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USE AND MAINTENANCE MANUAL

EN

GALAXY

HOT ROLLER LAMINATOR FOR HIGH

QUALITY PRODUCTION

MODEL : CWT GALAXY

YEAR OF CONSTRUCTION : 2019

MANUAL CODE : 756100330_EN

REVISION : 0

DATE : 07/03/2019

Translated from original languageRead carefully before use

Contents 1 1 General information: scope of this manual 1

1.1 Intended audience 1 1.2 Professionals involved 2 1.3 Manual use and storage 3 1.4 How to consult the manual 4

1.4.1 Description of the symbols/pictograms in the manual 4 1.4.2 Descriptions of the symbols used in the maintenance chapter 5

1.5 Manufacturer identification 5 1.6 Ownership of information 5 1.7 Marking date 6 1.8 Directives and reference standards 7 1.9 Declaration of conformity 8 1.10 Warranty 9 1.11 Assistance 9

2 Machine presentation 11

2.1 Machine parts 11

2.1.1 Self-locking spindle shaft 11

2.2 Operating principle 13 2.3 Intended and improper use 14 2.4 Technical data 15 2.5 Overall machine dimensions and weight 16

3 Safety 17

3.1 General warnings 17 3.2 Machine safety devices 19

GALAXYUSE AND MAINTENANCE MANUAL EN

MANUAL CODE: 756100330_EN

REVISION: 0

DATE: 07/03/2019FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation

3.2.1 Arrangement of fixed protective casing and safety photocells 20 3.2.2 Arrangement of emergency stop devices and the main electrical switch 21 3.2.3 Safety labels 22

3.3 Operator workstations 23 3.4 Personal protective equipment 24 3.5 Residual risks 25

4 Transportation and handling 27

4.1 General warnings 27 4.2 Lifting and transporting the machine - packaged components 28

4.2.1 Overall packaging dimensions and weight 28 4.2.2 Lifting the machine with packaging 28

5 Installation instructions 29

5.1 Environmental conditions and preparation for installation 29 5.2 Checks before installation 29 5.3 Unpacking 30

5.3.1 Removing the machine from the pallet with a forklift 31 5.3.2 Removing the machine from the pallet using slides 32 5.3.3 Disposing of packaging 33

5.4 Handling 33 5.5 Positioning 34 5.6 Connections 35

5.6.1 Electrical connections 35

5.7 Checks before putting into service 36

6 Control, adjustment and signalling devices 37

6.1 Positioning/Layout of the control devices 37 6.2 Main switch 38



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6.3 Control panel 38 6.4 Foot pedal control 41 6.5 Emergency buttons 41 6.6 Material tension adjustment knobs 42 6.7 Adjustment hand-wheel (lifts and lowers the upper roller) 42

7 Use 43

7.1 Putting into service 43 7.2 Starting processing 43 7.3 Cycle pause 43 7.4 Emergency stop 44 7.5 Restart after an emergency stop 44 7.6 Re-start after a black-out 44 7.7 Shut-down 44 7.8 Machine in safe conditions for various operations 45

7.8.1 Safely restarting the machine 45

7.9 Safety reset procedure 45 7.10 Quick roller heating procedure 46 7.11 “Soft” roller heating procedure 46 7.12 Foot pedal control activation procedure 48 7.13 Roller backwards movement activation procedure 48 7.14 Roller cooling procedure 49 7.15 Material centring procedure 50 7.16 Working pressure adjustment procedure 51 7.17 Material tension adjustment procedure 53 7.18 Material loading procedure 54

7.18.1 Procedure for applying self-adhesive film without protective liner (double-sided adhesive, application tape) 54



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7.18.2 Procedure for applying self-adhesive film with protective liner (coloured films, plastic coatings) 55 7.18.3 Procedure for mounting plastic coated images on the panel 56

7.19 Spindle shaft replacement procedure 57 7.20 Cutting unit adjustment and blade replacement procedure 59 7.21 Path diagrams of the material and the finished product 60

7.21.1 Spindle shaft definitions 60 7.21.2 Cold protective film lamination on sheets 61 7.21.3 Cold protective film lamination on panels 62 7.21.4 Double-sided adhesive lamination on sheets 63 7.21.5 Double-sided adhesive lamination on panels 64 7.21.6 Cold protective film and double-sided adhesive lamination on sheets 65 7.21.7 Mounting of image on panel already made adhesive 66 7.21.8 Mounting adhesive images on panels 67 7.21.9 Hot film lamination on sheets and rewinding the finished product 68 7.21.10 Double-sided adhesive lamination on sheets and rewinding the finished product 69

8 Maintenance 71

8.1 General warnings 71 8.2 Descriptions of the symbols used in the maintenance chapter 72 8.3 Routine maintenance 72

8.3.1 Routine maintenance summary table 72 8.3.2 Casing removal procedure 73 8.3.3 Photocell replacement / adjustment 74 8.3.4 General cleaning 75 8.3.5 Lubricating the upper rubber roller lifting screw 76 8.3.6 Chain lubrication 77

8.4 Special maintenance 78



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8.5 Oils and lubricants 78

9 Troubleshooting 79 10 Dismantling and disposal 81 11 Attachments 83



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1 General information: scope of this manual This manual is provided as an aid and a guide during the machine work phases. It contains information regarding use,

maintenance and troubleshooting, providing indications for the most suitable conduct for correct use and correct operation of

the machine as required by the Manufacturer.

This manual is an essential safety requirement and must accompany the machine throughout its life cycle. It is essential to

preserve and make this manual available to all persons involved in use and maintenance of the machine.

1.1 Intended audience The manual in question is addressed to qualified, adequately trained personnel for operation of the machine described in this

manual.

The manual in question is addressed to the operator responsible for operation of the machine and to the technicians authorised

for installation and maintenance.

This document and/or its parts cannot be reproduced or transmitted to third parties without prior authorisation from

FLEXA S.r.l.

Warning

The company FLEXA S.r.l. is not responsible for any damage to persons or property resulting from improper use not

indicated in this manual and in contrast to the information specified in the technical characteristics table related to

each model.

Warning

Operators must not perform interventions reserved for maintenance personnel or specialised technicians. The

manufacturer is not liable for damages resulting from failure to comply with this warning.



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DATE: 07/03/2019FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 1

1.2 Professionals involved Below is a description of the professionals who can work on the machine, depending on the type of activities to be carried out.

Operator

Mechanical maintenance technician

Electrical maintenance technician

Manufacturer’s Technician

Qualified personnel able to operate the machine, carry out loading and unloading of the product to bemachined/processed, carry out adjustment, cleaning, start-up operations or restore processing following anemergency stop. The operator is not authorised to perform maintenance.

Qualified technician able to operate the machine in normal conditions, is in charge of all mechanical operationsregarding the adjustment, maintenance and ordinary repairs described in this manual. It is not authorised to performoperations on electrical systems in the presence of voltage.

