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Doc. no..: DBE-047

769D Language
e: English
Translatio
on of the original document
INTRODUCTION
Copyright
Drawings, installation plans and operating instructions as well as designs,
catalogues, brochures, diagrams etc. are the intellectual property of Starlinger.
Duplication, reproduction, dissemination and distribution to third parties are
prohibited. Moreover, they must not be used to produce or have produced
machines or machine components.
Great care was taken in the creation of this documentation. However, Starlinger
reserves the right to make changes and improvements to the documentation.
Warranty and liability

The individual contractual conditions pertaining to the liability and warranty or the
respective conditions of the general sales and delivery terms of Starlinger always
apply. Starlinger accepts no liability for damage arising due to the owner failing to
adhere to the intended use.
lamiTEC LX/CX DBE-04769D PAGE 2 / 341

Translation of the original document
TABLE OF CONTENTS
ABOUT THIS DOCUMENT ................................................................................................ 9

1 TECHNOLOGICAL DESCRIPTION ............................................................................ 14
1.1 Area of application and intended use ................................................................. 14
1.2 Method of operation ............................................................................................ 14
1.3 LX standard version ............................................................................................ 15
1.4 Options ............................................................................................................... 21
2 TECHNICAL DATA ..................................................................................................... 23
3 INSTALLATION .......................................................................................................... 30
3.1 Installation overview ........................................................................................... 30
3.1.1 LX standard version ................................................................................... 30
3.1.2 CX version (optional) .................................................................................. 31
3.2 Installation site .................................................................................................... 31
3.3 Assembly ............................................................................................................ 32
3.3.1 Installation sequence.................................................................................. 33
3.3.2 Installing the switching cabinets ................................................................. 35
3.3.3 Assembling and installing the crane system .............................................. 36
3.3.4 Installing the OPP crane system (optional) ................................................ 39
3.3.5 Installing the web accumulator ................................................................... 43
3.3.6 Installing the double unwinder for fabric and OPP film ............................... 48
3.3.7 Installing the base frame ............................................................................ 53
3.3.8 Installing the extruder unit .......................................................................... 55
3.3.9 Installing the extruder unit with co-extruder (optional) ................................ 58
3.3.10 Installing the metal separator and extruder hopper .................................... 61
3.3.11 Installing the hot air oven ........................................................................... 63
3.3.12 Installing the corona (optional) ................................................................... 65
3.3.13 Installing the bottom rollers on the base frame .......................................... 67
3.3.14 Installing the coating unit ............................................................................ 68
3.3.15 Installing the register control (optional) for the OPP unwinder ................... 72
3.3.16 Installing the wide-slot die .......................................................................... 73
3.3.17 Installing the feed block and wide-slot die for the co-extruder (optional) ... 76
3.3.18 Installing the panelling on the base frame .................................................. 78
3.3.19 Installing the bridge (optional) .................................................................... 79
3.3.20 Installing the OPP unwinder (optional) ....................................................... 80
3.3.21 Assembling and installing the edge strip extractor ..................................... 82
3.3.22 Installing the "process-control" edge strip return (optional) ........................ 83
3.3.23 Installing the bagging station (optional) ...................................................... 84
3.3.24 Installing the winder.................................................................................... 86
3.3.25 Installing the volumetric dosing unit with feed station ................................ 91
3.3.26 Installing the gravimetric batch dosing unit (optional) ................................ 91

TABLE OF CONTENTS
3.3.27 Installing the vacuum conveyor (optional) .................................................. 91

3.3.28 Installing the cooling water distributor ........................................................ 92
3.3.29 Water connection ....................................................................................... 92
3.3.30 Electrical connection .................................................................................. 93
3.3.31 Pneumatic connection ................................................................................ 93
4 SETTINGS .................................................................................................................. 94
4.1 Pneumatic operating pressure ............................................................................ 95
4.2 Hydraulic operating pressure .............................................................................. 95
4.3 Cooling water circuit ........................................................................................... 96
4.4 Double unwinder ................................................................................................. 97
4.4.1 Adjusting the web edge control sensor ...................................................... 98
4.4.2 Calibrating the loadcell ............................................................................... 98
4.5 Adjusting the web accumulator start ................................................................... 99
4.6 Adjusting the hot air oven ................................................................................... 99
4.7 Corona (optional) .............................................................................................. 100
4.7.1 Adjusting the electrodes ........................................................................... 102
4.7.2 Adjusting the thickness monitoring device ............................................... 103
4.8 Extruder unit ..................................................................................................... 104
4.8.1 Setting the extruder control ...................................................................... 104
4.8.2 Setting the speed of the extruder drive .................................................... 104
4.8.3 Adjusting the melt filter on the extruder .................................................... 104
4.9 Co-extruder (optional) ....................................................................................... 106
4.9.1 Setting the co-extruder control ................................................................. 107
4.9.2 Speed of the co-extruder drive ................................................................. 107
4.9.3 Adjusting the melt filter on the co-extruder ............................................... 107
4.10 Adjusting the melt pressure control valve ......................................................... 108
4.11 Feed block (optional) ........................................................................................ 108
4.12 OPP unwinder (optional)................................................................................... 109
4.12.1 Adjusting the web edge control turning frame .......................................... 109
4.12.2 OPP unwinder (optional) web edge control .............................................. 111
4.12.3 Calibrating the loadcell ............................................................................. 112
4.13 Register control (optional) for the OPP unwinder ............................................. 113
4.14 Wide-slot die ..................................................................................................... 115
4.14.1 Adjusting the temperature ........................................................................ 116
4.14.2 Adjusting the coating width....................................................................... 116
4.14.3 Adjusting the die gap ................................................................................ 118
4.15 Coating unit....................................................................................................... 120
4.15.1 Adjusting the temperature of the chill roller .............................................. 121
4.15.2 Adjusting the pressure roller..................................................................... 122

TABLE OF CONTENTS
4.15.3 Adjusting the chill roller and pressure roller ............................................. 123

4.15.4 Adjusting the flow volume for the chill roller and pressure roller .............. 125
4.15.5 Positioning Teflon tapes ........................................................................... 126
4.15.6 Adjusting the speed of the coating unit .................................................... 128
4.16 Adjusting the central cutter ............................................................................... 128
4.17 Adjusting the turning device.............................................................................. 129
4.18 Edge trimmer .................................................................................................... 131
4.18.1 Positioning the cutting unit ....................................................................... 131
4.18.2 Adjusting the web edge control ................................................................ 132
4.18.3 Adjusting the edge trimmer with fixed blade............................................. 134
4.18.4 Adjusting the edge trimmer with crush cut knives .................................... 135
4.19 Edge strip extractor........................................................................................... 136
4.20 Adjusting the "process-control" edge strip return (optional).............................. 137
4.21 Adjusting the perforation system ...................................................................... 138
4.22 Micro perforating roller (optional) ...................................................................... 140
4.22.1 Setting the contact pressure..................................................................... 141
4.22.2 Adjust the engagement depth and parallelism ......................................... 142
4.22.3 Calibrating the gauge on the handwheel .................................................. 144
4.22.4 Adjusting the pin bushes .......................................................................... 144
4.23 Positioning the spreader roller (optional) .......................................................... 145
4.24 Winder .............................................................................................................. 147
4.24.1 Adjusting the traverse............................................................................... 148
4.24.2 Setting the pressure ................................................................................. 149
4.24.3 Calibrating the loadcell ............................................................................. 150
4.24.4 Pre-acceleration unit ................................................................................ 151
4.24.5 Adjusting the ioniser ................................................................................. 151
5 COMMISSIONING AND OPERATION ..................................................................... 152
5.1 Before initial commissioning ............................................................................. 152
5.2 Controls and display elements.......................................................................... 153
5.2.1 Overview .................................................................................................. 153
5.2.2 EMERGENCY STOP command devices ................................................. 156
5.2.3 Signal light for double unwinder ............................................................... 157
5.2.4 Signal light on the coating unit ................................................................. 157
5.2.5 Signal horn on the coating unit ................................................................. 158
5.2.6 Signal light for winder ............................................................................... 158
5.2.7 Signal light for the bagging station (optional) ........................................... 158
5.2.8 Signal light for the OPP unwinder (optional) ............................................ 158
5.2.9 Display...................................................................................................... 158
5.2.10 Pneumatic operating pressure gauge ...................................................... 159

TABLE OF CONTENTS
5.2.11 Hydraulic operating pressure gauge ........................................................ 159

5.2.12 Operating units ......................................................................................... 159
5.2.13 Other operating units ................................................................................ 174
5.3 Infeed diagrams ................................................................................................ 175
5.3.1 Infeed diagram of the double unwinder and web accumulator ................. 175
5.3.2 Infeed diagram of the coating unit ............................................................ 176
5.3.3 Infeed diagram with corona (optional) ...................................................... 177
5.3.4 Infeed diagram with spreader roller (optional) .......................................... 177
5.3.5 Infeed diagram of the coating unit, CX version (optional) ........................ 178
5.3.6 Infeed diagram of the winder .................................................................... 181
5.4 Commissioning ................................................................................................. 181
5.4.1 Switching on the machine ........................................................................ 182
5.4.2 Preparing the coating unit ........................................................................ 183
5.4.3 Preparing the double unwinder or OPP double unwinder (optional) ........ 188
5.4.4 Preparing the OPP single unwinder (optional) ......................................... 193
5.4.5 Preparing the winder ................................................................................ 196
5.4.6 Ensuring there is a supply of raw materials .............................................. 199
5.4.7 Prepare the melt filter ............................................................................... 200
5.4.8 Preparing the bagging station (optional) .................................................. 201
5.4.9 Moving the extruder unit ........................................................................... 202
5.4.10 Pneumatic expansion shafts .................................................................... 206
5.5 Operation .......................................................................................................... 207
5.5.1 Starting the machine ................................................................................ 213
5.5.2 Stopping the machine............................................................................... 214
5.5.3 Workstations............................................................................................. 214
5.5.4 Operating modes ...................................................................................... 215
5.5.5 Tasks to perform on the machine ............................................................. 216
5.5.6 Roll change on the double unwinder for fabric and OPP film (optional) ... 217
5.5.7 Roll change on the single unwinder (optional) ......................................... 223
5.5.8 Roll change on the winder ........................................................................ 224
5.5.9 Checking the roll quality (muting the safety light barrier) ......................... 229
5.5.10 Determining the coating weight ................................................................ 231
5.5.11 Special functions on the contact winder ................................................... 235
5.6 Switching off the machine ................................................................................. 239
5.7 Shutting down the machine .............................................................................. 241
5.7.1 EMERGENCY STOP command devices ................................................. 241
5.7.2 Method of operation ................................................................................. 242
6 MAINTENANCE ........................................................................................................ 244
6.1 Lubrication ........................................................................................................ 245

