when the web slides on the coating roller. It could be
caused by:
Web tension increase between the SL a) Excessive web tension before the coating unit.
coating unit and the laminating unit. b) Gathering of adhesive on the web sides and on the rubber-coated
coating impression roller (incorrect dragging between the coating
roller and its rubber-coated nip roller).
Impurities or adhesive clots between the two metering rollers.

To remove these stripes, during processing, it is necessary to make
Formation of longitudinal stripes
the fixed metering roller oscillate by means of the handwheel, without
without adhesive visible on the transfer
making the locking pin slide out from the hole.
roller surface.
If this is not sufficient: slide out the fixed metering roller locking pin,
rotate the roller backwards and slide the pin in the next hole.


a) Hardened adhesive residues left on the rotary metering roller.
Stains formation in the laminated web.
b) Rubber-coated rollers worn (transfer, coating or laminating rollers):
check and, if necessary, grind or replace.

a) Wrong Teflon walls positioning.
b) Walls wrongly fitted of their supports.
c) Deformed or anyhow damaged Teflon walls.
Excessive adhesive leakage from the
Teflon walls.
In the case of machine stop for long periods, this
inconvenience is normal. To prevent it from occurring
also when the machine is processing, the walls must be
brought nearer.
Gathering of adhesive on the transfer This may occur if the machine remains for a long period in slow
and coating rollers outside the coating running mode with the transfer roller lowered:
band. a) “TRANSFER” selector switch on position 1 instead of AUT.

a) Failed adjustment of the transfer roller (regulation brackets).
b) Excessive adhesive viscosity due to a too low temperature.
c) Excessive adhesive viscosity due to remaining too long between
the metering rollers.
Excessive coating roller motor strain.
These inconveniences could cause: an increase in
tension or a web breakage in between coating and
lamination. The transfer roller could, moreover, tend to
vibrate and hence produce transversal stripes on the
web.

6.3 Messages and alarms

On the Multifunction Panel are displayed the messages and the alarms given by the machine PC/PLC.

For information on the display, acknowledgement and cancellation of a message, please refer to the
Multifunction Panel documentation.

1. The operator must always give confirmation of having seen each message or alarm.
2. Always give the utmost attention to the messages and alarms displayed before resetting them.
3. Some failures or danger events bring the machine to a stop to which follows the pertinent alarm message. The
intervention requested from the operator differs from case to case. In some cases the operator must just be
informed, while in other cases he must carry out simple operations. In case of machine failure, it could be
necessary the intervention of qualified personnel for repairing or eliminating the causes that have generated the
alarm signal.
4. To reset a situation of machine alarm, once the cause has been eliminated, it is necessary to press the flashing
“MACHINE RESET” push-button on the machine.

Cleaning and maintenance
7 - CLEANING AND MAINTENANCE

Table of contents
7.1 Machine shutdown............................................................................................................................................................ 7.3
7.2 End of the working process .............................................................................................................................................. 7.4
7.3 Possible inactivity ............................................................................................................................................................. 7.5
7.4 Cleaning ........................................................................................................................................................................... 7.6

7.4.1 General Information ............................................................................................................................................................... 7.6
7.4.2 Cleaning products for rubber-coated rollers ........................................................................................................................... 7.7
7.5 Maintenance ..................................................................................................................................................................... 7.8
7.6 Cleaning and maintenance operations frequency............................................................................................................. 7.9
7.7 Lubricating oils/greases .................................................................................................................................................. 7.11
7.8 Cleaning products information ........................................................................................................................................ 7.12
7.9 Solvents information ....................................................................................................................................................... 7.13
7.10 Lubricating oils and greases information ........................................................................................................................ 7.14
7.11 Personal protective equipment (PPE) information .......................................................................................................... 7.15
7.12 Machine cleaning: code of practice ................................................................................................................................ 7.17
7.13 Cleaning at the end of the working process .................................................................................................................... 7.18
7.14 Rotogravure coating unit cleaning .................................................................................................................................. 7.19
7.15 SL coating unit cleaning (Frequency: end of processing) ............................................................................................... 7.21

7.15.1 Adhesive removal ................................................................................................................................................................ 7.22
7.15.2 Cleaning the transfer roller .................................................................................................................................................. 7.23
7.15.3 Cleaning the metering rollers ............................................................................................................................................... 7.23
7.15.4 Cleaning the coating roller ................................................................................................................................................... 7.24
7.15.5 Clenaing the collecting hopper............................................................................................................................................. 7.24
7.16 Laminating unit cleaning (Frequency: at the end of the working process) ...................................................................... 7.25
7.17 Cleaning of the drying oven with removable blowers (optional) ...................................................................................... 7.26
7.18 General machine cleaning (Frequency: every 15 days) ................................................................................................. 7.31
7.19 Cleaning scheduled every 500 hours ............................................................................................................................. 7.32
7.20 Maintenance operation every 100 hours ........................................................................................................................ 7.34
7.21 Maintenance operations every 2000 hours ..................................................................................................................... 7.35
7.22 Lubrication every 500 hours ........................................................................................................................................... 7.37
7.23 Lubrication every 2000 hours ......................................................................................................................................... 7.38

WARNING
The maintenance procedures defined in this Instruction Manual are the only ones to be carried
out by the Maintenance staff of the Purchaser of the laminating machine.
Any procedure that is NOT included in the present Instruction Manual shall have to be
previously authorized by NORDMECCANICA; namely, the operational steps of this
procedure shall have to be arranged by referring to NORDMECCANICA AFTER-SALES
SERVICE.
Moreover, the use of NON-ORIGINAL SPARE PARTS is potentially hazardous: the

specifications of the spare parts have been analysed when designing and constructing the
laminating machine, in order to define both the safe operational modes of the machine and the
correct maintenance procedures.
Any change in the above-mentioned specifications presents a potential hazard to
property and persons, as it may cause abnormal and unexpected behaviour of the
machine both during normal working cycle and while carrying out the operational
procedures.
The use of NON-ORIGINAL SPARE PARTS will invalidate the warranty and consequently
NORDMECCANICA shall not be held liable, civilly and criminally, for any damages to persons
or property.