Qualified technician able to operate the machine in normal conditions, is in charge of all the electrical operationsregarding the adjustment, maintenance and ordinary repairs described in this manual. Is able to work in the presenceof voltage on electrical cabinets and junction boxes.

Qualified technician provided by the manufacturer to carry out complex nature operations in particular situations or inany case according to what has been agreed upon with the user.



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1.3 Manual use and storage

This manual is intended to provide all the information necessary for correct use of the machine and its management as

autonomously and safely as possible.

Users and maintenance technicians must carefully read the instructions contained in this manual and any attachments before

performing any operations on the machine.

If any doubts arise regarding correct interpretation of the information in the documentation, contact the manufacturer for

necessary clarifications.

It is the competence and responsibility of the end user to study and optimise the machining process for which the machine was

purchased.

Warning

Read this manual carefully before operating the machine or taking any action on it. If you do not read it first, you may

not be able to recognise dangerous situations that can cause death or serious injury to yourself and others.

Caution

Keep this manual and all attached documentation in good conditions, legible and complete in all its parts. Store

documentation near the machine in an accessible location known to all operators and maintenance personnel and,

more generally, to all those who for various reasons may come into contact with the machine.

Warning

Store the manual in its original state. Do not rewrite, modify or delete manual pages or their contents. The

manufacturer declines all responsibility for any damage to people, animals and property caused by failure to comply

with the warnings and operating procedures described in this manual.

This manual is an integral part of the machine and must be kept for future reference.

Caution

This manual must be delivered together with the machine if it is transferred/sold to another user.

Caution

In case of loss or deterioration of the manual, request a copy from the Manufacturer, specifying the document

identification data: document name, code, revision and date of preparation.



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1.4 How to consult the manual

The manual is divided into chapters, paragraphs and sub-paragraphs, listed in the index: an easy way to find any topic of

interest.

The symbols used provide direct information on the type of information expressed by the symbol itself. For example, the

symbol:

1.4.1 Description of the symbols/pictograms in the manual Below are the various symbols used in the manual to highlight especially important information or the recipients of the

information itself.

Signals the presence of a Note.

Danger

The risks described in this way indicate a HIGH LEVEL of hazard which, if not avoided, could result in serious injury or

death.

Warning

The risks described in this way indicate a MEDIUM LEVEL of hazard which, if not avoided, could result in serious injury

or death.

Caution

The risks described in this way indicate a LOW LEVEL of hazard which, if not avoided, may result in minor or moderate

injury.

This symbol indicates a NOTE: especially important information or in-depth analysis.

This symbol indicates a REMINDER: the presence of a form, a drawing or an attached document which should be read

and, if required, filled in.



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1.4.2 Descriptions of the symbols used in the maintenance chapter This paragraph describes the symbols used in the maintenance chapter.

1.5 Manufacturer identification

FLEXA S.r.l.

Via dell'Industria, 11

31014 Colle Umberto (TV) Italy

e-mail: [email protected]

web: www.flexa.it

Tel.: 0438 38565 - Fax: 0438 38767

1.6 Ownership of information

Icon used Description

Mechanical type intervention

Electrical type intervention

Specifies the frequency of interventions

This document and/or its parts cannot be reproduced or transmitted to third parties without prior authorisation from

FLEXA S.r.l.



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1.7 Marking date

The identification plate is applied on the machine in the position shown in the figure.

Manufacturer's logo.A.

CE marking.B.

Manufacturer's name.C.

Machine model.D.

Serial number.E.

Supply voltage.F.

Nominal power.G.

Frequency.H.

Year of manufacture.I.

Mass.J.

Caution

Request a new identification plate whenever the one applied on the machine becomes illegible.



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1.8 Directives and reference standards List of directives and reference standards used for the design and construction of the machine.

Directives

2006/42/EC Machinery directive.

2014/35/EU Low voltage directive

2014/30/UE EMC Directive (electromagnetic compatibility).

Harmonised standards

UNI EN ISO 12100: 2010 Safety of machinery - General principles of design - Risk assessment and risk reduction.

UNI ISO/TR 14121-2: 2013 Safety of machinery - Risk assessment - Part 2: Practical guide and examples of methods.

UNI EN ISO 3744, 3745, 3746 and 11200-11204 Determination of sound power levels and sound energy levels of noise

sources using sound pressure.



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1.9 Declaration of conformity

The original document is supplied separately to this manual.



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1.10 Warranty

1.11 Assistance The purchaser must contact the Manufacturer directly (or the service centre if present) for any need related to the use,

maintenance or request for spare parts, specifying the machine identification data indicated on the identification plate.

The Customer can make use of the technical sales support of local agents or importers who are in direct contact with the

company FLEXA S.r.l.

In the event of failure or inconvenience that cannot be overcome, the Customer must directly contact the manufacturer whose

contacts are as follows:

The warranty is supplied separately or with the contract.

TELEPHONE: 469-758-2288EMAIL: [email protected] DEPARTMENT: [email protected]: www.cwtworktoolsusa.com

MAILING ADDRESS:

CWT Worktools USA1201 Tappan CircleCarrollton, TX. 75006USA

In the event of a change of ownership or company movement of the machine, it is always necessary to inform the

manufacturer or the reference service centre, even after the warranty period.



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2 Machine presentation PROFESSIONAL LAMINATOR equipped with heated upper roller for self-adhesive materials.

Lets you laminate, mount images and encapsulate. Designed to be reliable and easy to use for high quality results.

2.1 Machine parts

Front worktop.A.

Rear worktop.B.

Feed-in guide.C.

Shedding bar.D.

Control panel.E.

Adjustment hand-wheel (lifts and lowers the upper

roller).

F.

Fixed protective casing.G.

Recovery clutch adjustment.H.

Brake adjustment.I.

Foot pedal control.J.

Storage compartment.K.

Print storage tray (optional).L.

Recovery clutch adjustment (optional).M.

Material trimming blades (optional).N.

M1

Motorised rewinding shaft.

M2

Motorised rewinding shaft (optional).

F1-F2

Unwinding shafts (idler).

F3

Unwinding shaft (idler) - (optional).

R1

Upper rubber and heated roller (idler).

R2

Lower motorised rubber roller.

G1-G2

Guide rollers.



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2.1.1 Self-locking spindle shaft The spindle shafts, which are the same and interchangeable with one another, take on different functions in relation to the

position in which they are loaded into the machine (See par 2.1).

The shafts support 3-inch spindles (nominal) and are perfectly symmetrical (not polarised), thus allowing for easy placement on

the machine.

The shafts are equipped with two cords (A) for easy insertion of the core of the roll (B) on the shaft (C).

During shaft (C) rotation, the cords (A) block the core of the roll (B).



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2.2 Operating principle The PROFESSIONAL LAMINATOR WITH HEATED UPPER ROLLER performs mounting, laminating, image encapsulation and laying

of tape and double-sided adhesive application on various types of materials.