TABLE OF CONTENTS
6.1.1 Double unwinder ...................................................................................... 246

6.1.2 Crane system and OPP crane system (optional) ..................................... 247
6.1.3 Web accumulator ..................................................................................... 248
6.1.4 Extruder unit ............................................................................................. 249
6.1.5 Coating unit .............................................................................................. 250
6.1.6 Winder ...................................................................................................... 252
6.1.7 Co-extruder (optional) .............................................................................. 254
6.1.8 OPP single unwinder (optional) ................................................................ 255
6.1.9 OPP double unwinder (optional) .............................................................. 256
6.1.10 Register control (optional) ........................................................................ 257
6.2 Lubrication chart ............................................................................................... 258
6.2.1 Oils ........................................................................................................... 258
6.2.2 Greases .................................................................................................... 259
6.3 Maintenance overview ...................................................................................... 260
6.3.1 Daily maintenance tasks .......................................................................... 261
6.3.2 Weekly maintenance tasks....................................................................... 261
6.3.3 Monthly maintenance tasks ...................................................................... 262
6.3.4 Quarterly maintenance tasks.................................................................... 262
6.3.5 Six-monthly maintenance tasks................................................................ 263
6.3.6 Annual maintenance tasks ....................................................................... 263
6.3.7 Chain drives ............................................................................................. 263
6.3.8 Belt drives................................................................................................. 264
6.3.9 Electrical system ...................................................................................... 267
6.3.10 Safety switch ............................................................................................ 267
6.3.11 Pneumatic system .................................................................................... 269
6.3.12 Hydraulic system ...................................................................................... 269
6.3.13 Water circuit ............................................................................................. 269
6.3.14 Plastic glazing .......................................................................................... 270
6.4 Specific maintenance tasks .............................................................................. 271
6.4.1 Servicing the double unwinder ................................................................. 271
6.4.2 Maintaining the web accumulator and OPP web accumulator (optional) . 271
6.4.3 Maintaining the hot air oven ..................................................................... 275
6.4.4 Cleaning parts coated in plastic melt........................................................ 278
6.4.5 Replacing the silicone hose on the corona (optional) ............................... 280
6.4.6 Maintaining the extruder unit .................................................................... 282
6.4.7 Cleaning the metal separator ................................................................... 294
6.4.8 Replacing the heating sleeves ................................................................. 295
6.4.9 Maintaining the co-extruder (optional) ...................................................... 298
6.4.10 Maintaining the wide-slot die .................................................................... 304

TABLE OF CONTENTS
6.4.11 Maintaining the coating unit...................................................................... 308

6.4.12 Replacing the OPP double unwinder (optional) blade.............................. 317
6.4.13 Servicing the winder ................................................................................. 318
7 TROUBLESHOOTING .............................................................................................. 323
7.1 Entire machine .................................................................................................. 324
7.2 Hot air oven ...................................................................................................... 324
7.3 Double unwinder ............................................................................................... 325
7.4 Extruder ............................................................................................................ 325
7.5 Co-extruder (optional) ....................................................................................... 327
7.6 Coating unit....................................................................................................... 328
7.7 Perforation system ............................................................................................ 329
7.8 OPP unwinder (optional)................................................................................... 330
7.9 Winder .............................................................................................................. 331
7.10 DC drives .......................................................................................................... 332
7.10.1 Checking the DC drive for overheating .................................................... 332
7.10.2 Determining the cause that triggered the motor protection ...................... 333
7.10.3 Checking the frequency converter............................................................ 334
7.10.4 Checking the rotary encoder .................................................................... 334
7.11 Sensors ............................................................................................................ 335
7.11.1 Checking proximity switches .................................................................... 335
7.11.2 Checking the pressure sensor.................................................................. 336
7.11.3 Checking the thermocouple...................................................................... 336
7.11.4 Checking the light barrier ........................................................................ 338
7.11.5 Checking the ultrasound sensor ............................................................... 338
8 ENCLOSURES ......................................................................................................... 340
Tightening torques .................................................................................................... 340

ABOUT THIS DOCUMENT
ABOUT THIS DOCUMENT
Information
This document is part of the lamiTEC LX/CX documentation series that
comprises the following documents:
 General safety instructions
 Technical manuals
 Display user manual
 Manufacturer's documentation
The documentation series is intended for use by technically qualified and trained
personnel who are responsible for the installation, operation, servicing and
maintenance of the machine. It contains all of the information needed to work on
or with the machine safely and properly and must therefore be observed
precisely. Compliance with the stated instructions and guidelines will also
increase the service life and optimise the performance of the machine.
NOTE!
The documentation series must always be at hand where the
machine is used and must be read and used by everyone who
works on or with the machine.
Notation
This document uses the following notation:
Notation Representation Example

Reference Italics See the Layout plan
Designation, information Quotation marks "lamiTEC LX/CX"
(Push) button, switch Angle brackets <Main switch>
Multi-step instructions
In this document, multi-step instructions are presented as follows:
1. Step 1
2. Step 2
- Subtask
3. Step 3
 Result

ABOUT THIS DOCUMENT
Lists
In this document, lists are presented as follows:
 List item 1
 List item 2
- Sub-item / Subtask
 List item 3
 Result
Steps which do not have a particular defined order are also presented in the form
of lists. In such cases, the lists may have subtasks and results.
Indicator words
The following table provides an overview of the indicator words used and their
meaning:
Indicator word Meaning

Immediately hazardous situation which will lead to death or
DANGER!
serious injuries if the safety measures are not followed
Potentially hazardous situation, which may lead to death or
WARNING!
serious injuries if the safety measures are not followed
Potentially hazardous situation, which may lead to minor or
CAUTION!
slight injuries if the safety measures are not followed
Possible damage to property which may occur if the safety
NOTE!
measures are not followed
Pictograms
The machine bears a number of pictograms (see the Spare parts catalogue as
well as the manufacturer's documentation). Pictograms which are missing,
illegible or damaged must always be replaced immediately.
The following table provides information on the pictograms which are used and
their meaning:
Risk of foot injury
Risk of crushing

ABOU
UT THIS
S DOCU
UMENT
T
Risk of
o tripping
Risk of
o injuries to
o the hands
Risk of
o cuts
Risk of
o crushing in the rotating rollers
Risk of
o being dra
awn in
Risk of
o injury on tthe pin rolle
er
Risk of
o burns
Dange
er from elecctric currentt
Warning: magnettic field
Do not excceed the max. load-bearing capaccity!
Acces
ss is prohibiited for pers
sons with pa
acemakers
lamiTEC LX/CX DBE-04769D PAGE

P 11 / 341
Translatio
ABOUT THIS DOCUMENT
Do not linger under suspended loads!
Transporting personnel is prohibited!
Do not stand on surface!
Wear protective gloves!
Hearing protection mandatory!
Wear a hard hat!
Wear eye protection!
Switch off before performing work!
Pay attention to the operating instructions!
This document contains additional pictograms with various purposes. The

following table provides information on the pictograms which are used and their
meaning:
General warning

ABOUT THIS DOCUMENT
Important information
Reference to further information
Terms and abbreviations

In this document, the lamiTEC LX/CX coating machine is referred to as "the
machine" for short. The standard version is known as the LX. The version for
producing fabric coated in OPP film, and its components, are identified with the
suffix CX or OPP (oriented polypropylene).
The raw material with which the plant is fed is referred to as "the coating
material", "the material", or as "pellets".
The material to be coated is referred to as "the fabric" or "the fabric web". The
coated fabric web is wound into a roll and is referred to as "the product". All
important abbreviations are explained within the document.
Figures
The diagrams used in this document are example images, which may deviate
from your machine slightly, depending on the particular application. In the
interests of providing a clearer overview, in some diagrams the safety guards and
other components are not shown.

1. TECHNOLOGICAL DESCRIPTION
1 TECHNOLOGICAL DESCRIPTION
1.1 Area of application and intended use

The machine coats a fabric tube (double and flat) or a flat fabric web, based on
polyolefin with PP/LDPE, in a single process. An automated production process
unwinds the fabric web to be coated, coats it and winds it up again.
The fabric web is unwound, turned over, guided through and wound back up
again fully automatically and is controlled by the control unit.
Tasks to perform on the machine

 Loading the machine (see Chapter 5)
 Monitoring the functions and processes on the loom (see Chapter 5)
 Quality control (see Chapter 5.5.9 and 5.5.10)
 Configuring settings (see Chapter 4)
 Lubrication and maintenance tasks (see Chapter 6 and the respective
manufacturer's documentation)
 Troubleshooting (see Chapter 7 and the respective lamiTEC LX/CX
display manual)
The machine is designed for two-person operation.
1.2 Method of operation

The fabric is unwound at the unwinder. The fabric is then fed into the web
accumulator, heated using the hot air oven and fed into the coating unit. The
fabric can be coated on both sides in a single process with the aid of a turning
device. The fully coated fabric web is wound back into a roll at the winder.

1.3 LX standard version

The machine consists of the following components:
 Crane system
 Unwinder
 Web accumulator
 Hot air oven
 Raw material feed system
 Extruder unit with wide-slot die
 Coating unit
- Perforation system
- Chill roller
- Central cutter
- Edge trimmer
- Turning device
 Edge strip extractor
 Winder

The following figure provides an overview of the position of the individual

components:
Fig. 4769/1002
1 Crane system 5 Extruder unit with wide-slot die

2 Unwinder 6 Coating unit
Receptacle for edge strip
3 Web accumulator 7
extraction
Volumetric dosing unit with feed
4 8 Winder
station
Unwinder
The unwinder is implemented in the form of a double unwinder. The double
unwinder unwinds the fabric from a roll and feeds it to the machine.
Web edge control

The web edge control monitors the course of the edge of the fabric and controls
the position of the roll using an adjustment unit. This ensures that the position of
the fabric web is controlled as it runs into the machine.