7.1 Machine shutdown

In normal conditions, full machine shutdown occurs by turning the main switch to “O” (OFF).
In emergency conditions, full machine shutdown occurs by pressing the most accessible emergency
push-button and by turning the main switch to “O” (OFF).
Procedure for machine shutdown under normal conditions:

1. Stop the machine.
2. Disable all motors (unwinders, winder, any pulling units).
3. Unload all reels from the unwinders/winder;
4. Ensure that the rollers thermoregulating units and all the auxiliary systems are switched off.
5. Close any stopcocks or manual valves (air, water).
6. Turn the main switch to “O”.
7. If needed proceed with the end processing operations.

7.2 End of the working process

At the end of the working process it is necessary to clean the machine promptly, so as to avoid the
adhesive drying up.
Procedures for preparing the machine for cleaning:

1. Stop the machine.
2. Restart the coating unit slow running mode to prevent the material from drying up.
3. Ensure that the oven is switched off.
4. Disable all motors (unwinders, winder, any pulling units) to release the webs.
5. Ensure that all the nip rollers are open.
6. The machine is now ready for the cleaning operations.

7.3 Possible inactivity

If a long period of not using the machine is foreseen, it is necessary to carry out the following operations for
preparing the machine inactivity:
1. Remove the webs and reels.
2. Open the rubber-coated nip rollers and block them to prevent the rubber from deforming (e.g., slide a piece of
wood under the supports).
3. Block in the raised position the SF unit transfer roller (for machines fitted with semiflexo coating unit) by turning
the regulation brackets raising knob, to prevent the rubber from deforming.
4. Detach or disconnect every electrical, air and water power supply.
5. Grease the parts that could be affected by atmospheric agents.
6. Protect the operator’s panels with a plastic film.
7. In the event that the temperature may fall below 0 °C, drain the rollers thermoregulation system or add an
antifreeze solution.

7.4 Cleaning
Good general cleaning is essential to ensure:
- optimum operating conditions (safety and comfort),
- correct operating machine,
- improved end product quality.
A thorough and regular cleaning does moreover allow promptly noticing any arising problems (wear, damages,
etc.). In particular, keep all controlling devices clean so that the identification symbols are clearly legible: covered or
slippery push-buttons could cause incorrect selections and inappropriate commands. Keep also well clean the see-
through panels. Clean the machine with special detergents using rags and non-abrasive means (pay particular
attention to the see-through panels).
FORBIDDEN OPERATION
It is forbidden to use aggressive or corrosive products for cleaning metal parts, paint, plastic materials
and rubber.
It is forbidden to make the machine wet with water.

Do not use solvents and abrasive or corrosive products for cleaning sensors, filters, reflectors, operator
panels, touch screens and delicate components.
Some machine parts are particularly sensitive and could be seriously damaged by unsuitable cleaning operations,
e.g., a protective grease layer could be removed or dust could get into sensitive components.
FORBIDDEN OPERATION
If not expressly indicated it is forbidden to use air, liquids or steam under pressure.
Information for the maintenance technician/operator:

Wear gloves and appropriate clothing to protect from the cleaning solvent and from the rollers
temperature.
During cleaning operations with solvent ALWAYS leave the exhaust system running.
Put the solvent and rags used for cleaning in a safe place.

7.4.2 Cleaning products for rubber-coated rollers
Risk of damages to rubber-coated rollers.

Only use the products indicated in the following table for cleaning the rubber-coated rollers used in the
machine to which this Instruction Manual refers. Other cleaning products different from those indicated
could cause irreversible damage to the rubber-coated surfaces.
Moreover, do not use metal blades, brushes, high-pressure washers or other abrasive means: only use
lint-free cotton cloths.
No. “Rossini” code Use Cleaning product

1 23C85 sleeve for not antistatic coating impression use a mixture consisting of:
Speedwell neopress roller 75% alcohol + 25% ethyl acetate
2 23C85 stat sleeve for antistatic coating impression roller use a mixture consisting of:
Carbosleeve 75% alcohol + 25% ethyl acetate
neopress
3 62G80 SL transfer roller 1st washing phase:
Polycoat, green softner
2nd washing phase:

100% ethyl acetate
4 52G80 stat antistatic transfer roller for solvent-based use a mixture consisting of:
Neoflex, black adhesive 75% alcohol + 25% ethyl acetate
5 10F80 transfer roller for monocomponent use a mixture consisting of:
Hypalon, blue adhesives and “hot melt” 75% alcohol + 25% ethyl acetate
6 White silicone transfer roller for wax use:
100% ethyl acetate
7 17B85 laminating nip roller use:
Neopress, red a) benzine
or
b) 75% alcohol + 25% ethyl
acetate
8 03C55 aluminium idle rollers with rubber 55 shore A use a mixture consisting of:
Idrolast, black 75% alcohol + 25% ethyl acetate
9 16D40 aluminium idle rollers with soft rubber 40 use a mixture consisting of:
Microlast foam rubber shore 00 (approx. 5 shore A) 75% alcohol + 25% ethyl acetate
10 44G60 stat use:
100% ethyl acetate
11 19D40 use a mixture consisting of:
Sponge rubber 75% alcohol + 25% ethyl acetate

The type of rubber used for the rollers mounted in the machine, to which this Instruction Manual refers,
is indicated in table T 2.4, page 2.46.

7.5 Maintenance
The scheduled interventions that NORDMECCANICA S.p.a. indicates as necessary are overhaul operations aimed
at improving the performance of a system or of a part thereof. The maintenance intervention is not subordinate to
malfunctions but it ensues from improvement needs expressed both by the user and by the maintenance
personnel. For this reason, said maintenance operation is called “proactive”, as opposed to “corrective” which does
not aim at improving the system performance, but only at restoring it to its previous state.
It is therefore recommended that the indicated procedures and timings be followed to warrant an optimum machine
performance level.

Any maintenance intervention must be always carried out with the machine stopped. For NO reason
can the maintenance personnel or the operator carry out any maintenance activity with the
machine running or turned on.
FORBIDDEN OPERATION
It is absolutely forbidden to tamper with or to bypass the electrical, electronic and mechanical safety
systems and devices.

The over-familiarity with maintenance procedures, deriving from the cyclical and periodical actions
repetition, can lead to a too casual approach towards maintenance intervention with consequent
decrease of the attention level. This attitude can be a cause for possibly very serious and irreversible
harm to people and property. It is therefore advisable to always proceed with the greatest care; in case
of doubt consult the Instructions Manual or contact NORDMECCANICA Customer Service.