It only takes a few seconds to replace the material thanks to the extreme simplicity of loading and removing the rolls.

The machinable materials are indicated in the technical data tables (see par. 2.4).

Machining is carried out by passing the material on a pair of rollers. The upper roller is heated.

The machine, equipped with 3 spindle shafts, works with great precision and large production volumes.

The machine is equipped with a control panel, through which it is possible to set and view the main operating features.

For the material passage diagrams see par. 7.21.



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2.3 Intended and improper use The PROFESSIONAL LAMINATOR WITH HEATED UPPER ROLLER is uniquely designed for:

Cold adhesive film lamination of prints on various types of paper (for example inkjet printers, electrostatic printers,

offset printers or photographic printers).

The laying of double-sided adhesive film on various types of printed or non-printed supports.

The laying of double-sided adhesive film directly on various types of panels (for example: wood, plastic, foam-board).

The mounting of prints (for example from inkjet printers, electrostatic printers, offset printers, photographic printers) on

various types of panels (for example: wood, plastic, foam-board).

This machine is only suitable for cold lamination.

The dimensions, material and weight of the machinable products are reported in the technical data.

Cold lamination is intended as when the roller temperature does not exceed 50°C.

Danger

The machine has not been designed to operate in potentially explosive areas.

Warning

The machine must only be used for the purposes for which it was designed and built and as established in the contract.

Warning

The machine must be used protected from weathering (for example: rain, hail, snow, fog) and only in industrial/craft

environments.

In case of malfunction, failure, breakage etc., always consult this manual before working on the machine. Contact

FLEXA S.r.l. when necessary.

Do not use the machine with products that are of a size or raw material differing from those for which it has been built

and defined in the contract.



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2.4 Technical data

General technical characteristics of the machine

Description U.M. Data

Absorbed power W 2500

Power supply V 230(2P+T)

Frequency Hz 50-60

Machine environmental operatingtemperature °C 18÷35

Relative humidity % 30÷80

Sound pressure level at theoperator workstation dB(A) <70

Worktop height mm 890

Useful working width mm 1600

Maximum distance between therollers mm 40

Performance characteristics


Min. max. feeding speed (with electronicvariation) m/min 0÷5

Upper roller temperature °C 0÷50

Mass of machine parts that require frequent handling


Spindle shaft weight(empty) kg 3

Characteristics of treated product


Diameter (max.) mm 200

Max. weight of spindle shaft (withmaterial) kg 50

Machinable materials

Description

Printed flexible materials

Rigid panels

Cardboard (packaging)

Car wrapping

Floor graphics

Backlit displays

Graphics for exhibitions, events

Banner roll-up & Display pop-up

Table displays



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2.5 Overall machine dimensions and weight


A mm 1270

B mm 2000

C mm 820

Machine weight kg 215



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3 Safety

3.1 General warnings

The machine can only be used by trained. authorised operators and for the sole purpose for which it was designed and

built.

Danger

Carefully read this manual before starting the machine.

Danger

Do not use the machine under the influence of drugs or other substances that can alter your capacity for attention and

reaction.

Danger

Authorised operators must perform only operations or interventions that they are responsible for or assigned to

according to their role and qualification.

Warning

Do not make any changes to the machine in order to obtain performance other than that for which it was designed and

built unless authorised to do so by the manufacturer.

Warning

Do not neutralise, remove, modify or otherwise render the safety, protection and/or control devices of the machine

inefficient.

Warning

Always keep the work areas and access to the machine free from materials and/or components that can impede

movements or be a source of danger for the operator.

Caution

The work area must always be properly lit.

Danger

Do not place hands, arms or any part of the body in areas where there are moving parts.



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Warning

At the end of any operation that involved the removal of guards, provide for their restoration and make sure that they

are put back in their correct position and original effectiveness.

Danger

Keep flammable substances away from the machine.

The machine has been built in compliance with the technical safety standards in force at the time of its design.

The instructions and safety warnings in this manual have been written taking into account that the user complies with

directives protecting the environment and health and safety in the workplace.



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3.2 Machine safety devices

The machine safety devices include all technical means put in place to allow use of the machine in safe conditions in compliance

with the regulations in force at the time of design of the machine itself.

The machine is equipped with:

Caution

Safety component replacement is an operation that affects the safety of the machine. This operation must be carried

out in compliance with the machine manufacturing specifications.

Safety devices must be maintained in efficient conditions. Use original spare parts only for the replacement of any

safety components.

-

Fixed protective casing.

These are mounted on the machine structure with removable plastic rivets. You will need to remove the

rivets in order to remove the protective casing.

- Safety photocells.

- Emergency buttons.

- Main electrical switch.

- Safety labels.



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A.

B.

3.2.1 Arrangement of fixed protective casing and safety photocells The following figure shows the location of the protective casing and safety photocells present on the machine.

Fixed protective casing: these are mounted on the machine structure with removable plastic rivets.

Safety photocell composed of emitter and receiver.

The machine is equipped with a safety light curtain to safeguard hands from possible crushing. The light curtain is

active during the machine autotest and when the rollers are turning.

To reset the safety photocells, see par. 7.9.



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3.2.2 Arrangement of emergency stop devices and the main electrical switch

A. Emergency buttons

B. Main electrical switch.

The machine is equipped with emergency stop buttons that can immediately stop the operating cycle.

Emergency buttons must not be used as ordinary stop commands.

To restart after an emergency stop, see par. 7.5.

In the event of an emergency stop with the rollers hot, restart roller rotation as soon as possible. If the machine

remains stationary for a prolonged amount of time, move the rollers away from each other.



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3.2.3 Safety labels The following safety labels are provided on the machine.

ADanger: the surface of the rollers is hot.

Keep hands away from rollers, risk of burns.

Caution

Labels must be replaced if worn or illegible.



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A.

B.

C.

3.3 Operator workstations The following image indicates the positions that the operator must occupy to command and control the machine operating

cycle.

Operator intervention area for operating the machine and any material loading.

Operator intervention area for the control and, if the work so requires, manual unloading of the product.

Machine direction of work

Operator intervention area dimensions U.M. Dimensions

D mm 1250

E mm 2460

Descriptions of the direction, way and side (right and left) are to be understood relative to the position of the operator

during machine operation.



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3.4 Personal protective equipment

Caution

Personnel working on the machine must wear the personal protective equipment (PPE) indicated in the following table.

PPE Operation

Always wear

Caution

The operator must comply with the accident prevention regulations in force in the country where the machine is used.

Caution

The assigned PPE cannot be changed. The manufacturer declines all responsibility for any damage to persons caused by

failure to use the PPE.

Caution

Operators and maintenance personnel must not wear clothing or accessories that could get caught in machines, such

as: loose clothing, ties, belts, necklaces, bracelets, watches, earrings, rings, etc.



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3.5 Residual risks The following zones, defined at residual risks, are present on the machine:

Zone A: rubber rollers

During machine maintenance, personnel is subjected to some residual risks which, due to the nature of the various

operations to be carried out, cannot be completely eliminated.