Pneumatic braking device

A sensing roller and loadcell measure the web tension and adjust the pneumatic
braking device accordingly.
Pneumatic expansion shaft

The pneumatic expansion shaft is equipped with clamping bars to clamp the core.
Crane system
The crane system is used for lifting on and lifting off or bringing in and taking
away the roll in the area of the double unwinder. The crane system is equipped
with two electric chain hoists, each with a 1,000 kg load-bearing capacity.
Volumetric dosing unit with feed station

The pellet conveyor system conveys the material from the feed containers of the
feed station into the downpipes of the dosing unit. The downpipes of the
secondary components are connected to the downpipe of the main component by
adjustable dosing pipes. In this area, the secondary components flow in the set
mixing ratio with the main component into the collecting container. The completed
material mixture is conveyed from the collecting container to the extruder.
For further information on the volumetric dosing unit with feed

station, see the Technical manual for the voluTEC volumetric
dosing unit with feed station.
Web accumulator
When the roll is changed on the double unwinder, the web accumulator ensures
that the speed of the coating unit remains constant.
Hot air oven

The fabric web is pre-heated in the hot air oven before coating.
Coating unit
The coating is applied to the pre-heated fabric web. If the fabric web is coated on
both sides, it is turned on the turning device and coated again.
Chill and pressure roller

Cools the coating applied to the fabric. The unit can be adjusted horizontally
manually and vertically by a motor relative to the wide-slot die.

Teflon tapes
The Teflon tapes prevent the plastic melt (cover coating) extruded by the fabric
web from sticking to the pressure roller. The adjustment is made manually.
Central cutter
For double-sided coating, the fabric webs - which run adjacent to one-another
and are joined together by a cover coating - are cut down the centre.
Edge trimmer
The edge trimmer consists of two cutting units. They cut enough of the cover
coating from each edge of the fabric web that a surplus still remains. On the edge
trimmer, two crush cut knives are pressed against the hardened steel roller
pneumatically.
An upright blade may be used for the edge trimmer, instead of the crush cut
knives.
Turning device
The turning triangle of the turning device turns the fabric web for coating on both
sides.
Perforation system
The perforation system produces a specific level of air permeability in the coated
fabric web for subsequent processing. The fabric web is pressed against a
backing roller by the pin roller and perforated.
Extruder unit
In the extruder an extruder screw transports the coating material through a
heated extruder cylinder and on to the melt filter. During this process, the material
is plasticised and homogenised. The extruder unit is moved in and out on a base
frame.
Metal separator
The metal separator removes ferromagnetic impurities from the pellets.

Melt filter
The melt filter of the extruder unit takes the form of an automatic filter.
The filter block of the melt filter is equipped with heating elements and a filter
tape. The flow of plastic melt is cleaned by the filter tape. After a given period of
time, the filter tape moves onwards. The melt filter is positioned between the
extruder and the melt pressure control valve.
Melt pressure control valve

The melt pressure control valve keeps the pressure in the extruder constant.
Wide-slot die
The heated wide-slot die applies the plastic melt (coating) to the fabric. The
coating width can be adjusted. Gases produced during this process are extracted
via an extraction device.
For information on the wide-slot die, see the manufacturer's

documentation.
Edge strip extractor

The cut-off edge strips are extracted and transported to a receptacle.
Winder
The winder is implemented in the form of a contact winder. The contact winder
winds the coated fabric into a roll on a core.
Oscillator
Ensures that the roll has an even composition. The composition of the layers of
the roll is regulated by a motor.
Cutting unit
During a roll change, the fabric web is severed by a pneumatically powered
cutting unit.
Contact roller
The coated fabric web is wound back up again with the aid of contact roller.

Lifting device
The prepared pneumatic expansion shaft with the core clamped is raised for a roll
change.
Pneumatic expansion shaft

The pneumatic expansion shaft is equipped with clamping bars to clamp the core.
Pre-acceleration unit
During a roll change, the expansion shaft is brought up to the speed of the
coating unit with assistance from the pre-acceleration unit.
Display (central control unit)

The central control unit display is located at the coating unit. It is used to set and
view all parameters. In addition, you can select from a series of predefined
options.
For further information on the display, see the lamiTEC LX/CX

display user manual.
Other operating units

You can find additional operating units at the following locations on the machine:
 On the crane system
 On the unwinder
 On the base frame
 On the coating unit on the operating and drive side
 On the OPP unwinder (optional)
 On the winder
 On the OPP crane system (optional)

1.4 Options
The following options are available for the machine:
graviTEC gravimetric batch dosing unit with feed station

The pellet conveyor system conveys the material from the feed containers of the
feed station into the component container of the batch dosing unit. The batch
dosing unit weighs out the individual components in the set mixing ratio and
mixes them. The completed mixture is then conveyed into a collecting container,
and from there onward to the extruder.
For further information on the gravimetric batch dosing unit, see

the Technical manual for the graviTEC gravimetric batch dosing
unit.
Vacuum conveyor
The pellets (coating material) are conveyed via pipes to the extruder hopper by a
negative pressure generated by a fan.
Corona
The fabric is guided through the corona. An air plasma is formed between the
high-voltage electrodes and the backing roller. This causes the surface of the
fabric to be oxidised, and ensures better adhesion of the coating to the fabric.
The high voltage electrodes are pivoted in or out. The parameters for the corona
are entered on the display.
The high voltage electrodes are available in the following versions:
 Steel electrodes
 Ceramic electrodes (optional)
For further information on the corona, see the manufacturer's

documentation.
"Process-control" edge strip return

The cut-off edge strips are fed back into the hopper of the extruder. The edge
strips are ground in a cutting mill and then conveyed to the extruder hopper via a
transport system.
The "process-control" edge strip return (return to the pellet hopper on the
extruder) is suited exclusively for use with detached sections of cover coating, but
not sections of fabric.

For further information on the "process-control" edge strip return,

see the manufacturer's documentation.
Micro perforating roller

The micro perforating roller produces a specific level of air permeability in the
coated fabric web for subsequent processing. The fabric web is pressed against
a backing roller by the pin roller and perforated.
Spreader roller
Smooths out the fabric web in an outwards direction before coating.
Smooth chill roller

A chill roller with smooth surface helps to achieve a smooth coating.
Bagging station
The cut-off edge strips are extracted, ground and conveyed to a bagging station,
where the ground edge strips are filled into suitable containers (e.g. Flexible
Intermediate Bulk Containers (FIBC)).
CX version
The following options are available for producing fabric coated in OPP film:
 Co-extruder with melt filter (manual sieve changer)
 Feed block with wide-slot die for OPP
 OPP crane system
 OPP unwinder
 Register control (optional)
The following variants are available for unwinding OPP:

 OPP single unwinder
 OPP double unwinder with web accumulator (optional)

2. TECHNICAL DATA
2 TECHNICAL DATA
Dimensions of the standard machine

Length 21.83 m
Width 8.86 m
Height 4.86 m
Dimensions of the CX version (optional)

Length 25.33 m
Length with OPP double unwinder (optional) 27.33 m
Width 8.86 m
Height 4.86 m
For information on space requirements for the machine as well as

on the required working area, see Layout plan.
For information on the technical data for the individual purchased

components see the respective manufacturer's documentation.
Production data
Max. speed 220 m/min
Max. roll change speed 220 m/min
Coating weight 15 - 40 g/m²
Max. working width (fabric coating) for fabric coating on both
720 mm
sides
Min. working width (fabric coating) for fabric coating on both
400 mm
sides
Max. working width (fabric coating) for fabric coating on one
1,500 mm
side
Min. working width (fabric coating) for fabric coating on one
850 mm
side

2. TECHNICAL DATA
Extruder
Screw diameter D 90 mm
Screw length 33 D
Max. screw speed 250 rpm
Drive power 101 kW
Number of zone heaters 6
Heating capacity 50.4 kW
Max. output (depending on material mixture) 420 kg/h
Number of zone heaters, melt discharge unit 5
Heating capacity, melt discharge unit 24.3 kW
Co-extruder (optional)
Screw diameter D 45 mm
Screw length 33 D
Max. screw speed 350 rpm
Drive power 47 kW
Number of zone heaters 4
Heating capacity 35 kW
Max. output (depending on material mixture) 115 kg/h
The speed, coating weight, roll change speed and the screw
speed depend on the particular machine specifications, on the
fabric structure and on the quality and weight of the fabric!
Wide-slot die
Working width 1,500 mm
Die slot width 1,700 mm
Die lip hole 0.1 - 0.9 mm
Number of zone heaters, wide-slot die 7

2. TECHNICAL DATA
Wide-slot die for OPP (optional)

Die slot width 1,700 mm
Die lip hole 0.1 - 0.9 mm
Number of zone heaters, wide-slot die 9
Hot air oven

Regulated heating surface 1
Air speed 10 m/s
Adjustable ± 0.75 m/s
Heating duct length 2,600 mm
Temperature range 0 - 200°C
Double unwinder
Max. roll diameter 1,300 mm
Max. roll width for coating on both sides 720 mm
Max. roll width for coating on one side 1,500 mm
Max. roll weight 1,950 kg
OPP single unwinder (optional)

Roll width 1,500 mm
OPP double unwinder (optional)

Max. roll width for coating on both sides 1,500 mm

2. TECHNICAL DATA
Winder
Max. roll width for coating on both sides 720 mm
Max. roll width for coating on one side 1,500 mm
Crane system
Load-bearing capacity per chain block 1,000 kg
OPP crane system (optional)

Load-bearing capacity per chain block 1,000 kg
Compressed air requirements

Operating pressure 5 - 7 bar
Air consumption See the Layout plan
Electrical data
Connected load See the Layout plan
Electrical supply (voltage, frequency and conductor cross- See Electrical circuit
section) diagrams
Water cooling unit

For supplying the water cooling unit See the Layout plan
The machine is not suitable for outdoor use! The ambient

temperature for production and storage areas must be between 18
°C and 40 °C!
For further information on ambient conditions for the production

and storage areas, see the Technical specifications.

2. TECHNICAL DATA
Noise
Level 86 dB(A)
For information on the technical data of the volumetric dosing unit

with feed station, see the Technical manual for the voluTEC
volumetric dosing unit with feed station.
For further information on the technical data of the gravimetric

batch dosing unit (optional), see the Technical manual for the
graviTEC gravimetric batch dosing unit with feed station.
For further information on the technical data of the following

machine components, see the corresponding manufacturer's
documentation.
 Wide-slot die
 Electric chain hoists of the crane system with double unwinder
 Wide-slot die and feed block for
fabric coated in OPP film (optional)
 "Process-control" edge strip return (optional)
 Corona (optional)
 Electric chain hoists of the OPP crane system (optional)

2. TECHNICAL DATA
Type plates on the LX standard version
Fig. 4769/2002
1 Machine type plate 2 Crane system type plate

2. TECHNICAL DATA
Type plates on the CX version
Fig. 4769/2003
1 Machine type plate 3 OPP crane system type plate

2 Crane system type plate

3. INSTALLATION
3 INSTALLATION
3.1 Installation overview
3.1.1 LX standard version
Fig. 4769/3055
1 Crane system 4 Extruder unit

2 Unwinder 5 Coating unit
3 Web accumulator 6 Winder
The figure is only a standard example. The precise setup of the

machine will depend on your particular application, and may
therefore deviate from the above.
We reserve the right to modify the technical specifications as part
of the technological development process.