7.6 Cleaning and maintenance operations frequency

FORBIDDEN OPERATION
Cleaning is forbidden while the machine is in “PROTECTION OFF” mode.
The tables below summarize the cleaning and scheduled maintenance interventions that must be carried out to
maintain the machine in perfect working order.
The tables summarize the three main types of intervention:
- cleaning
- scheduled maintenance
- lubrication/greasing
T 7.1 – Cleaning interventions
Cleaning Frequency Personnel assigned

RT coating unit at the end of the working process operator
SL coating unit at the end of the work. process operator
Laminating unit at the end of the working process operator
Drying oven with removable
weekly operator
blowers (optional)
General machine cleaning 15 days operator
Electrical cabinet 500 hours electrical maintenance technician
Filter of the compressed air
500 hours mechanical maintenance technician
supply unit
T 7.2 – Scheduled maintenance interventions
Scheduled maintenance Frequency Personnel assigned

Vapour exhaust system 100 hours operator
Electrical cabinet and operator 2000 hours electrical maintenance technician
panels
Idle rollers 2000 hours operator
Transfer rollers 2000 hours operator
Winder drive belt 2000 hours mechanical maintenance technician
Coating roller drive belt 2000 hours mechanical maintenance technician
Laminating roller drive belt 2000 hours mechanical maintenance technician
Unwinders and winder 2000 hours mechanical maintenance technician

T 7.3 – Lubrication interventions
Lubrication/Greasing Frequency Personnel assigned

SL coating unit 500 hours mechan. mainten. technician
Ball joints 2000 hours mechan. mainten. technician
Coating column 2000 hours mechan. mainten. technician
Laminating column 2000 hours mechan. mainten. technician
Bearings of the oven rollers 2000 hours mechan. mainten. technician
Solventless trolley 2000 hours mechan. mainten. technician
Shaftless unwinders/winder 2000 hours mechan. mainten. technician
Bearings Long period mechan. mainten. technician
Unwinders and winder Long period mechan. mainten. technician
Laminating column Long period mechan. mainten. technician
Coating unit Long period mechan. mainten. technician
Rotogravure trolley Long period mechan. mainten. technician
Worm reduction gears --- ---
T 7.4 – General maintenance interventions
General maintenance Frequency Personnel assigned

Replacing the laminating roller --- mechan. mainten. technician
Replacing the rubber-coated transfer roller --- mechan. mainten. technician
The operations summarized in the above tables and described in detail in the subsequent sections do not cover all
maintenance activities required for the machine, but represent the basic operations that can be carried out by the
Purchaser’s personnel.
Any supplementary maintenance interventions shall have to be carried out by NORDMECCANICA

S.p.a. Customer Service.

7.7 Lubricating oils/greases

The table hereunder includes the oils and greases to be used for the lubrication of mechanical parts.
T 7.5 – Oils/greases table

Lubrication
Lubrication point Type Normal lubrication
food grade
Reduction gears Oil Shell Omala Oil S2 G220 Shell Cassida Fluid GL 460
Roloil Superlubricant GEL(1)

Bearings of all rollers, oven included Grease Orapi CT 615
NLGI 2
Skids, bushes and ball-bearing

Grease Shell Gadus S2 V100 NLGI3 Orapi CT 615
guides, tailstocks
(1)
PTFE-based.

7.8 Cleaning products information

It is possible to use different cleaning products (solvents, thinners, etc.) depending on the type of processing, the
type of adhesives coated and the different national regulations. Nordmeccanica S.p.a. cannot however guarantee,
for all marketed products, their risk-free characteristics, their non-toxicity and their non-corrosion of the materials;
for this reason it is advisable to solely use products which are compatible and suitable for the adhesives used and
for the rubber-coated rollers (for these latter ones strictly comply with the indications of the rollers Supplier).
It is the Purchaser’s responsibility to ensure that the products used for cleaning the laminating machine
are explicitly indicated and compatible with the surfaces to be cleaned and with the adhesives residues
to be removed.

The rubber-coated rollers require specific cleaning precautions. Follow the cleaning
recommendations given on the label of each roller.

7.9 Solvents information

Solvents are used in two different ways:
- in solution with the adhesive/ink/lacquer, for solvent processes;
- for cleaning, both for solvent and solventless processes.
It is possible to use different types of solvent, depending on the type of processing, the type of
adhesives/inks/lacquers coated and the different national regulations. Nordmeccanica S.p.a. cannot however
guarantee, for all marketed products, their risk-free characteristics, their non-toxicity and their non-corrosion of the
materials; for this reason it is recommended to exclusively use:
ETHYL ACETATE
It is the Purchaser’s responsibility to ensure that any other solvent used is explicitly indicated for the
processes to be carried out and for the wanted product.

The solvent concentration monitoring system is originally calibrated for using ETHYL ACETATE. In the
case of using other solvents, it is necessary to make a new calibration to the system (please
refer to the specific documentation).

The rubber-coated rollers require specific cleaning precautions (solvents or solvent mixtures). Follow
the cleaning recommendations given on the label of each roller.

7.10 Lubricating oils and greases information
Information for the operator and the mechanical maintenance technician:

For all operations involving contact with lubricating oils or greases, it is recommended to always use
personal protective equipment (gloves, mask and suitable clothing). Additionally, to avoid direct and
prolonged contact with the skin, the gloves and the overall must be frequently washed: do not wear
them if noticeably soiled with oil or grease.
Risk of harming the environment!

At the time of the disposal, oils and greases must be considered special waste and should be
separately collected and disposed of in accordance with current regulations. Do not dispose of them
into the environment.
In the following sections are set out the recommended oils and greases and, when possible, some of the most
common alternatives on the market; in case they were absolutely not available in the own country, it is
recommended that products of proven compatibility and correspondence are used.

Greases are not generally mixable together: in case of changing the type of grease used, it is
recommended the total removal of the original grease and the accurate cleaning of the greased part to
remove any residue.