Warning

Burn hazard.Keep hands away from the two rollers, use suitable means

of hand protection.

Warning

Risk of abrasion.

Keep hands away from the two rollers. If the safety

photocells are not working, promptly press the emergency

stop button, then manually raise the upper roller.

Warning

Risk of crushing.

Keep hands away from the two rollers. During manual

descent of the roller, the safety photocells cannot protect

hands (or other parts of the body) from coming between

the rollers.



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Zone B: trimming blades

Handling of rolls

Warning

Risk of cutting when positioning the material trimming

blades.Handle blades with care and wear gloves.

Warning

Coils with weight less than 50 kg must be handled by two operators. Coils with weight exceeding 50 kg must be handled

using lifting equipment.



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4 Transportation and handling The packaging type and method is chosen according to the means of transport used and the place of destination of the goods.

Packaging is always accompanied by a packing list.

Transport of the packaging to the place of installation is the responsibility of the customer.


Always check the suitability and conditions of the packaging lifting devices and means.

Storage

Comply with the following instructions during temporary machine storage.

Warning

The instructions provided in this chapter are intended only for handling the packaging at the customer's site.

Warning

Lift the machine following the instructions provided in this chapter.

Warning

Use appropriate, tested and certified lifting equipment.

Warning

Lifting and transport must be carried out by personnel who has been instructed and trained for this purpose.

Warning

The machine must be stored protected from weathering (for example: rain, hail, snow, fog) and only in industrial/craft

environments.

Warning

Storage areas must have an ambient temperature between + 5°C and + 35°C with relative humidity below 85%.

Danger

Keep flammable substances away from the machine.



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4.2 Lifting and transporting the machine - packaged components

4.2.1 Overall packaging dimensions and weight

4.2.2 Lifting the machine with packaging

Danger

Be careful during all transport and handling operations. Do not stand under suspended loads.

Warning

Verify the weight to be lifted and the pre-set hooking points on the packaging or on the documentation attached to it.

Use suitable lifting equipment.


A mm 1450

B mm 2100

C mm 950

Package weight kg 250

Use a forklift truck as shown in the figure for lifting and

handling.



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5 Installation instructions

5.1 Environmental conditions and preparation for installation The area where the machine is to be installed must allow for a good support base, good natural and/or artificial lighting

(according to current regulations) that guarantees that the operator has good visibility over the work and can monitor the area

surrounding the machine so as to prevent the approach of third parties.

The machine has been designed and built to work in normal environmental conditions in industrial warehouses as required by

current legislation.

5.2 Checks before installation Prerequisites necessary for installation:

Check that all agreed arrangements are respected.

Check that the lighting system is adequate.

Check that flooring meets the agreed specifications.

Installation operations and the first machine start-up are carried out by FLEXA S.r.l.

Caution

The machine must not be installed if it shows obvious signs of damage.

In the case of special provisions, layouts and characteristics are provided in the contract phase that must be complied

with, as regards foundation, connections and environmental conditions.

Danger

The machine must not be installed in partially or totally explosive atmospheres.

See technical data par. 2.4

Prior to delivery of the machine, FLEXA S.r.l. provides the Customer with the necessary information and specifications

in order to prepare the areas where the machine will operate.



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5.3 Unpacking Below are instructions for correct unpacking of the machine.

Remove the outer packaging, taking care not to damage the machine.

The original packaging, including the pallet, must be kept for any shipment of the machine to the manufacturer. It will

be the manufacturer's discretion whether to accept machines without the original packaging.

1. Remove the external packaging.2. Check the machine conditions, paying particular attention to:

Side panelling.●

Rubber roller lining: must be perfectly smooth, free of fingerprints, bubbles, grooves, missing portions or cuts.●

Drive pedal (no cracks or damaged cable).●

Spindle axes: must be intact, positioned on their supports, free of dents and complete in all parts.●

Contact the manufacturer if any damage is noted. Photograph the damage and send photos to the manufacturer.

3. Cut the straps holding the machine to the pallet.

Caution

The straps are pulled taut. Move to the side of them at an arm's distance and cut them.



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5.3.1 Removing the machine from the pallet with a forklift Remove the machine from the pallet using a forklift.

Place the forks as shown in the figure.

- Fork positioning point in order to lift the machine.



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1.

2.

3.

4.

5.3.2 Removing the machine from the pallet using slides The transport pallet is equipped with slides to facilitate machine removal.

Proceed as follows:

Remove any accessories that may fall during descent.

Remove the wooden stops (A).

Lower the slides (B) and have them rest on the ground.

Slowly move the machine down the slides until it rests on the ground.

Caution

The machine descent must be carried out by two persons, one on each side.

Caution

Wear personal protective equipment (PPE). See par. 3.4.



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5.3.3 Disposing of packaging

5.4 Handling Unpacked machines can be handled having them slide on four wheels. The wheels are equipped with a brake.

Dispose of the packaging in a differentiated manner.

Keep in mind the different nature of the components (i.e.: Metals, plastic, rubber, etc.) and dispose of the various parts

in compliance with the local regulations in force.

To move the machine:

Release the locks (A) to release the wheels (B).1.

After positioning the machine, press on the stops (B)

to lock the wheels (A).

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5.5 Positioning The machine must be positioned at a suitable distance from walls and other machines, so as to allow access on each side for

checks and maintenance.

Position the machine respecting the minimum distances indicated in the following image.

The flooring on which the machine will be positioned must be flat and free of bumps. The flooring must be suitable for

the mass of the machine, including accessories and materials that will be processed.



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5.6 Connections

5.6.1 Electrical connections

The following table defines the conditions for making connections.

Consult the technical data and diagrams provided to determine the type, cross-section and position of the power

supply cable.

Machine conditions: Machine with the main switch in position "0" (OFF).Authorised personnel: Operator.

The power supply system must comply with the regulatory characteristics of the country of installation.

The electrical connection must only be carried out when positioning/fixing has been completed and when all the parts

possible making up the machine have been assembled.

Check that the power supply corresponds to the data indicated on the machine plate.

Connect the machine plug (B) to the power supply

socket (A).

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1.

2.

3.

4.

5.

6.

5.7 Checks before putting into service

Carry out the following checks before starting the machine:

Verify that the connections are complete and have been executed properly.

Verify complete and correct assembly of all parts.

Verify correct and complete assembly of the fixed guards.

Verify correct functioning of the safety devices.

Verify that the machine is completely free of assembly equipment and materials.

Verify that a general cleaning of the machine has been performed.

FLEXA S.r.l. Is responsible for the first commissioning of the machine.

Do not operate them machine if any one of the points listed in this paragraph is not successful.