3. INSTALLATION
3.1.2 CX version (optional)
Fig. 4769/3056
1 Crane system 6 Winder

2 Unwinder 7 OPP web accumulator (optional)
3 Web accumulator 8 OPP unwinder
4 Extruder unit 9 Co-extruder
5 Coating unit 10 OPP crane system
The figure is only a standard example. The precise setup of the

machine will depend on your particular application, and may
therefore deviate from the above.
We reserve the right to modify the technical specifications as part
of the technological development process.
3.2 Installation site

The base on which the machine is positioned must be level and capable of
withstanding the resulting loads. The foundation must not transfer the vibration
which can be generated by the machine during operation. The acceptable loading
capacity of the floor must be at least 25,000 N/m².

3. INSTALLATION
3.3 Assembly
The machine is supplied in a pre-assembled state. For transport reasons, certain
parts can only be fitted after the machine has been unloaded from the container
or positioned.
WARNING!
Danger of death due to falling parts!
The lifting device, forklifts and lifting gear used for loading,
transportation and installation tasks must comply with applicable
legislation and be suitable for the load.
It is not permitted to stand under a suspended load!
WARNING!
Risk of injury from loose parts!
Be careful when lowering loose components, cables and hoses!
WARNING!
When working at heights, a suitable safety harness must be used!
NOTE!
Use the supplied special tools, supplies and spare parts, and then
store them in the proper manner after work is complete.
NOTE!
All nuts and bolts that are not exposed to high temperatures must
be secured during assembly with the supplied thread lock
(Loctite)!
NOTE!
Parts that are subjected to very high temperatures must be thinly
coated with a high-temperature thread paste (Molykote HSC) prior
to installation!
After unloading, the machine's separate components must be positioned and

aligned in accordance with the Layout plan.
For precise information on setting up the machine, see the Layout

plan.

3. INSTALLATION
3.3.1 Installation sequence
LX standard version
The components for the standard version are assembled in the following order:
1. Assembling and installing the crane system
2. Installing the switching cabinets
3. Installing the web accumulator
4. Installing the double unwinder for fabric
5. Installing the base frame
6. Installing the extruder unit
7. Installing the metal separator and extruder hopper
8. Installing the hot air oven
9. Installing the corona (optional)
10. Installing the bottom rollers on the base frame
11. Installing the coating unit
12. Installing the wide-slot die
13. Installing the panelling on the base frame
14. Assembling and installing the edge strip extractor
15. Installing the "process-control" edge strip return (optional)
16. Installing the bagging station (optional)
17. Installing the winder
18. Installing the appropriate raw material feed system
- voluTEC volumetric dosing unit with feed station
- graviTEC gravimetric batch dosing unit (optional)
- Vacuum conveyor (optional)
19. Installing the cooling water distributor
Mark out the working areas using the supplied marking tape in
accordance with the Layout plan

3. INSTALLATION
CX version (optional)
The components for the CX version are assembled in the following order:
1. Assembling and installing the crane system
2. Installing the OPP crane system
3. Installing the switching cabinets
4. Installing the web accumulator
5. Installing the double unwinder for fabric
6. Installing the base frame
7. Installing the extruder unit with co-extruder
8. Installing the metal separator and extruder hopper on the extruder unit
9. Installing the metal separator and extruder hopper on the co-extruder
10. Installing the hot air oven
11. Installing the corona (optional)
12. Installing the bottom rollers on the base frame
13. Installing the register control for OPP unwinder (optional)
14. Installing the coating unit
15. Installing the feed block and wide-slot die for OPP (optional)
16. Installing the panelling on the base frame
17. Installing the OPP web accumulator (only if using the OPP double
unwinder)
18. Installing the bridge
19. Installing the appropriate version of the OPP unwinder
- Single unwinder
- OPP double unwinder (optional)
20. Installing the winder
21. Assembling and installing the edge strip extractor
22. Installing the "process-control" edge strip return (optional)
23. Installing the bagging station (optional)
24. Installing the appropriate raw material feed system
- voluTEC volumetric dosing unit with feed station
- graviTEC gravimetric batch dosing unit (optional)
- Vacuum conveyor (optional)
25. Installing the cooling water distributor

3. INSTALLATION
Mark out the working areas using the supplied marking tape in
3.3.2 Installing the switching cabinets

The switching cabinets (1) should be installed in accordance with the Layout
plan.
Fig. 4769/3066 Fig. 4769/3067 Fig. 4769/3068
1 Switching cabinet 4 Forks of the lift truck or forklift

2 Ropes or chains A Tilt angle
3 Lifting-eye nuts
Procedure
When using a rope or chain (2) for positioning, the load suspension equipment
must be attached to the lifting-eye nuts (3). If using a lift truck or forklift, the
forks (4) must be long enough to reach all the way under the switching cabinet (1)
and the base at the outer edge.
Positioning method Tilt angle (A) Max. loading capacity (F)

45° 4,800 N
Rope/chain 60° 6,400 N
90° 13,600 N
Lift truck / forklift 14,000 N

3. INSTALLATION
NOTE!
If positioning using ropes or chains, ensure that all ropes or chains
are of even length!
Follow the manufacturers' instructions!
3.3.3 Assembling and installing the crane system

Assembly and installation of the crane system can be subdivided into the
following steps:
1. Install the supporting frame
2. Install the end support and chain hoists
3. Install the lower uprights and the supporting frame
Installing the supporting frame

Before installing the crane system, the supporting frame must first be installed.
Fig. 4769/3002
1 Upper upright 5 Eye bolt

2 Crane support 6 Stop buffer
3 Crossbeam 7 Eye bolt
4 Cable guide lateral connection

3. INSTALLATION
Procedure
1. Position all four upper uprights (1) in accordance with the Layout plan
2. Fit the crossbeam (3) to the upper uprights (1)
3. Fit the crane support (2) to the upper uprights (1)
4. Fit the cable guide lateral connection (4) between the two crane
supports (2)
5. Fit the eye bolts (5) to the crossbeam (3)
6. Fit the eye bolts (5) to the cable guide lateral connection (4)
7. Fit one eye bolt (7) to each upper upright (1)
8. Hook the wire ropes into the eye bolts (7)
9. Fit one stop buffer (6) at the start and end of each crane support (2)
Installing the end support and chain hoists
Fig. 4769/3003
2 Crane support 12 Load hook

8 Castor running gear 13 Electric chain hoist
9 Crossbeam 14 Position switch
10 Gearbox 15 Beam
11 Chain box

3. INSTALLATION
Procedure
1. Fit the electric chain hoists (13) and the castor running gear (8) to the
supports (15) on both sides.
2. Fit the gearbox (10) with the chain box (11) to the crossbeam (9).
3. Fit the fully assembled lifting unit with the electric chain hoists (13) and
the castor running gear (8) to the crane supports (2).
4. Screw the load hook (12) into the hook nut
5. Fit the position switch (14)
6. Before fitting to the lower uprights (16) (see Fig. 4769/3019), the
function of the electric chain hoists must be checked in full
For further information on the electric chain hoists, see the

manufacturer's documentation.
Installing the lower uprights and the supporting frame

If the supporting frame has been fully preassembled, it can be fitted to the lower
uprights (16).
Fig. 4769/3019
1 Upper upright 19 Turnbuckle

16 Lower upright 20 Bolt with nut
17 Levelling elements 21 Eye bolt
18 Wire rope

3. INSTALLATION
Procedure
1. Attach suitable load suspension equipment to the preassembled
supporting frame and raise using a suitable lifting device
2. Attach all four lower uprights (16) to the upper uprights (1) with bolts
and nuts (20)
3. Position and fasten the levelling elements (17) to the floor with frame
screws in accordance with the Layout plan
4. Position the crane system and lower it carefully onto the levelling
elements (17) with the lifting device in accordance with the Layout plan
5. Align the crane system horizontally with the levelling elements (17)
- Check the horizontal alignment using a spirit level
6. Mount the wire ropes (18) in the eye bolts (21) and tension with a
turnbuckle (19)
7. Fit the cable ducts in accordance with the Layout plan and connect the
cables in accordance with the circuit diagram
3.3.4 Installing the OPP crane system (optional)

Installation and setup of the OPP crane system can be subdivided into the
following steps:
1. Install the supporting frame
2. Install the end support and chain hoists
3. Install the lower uprights and the supporting frame
NOTE!
Incorrect installation call cause damage to property!
If a single unwinder is being used, when the crossbeam (3) is
installed, holes marked with (E) must be used, and for an OPP
double unwinder (optional), the holes marked with (D).

3. INSTALLATION
Installing the supporting frame

Before installing the OPP crane system, the supporting frame must first be
installed.
Fig. 4769/3036
1 Upper upright 6 Stop buffer

2 Crane support 7 Eye bolt
3 Crossbeam 8 Eye bolt
4 Cable guide lateral connection D Holes for double unwinder
5 Eye bolt E Holes for single unwinder
Procedure
1. Position all four upper uprights (1) in accordance with the Layout plan
- Fit the crossbeam (3) to the upper uprights (1)
 If a single unwinder is being used, when the rear uprights (1) are
installed, holes marked with (E) must be used, and for an OPP
double unwinder (optional), the holes marked with (D).

3. INSTALLATION
2. Fit the crane supports (2) to the upper uprights (1)

3. Fit the cable guide lateral connection (4) between the two crane
supports (2)
4. Fit the eye bolts (5) to the cable guide lateral connection (4)
5. Fit one eye bolt (7) to each upper upright (1)
6. Fit the eyebolt (8) and angle to the rear crossbeam (3)
7. Hook the wire ropes into the eye bolt (7)
8. Fit one stop buffer (6) at the start and end of each crane support (2)
Installing the end support and chain hoists
Fig. 4769/3037
2 Crane support 12 Load hook

8 Castor running gear 13 Electric chain hoist
9 Crossbeam 14 Position switch
10 Gearbox 15 Beam
11 Chain box
Procedure
1. Fit the electric chain hoists (13) and the castor running gear (8) to the
supports (15) on both sides.
2. Fit the gearbox (10) with the chain box (11) to the crossbeam (9).