7.11 Personal protective equipment (PPE) information

Before any operation involving interacting with the machine or its components, it is necessary to have the suitable
personal protective equipment for the interventions to carry out. The choice of equipment to be used must be
made by the “Health and Safety Manager” appointed at the Purchaser’s premises. Nonetheless, in the table
below are listed some PPE that NORDMECCANICA S.p.a. suggests to have always available because their usage
represents the minimum safety level that must be guaranteed to all personnel interacting with the machine during
any transport, installation, processing, maintenance and disposal stage.
T 7.6 – Personal protective equipment
Equipment Type of protection Operations requiring their use

GLOVES - Contact with adhesive/lacquer/ink.
- Contact with solvent.
Protection of the hands from contact with - Contact with sharp objects.
sharp objects and from skin-irritating or toxic - Contact with the web edges.
substances. - Contact with cleaning tools.
- Contact with the rubber-coated rollers.
- Contact with the heating drums.
- Contact with the coating and metering rollers.
- Contact with the sliding safety doors.
- Contact with the removable protective panels.
OVERALL - Contact with rotating rollers, even if at low speed.
- Contact with sliding parts.
Protection against the risk of entrapment, - Access to areas with difficult passageway.
dragging and direct skin contact with irritant - Contact with adhesive/lacquer/ink.
or toxic substances. - Contact with solvent.
- Contact with cleaning tools.
- Driving the lift truck for handling the reels.
HELMET - Access to areas with difficult passageway.

- Web threading.
Head protection against the risk of cutting or - Oven cleaning.
knocking injuries and against the risk of - Visual inspection operations requiring access inside
impact traumas. the machine.
- Access to areas with potential slipping risk.
GLOVES, - Contact with adhesive/lacquer/ink.

SAFETY FACE MASK - Contact with solvents.
- Interventions on parts under pressure or contact with
Eye or face protection against the possible them.
contact with substances which are irritating - Machine cleaning.
or hazardous for the skin, eyes or mouth - Proximity to machine parts that could eject fluids
(face mask). under pressure.

SAFETY SHOES - Maintenance interventions.

- Cleaning operations.
Feet protection against possible harm due to - Assembling/disassembling the machine or its
crushing, cutting, slipping. components.
- Processing.
Personnel that has to make use of PPEs:
- Operators
- Electrical maintenance technicians
- Mechanical maintenance technicians
In addition, it must be considered the possibility of having available, at the premises where the machine is installed,
any PPE to be worn by personnel outside the company that in whatever capacity might be authorized to interact
with the machine.
Current local regulations concerning safety in the workplace.

7.12 Machine cleaning: code of practice
1. Consider the opportunity of using personal protective equipment.
2. During the cleaning operations with solvent, ALWAYS leave the exhausting system running.
3. Store the solvent and the rags used for the cleaning operation in a safe place, away from both staff and
machine.
- Processes with water-based adhesives
As cleaning solvent, it is possible to use water: slide off the webs and immediately proceed to wash all the
components that have come into contact with the adhesive before the latter dries up.
- Processes with solvent-based adhesives or SL adhesives
Slide off the webs and immediately proceed to wash all the components that have come into contact with
the adhesive, before the latter dries up.

7.13 Cleaning at the end of the working process

At the end of the working process, it is necessary to proceed immediately with the machine cleaning operations
before the adhesive dries up.
Information for the mechanical maintenance technician/operator:

Manually stop the SL adhesive feed (for machines fitted with SL coating unit) before the end of the
working process, so that only a small amount of it remains to be cleaned in the machine.
Procedure:
1. MACHINE STATUS: STATIONARY
2. Restart the slow running mode of the coating units, so as not to let the adhesive dry up.
3. Disable all motors (unwinders, winder, any pulling units) to release the webs.
4. Ensure that all the nip rollers are open.
5. Proceed with cleaning the machine.

7.14 Rotogravure coating unit cleaning

MACHINE STATUS: ....... STATIONARY
ASSIGNED STAFF: ........ OPERATOR

Cleaning frequency: at the end of the working cycle.
Eliminating the risk of damages to the machine.

Use solvent only to remove the adhesive; strictly avoid scraping the surface with any tool or implement.
The adhesive tank and pans can be supplied, upon request, with Teflon non-stick coated interior.
When dry, what remains of the adhesive is a film that can easily be removed.
Procedure:
1. Set the machine function to “CLEANING” by means of the following selector switch:
Coating column
1 - PROTECTIONS OFF 2 – NORMAL
3 - CLEANING 4 - AUTO CLEANING
2. Leave the doctor blade lowered in the working position and set the coating unit in motion in slow running
mode.
3. Ensure that the exhaust hood is operative: rotate the “HOOD EXHAUST FAN” selector switch on position 1,
local control panel LCP21 (left side).
4. Clean the rubber-coated coating impression roller if dirty.
5. Stop the adhesive feed pump.
6. Remove the trolley top cover and bring down the lower adhesive pans by turning the relevant crank.
7. Try to completely empty the internal adhesive pan (by tilting it on one side), extract it from the trolley and move
it away.
8. Lift the outer collecting pan and bring it back in the working position.
9. Pour plenty of solvent on the coating roller for a first main cleaning (the cleaning solvent falls in the pan below
and drains out towards the round tank.

10. Raise the doctor blade by turning the “DOCTOR BLADE” selector switch on position 0 on local control panel
LCP21.
11. Complete the coating roller cleaning operation by using rags well soaked in solvent (change the rag
frequently).
12. Stop the rotation of the two rollers by acting on the “COATING STOP” selector switch on local control panel
LCP21.
13. Thoroughly clean the doctor blade, the counter-doctor blade and the doctor blade holder while taking great
care not to get cut (if necessary remove the components); fit onto the doctor blade the protective plastic
profile.
14. Disconnect from the trolley the feed and return pipes of the adhesive tank.
15. Use the pump to transfer the entire tank content in a suitable container.
16. Activate the pump to make the solvent in the container recirculate for washing it internally.
17. Lower and remove also the trolley outer pan.
18. Wash with solvent the two pans and the round tank.
19. Thoroughly dry all the cleaned components and reassemble them.
Eliminating the risk of releasing vapours and fire

Place in a suitable place the left-over adhesive and the solvent-soaked rags.

7.15 SL coating unit cleaning (Frequency: end of processing)


Cleaning frequency: at the end of the working cycle.
Transfer roller At the end of the working process, it is advisable to disassemble and separately clean the
roller.
Metering rollers For their cleaning it is necessary to make the motor rotate despite the absence of the
transfer roller.
Eliminating the risk of damages to the machine.