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6 Control, adjustment and signalling devices

6.1 Positioning/Layout of the control devices The image below shows the location of the control devices on the machine.

A Main switch Par. 6.2B Control panel Par. 6.3C Foot pedal control Par. 6.4D Emergency buttons Par. 6.5E Material tension adjustment knobs Par. 6.6F Adjustment hand-wheel (lifts and lowers the upper roller). Par. 6.7



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6.2 Main switch

6.3 Control panel The control panel lets you set up and manage the various machine processing phases.

Main switch

Two-position switch:

Indicator light off: the machine is not being powered.●

Indicator light on: the machine is being powered.●

Press the safety reset button via the main switch after having switched on the machine.

Safety reset button.A.

Roller pressure indicator LED.B.

Roller speed adjustment knob.C.

Roller rotation activation button.D.

Roller rotation deactivation button.E.

Roller backwards movement activation button.F.

Vacuum feed table activation button (optional).G.

Pedal operation activation/deactivation buttons.H.

Personalised function activation button.I.

Upper roller heating activation button.J.

Temperature selection button.K.



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Safety reset button

Press the safety reset button to restore normal safety safety light curtain device operation.

Press the safety reset button via the main switch after having switched on the machine.

Roller pressure indicator LED

The LED switches on to indicate roller pressure.

To adjust roller pressure, see par. 7.16.

Roller speed adjustment knob

Turn the knob clockwise to increase roller speed.●

Turn the knob counter-clockwise to decrease roller speed.●

To stop roller rotation, turn the knob beyond zero (you will hear a

“click”).

Maximum feeding speed is indicated in par. 2.4.

Roller rotation activation button

Press this button to activate roller rotation.

The roller speed adjustment knob must be positioned between zero and max.

Roller rotation deactivation button

Press this button to deactivate roller rotation.

Roller rotation stops also by completely turning the roller speed adjustment knob in the counter-

clockwise direction, beyond zero (you will hear a “click”).

Roller backwards movement activation button (manned control)

Press and hold this button to activate roller backwards movement.

For roller backwards drive operation, see par. 7.13.

Caution

The machine can be operated by one person only when the roller backward drive is active.



REVISION: 0


Vacuum feed table activation button

Press this button to activate/deactivate the vacuum feed table (optional).

Pedal operation activation/deactivation buttons

Press this button to activate/deactivate pedal operation.

The rollers stop if pedal operation is activated. Press the pedal to start up roller rotation.●

The rollers stop if pedal operation is deactivated. Press the rotation activation button to start up

roller rotation.

●

The lit LED indicates which function is active.

For pedal control operation, see par. 6.4.

Personalised function activation button

The function of these buttons can be customised according to customer requirements (for example,

starting a vacuum fan outside the machine, switching on a lamp, etc.).

Upper roller heating activation button

Press this button to activate/deactivate roller heating.

The lit LED indicates roller heating activation.

During heating/cooling operation, the rubber rollers must be in rotation and in contact with one

another. A failure to comply with this rule could cause the heated rubber rollers to become

deformed.

To adjust the temperature, see par. 7.10 and 7.11.

Temperature selection button

Repeatedly press this button to select the desired temperature.

The lit LED indicates the active temperature.

During operation, the rubber rollers must be in rotation and in contact

with one another. A failure to comply with this rule could cause the

heated rubber rollers to become deformed.

To adjust the temperature, see par. 7.10 and 7.11.



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6.4 Foot pedal control

6.5 Emergency buttons

A. Foot pedal control.

Press to start up roller rotation.

Release the pedal to stop roller rotation.

It is possible to activate/deactivate the pedal function

without stopping the rollers. Press and hold the pedal

control, press the pedal operation

activation/deactivation button.

Roller feeding speed is regulated via the roller speed

adjustment knob (see par. 6.3).

Emergency button

When pressed, causes deactivation of the functional processes (immediate stop of all machine

movements and equipment dependent on it).

To reset operation, turn it clockwise and the button automatically comes back up.

The emergency button must not be used as an ordinary operating cycle stop command.

In the event of an emergency stop with the rollers hot, restart roller rotation as soon as possible. If the machine

remains stationary for a prolonged amount of time, move the rollers away from each other.



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6.6 Material tension adjustment knobs

6.7 Adjustment hand-wheel (lifts and lowers the upper roller)

Adjustment knob

Turn clockwise to increase material tension.●

Turn counter-clockwise to decrease material tension.●

The material being processed must be kept slightly taut.

For material tension adjustment mode, see par. 7.17.

Adjustment hand-wheel

The adjustment hand-wheel lifts and lowers the upper roller:

Turn clockwise to lift the upper roller.●

Turn counter-clockwise to lower the upper roller.●

For adjustment hand-wheel use, see par. 7.16.



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7 Use

7.1 Putting into service Putting the machine into service is carried out upon completion of installation operations and in practice consists of the first

start-up.

Follow the procedure below to put into service:

Make the electrical connection (see par. 5.6.1).

Set the main electrical switch to position 1 or ON (see par. 6.2).

Reset any emergency buttons activated (see par. 6.5).

Press the safety reset button.

7.2 Starting processing Perform the following operations to start processing:

If the rollers need to be heated, choose the type of roller heating. See par. 7.10 and 7.11

Check the laminating speed set on the potentiometer located on the control panel.

Verify that the parameters set correspond exactly to the processing that must be performed.

Load the material to be processed into the machine.

Press the roller rotation start button to begin processing. See par. 6.3.

7.3 Cycle pause

Warning

Remove any equipment, materials or objects used for

installation or other from the machine.

The presence of equipment or parts not belonging to the

machine can cause damage to people or to the machine

itself.

At this point, the machine is ready to start working or it can be switched off.

To start working, see par. 7.2.

Roller rotation deactivation

Press this button to deactivate roller rotation.

Roller rotation stops also by completely turning the roller speed adjustment knob in the counter-

clockwise direction, beyond zero (you will hear a “click”).



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●

●

●

7.4 Emergency stop Press one of the emergency buttons on the machine to immediately stop all its functions.

7.5 Restart after an emergency stop To restore the cycle after an emergency stop:

Resolve the cause that led to the emergency stop.

Deactivate the emergency button, turning the button counter-clockwise.

Press the safety reset button.

Restart processing. See par. 7.2.

7.6 Re-start after a black-out To restart the machine after a black-out:

Perform the operations described in par. 7.2.

7.7 Shut-down

The emergency stop causes deactivation of the auxiliary circuits and consequently an immediate stop of all machine

movements.

When they are hot, the rollers can deform if left stationary for prolonged periods of time.

They must always be kept in rotation for cooling.

If they need to be stopped, for example for an emergency stop, restart them as soon as possible.

When they are hot, the rollers can deform if stopped and left in contact with one another.

If they need to be stopped, move them away from one another.

The machine is switched off by setting the main electrical switch to pos. OFF or 0.

The machine can be switched off only after the two rubber rollers have cooled down.

Stopping rotation of the two rubber rollers while they are still hot may damage them as they tend to become oval-

shaped.