3. INSTALLATION
3. Fit the fully assembled lifting unit with the electric chain hoists (13) and
the castor running gear (8) to the crane supports (2).
4. Screw the load hook (12) into the hook nut
6. Before fitting to the lower uprights (16) (see Fig. 4769/3038),
the function of the chain hoists must be checked in full
For further information on the chain hoists, see the manufacturer's

documentation.
Installing the lower uprights and the supporting frame

If the supporting frame has been fully preassembled, it can be fitted to the lower
uprights (16).
Fig. 4769/3038
1 Upper upright 19 Turnbuckle

16 Lower upright 20 Bolt with nut
17 Levelling elements 21 Eye bolt
18 Wire rope

3. INSTALLATION
Procedure
1. Attach suitable load suspension equipment to the preassembled
supporting frame
2. Lift with a suitable lifting device
3. Attach all six lower uprights (16) to the upper uprights (1) with nuts and
bolts (20)
4. Position and fasten the levelling elements (17) to the floor with frame
5. Position the OPP crane system and lower it carefully onto the levelling
elements (17) with the lifting device in accordance with the Layout plan
6. Align the OPP crane system horizontally with the levelling elements (17)
7. Mount the wire ropes (18) in the eye bolts (21) and tension with a
turnbuckle (19)
3.3.5 Installing the web accumulator

If a double unwinder is being used for the OPP film (optional), an additional OPP
web accumulator is positioned between the coating unit and the double unwinder.
The installation process described below must be performed in the same way for
both web accumulators. For certain tasks, however, a different procedure is
required. If this is the case, a notice will appear to this effect.
Installation and setup of the web accumulator can be subdivided into the
following steps:
1. Move the web accumulator into the fitting position
2. Fit the gear motor
3. Move the web accumulator into the installation position
4. If a web accumulator for the fabric is installed, fit the guide axles

3. INSTALLATION
Moving the web accumulator into the fitting position

The web accumulator (1) is supplied in the transport position (E). Before fitting
and installation, the web accumulator (1) must be moved into the fitting
position (F).
Fig. 4769/3021
1 Web accumulator E Transport position

8 Transport bracket F Fitting position
9 Transport retainer
Procedure
1. Attach suitable load suspension equipment to the web accumulator (1)
2. Move the web accumulator (1) from the transport position (E) into the
fitting position (F) using a suitable lifting device
3. Remove the transport bracket (8).
4. Remove the transport retainer (9).

3. INSTALLATION
Fitting the gear motor
Fig. 4769/3040
1 Web accumulator 5 Shaft end

2 Bolts 6 Motor bracket
3 Shaft cover 10 Casing
4 Gear motor
Procedure
1. Fit the motor bracket (6) to the web accumulator (1)
2. Fit the gear motor (4) to the motor bracket (6) with bolts (2)
- Connect the gear motor (4) with the shaft end (5)
3. Fit the shaft cover (3)
4. Fit all casing (10) panels to the web accumulator (1)

3. INSTALLATION
Moving the web accumulator into the installation position
Fig. 4769/3041
1 Web accumulator F Fitting position

6 Nut G Installation position
7 Levelling bar H Web accumulator detail view
11 Bolt anchor J OPP web accumulator detail view
12 OPP levelling bar
Procedure
1. Position the levelling bars on the floor in accordance with the Layout
plan
- Web accumulator for fabric (H): on the levelling bars (7)
- OPP web accumulator (optional) (J): on the levelling bars (12)
2. Attach a suitable lifting device to the relevant web accumulator (1)
3. Move the web accumulator (1) from the fitting position (F) into the
installation position (G) using a suitable lifting device
4. Position the web accumulator (1) on the levelling bars in accordance
with the Layout plan
- Web accumulator for fabric (H): on the levelling bars (7)
- OPP web accumulator for fabric (optional) (H): on the levelling
bars (12)

3. INSTALLATION
5. Fasten the levelling bars (7) and (12) to the floor using bolt anchors (11)
6. Align the web accumulator (1) horizontally using the nuts (6)
If a web accumulator for the fabric is installed, fit the guide axles
The arrow indicates the fabric conveying direction.

Fig. 4769/3096
1 Axle holders 3 Bolts

2 Guide axles 4 Bolts
Procedure
1. Fit the axle holders (1) on the fabric infeed side with the bolts (3) and (4)
- Add a washer to the bolts (4)
2. Fit the guide axles (2) to the axle holders (1)

3. INSTALLATION
3.3.6 Installing the double unwinder for fabric and OPP film
The installation process described below must be performed in the same way for
the double unwinder and the OPP double unwinder (optional). For certain tasks,
however, a different procedure is required. If this is the case, a notice will appear
to this effect.
Assembly and installation of the double unwinder can be subdivided into the
following steps:
1. Installing the double unwinder
2. Installing the web edge control components
3. Installing the components for web edge control for the double fabric
unwinder
4. Installing the drives of the OPP double unwinder (optional)
Installing the double unwinder
Fig. 4769/3070
The arrow indicates the fabric conveying direction.

1 Double unwinder 4 Groove wheel
2 Bottom rail 13 Transport bracket
3 Guide rail X Load attachment points

3. INSTALLATION
Procedure
1. Remove the transport bracket (13)
2. Position the guide rail (3) and fasten it to the floor with frame screws in
3. Position the bottom rail (2) and align parallel to the guide rail (3) in
4. Fasten the bottom rail (2) to the floor using frame screws
5. Attach suitable load suspension equipment to the load attachment
points (X)
6. Lift the double unwinder (1) with a suitable lifting device and position it
on the bottom rail (2) and guide rail (3)
 All groove wheels (4) must be positioned evenly on the guide rail (3)
7. Remove the eye bolts from the load attachment points (X)
Installing the web edge control components

Once the double unwinder or OPP unwinder (optional) have been installed (see
Chapter 3.3.20), the components for the web edge control must be fitted.
Fig. 4769/3043
3 Guide rail 8 Spindle with universal joint

5 Gear motor 9 Position switch
6 Bracing strap 14 Stop bracket
7 Bracket

3. INSTALLATION
Procedure
1. Fit the bracing strap (6) to the guide rail (3)
2. Fit the bracket (7)
3. Thread the spindle with universal joint (8) into the bracket bearing (7)
and the bracing strap (6)
4. Fit the gear motor (5) to the guide rail (3)
6. Fit the stop brackets (14)
7. Tighten all bolts and nuts to the specified tightening torque (see
Chapter 8)
Installing the components for web edge control for the double fabric
unwinder
Fig. 4769/3044
2 Bottom rail 11 Beam

10 Deflection roller 12 Bracket
Procedure
1. Position the beam (11) with sensor and motor in accordance with the
Layout plan
2. Align the beam (11) parallel and horizontally to the deflection roller (10)
3. Fasten the brackets (12) to the floor with frame screws

3. INSTALLATION
Installing the deflection rollers and contact rods on the OPP double
unwinder (optional)
Fig. 4769/3072
1 OPP double unwinder 3 Deflection rollers

2 Contact rods 4 Deflection mounting
Install the deflection rollers (3) and contact rods (2) with the deflection
mountings (4) on the OPP double unwinder (1).
Installing the drives of the OPP unwinder (optional)
CAUTION!
Risk of injuries to the hands when opening the bearing cap!
Never reach into the gap at the bearing caps when opening the
bearing caps!
The installation process described below for OPP unwinder drive must be
performed in the same way for the OPP double unwinder (optional) drives and
the OPP single unwinder drive.

3. INSTALLATION
Fig. 4769/3073
1 OPP unwinder 20 Bearing cap

15 Cylindrical pins 21 Groove
17 Shim 22 Spacer
18 Gear motor 23 Spacer
19 Support
Procedure
1. Fit the spacer (22) to the OPP unwinder (1)
2. Fit the bearing cap (20) to the OPP unwinder (1)
 When fitting the bearing cap (20), make sure that the cylindrical
pins (15) are in the groove (21).
 The bearing caps (20) must be adjusted in accordance with the
3. Fit the supports (19) to the gear motor (18)
4. Insert the spacer disc (23) onto the shaft stub on the bearing cap (20)
5. Insert the gear motor (18) with support (19) onto the bearing cap (20)
and spacer (22)
6. Fasten the gear motor (18) with the shim (17)

3. INSTALLATION
3.3.7 Installing the base frame
Fig. 4769/3071
1 Uprights 9 Beam
2 Uprights 10 Beam
3 Uprights 11 Operating side beam
4 Uprights 12 Drive side beam
5 Uprights 13 Nuts
6 Uprights H Detail: Stop buffers and switch plate
Procedure
1. Position the uprights (1) to (6) on the floor and screw together with the
beams (9) and (10)
2. Install uprights (1) to (6) with the beams (9) and (10) attached in
3. Fit the beam, drive side (12)
4. Align the base frame horizontally with the nuts (13)

3. INSTALLATION
Fig. 4769/3090
7 Bracket with stop buffer 8 Switch plate
5. LX standard version:
- Install the bracket with stop buffer (7) to the beam (9), using
holes (K)
- Install the switch plate (8) to the beam (9), using holes (M)
6. CX version:
- Install the bracket with stop buffer (7) to the beam (9), using
holes (L)
- Install the switch plate (8) to the beam (9), using holes (N)
7. Fit the beam, operating side (11)
8. Fasten uprights (1) to (6) to the floor
9. Once the extruder unit (see Chapter 3.3.8) and co-extruder (optional)
(see Chapter 3.3.9) have been fitted, install the operating side
beam (11)

3. INSTALLATION
3.3.8 Installing the extruder unit
Fig. 4769/3004
1 Extruder unit 2 Transport frame
Procedure
1. Attach a suitable lifting device to the transport frame (2)
2. Lift the extruder unit (1) with transport frame (2)
 The total weight of the extruder unit (1) with transport frame (2) is
3,200 kg.
3. Position the extruder unit (1) on the base frame
- Position the groove wheels (3) on the rail (4)
4. Install the operating side beam (11) (see Chapter 3.3.7, Fig. 4769/3071)
5. Remove the transport frame (2)

3. INSTALLATION
Fig. 4769/3052
3 Groove wheel 7 Toothed belt

4 Rail 8 Cable tray
EMERGENCY STOP pull cord
5 Bracket for dosing hoses 9
for the extruder unit
6 Cable tray 10 Operating platform
6. Align the extruder unit (1) to the base frame

 All groove wheels (3) must be positioned on the rail (4) evenly.
7. Fit the cable tie (6)
8. Fit the bracket for the dosing hoses (5)
9. Fit and tension the toothed belt (7) (see Chapter 6.4.6, Fig. 4769/6022)
10. Fit a cable tray (8) for the energy chain
11. Hook in the cable for the extruder unit (9) EMERGENCY STOP pull
cord
12. Install the operating platform (10), including railings

3. INSTALLATION
Fig. 4769/3061
10 Operating platform A Drive side

11 Ladder B Operating side
NOTE!
When carrying out work on the extruder unit (1), the supplied
ladder (11) must be used.
The extruder unit (1) must be in maintenance position when the
ladder (11) is hooked into place (see Chapter 5.4.9).
Moving the extruder unit may cause damage to property!
When not being used, the ladder (11) must be stored on the
upright (see Chapter 3.3.16, Fig. 4769/3047).
Wear a hard hat when accessing the operating platform!
Access to marked areas prohibited!
13. Hook in the ladder (11)

14. Install the cable ducts in accordance with the Layout plan
15. Feed in the cables and hoses and connect in accordance with the
Circuit diagram

3. INSTALLATION
3.3.9 Installing the extruder unit with co-extruder (optional)
Fig. 4769/3074
1 Co-extruder 10 Bracket for connection pipe

2 Transport frame 11 Transport bracket
Procedure
1. Attach a suitable lifting device to the transport frame (2)
2. Lift the co-extruder (1) with transport frame (2)
 The total weight of the co-extruder (1) with transport frame (2) is
1,800 kg.