To avoid serious damage to the machine, the purposely-supplied substitute
hub must be always installed in place of the transfer roller: only in this way
can the articulated joint rotate in safe mechanical conditions.
F 7.1 – Substitute hub
Elimination of the risk of limbs dragging and crushing

The normal metering motor rotating direction is not very favourable for
cleaning operations, as it tends to drag the rag between the two metering
rollers, with consequent risk for the operator.
The SL coating unit has a specific function available for cleaning: when the
transfer roller is not in the machine, the metering roller rotates in the
opposite direction and it can be safely cleaned.
A special sensor installed on the transmission side detects the transfer roller presence: if the roller is not in the
machine, the metering motor reverse rotation mode is enabled.

7.15.1 Adhesive removal

1. Set the machine function to “NORMAL” by means of the following selector switch:
Coating column
2. Leave the front door lowered.
3. Ensure that the exhaust hood is operative: (rotate the “HOOD EXHAUST FAN” selector switch on position 1).
4. Disable the adhesive feed (by turning the “ADHESIVE FEED” selector switch to position “O”).
5. Disable the adhesive feed slide movement (by turning the “ADHESIVE SLIDE” selector switch on position 0).
6. Remove the adhesive feed nozzle.
7. Make sure the coating impression roller is completely up (turn the “COATING IMPRESSION ROLLER” on
“open”).
8. Make sure the transfer roller is completely up (turn the “TRANSFER“ selector switch on 0).
9. Press the “METERING ROLLER: ADHESIVE REMOVAL” push-button once only; if the conditions are met, it
will light up.
10. Press the “METERING ROLLER: ADHESIVE REMOVAL” push-button again and keep it pressed to confirm
and carry out the discharge of adhesive left between the rollers.
If the “METERING ROLLER: ADHESIVE REMOVAL” push-button does not light up, the entire
procedure must be repeated.
11. Release the “METERING ROLLER: ADHESIVE REMOVAL” push button to stop the movement of the rollers.
12. Open the front door and pour solvent between the metering rollers.
13. Lower the transfer roller (turn the “TRANSFER“ selector switch on 1).
14. Lower the front door and repeat the operations from point “8” to point “10”.
15. Repeat the operations from point “8” to point “14” until the adhesive is completely diluted by the solvent
(approx. 2-3 times).

7.15.2 Cleaning the transfer roller

Coating column
2. Make sure the transfer roller is completely up (turn the “TRANSFER“ selector switch on 0).
3. Disconnect and remove the adhesive feed slide (slide it from its trolley housing).
4. Disconnect, remove and clean the adhesive level sensor.
5. Turn off the roller conditioning unit/s.
6. Pull the transfer roller out by following the relevant instructions (section 7.26).
7. Thoroughly clean the rubber-coated transfer roller by using solvent-soaked rags.
7.15.3 Cleaning the metering rollers

Coating column
2. Raise the front door.
Burn hazard:
Check that the temperature of the chromed rollers is sufficiently low so as not to represent a danger.
4. Remove the Teflon retaining walls and thoroughly clean them (be careful not to damage them at the tip).
5. By acting on the two adjustment handwheels, increase the distance between the two metering rollers to the
maximum.
6. Thoroughly clean the motorized metering roller by making it rotate with the foot control.
7. Thoroughly clean the fixed metering roller by making it rotate with the manual handwheel.

7.15.4 Cleaning the coating roller

Coating column
2. Raise the front door.
3. Turn off the roller conditioning unit.
5. Clean the rubber-coated coating impression roller thoroughly, if dirty.
6. Make sure the coating impression roller is completely up (turn the “COATING IMPRESSION ROLLER”
selector switch on “open”).
Burn hazard:
Check that the coating roller temperature is sufficiently low so as not to represent a danger.
7. Thoroughly clean the coating roller by making it rotate with the foot control.
7.15.5 Clenaing the collecting hopper

1. Clean the collecting hopper by lifting and pulling it towards the outside.
To avoid cleaning the collecting hopper each time, it is advisable to smear its bottom with grease and
to cover it with a plastic sheet.

7.16 Laminating unit cleaning (Frequency: at the end of the working process)
MACHINE STATUS: ................. STATIONARY
ASSIGNED STAFF: .................. OPERATOR
The laminating unit needs to be cleaned as it can come into direct contact with the adhesive:
- at the web sides,
- in case the web to be laminated breaks.

If the laminating unit gets too dirty, check the coating settings (rubber-coated sleeve, transfer roller,
webs width, any web misalignment, etc.).
Procedure:
2. Check that the laminating nip roller temperature is sufficiently low so as not to represent a danger.
3. Reduce the activating pressure of the rubber-coated laminating nip roller to zero by the way of the two
dedicated pressure regulators so that the nip roller can be manually opened or closed in safe conditions.
4. Open the protection between the laminating nip roller and the rubber-coated nip roller.
5. Thoroughly clean the rubber-coated laminating nip roller by opening it and making it rotate by hand.
6. Thoroughly clean the exposed part of the laminating nip roller.
7. Close the guard and make the laminating nip roller rotate a little by pressing the “LAMINATOR JOG” push-
button on local control panel LCP24 (front side).
8. Reopen the protection and clean the exposed part of the laminating nip roller, repeating the process until
cleaning is completed.
9. Bring the protection back in the working position.

7.17 Cleaning of the drying oven with removable blowers (optional)

ASSIGNED STAFF: .................. 2 OPERATORS
Frequency: Weekly
The indicated frequency shall be considered as the maximum allowable value: more frequent
cleaning (daily) may be necessary depending on the type of adhesive used and the working
conditions.
Equipment: • Ladder with guard-rails and wheels (see image shown for illustrative purposes only)
• Portable industrial thermometer
• Fork spanner No. 8
PPE: Gloves, safety shoes, helmet, eye protection.
Obligation: The purchaser shall arrange an area suitable for cleaning the blowers.
Forbidden but reasonably foreseeable operation:

It is forbidden to move the ladder, when a person is on it. The person assigned to removal/installation of the
blowers must get off the ladder when it has to be moved.
F 7.2 – Example of a ladder for removal/installation of removable blowers from/in the drying oven
The drying oven can sometimes come in direct contact with the adhesive; therefore, it needs to be cleaned:

Procedure:
1) Switch off the oven.