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7.8 Machine in safe conditions for various operations Setting the machine in safe conditions means making it impossible to start or carry out any movement whenever it is necessary

to intervene directly on it or on its parts, for example for cleaning, maintenance, etc.

To set the machine in safe conditions:

Switch off the machine. See par. 7.7.

Disconnect the machine plug from the power supply socket.

7.8.1 Safely restarting the machine To restart the machine:

Reset the electrical connections. See par. 5.6.1.

Switch on the machine. See par. 7.2.

7.9 Safety reset procedure

A self-diagnosis cycle will be carried out after the machine has been switched on via the main switch.

If the self-diagnosis cycle is positive, put the following procedure into effect:

The LED flashes and there is no acoustic signal.1.

Press the safety reset button.2.

The LED stays on with a steady light (the machine is ready to start).3.

If the self-diagnosis cycle is negative, put the following procedure into effect:

The LED flashes and there an intermittent acoustic signal.1.

Press the safety reset button.2.

The LED continues to flash (the safety device has been triggered).3.

Check the safety devices to reset machine operation.4.



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7.10 Quick roller heating procedure In the cold seasons or when processing low-quality materials, it is possible to heat the upper roller in order to eliminate or at

least limit problems linked to “silvering,” an effect strictly related to the quality of the adhesives used in the protective film and

to the roughness of the protective liner.

Silvering leads to slightly grey streaks on laminated prints, especially on dark colours.

Heating the protective film, and as a result also the adhesive, significantly reduces or entirely eliminates this occurrence.

The problem cannot be resolved by increasing the pressure between the rubber rollers, as this creates the formation of creases

on the print support.

During the winter months, roller temperature could be too low and “soft” heating (see par. 7.2.2) may not be enough to bring

the roller up to temperature.

Before activating quick heating of the rollers, make sure that there is no material being processing between the rollers and that

the protective liner recovery clutch is not excessive, to prevent that material on the unwinding shaft be rewound.

Perform the following operations to start processing after putting the machine into service:

The approximate times for reaching the selected working temperatures are as follows:

About 20 minutes for 30°C.

About 28 minutes for 40 °C.

About 40 minutes for 50 °C.

Keep the upper roller and lower roller in contact using

the adjustment hand-wheel.

1.

Set rol ler speed between 3 and 5 v ia the

potentiometer (A) .

2.

Press button (B) to activate upper roller heating.3.

Repeatedly press button (C) to select the

temperature.

4.

Press and hold buttons (C) and (D) simultaneously.5.

Button (B) LED will begin flashing; release buttons (C)

and (D).

6.

Press button (E) to activate roller rotation.7.

Once the selected temperature has been reached,

button (B) LED will stop flashing, becoming lit steadily.

8.

To end quick heating, press button (B).

During operation, the rubber rollers must be in rotation and in contact with one another. A failure to comply with this

rule could cause the heated rubber rollers to become deformed.

Quick roller heating must only be carried out once per work cycle. Two or more consecutive times could seriously

damage the rubber roller.



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7.11 “Soft” roller heating procedure In the cold seasons or when processing low-quality materials, it is possible to heat the upper roller in order to eliminate or at

least limit problems linked to “silvering,” an effect strictly related to the quality of the adhesives used in the protective film and

to the roughness of the protective liner.

Silvering leads to slightly grey streaks on laminated prints, especially on dark colours.

Heating the protective film, and as a result also the adhesive, significantly reduces or entirely eliminates this occurrence.

The problem cannot be resolved by increasing the pressure between the rubber rollers, as this creates the formation of creases

on the print support.

During the summer seasons, the roller temperature is on average 25-35°C and therefore quick heating is not required.

Before activating quick heating of the rollers, make sure that there is no material being processing between the rollers and that

the protective liner recovery clutch is not excessive, to prevent that material on the unwinding shaft be rewound.

Perform the following operations to start processing after putting the machine into service:

Keep the upper roller and lower roller in contact using

the adjustment hand-wheel.

1.

Set rol ler speed between 3 and 5 v ia the

potentiometer (A) .

2.

Press button (B) to activate roller rotation.3.

Press button (C) to activate upper roller heating.4.

Repeatedly press button (D) to select the

temperature.

5.

During operation, the rubber rollers must be in rotation and in contact with one another. A failure to comply with this

rule could cause the heated rubber rollers to become deformed.



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7.12 Foot pedal control activation procedure

Press the foot pedal control activation button on the control panel.

The command is press-and-hold. Keep the pedal pressed until the operation is complete (see par. 6.4).

7.13 Roller backwards movement activation procedure

Press the roller rotation deactivation button (A).1.

Press and hold the roller backwards movement button

(B).

2.

You will hear an acoustic signal if the safety light

curtain is not engaged.

3.

Roller backwards movement will activate with a fixed

speed, pre-set by the manufacturer.

4.

Release the roller backwards movement button (B) to

stop roller rotation.

5.

To avoid triggering the safety light barrier,

simultaneously press the roller backwards movement

activation button (B) and the safety reset button (C).

Caution

The machine can be operated by one person only when

roller backward movement is active.



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7.14 Roller cooling procedure It is a good idea to cool the rollers down after processing.

Before activating roller cooling, make sure that there is no material being processing between the rollers and that the protective

liner recovery clutch is not excessive, to prevent that material on the unwinding shaft be rewound.

Perform the following operations:

Press button (A) to deactivate roller heating.1.

The corresponding LED will switch off.2.

Leave the rollers in rotation and in close contact for at

least 20 minutes from when heating is deactivated.

3.

Press button (B) to deactivate roller rotation.4.

Lift the upper roller using the adjustment hand-wheel.5.

During the cooling operation, the rubber rollers must be in rotation and in contact with one another. A failure to

comply with this rule could cause the heated rubber rollers to become deformed.



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7.15 Material centring procedure

The material rolls must be centred on the machine to prevent imbalances in material tension and working pressure.

Optimal lamination is achieved working at the centre of the machine, even for small size materials.

The dimensions of the materials must be equivalent to prevent excess adhesive lamination with respect to the image

to be laminated. An extra area of maximum 2 cm is permitted. With extra areas over 2 cm, the adhesive lamination can

stick to the worktops and make feeding of the material difficult, resulting in the forming of creases.

Optimal lamination is achieved when the image to be laminated is larger than the film to be applied.



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7.16 Working pressure adjustment procedure Working pressure is an essential parameter for successful lamination.

Insufficient pressure does not favour uniform joining of the materials, resulting in the formation of bubbles, a silvering effect

and the detachment of the lamination from the image or from the panel.

Pressure that is too high pressure can generate creases, drifting of the lamination and deformation of the support to be

laminated when it is not equipped with great mechanical resistance.

Correct adjustment of the working pressure is carried out, for example, with material scraps, or rather of the "sandwich" of the

materials to be laminated.

In this way, it is possible to calibrate the working pressure on the actual thickness of the materials, both paper and panels.

Bring the upper roller to a height greater than the thickness of the panel to be laminated, then adjust the pressure.