3. INSTALLATION
Fig. 4769/3076
2 Transport frame 5 Base frame

3 Groove wheel 6 Uprights
4 Rail 11 Transport bracket
3. Position the co-extruder (1) on the base frame (5)

- Position the groove wheels (3) on the rail (4)
4. Fit the upright (6) which will hold the hose
5. Remove the transport frame (2)
6. Align the co-extruder (1) to the base frame
 All groove wheels (3) must be positioned on the rail (4) evenly.
7. Position the extruder unit (7) on the base frame(5) as described in
Chapter 3.3.8
8. Install the operating side beam (11) on the base frame (5) (see
Chapter 3.3.7, Fig. 4769/3071)

3. INSTALLATION
Fig. 4769/3077
1 Co-extruder 8 Operating platform

5 Base frame 9 Coupling
6 Transfer piece 12
for the extruder unit
7 Extruder unit
9. Connect the extruder unit (7) and co-extruder (1) to the coupling (9)
10. Fit and tension the toothed belt (see Chapter 6.4.6, Fig. 4769/6022)
11. Fit a cable tray for the energy chain
12. Hook in the cable for the extruder unit (12) EMERGENCY STOP pull
cord
13. Install the operating platform (8), including railings
14. Remove the transport bracket (11) (see Fig. 4769/3076)
 The procedure for installing the transfer piece (6) is described in
Chapter 3.3.17.

3. INSTALLATION
NOTE!
Use the supplied ladder when working on the extruder unit (7) or
co-extruder (1).
ladder is hooked into place (see Chapter 5.4.9).
Moving the extruder unit (7) may cause damage to property!
When not being used, the ladder (11) must be stored on the
upright (see Chapter 3.3.16, Fig. 4769/3047).
3.3.10 Installing the metal separator and extruder hopper

An extruder hopper and metal separator must be installed on both the extruder
unit and the co-extruder (optional). The procedure described below must be
performed in the same way on the extruder unit and the co-extruder (optional).
WARNING!
The metal separators for the extruder and co-extruder (optional)
generate a strong magnetic field!
Risk to life for persons with pacemakers!
Personnel who are wearing a pacemaker must not stand within

the magnetic field!

3. INSTALLATION
Fig. 4769/3007
1 Cover 4 Adapter
2 Metal separator 5 Extruder cylinder
3 Pellet hopper 6 Clips
Procedure
1. Fit the adapter (4) with the aid of the hoop (6) to the extruder
cylinder (5)
2. Fit the pellet hopper (3) to the adapter (4)
3. Fit the metal separator (2) to the pellet hopper (3)
4. Fit the cover (1) to the metal separator (2)

3. INSTALLATION
3.3.11 Installing the hot air oven

Before fitting the hot air oven, the rollers must be fitted to the base frame.
Fig. 4769/3092
4 Roller 7 Roller
Elongated holes for installation
5 Beam P
with no corona
Elongated holes for installation
6 Roller Q
with corona
Procedure
1. Align and fit the roller (4) parallel to the edge of the beam (5)
2. Align and fit the roller (7) parallel to the roller (4)
- Standard version: Install the rollers (7) in the elongated holes (P).
- Version with corona (optional): Install in the elongated holes (Q)
3. Fit the roller (6)

3. INSTALLATION
The hot air oven is fitted after fitting the rollers.
Fig. 4769/3008
1 Uprights 3 Base frame

2 Hot air oven
Procedure
1. Position the hot air oven (2) on the base frame (3) using a suitable
lifting device
2. Fit the hot air oven (2) to the upright (1) and to the base frame (3)
3. Fit the upright (1) to the base frame (3)
4. Adjust the hot air oven (2) so it is level
6. Thread in the cables and hoses and connect in accordance with the
circuit diagram

3. INSTALLATION
3.3.12 Installing the corona (optional)
DANGER!
Danger to life from electric current!
Work on high-voltage components must only be carried out by
trained high-voltage technicians!
Safety measures for work on high-voltage components must be
adhered to!
DANGER!
Ozone produced during "corona discharge" can cause irritation of
the airways and fatigue. Exposure to ozone can cause those
affected to experience severe temple headaches.
 If the smell of ozone is detected, stop the machine
immediately with the <Stop> push button and deactivate the
corona on the display (see the lamiTEC LX/CX display user
manual).
 The operator must ensure that the ozone produced is
channelled outside and/or neutralised.
 The locally applicable regulations must be observed!
WARNING!
The corona generates a strong magnetic field!

the magnetic field!

documentation.

3. INSTALLATION
Fig. 4769/3089
1 Transverse connector 8 Blower

2 Beam 9 Cyclone
3 Base frame 10 Support
4 Corona 11 Uprights
5 Suspension bracket 12 Tank
6 Thickness sensor 13 Piping
7 Mounting bracket
Procedure
1. Fit the two transverse connectors (1) to the upright of the hot air oven
and to the base frame (3)
2. Fit the suspension bracket (5) to the corona (4)
3. Fit the corona (4) to the transverse connectors (1)
4. Fit the thickness sensor (6) to the mounting brackets (7) on the hot air
oven

3. INSTALLATION
5. Fit the blower (8) to the base frame (3)

6. Fit the cyclone (9) with the support (10) to the upright (11)
7. Clamp the tank (12) to the cyclone (9)
8. Connect the pipes (13) from the corona (4) to the cyclone (9)
9. Guide the pipe connection outside for routing the ozone
3.3.13 Installing the bottom rollers on the base frame
Fig. 4769/3015
1 Bottom rollers 3 Base frame

2 Bottom rollers 4 Rollers
Procedure
1. Position the bottom rollers (1) and (2) in accordance with the Layout
plan
- Align the bottom rollers (1) parallel to the rollers (4) on the base
frame (3)
2. Fasten the bottom rollers (1) and (2) to the floor using frame screws

3. INSTALLATION
3.3.14 Installing the coating unit
Fig. 4769/3087
1 Levelling bars 4 Nut

2 Coating unit 7 Transport lock
3 Base frame of the coating unit X Load attachment points
Procedure
1. Position and fasten the levelling bars (1) to the floor in accordance with
the Layout plan
points (X) or use a lifting device under the base frame (3) of the coating
unit
3. Position the coating unit (2) on the levelling bars (1) with a suitable
lifting device
4. Horizontally align the coating unit (2) with the nuts (4)
6. Thread in the cables and hoses and connect in accordance with the
circuit diagram

3. INSTALLATION
Fig. 4769/3088
2 Coating unit 6 Uprights

3 Base frame of the coating unit 8 Step
5 Angle bracket 9 Handrail
7. Fit the coating unit (2) with the angle bracket (5) to the uprights (6) on
the base frame
8. Remove the transport locks (7)
9. Fit the step (8) with handrail (9)
10. Fit all safety switches and safety covers to the operating side and drive
side of the coating unit

3. INSTALLATION
Checking the alignment of the coating unit
Fig. 4769/3057
2 Base frame 12 Measure

3 Connecting beam 13 Extruder runner rail
11 Spirit level x 1,250 mm
Check the distance (x) between the extruder running rail (13) and the connecting
beam (3) on the operating side and drive side as shown in Fig. 4769/3057. The
distance must be equal on both sides; correct the distance (x) if necessary. Then
check the horizontal alignment of the coating unit and adjust if necessary.

3. INSTALLATION
Fig. 4769/3065
11 Spirit level 14 Plate

12 Measure w 510 mm
13 Extruder runner rail beam
Check the distance (w) between the plate (14) and the extruder runner rail
beam (13) on the operating side and drive side as shown in Fig. 4769/3065.
Fig. 4769/3058
15 Fork head
Adjust the distance (w) on the drive side and on the operating side with the fork
heads (15). Distance (w) must be equal on both sides.

3. INSTALLATION
3.3.15 Installing the register control (optional) for the OPP unwinder
The attachment (3) for the print mark readers of the register control comes pre-
mounted to the coating unit. The repeat roller adjuster (1) and the bottom
rollers (2) are fitted on the floor, underneath the hot air oven.
Fig. 4769/3080
Attachment for print mark

1 Repeat roller adjuster 3
readers
2 Bottom rollers 4 Nuts
Procedure
1. Position and fasten the repeat roller adjuster (1) to the floor using bolt
anchors, in accordance with the Layout plan
- Align the rollers for the repeat roller adjuster (1) parallel to the rollers
on the base frame
2. Horizontally align the repeat roller adjuster (1) with the nuts (4)
3. Position the bottom rollers (2) according to the Layout plan and fix to
the floor using frame screws
- Align the bottom rollers (1) parallel to the rollers on the base frame

3. INSTALLATION
3.3.16 Installing the wide-slot die
Fig. 4769/3082
1 Wide-slot die 4 Protective grille

2 Die adapter 5 Suction nozzle
3 Cover C 210/250 Nm
Procedure
1. Position the wide-slot die (1) on the die adapter (2) with a suitable lifting
device
2. Fit the wide-slot die to the die adapter (2) with bolts
- Coat the bolts with a high-temperature paste (Molykote HSC)
NOTE!
All bolts in parts carrying melt must be tightened cold to the max.
tightening torque (see Chapter 5.4.2, Fig. 4769/5017 and Fig.
4769/5059)!
- Tighten the bolts cold to tightening torque (C) 210 Nm

- Tighten the bolts evenly and in a diagonal pattern
- Align the wide-slot die (1) parallel to the chill roller on the coating
unit and parallel to the edge of the beam (5) (see Chapter 3.3.11,
Fig. 4769/3092)

3. INSTALLATION
3. Only install the pressure sensors and thermocouples for the individual
wide-slot die (1) zone heaters when the machine is at operating
temperature
4. Fit the covers (3)
5. Fit the protective grille (4)
6. Fit the suction nozzles (5)
Fig. 4769/3047
1 Wide-slot die 11 Base frame

6 Blower 12 Receptacle
7 Slide-in tube 15 Hose
8 Piping 16 Ladder
9 Holder A Drive side
10 Uprights B Operating side
7. Fit the blower (6)

8. Position the upright (10) and fasten it to the floor with frame screws in
9. Fit the piping (8), incl. slide-in tube (7), to the blower (6) and to the
upright (10)
NOTE!
The operator must ensure that gases produced at the wide-slot
die (1) are channelled outside and/or neutralised.