1.1) Press the “MACHINE STOP” push-button to activate the normal stop of the laminating machine and
therefore, of the oven.
1.2) After stopping the machine, the fans for solvent vapour extraction remain in operation for about 2
minutes so as to discharge the vapours completely and to prevent their stagnation inside the oven
(operation called purging).
1.3) Wait for the fans to come to a standstill.
2) Wait 20 minutes after the fans have stopped before carrying out the operation.
Potential risk:
Burn and scald hazard.

Do not carry out disassembling and cleaning operations until after 20 minutes from the oven switch-
off.
3) Position the ladder near the side doors of the drying oven, on the operator side, at a distance of about one
metre from the machine frame.
4) Open the oven access doors (1, F 7.3)
F 7.3 – Access doors
5) Using a portable industrial thermometer, if available, check if the surface temperature of the blowers is <40 °C.

6) Unscrew and remove the front fixing nut (2, F 7.4) of the blower, by using a fork spanner No. 8.
F 7.4 – Fixing nut
7) Note that each blower is identified by a numerical code (3, F 7.5) engraved on the front side. In the next
assembly phase, the positional order must be observed (Ref.: next point 12).
F 7.5 – Numerical code

8) Extract the blower (4, F 7.6).
F 7.6 – Handle for blower extraction

Each blower weighs 8 kg and its length corresponds approximately to the width of the web to be used
in the machine.
9) The operator standing on the ladder shall hand the blower to the operator on the ground: Getting off the ladder
while holding the blower is not allowed.

Both people assigned to the operation must wear a protective helmet (in addition to gloves and safety
shoes).
10) Transport the blowers into the area reserved for cleaning operations.
10.1) Remove any traces of solvent by means of a razor-blade scraper.
10.2) If needed, use a metal brush to completely remove all traces of solvent.
Beware:
During cleaning operations proceed carefully, so as not to cause deep scratches on the metal
surface.
11) Bring the blowers back near the machine.
12) Each blower has an identification number engraved on the front side (3, F 7.5): it is necessary to maintain the
numerical sequence when mounting the blowers. Do not invert the position of the blowers.

13) Insert each blower into its guides and lock it with the fixing nut (2, F 7.4).
14) After installation, make sure no working tools or foreign bodies are left behind inside the drying oven.
15) Close the drying oven access doors (1, F 7.3).
16) Remove the ladder.
17) The cleaning procedure is now terminated.

7.18 General machine cleaning (Frequency: every 15 days)

ASSIGNED STAFF: .................. OPERATOR
Clean the machine covers, the panels and the controls with soft and dry cloths, or soaked with a cleansing solution.

Do not use any kind of solvent such as alcohol, ethyl acetate, etc., so as not to damage the surfaces
and the machine components. Do not even use either water or steam under pressure.
Procedure:
2. By using a dry cloth, a soft bristle brush and compressed air, clean the sensors and the electronic devices that
may be dirty with dust or the like. If necessary, use air exhausters and suitable equipment.
3. Keep clean and uncluttered the work area to ensure maximum personnel safety. In particular, wash off all oil
and grease marks from the floor.

7.19 Cleaning scheduled every 500 hours
ELECTRICAL CABINET
ASSIGNED STAFF: ........ ELECTRICAL MAINTENANCE TECHNICIAN
Clean the ventilation filters of the electrical cabinets by using an ordinary vacuum cleaner.
FORBIDDEN OPERATION
Do not use compressed air to clean the filters.
Documentation from the supplier of the conditioning system of the electrical cabinets.

FILTER FOR THE COMPRESSED AIR SUPPLY UNIT

ASSIGNED STAFF: ........ MECHANICAL MAINTENANCE TECHNICIAN
ACTION: ......................... VISUAL CHECK / CLEANING
FREQUENCY: ................ 500 hours
Check the condensate drain and clean the inlet filter.
Documentation from the supplier of the compressed air inlet unit.
F 7.7 – Compressed air inlet unit

2. Condensate tank
4. Filter

7.20 Maintenance operation every 100 hours
VAPOUR EXHAUSTING SYSTEM

ACTION: ......................... VISUAL CHECK / REPLACEMENT
1. Check the filters on the vapour exhausting intake openings and visually assess their degree of clogging
2. If necessary, replace them.

During the SL process the filters get completely clogged up: hence they must surely be replaced. If the
machine is instead used for other processes, the filters can be replaced less frequently.

7.21 Maintenance operations every 2000 hours
ELECTRICAL CABINET AND OPERATOR PANELS

ASSIGNED STAFF: ........ ELECTRICAL MAINTENANCE TECHNICIAN
ACTION: ......................... VISUAL CHECK / CORRECTIVE INTERVENTION
Check the terminal blocks integrity and the connections mechanical firmness: if necessary, tighten them well.
IDLE ROLLERS
ACTION: ......................... CHECK THE WEAR CONDITIONS / REPLACEMENT
FREQUENCY: ................ 2000 HOURS
Procedure:
1. Check that the bearings are not seized and that they do not produce any unusual noise.
TRANSFER ROLLERS
ACTION: ......................... CHECK THE WEAR CONDITIONS / REPLACEMENT
FREQUENCY: ................ 2000 HOURS
Procedure:
1. Check that the bearings are not seized and that they do not produce any unusual noise.

WINDER DRIVE BELT

ACTION: ......................... VISUAL CHECK / TENSION ADJUSTMENT
FREQUENCY: ................ 2000 hours
Procedure:
1. Check that the belt tension is correct.
2. If necessary adjust the belt tensioner to re-establish the correct belt tension
3. Visually check the belt for wear. If necessary, replace.
COATING ROLLER DRIVE BELTS

FREQUENCY: ................ 2000 hours
Procedure:
1. Check that the two belts are properly tightened.
2. If necessary intervene on the motor flange (first belt) and on the belt tensioner (second belt).
LAMINATING ROLLER DRIVE BELT

FREQUENCY: ................ 2000 HOURS
Procedure:
1. Check that the belt tension is correct.
2. If necessary intervene on the belt tensioner.