Pressure adjustment hand-wheel

The adjustment hand-wheel lifts and lowers the upper roller:

Turn clockwise to lift the upper roller.●

Turn counter-clockwise to lower the upper roller.●



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Pressure adjustment

Follow the procedure below to adjust pressure:

Move the upper roller in contact with the print using the corresponding

hand-wheel.

1.

Turn the hand-wheel further counter-clockwise, the roller pressure will

increase.

2.

View roller pressure by how the LEDs light up:3.

Green LED: ideal pressure●

Orange LED: high pressure●

Red LED: pressure too high●

Turn the hand-wheel clockwise to decrease roller pressure.

The image shows creases, a typical lamination defect due to

too much pressure.



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7.17 Material tension adjustment procedure Optimal adjustment is achieved when the material is stretched on the upper roller and feeds free of creases. It is best to keep

the braking force to a minimum to prevent the material from stretching out during lamination.

Adjustment knob

Turn clockwise to increase material tension.●

Turn counter-clockwise to decrease material tension.●

Shaft clutch adjustment

Follow the procedure below to adjust the clutch:

Arrange the materials. See par. 7.18.1.

Completely decrease the clutch brake.2.

Start up the work cycle at low speed.3.

Gradually increase the clutch brake to start shaft rotation.4.

The recovery speed increases as the diameter of the roll increases.

Decrease the clutch brake to maintain correct shaft rotation.

The material being processed must be kept slightly taut.

Excessive tensioning of the material can cause excessive drive system

stress and rewinding of the material being processed. Excessive stress

can trigger the motor thermal protection and damage the inverter

and/or the transmission system for motion to the shafts.



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7.18 Material loading procedure

7.18.1 Procedure for applying self-adhesive film without protective liner (double-sided adhesive,

application tape)

Raise the upper roller (R1).1.

Stretch the adhesive film (B) evenly on the upper

roller (R1).

2.

Block the adhesive film (B) on the rear worktop.3.

Position the support to be processed (C) on the

worktop (D).

4.

Completely lower the upper roller (R1) and adjust

pressure.

5.

Detach the adhesive film (B) from the rear worktop.6.

Start the work cycle.7.

Stretch the adhesive film evenly during film application operations.

If the support to be processed is not rigid, position the initial margin over the slit between the lower rubber roller and

the rear worktop.



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7.18.2 Procedure for applying self-adhesive film with protective liner (coloured films, plastic coatings)


Separate the protective liner (B).2.

Stretch the adhesive film (C) evenly on the upper

roller (R1).

3.

Block the adhesive film (C) on the rear worktop.4.

Block the protective liner (B) on the cardboard core on

the rewinding shaft (M1).

5.

Position the support to be processed (D) on the

worktop (E).

6.


pressure.

7.

Detach the adhesive film (C) from the rear worktop.8.


Stretch the adhesive film evenly during film application operations.

If the support to be processed is not rigid, position the initial margin over the slit between the lower rubber roller and

the rear worktop.



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7.18.3 Procedure for mounting plastic coated images on the panel

Perform the following procedure to mount an image on a

panel that already has a double-sided adhesive:


Evenly lift a part of the protective liner (A) of the

panel (B).

2.

Centre the image (C) on the panel (B).3.

Have the image (C) adhere uniformly on the adhesive

(D).

4.

Position the panel (B) between the upper roller (R1)

and the lower roller (R2).

5.


pressure.

6.

Rest the image (C) on the upper roller (R1).7.


Gradually remove the protective liner (A).9.



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7.19 Spindle shaft replacement procedure

Spindle shaft removal

Machine conditions: Machine stopped.Authorised personnel: 2 operators.Personal protective equipment: See par. 3.4 or PPE IMAGE.Necessary equipment: Lifting device.

Spindle shaft handling must be performed by two operators or by means of a lifting device.

The movement of the axes is greatly facilitated if performed at the rear of the machine.

Manually rotate the spindle shaft (A) until the locking pin (B) is in a

horizontal position.

●

Lift and tilt the spindle shaft (A) to extract the pivot pin (B) from the

support (C).

●

At the opposite end of the spindle shaft (A), pull the pivot pin (D) out of

the locking pin (E).

●



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Repositioning the spindle shaft

Spindle shaft handling must be performed by two operators or by means of a lifting device.

After having replaced the roll:

Slightly tilt the spindle shaft (A) and move it close to the locking pin (E).●

Orient the pivot pin (D) in parallel with the locking pin (E).●

Move the pivot pin (D) closer and engage it in the locking pin (E).●

Connection is made on the clutch side.

At the opposite end of the spindle shaft, insert the pivot pin (B) into the

support (C).

●



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1.

2.

3.

7.20 Cutting unit adjustment and blade replacement procedure

To replace the cutting blade:

Remove the screws (E).

Replace the cutting blade (D).

Reposition the cutting blade (D) and tighten the screws (E).

Machine conditions: Machine stopped.Authorised personnel: Operator.Personal protective equipment: See par. 3.4 or PPE IMAGE.Necessary equipment: Screwdriver.

To adjust the cutting unit:

Loosen the knob (A) to move the cutting unit (B) along

the guide.

1.

Tighten the knob (A) to lock the cutting unit (B) in a

desired position.

2.

Cut the paper, loosen the knob (C) and position the

blade (D).

3.

Tighten the knob (C).4.

If the cutting blade (D) is worn, change the side of the cutting edge or replace it.



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7.21 Path diagrams of the material and the finished product

7.21.1 Spindle shaft definitions

M1

Motorised rewinding shaft.

M2

Motorised rewinding shaft (optional).

F1-F2

Unwinding shafts (idler).

F3

Unwinding shaft (idler) - (optional).

R1

Upper rubber and heated roller (idler).

R2

Lower motorised rubber roller.

G1-G2

Guide rollers.



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7.21.2 Cold protective film lamination on sheets

M1

Liner rewinding.

F1

Roll with lamination film with external/internal liner.

A

Direction of rotation of the roll with external liner.

B

Direction of rotation of the roll with internal liner.

C

Liner.

D

Images to be laminated arranged on a sheet.



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7.21.3 Cold protective film lamination on panels

M1

Liner rewinding.

F1


A


B


C

Liner.

D

Panel to be laminated.



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7.21.4 Double-sided adhesive lamination on sheets

F1

Roll with double-sided adhesive.

A




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7.21.5 Double-sided adhesive lamination on panels

F1


A




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7.21.6 Cold protective film and double-sided adhesive lamination on sheets

M1-M2

Liner rewinding.

F1-F3


A


B


C

Liner.

D


F2




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7.21.7 Mounting of image on panel already made adhesive

A


B

Double-sided adhesive.

C

Liner, to be removed manually.

D

Images arranged on a sheet, to be applied to the panel.



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7.21.8 Mounting adhesive images on panels

A

Panel.

B

Adhesive images arranged on a sheet, to be applied to the

panel.