3. INSTALLATION
10. Install the receptacle (12) under the wide-slot die (1) on the drive
side (A) in at accordance with the Layout plan
11. Connect the hose to the (15) piping (8) and close the ball valve at the
bottom of the hose (15)
12. Hook the ladder (16) on the upright (10)
NOTE!
The ladder (16) must be used when carrying out work on the
extruder unit.
ladder (16) is hooked into place (see Chapter 5.4.9).
The ladder (16) must be stored on the upright (10) whenever it is
not being used.
Checking the distance between the wide-slot die and the base frame
Fig. 4769/3016
1 Wide-slot die 14 Measure

11 Base frame u Approx. 420 mm
13 Chill roller
Check the distance (u) between the wide-slot die (1) and the base frame (11) on
the operating side and drive side as shown in Fig. 4769/3016 and correct
distance (u) if necessary. Distance (u) must be equal on both sides.

3. INSTALLATION
3.3.17 Installing the feed block and wide-slot die for the co-extruder (optional)
Fig. 4769/3051
1 Feed block 5 Melt filter of the co-extruder

2 Melt pressure control valve 6 Co-extruder
3 Transfer piece 7 Extruder
4 Corner piece
Procedure
1. Fit the feed block (1) to the melt pressure control valve (2)
NOTE!
tightening torques (see Chapter 5.4.2, Fig. 4769/5037)!

- Adjust the feed block (1) so it is level
2. Fit the transfer piece (3) between the feed block (1) and the corner
piece (4)
- Apply the squeeze-type gaskets (see Chapter 6.4.9, Fig. 4769/6040)
3. Remove the connection tube bracket (see Chapter 3.3.9,
Fig. 4769/3074).

3. INSTALLATION
Fig. 4769/3053
1 Feed block 10 Wide-slot die

8 Suction nozzles 11 Cover
9 Protective grille X Load attachment points
4. Attach suitable lifting device at the load bearing points (X)

5. Position the wide-slot die (10) on the feed block (1) with a suitable lifting
device
6. Fit the wide-slot die (10) to the feed block (1) with bolts
NOTE!
tightening torque (see Chapter 5.4.2, Fig. 4769/5037)!

- Adjust the wide-slot die (1) so it is level
- Align the wide-slot die (1) parallel to the chill roller on the coating
unit and parallel to the edge of the beam (5) (see Chapter 3.3.11,
Fig. 4769/3092)
7. Only install the pressure sensors and thermocouples for the individual
wide-slot die (1) zone heaters when the machine is at operating
temperature

3. INSTALLATION

9. Fit the protective grille (9)
11. Fit the blower, piping and uprights for the die extractor (see Chapter
3.3.16, Fig. 4769/3047)
12. Check the distance between the wide-slot die and the base frame (see
Chapter 3.3.16, Fig. 4769/3016)
3.3.18 Installing the panelling on the base frame
Fig. 4769/3059
1 Left upright 7 Safety switch

2 Left door 8 Bracket
3 Crossbeam 9 Angle with actuator
4 Foot plate 10 Bolt
5 Right door 11 Running wheel
6 Right upright 12 Cover
Procedure
1. Fit the crossbeam (3) between the left (1) and right (6) uprights
2. Fit the angle (8) to the crossbeam (3)
3. Fit the safety switch (7) for the left door (2) to the bracket (8) (see
Chapter 6.3.10)
4. Fit the safety switch (7) for the right door (5) to the right upright (6)
(see Chapter 6.3.10)

3. INSTALLATION
5. Fit angles with actuator (9) to both doors (2) and (5)
6. Partially remove the guide profile from the base frame
7. Mount doors (2) and (5)
- The running wheels (11) must be located in the recesses on the
crossbeam (3)
8. Horizontally align the crossbeam (3) using the bolts (10)
 It must be possible to move both doors (2) and (5) slightly by hand
 The actuators must engage in the safety switch (7).
9. Fit the guide profiles and cover (12)
10. Fit the foot plates (4)
3.3.19 Installing the bridge (optional)
Fig. 4769/3054
1 Coating unit 6 Signal tower

2 Ladder 7 Base
3 Operating side connecting beam 8 Bridge
4 Drive side connecting beam 9 Step
5 Turning frame

3. INSTALLATION
Procedure
1. Install the bridge (8), including railings
2. Hook in the ladder (2)
3. Fit the operating side connecting beam (3) and drive side connecting
beam (4) to the coating unit (1) and to the step (9)
4. Align it with the connecting beams (3) and (4) so it is horizontal
5. Fit the turning frame (5) to the connecting beams (3) and (4)
6. Fit the signal tower (6) to the base (7) of the operating side connecting
beam (3)
7. Attach the deflection roller on the step (9) between the connecting
beams (3) and (4)
8. Attach the deflection roller on the bridge (8) between the connecting
beams (3) and (4)
3.3.20 Installing the OPP unwinder (optional)

The OPP unwinder uses either a single unwinder design or an OPP double
unwinder design (optional) with an additional OPP web accumulator, depending
upon the desired application. For information on installing the OPP double
unwinder, see Chapter 3.3.6.
Fitting and installation of the single unwinder can be subdivided into the following
steps:
1. Install the single unwinder
2. Fit the components for web edge control (see Chapter 3.3.6,
Fig. 4769/3043)
3. Fit the OPP unwinder drive (see Chapter 3.3.6, Fig. 4769/3073)

3. INSTALLATION
Installing the single unwinder
Fig. 4769/3046
1 Single unwinder 4 Groove wheel

2 Bottom rail X Load attachment points
3 Guide rail
Procedure
1. Position the guide rail (3) and fasten it to the floor with frame screws in
2. Position the bottom rail (2) and align parallel to the guide rail (3) in
3. Fasten the bottom rail (2) to the floor using frame screws
points (X)
5. Lift the single unwinder (1) with a suitable lifting device and position it
on the bottom rail (2) and guide rail (3)
 All groove wheels (4) must be positioned evenly on the guide rail (3)
6. Remove the eye bolts from the load attachment points (X)

3. INSTALLATION
3.3.21 Assembling and installing the edge strip extractor
Fig. 4769/3097
1 Edge trimmer 4 Wire-mesh container

2 Blower 5 Uprights
3 Piping 6 Injector
Procedure
1. Position the upright (5) according to the Layout plan and fix to the floor
using frame screws
2. Position the blower (2) and fasten it to the floor with frame screws in
3. Fit the injector (6) to the blower (2)
4. Fit the pipes to the edge trimmer (1) beginning at the upright (5) in
5. Install the wire-mesh container (4) in accordance with the Layout plan

3. INSTALLATION
3.3.22 Installing the "process-control" edge strip return (optional)
Fig. 4769/3081
1 Cutting mill 3 Piping

2 Return feed system 4 Hose
Procedure
1. Install the cutting mill (1) in accordance with the Layout plan
2. Fit the return feed system (2) to the extruder
3. Establish the connection from the cutting mill (1) to the return feed
system (2) with piping (3) and a hose (4), in accordance with the Layout
plan


3. INSTALLATION
3.3.23 Installing the bagging station (optional)
Fig. 4769/3084
1 Frame 3 Bolts
2 Uprights 4 Tank
Procedure
1. Attach all four uprights (2) to the frame (1) using the bolts (3) and
washers
2. Fit the tank (4)

3. INSTALLATION
Fig. 4769/3085
2 Uprights 5 Pneumatic cylinder
3. Mount pneumatic cylinders (5) to all four uprights (2)

4. Connect the pneumatic cylinders (5) in accordance with the Pneumatic
diagram
5. Perform wiring in accordance with the Circuit diagram
6. Attach suitable load suspension equipment to the frame (1)
7. Lift the bagging station using a suitable lifting device, and position it in
8. Fasten the upright (2) to the floor with frame screws
9. Carry out steps 1 to 8 for the second bagging station

3. INSTALLATION
Fig. 4769/3086
6 Bagging station 9 Flap box

7 Bagging station 10 Pipes
8 Blower 11 Flap box
10. Fit the flap box (9) to the blower (8)

11. Connect the pipes from the flap box (9) to bagging station (6) and
bagging station (7)
- Install the flap box (11)
12. Connect the pipes (10) for the "process control" edge strip return
(optional) to the return feed system
3.3.24 Installing the winder

Assembly and installation of the winder can be subdivided into the following
steps:
1. Installing the contact winder
2. Fitting the oscillator
3. Fitting the infeed roller
4. Fitting the unwinding aid and unwinding locking device

3. INSTALLATION
Installing the contact winder
Fig. 4769/3078
1 Guide rail 6 Transport bracket

2 Guide rail 13 Transport beam
3 Contact winder X Load attachment points
Procedure
1. Remove all four transport brackets (6) inside the contact winder (3)
2. Position the guide rail (2) on the floor and fasten with frame screws in
- Adjust the guide rail (2) so it is level
points (X)
4. Lift the contact winder (3) with a suitable lifting device, then lower on to
the guide rail (2)

3. INSTALLATION
Fig. 4769/3027
1 Guide rail 4 Running wheel

2 Guide rail 5 Groove wheel
3 Contact winder
5. Position the guide rail (1) under the contact winder

6. Fit the groove wheel (5) to the guide rail (2)
7. Thread the groove wheel (4) into the guide rail (1)
8. Fasten the guide rail (1) to the floor with frame screws
9. Remove the transport beam (13) (see Fig. 4769/3078)

3. INSTALLATION
Fitting the oscillator
Fig. 4769/3028
1 Guide rail 8 Rod

3 Contact winder 9 Adjustment plate
6 Plate with spacers 10 Lever
7 Tube
Procedure
1. Fit the plate with spacers (6) to the guide rail (1)
2. Fit the lever (10) and adjustment plate (9)
3. Insert the rod (8) into the pipe (7) and attach to the adjustment plate (9)
and the plate (6)