7.22 Lubrication every 500 hours

SL COATING UNIT
ACTION: ......................... LUBRICATION
FREQUENCY: ................ 500 hours
Procedure:
1. Lubricate the transfer roller sliding supports.
1. Sliding support
2. Lubricate the link rods of the transfer roller articulated joint.
1. Link rod of articulated joint

Refer to oils/greases table (→ table T 7.5)

7.23 Lubrication every 2000 hours
PNEUMATIC CYLINDERS BALL JOINTS (Dancing rollers and nip rollers)

FREQUENCY: ................ 2000 HOURS
Procedure:
1. Grease all the ball joints of the pneumatic cylinders for moving the dancing rollers and the nip rollers.


COATING COLUMN
FREQUENCY: ................ 2000 HOURS
Procedure:
1. Grease the skids of the two coating impression roller slides.
1. Nipple of impression roller slide


LAMINATING COLUMN
FREQUENCY: ................ 2000 HOURS
Procedure:
1. Grease the bushings of the laminating nip roller arms.
1. Nipple of the laminating nip roller
2. Grease the cooling drums bearings.
2. Nipple of the cooling drum


BEARINGS OF THE OVEN IDLE ROLLERS

FREQUENCY: ................ 2000 HOURS OR WHEN REPLACING
Procedure:
1. Get up on to the walkway and reach the oven shoulder on which are located the nipples for each bearing to be
lubricated.
2. Lubricate the bearings of the idle rollers by means of a grease pump to be fixed to the specific nipples.
1. Nipple of the oven idle rollers


SOLVENTLESS TROLLEY
FREQUENCY: ................ 2000 HOURS
Procedure:
1. Lubricate the bearings of the coating roller.
1. Nipple of the coating roller
2. Lubricate the bearings of the metering rollers.
2. Nipple of the driven roller

3. Nipple of the fixed roller


UNWINDER/WINDER (SHAFTLESS)
FREQUENCY: ................ 2000 HOURS
Procedure:
1. Lubricate the bearings of the ball-bearing guide.
1. Nipple on ball-bearing guide


7.24 Long-term lubrication

Some components are designed for long-term lubrication and preventive maintenance is not foreseen for them. In
the event of supplementary maintenance interventions, e.g. due to wear, use the oils/greases indicated
below.
ON THE ENTIRE MACHINE

FREQUENCY: ................ ONLY IN CASE OF SUPPLEMENTARY MAINTENANCE INTERVENTIONS
- grease the fixed idle rollers bearings

- grease the bearings of the idle misaligning rollers
- grease the dancing rollers bearings
- grease the bearings of the lay-on roller on the winder
- Grease the bearings of the rollers with the load cells.

Refer to oils table (→ table T 7.5)

UNWINDERS/WINDER (SHAFTLESS)
- In the event of supplementary maintenance interventions involving removal of the reel clamping cones or
replacement of the sliding ball sleeves.
1. Bearings for sliding ball sleeves

2. Bearings for reel clamping cones

LAMINATING COLUMN
Procedure:
1. Lubricate the bearings of the laminating roller.

COATING UNIT
- Lubricate the chromed metering roller reduction gear.

- Lubricate the transfer roller reduction gear.

ROTOGRAVURE TROLLEY
Procedure:
1. Grease the bearings of the coating roller.

WORM REDUCTION GEARS

The worm reduction gears are designed for lifetime lubrication and thus devoid of refill/drain
caps.

7.25 Manual procedure for replacing the laminating roller

ASSIGNED STAFF: ........ 1 MAINTENANCE TECHNICIAN
Before carrying out any operation for removing the laminating roller, it is imperative to:
- disconnect the machine from the energy sources (both electrical and pneumatic);
- put up "Maintenance in progress" signs near both the operator work stations and the energy
connections.
To disassemble the laminating roller, follow the indications below:
1) Completely open the reel-holder arms of unwinder B by acting on the “REEL CLAMPING “ selector switch.
2) Remove the idle roller (1 - F 7.8) by unscrewing the fastening screws by means of a 6-mm Allen key.
F 7.8 – Idle roller removal
3) Remove the protective casing (2 - F 7.9) by using a 6-mm Allen key.
F 7.9 – Removing the casing

4) Turn the safety bar (1 F 7.10) through 90° by using the handles.
F 7.10 – Safety bar
5) Install the two sliding bars (1, F 7.11) by fastening each one with two screws (2, F 7.11) on the laminating
column shoulders. Use a size 10 Allen key. Visually check that the sliding bars are properly positioned under the
roller rotation pins, as shown in the figure below:
F 7.11 - Sliding bars (the sliding bars may have different shapes according to the machine model)
front view

rear view
1. Sliding bar
2. Bar fixing screw
Information:
When properly installed, the sliding bars should be slanting towards the inside of the laminating
column so as to prevent the roller from accidentally sliding outwards.
6) Using a size 8 Allen key, remove the fixing screws (2, F 7.12), then pull out the two roller support brackets (1, F
7.12).
F 7.12 - Roller support brackets

Roller left support bracket Roller right support bracket
1. Roller support bracket

2. Fixing screws for roller support bracket

7) Manually pull out the roller from the mounts and roll it outwards on the sliding bars until it reaches the limit stop.
F 7.13 - Roller at the limit stop
The red arrows in the figure above indicate the correct direction for roller removal
1. Roller mount (one on each side)
2. Limit stop on sliding bar (one on each bar)
8) Lift the roller vertically and remove it.
The mass of laminating roller is about 90 kg.

Use lifting equipment having suitable load capacity.
The roller must be removed by two authorized and trained maintenance technicians, who must wear
such suitable P.P.E. as required by the R.S.P.P. (Head of the Prevention and Protection Service -
Italy) or by an equivalent professional role pursuant to the regulations in force in the Country where the
machine is being used.
F 7.14 - Lifting the roller
The red arrows in the figure above show the lifting direction of the roller
9) After removing the roller, position the new one on the sliding bars and manually push it inside the laminating
column.

While inserting the roller into the column, manually lift the roller supports (1, F 7.15) so as to make
the roller shaft bearing (2, F 7.15) perfectly mesh with relevant seat in the support.
F 7.15 - Inserting the roller
The red arrows in the figure above indicate the correct direction for roller insertion
1. Roller mount (one on each side)
2. Bearing on roller shaft (one on each side)
10) Using a size 8 Allen key, put the two roller support brackets back in place and tighten all the fixing screws.
F 7.16 - Repositioning the roller support brackets
1. Roller support bracket

2. Fixing screws for roller support bracket
11) Using a size 10 Allen key, remove the four fixing screws from the sliding bars.