C

Liner, to be removed manually.



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7.21.9 Hot film lamination on sheets and rewinding the finished product

F3

Roll with hot lamination film with glue on the

external/internal side.

A

Direction of rotation of the roll with glue on the external side.

B

Direction of rotation of the roll with glue on the internal side.

C


M2

Rewinding the finished product.



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7.21.10 Double-sided adhesive lamination on sheets and rewinding the finished product

F3


A


M2

Rewinding the finished product.



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REVISION: 0


8 Maintenance


Maintenance personnel must be informed of the movements and functions of each component belonging to the part on which

maintenance must be carried out.

Maintenance personnel should keep a record of all operations performed.

Warning

The authorised operators must only perform those interventions that fall within their specific competence on the

machine and must wear the necessary and appropriate PPE (personal protective equipment).

Danger

All maintenance, cleaning or repair operation carried out with the electrical system live can cause serious accidents to

people, including death.

Warning

Always disconnect the machine from energy sources before carrying out maintenance and/or replacement operations.

Danger

The operations described in this chapter must be performed by a single operator in order to avoid accidental or

involuntary activations.

Warning

All maintenance must be carried out only after putting in place the "machine safety procedure" (see par. 7.8).



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8.2 Descriptions of the symbols used in the maintenance chapter This paragraph describes the symbols used in the maintenance chapter.

8.3 Routine maintenance Routine maintenance is the set of operations that must be performed at a defined frequency. They are intended to keep the

machine in good operating condition.

8.3.1 Routine maintenance summary table Abbreviations for types of interventions: E = Electrical; M = Mechanical; S = Software

Icon used Description

Mechanical type intervention

Electrical type intervention

Specifies the frequency of interventions

Caution

Perform routine maintenance with precision and at the frequency indicated by the manufacturer.

The table reported in the paragraph 8.3.1 "Routine maintenance summary table" indicates all the recommended

interventions, indicates the frequency with which they will have to be performed and, in the last column, shows the

paragraph describing the procedure to be performed for the operation.

Routine maintenance table

Type Description Frequency Reference

M Casing removal procedure When needed 8.3.2

E Photocell replacement / adjustment When needed 8.3.3

M General cleaning Daily 8.3.4

M Lifting screw lubrication Every 6 months 8.3.5

M Chain lubrication Ogni anno 8.3.6



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1.

2.

8.3.2 Casing removal procedure

Replace the protective casings.

Exert force under the locking head (A) using a screwdriver or a suitable tool.

Remove the panel (B).

Type of intervention Performed by Frequency

When needed

PPE to be used Materials and equipment

Common workshop

tools

●

Warning

Set the machine in safe conditions (see par. 7.8).



REVISION: 0


1.

1.

2.

3.

8.3.3 Photocell replacement / adjustment

Remove the protective casing (electrical control side).

Photocell replacement

Replace the photocell (A).

Photocell adjustment

Loosen the screws (B).

Align the photocell (A) to the receiver (C) on the opposite side.

Tighten the screws (B).


When needed


Common workshop

tools

●

Caution

This maintenance must only be performed by an electrical maintenance technician.

To remove the protective casings, see par. 8.3.2.



REVISION: 0


8.3.4 General cleaning

The rubber rollers and worktops must be free of any dust and adhesive residues.

To clean the machine, use a cotton cloth dampened with water and neutral detergent or 80% isopropyl alcohol.

Use an industrial vacuum cleaner to remove residues.

During cleaning, check the status and conditions of the various machine parts. Contact the maintenance technician for possible

servicing in the case of anomalies or damage.


Daily


Cotton cloth.●

Neutral detergent.●

Industrial vacuum

cleaner.

●

Warning


Caution

If the machine operates in dusty environments, clean more frequently.

Danger

Before using any flammable substances, verify the absence of any source of fire ignition.

Ventilate the room well during and after cleaning the machine.

In the event of very persistent dirt, the use of universal nitro thinner is allowed. The affected area must be cleaned

quickly; do not stay in the same area for more than a minute.

The use of other more aggressive substances (i.e. toluene, acetone, etc.) can damage the machine.



REVISION: 0


8.3.5 Lubricating the upper rubber roller lifting screw

Remove both protective casings (drive side and electrical control side).

Lubricate the lifting screw (A) using a brush.


Every 6 months


Common workshop

tools.

●

10 g of grease for

screw (A) and (B).

●

20 g of grease for

screw (C).

●

For lubricant type, see

par 8.5

●

Warning





REVISION: 0


1.

2.

3.

8.3.6 Chain lubrication

Remove the protective casing (drive side).

Use a brush to lubricate the chains (A).

Replace the protective casings.


Every year


Common workshop

tools.

●

Brush.●

20 g of grease for

chain (A).

●

Warning





REVISION: 0


8.4 Special maintenance Special maintenance is the set of maintenance operations that do not have the purpose of maintaining the machine, but are

maintenance operations that can occur or are used for improvements.

8.5 Oils and lubricants

These maintenance operations are entrusted directly to the manufacturer's specialised technicians.

UseQuantity

Brandkg

Grease for lifting screw - Arexons GC300

Grease for chains - Arexons GC300



REVISION: 0


9 Troubleshooting

Problems Cause Solutions Ref. Paragraph

The main switch is set to "I -

ON", but the machine does

not switch on.

The plug is not inserted in the

outlet.Insert the plug in the outlet. 5.6.1

The cable is damaged. Replace the damaged cable. 5.6.1

The outlet is not providing power. Check the electrical power line. 5.6.1

The machine is on but the

lower rubber roller is not

rotating.

The emergency button is pressed.Turn the button to release it and

press the reset button.6.5

The safety reset button has not

been pressed.Press the safety reset button. 6.3

The safety light curtain beam has

been interrupted.

Remove the cause of the light

curtain interruption and press the

safety reset button.

6.3

Pedal operation has been activated. Deactivate pedal operation. 6.3

The roll on the unwinding

shaft is turning with difficulty.Excessive brake regulation.

Reduce the braking intensity using

the adjustment knob.6.6

The liner is too taut and tends

to unwind the roller

positioned on the spindle

shaft.

Excessive clutch regulation.Reduce the force of the clutch via

the adjustment knob.6.6

The printed material tends to

create small undulations

during lamination.

Excessive working pressure

between the two rubberised rollers.

Increase the distance between the

rubber rollers via the adjustment

knob.

7.16



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10 Dismantling and disposal To scrap the machine or its parts, you need to dispose of it in a differentiated manner, keeping in mind the different nature of

the components (i.e.: metals, plastic parts, rubber, oils, etc.).

Hire specialised disposal companies and in any case observe the laws in force concerning waste disposal.



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11 Attachments

Description Code

Wiring diagram 711039020 - 110V711039040 - 230V

Spare parts catalogue



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REVISION: 0


FLEXA Sr.l. reserves the right to make technical changes to this manual without prior notice.

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