F 7.17 - Removing the sliding bars

Front view
Rear view
1. Sliding bar
2. Bar fixing screw
12) Reposition the safety bar (1 F 7.18).
F 7.18 - Safety bar

13) Put the protective casing (2 - F 7.19) back in place by inserting and tightening the fixing screws by means of 6-
mm Allen key
F 7.19 – Repositioning the casing
14) Put the idle roller (1 - F 7.20) back in place by inserting and tightening the fixing screws by means of 6-mm
Allen key.
F 7.20 - Repositioning the idle roller

7.26 Replacing the rubber-coated transfer roller

ASSIGNED STAFF: ........ 1 MAINTENANCE TECHNICIAN

In consideration of the rollers weight, to safely carry out the operations it is necessary to use the
transfer rollers handling trolley.
Procedure for removing the transfer roller:
1. Ascertain that the machine has stopped.
2. Disconnect and remove, if installed:

- the adhesive level sensor
- the adhesive feed slide
3. Unscrew the bracket fixing screws and remove the two lock and regulation brackets (one for each side) of the
transfer roller.
4. Open the protective casing of the transfer roller articulated joint.

5. By turning the outer knob, make the articulated joint rotate in order to bring the lock nut in an accessible
position.
6. Loosen the lock nut, using the supplied key, and open the joint.
7. Fully lower the hooks of the roller handling trolley by acting on the handwheel.
1. Hook
2. Chain handling the hook
3. Handwheel

8. Push the roller handling trolley in front of the coating unit as far as to bring the two arms of the same trolley to
hook up to the transfer roller extremities.
9. Lift the hooks by means of the handwheel.
10. After removal of the transfer roller from its supports, make the trolley move backward to extract the transfer
roller.

Absolutely avoid operating the machine in this condition, i.e. without the transfer roller: the opened
articulated joint could cause serious damage. When necessary for clearing operations, ALWAYS
install the purposely supplied substitute hub (see figure).

11. To install a new transfer roller, proceed in the reverse order as that described for its removal.
12. Verify that the anti-crushing bar position is correct.

Super Combi Manual C-3154 - SC4000 L1300 - Ago 19 - en

Uploaded by

Copyright:

Available Formats

Super Combi Manual C-3154 - SC4000 L1300 - Ago 19 - en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Super Combi Manual C-3154 - SC4000 L1300 - Ago 19 - en

Uploaded by

Copyright:

Available Formats

SUPER COMBI 4000 L1300

SERIAL NO. C-3154

Drawn up according to Directives

NORDMECCANICA S.p.A. - ITALIA - Strada dell’Orsina 16/A - 29122 Piacenza

Manual code: C-3154

Chapter 1 GENERAL INFORMATION......................................................................................................... 1.1

Chapter 2 TECHNICAL DESCRIPTION ...................................................................................................... 2.1

Chapter 3 SAFETY ...................................................................................................................................... 3.1

Chapter 4 TRANSPORT AND INSTALLATION .......................................................................................... 4.1

Chapter 5 USE ............................................................................................................................................. 5.1

Chapter 6 PROCESSING FLAWS AND TROUBLESHOOTING................................................................. 6.1

Chapter 7 CLEANING AND MAINTENANCE .............................................................................................. 7.1

ID code: SUPER COMBI 4000 – C-3154 – 08/2019 4

PURPOSE OF THIS MANUAL

WHO SHOULD USE THIS MANUAL

ID code: SUPER COMBI 4000 – C-3154 – 08/2019 5

SAFE KEEPING OF THIS MANUAL

SUPPLEMENTS AND REVISIONS

HOW TO USE THIS MANUAL

ID code: SUPER COMBI 4000 – C-3154 – 08/2019 6

SYMBOLS USED IN THE TEXT

0421 EXAMINE – CHECK

0717 CALL FOR MAINTENANCE

0981 DATA CARRIER

ID code: SUPER COMBI 4000 – C-3154 – 08/2019 7

SYMBOLS USED IN TECHNICAL DRAWINGS

ID code: SUPER COMBI 4000 – C-3154 – 08/2019 8

ENCLOSURES AND RELEVANT CODES

ID code: SUPER COMBI 4000 – C-3154 – 08/2019 9

1.1 Identification data of the Manufacturer ............................................................................................................................. 1.2

1.2 Instruction manual identification data ............................................................................................................................... 1.2

1.3 Identification data of the Machine ..................................................................................................................................... 1.3

1.4 Requesting technical assistance ...................................................................................................................................... 1.4

1.5 Spare parts ordering ......................................................................................................................................................... 1.4

1.6 Machine function .............................................................................................................................................................. 1.5

1.7 Intended use ..................................................................................................................................................................... 1.6

1.8 Misuses ............................................................................................................................................................................ 1.6

1.9 Reasonably foreseeable misuses ..................................................................................................................................... 1.6

1.10 Limitation of use ............................................................................................................................................................... 1.6

1.11 General safety provisions ................................................................................................................................................. 1.7

1.12 Limitation of liability .......................................................................................................................................................... 1.7

1.13 Machine testing ................................................................................................................................................................ 1.7

1.14 Warranty ........................................................................................................................................................................... 1.8

1.15 Demolition and disposal ................................................................................................................................................... 1.9

ID code: SUPER COMBI 4000 – C-3154 – 08/2019 1.1

1.1 Identification data of the Manufacturer

Strada dell’Orsina 16/A – 29122 PIACENZA (ITALY)

Phone +39 0523 596411

1.2 Instruction manual identification data

ID code: SUPER COMBI 4000 – C-3154 – 08/2019 1.2

1.3 Identification data of the Machine

MACHINE: ................................................LAMINATING MACHINE

ID code: SUPER COMBI 4000 – C-3154 – 08/2019 1.3

1.4 Requesting technical assistance

you can contact Nordmeccanica S.p.a. After Sales Service:

Strada dell’Orsina 16/A – 29122 PIACENZA (ITALY)

Phone +39 0523 596411

1.5 Spare parts ordering

Strada dell’Orsina 16/A – 29122 PIACENZA (ITALY)