3. INSTALLATION
Fitting the infeed roller
Fig. 4769/3079
1 Guide rail 14 Infeed roller
Fit the infeed roller (14) to the guide rail (1).
Fitting the unwinding aid and unwinding locking device
Fig. 4769/3029
11 Unwinding aid 12 Unwinding locking device
Procedure
1. Position the unwinding aid (11) and unwinding locking device (12) and
fasten to the floor with frame screws in accordance with the Layout plan

3. INSTALLATION
3.3.25 Installing the volumetric dosing unit with feed station

The volumetric dosing unit with feed station must be installed in accordance with
the Layout plan.
For further information on installing the volumetric dosing unit with

feed station, see the Technical manual for the voluTEC volumetric
3.3.26 Installing the gravimetric batch dosing unit (optional)

The gravimetric batch dosing unit must be installed in accordance with the Layout
plan.
For further information on installing the gravimetric batch dosing

unit (optional), see the Technical manual for the graviTEC batch
3.3.27 Installing the vacuum conveyor (optional)
Fig. 4769/3093
1 Pellet feed station 4 Connection (for pellets)

2 Extraction nozzle 5 Switchover valve
3 Connection (for air) 6 Pellet hopper

3. INSTALLATION
Procedure
1. Position the pellet feed station (1) and fasten it to the floor with frame
2. Fit the pellet hopper (6) to the extruder
3. Attach a conveyor tube between the extraction nozzle (2) and the
connection (4)
4. Attach a hose between the connection (3) and the hose nozzle of the
switchover valve (5)
3.3.28 Installing the cooling water distributor
Fig. 4769/3095
1 Bracket 3 Tube
2 Nut 4 Bypass
Procedure
1. Attach a suitable lifting device to the base (1)
2. Position the cooling water distributor bracket (1) and fasten it to the floor
with frame screws in accordance with the Layout plan
3. Align the pipe (3) with the nut (2) if necessary
4. Fit the bypass (4)
3.3.29 Water connection

All lines for the water supply up to the machine must be already installed. The
connection should be made in accordance with the Layout plan.
For further information on the water connection, see the Layout

plan.

3. INSTALLATION
3.3.30 Electrical connection

Work on the electrical equipment may only be performed by qualified electricians
and must comply with local regulations.
For further information on the machine's wiring, see the Circuit

diagram.
3.3.31 Pneumatic connection
NOTE!
The pneumatic system is designed to be oil-free.
The supplied compressed air must be free of oil and water!
All lines for the compressed air supply up to the machine must be already
installed. The connection should be made in accordance with the Layout plan.
For further information on the pneumatic connection, see the

Layout plan.

4. SETTINGS
4 SETTINGS
DANGER!
Risk of injury due to moving machinery!
When configuring settings on the machine, the <Main switch>
must always be set to OFF ("0" position) and be safeguarded
against being switched back on!
The machine must remain switched on for certain tasks. If this is

the case, a notice to this effect will appear in the document.
WARNING!
Risk of injury due to residual pneumatic energy!
The pneumatic system is under pressure, even after the machine
has been switched off.
Before carrying out work on the pneumatic system, it is vital that
you depressurise the system!
WARNING!
Risk of injury due to residual hydraulic energy!
The hydraulic system is under pressure, even after the machine
Before performing work on the hydraulic system, it is vital that you
depressurise the system!
WARNING!
When working at heights, a suitable ladder must be used.
Work at heights not reached by the ladder may only be performed
when using a suitable safety harness.
NOTE!
When carrying out adjustment tasks, unless otherwise stated, the
extruder unit must be in maintenance position (see Chapter 5.4.9).
For further information on the settings for purchased components,

see the respective manufacturer's documentation.
For further information on the settings for the display, see the
lamiTEC LX/CX display user manual.

4. SETTINGS
4.1 Pneumatic operating pressure

After creating the compressed air connection, the operating pressure must be set
to between 5 - 7 bar on the maintenance unit (1). The maintenance unit (1) is
located in the side box of the coating unit on the drive side.
Fig. 4769/4042
1 Maintenance unit A Drive side

2 Covers B Operating side
Procedure
1. Remove the covers (2)
2. Adjust the operating pressure on the maintenance unit (1)
4.2 Hydraulic operating pressure

The gauge for hydraulic operating pressure on the winder is located on the
winder operating unit (see Chapter 5.2.12, Fig. 4769/5082).
The speeds of the hydraulic pistons can be adjusted as necessary using the
throttles on valves on the hydraulic unit (see the manufacturer's documentation).

4. SETTINGS
4.3 Cooling water circuit
CAUTION!
Trip hazard on the cooling water distributor!
Pay attention to the bracket!
Fig. 4769/4073
1 Lever 4 Control valve

2 Pressure gauge 5 Lever
3 Valves
Lever positions
Open Closed

4. SETTINGS
The following machine parts are supplied with cooling water via the water supply
unit:
Switching cabinet heat exchanger

A Chill roller and pressure roller supply G
return
Switching cabinet heat exchanger
B Chill roller and pressure roller return H
supply
C Cooler return I Extruder return
D Cooler supply J Extruder supply
E Display heat exchanger return K Co-extruder (optional) return
F Display heat exchanger supply L Co-extruder (optional) supply
The following must be observed with regard to the water supply unit:
 Max. cooling water supply temperature 15 °C
 The pressure indicated on the pressure gauge (2) when the pump is
running must be min. 5 bar
 For operation, open the ball valves with the levers (1), and slightly open
the ball valve on the bypass with the lever (5)
 Check the marking on the hexagon on the valve (3)
 If the marking is vertical, the valve (3) is open, if the marking is
horizontal, the valve is closed.
NOTE!
Possible negative impact on machine output.
The temperature of the cooling water at the sleeve on the extruder
cylinder or cylinder of the co-extruder (optional) must be above
20°C!
If the water temperature is reduced, the water condenses in the
infeed zone of the extruder and co-extruder (optional) and the
cylinder bores and the extruder screw oxidise.
For further information on cooling water requirements, see the

technical specification.
4.4 Double unwinder

CAUTION!
Trip hazard in the area of the double unwinder!
Beware of the guide rails!

4. SETTINGS
4.4.1 Adjusting the web edge control sensor

The position of the sensor is dependent on the width of the fabric web. The
position of the sensor on the web edge is changed by an actuator, and must be
set on the display (see the lamiTEC LX/CX display user manual).
4.4.2 Calibrating the loadcell
The machine must be switched on to calibrate the loadcell (see

Chapter 5.4.1). Pay attention to all safety instructions, as during
operation (see Chapter 5.5).
Fig. 4769/4037
1 Calibration weight 5 - 25 kg 4 Deflection roller

2 Sensing roller 5 Rope
3 Loadcell

4. SETTINGS
Procedure
1. Remove the drawn-in web in order to relieve the load on the sensing
roller (2)
2. On the display, select the corresponding loadcell (3) and start
calibration (see the lamiTEC LX/CX display user manual)
3. Secure the calibration weight (1) to a rope (5) and thread in the rope (5)
in accordance with the feed diagram (see Chapter 5.3.1)
- Recommended weight: 5 - 25 kg
4. Secure the rope (5) in the direction of the arrow in order to put a load on
the sensing roller (2)
5. On the display, perform the necessary steps (see lamiTEC LX/CX
display user manual)
6. Remove the calibration weight (1) and rope (5)
4.5 Adjusting the web accumulator start

When the roll is changed on the double unwinder or OPP double unwinder
(optional), the respective web accumulator ensures that the speed remains
constant.
The diameter of the roll for starting the web accumulator is adjusted on the
display (see the lamiTEC LX/CX display user manual).
4.6 Adjusting the hot air oven

Preheating the fabric web in the hot air oven ensures better adhesion of the
coating material.
The speed of the blower and the temperature set values are adjusted on the
display (see the lamiTEC LX/CX display user manual). The temperature is
dependent on the specification of the fabric to be processed. The temperature
must be determined during operation (max. 180°C):
 Guide value for 25 g coating weight/2 x 65 µm  approx. 120°C
If the speed of the coating unit is reduced or the machine stops, to avoid
shrinkage from the fabric web spending too long in the hot air oven, the bottom
section of the hot air oven can be pivoted out. In addition, the air for preheating is
redirected.
The flap position in the hot air oven is factory set, and can be altered if needed.
To ensure that the air is redirected, the flap position in the hot air oven must be
set using the stop on the drive side.

4. SETTINGS
Fig. 4769/4004
1 Nut v Approx. 35 mm
2 Bolt for stop
Procedure
1. Loosen the nuts (1)
2. Rotate the nut (2) and set the distance (v)
3. Tighten the nuts (1) in opposite directions
4.7 Corona (optional)
DANGER!
adhered to!

4. SETTINGS
DANGER!
manual).
WARNING!

the magnetic field!

documentation.
The fabric is guided through the corona. An air plasma is formed between the
high-voltage electrodes and the backing roller. This causes the surface of the
fabric to be oxidised, and ensures better adhesion of the coating to the fabric.
The high voltage electrodes are pivoted in or out.
The corona is activated or deactivated on the display.
If the corona is activated on the display, it is switched on automatically when the
machine starts up and switched off when it stops.
The parameters for the corona are entered on the display.

4. SETTINGS
4.7.1 Adjusting the electrodes

A sign provides information on the spacing between the electrodes. The spacing
should differ depending on the version.
The electrodes are available in the following versions:
 Steel electrodes (Fig. 4769/4071)
 Ceramic electrodes (optional) (Fig. 4769/4072)
Fig. 4769/4071 Fig. 4769/4072
Vertical adjustment for positioning the height of the electrodes.

The setting must be the same on the operating and drive side.
Horizontal adjustment for adjusting the parallelism of the electrodes.

The setting must be the same on the operating and drive side.

4. SETTINGS
4.7.2 Adjusting the thickness monitoring device

Before feeding the fabric web into the hot air oven, a thickness check is
performed. If the set thickness is exceeded, the switch plate (2) is raised causing
the electrodes in the corona to be swivelled upwards.
Fig. 4769/4006
1 Hot air oven 4 Stop buffer

2 Switch plate 5 Proximity switch
3 Nut
Procedure
2. Adjust the stop buffer (4)
3. Tighten the nut (3)
 The setting must be the same on the operating and drive side.
4. Adjust the proximity switch (5) if necessary
 The proximity switch (5) must be adjusted such that distance to the
switch plate is approx. 1 mm.

4. SETTINGS
4.8 Extruder unit

In the extruder an extruder screw transports the coating material through a
heated cylinder and on to the melt filter. During this process, the material is
plasticised and homogenised. The extruder is moved in and out on a base frame.
The metal separator removes ferromagnetic impurities from the pellets, which
pass into the extruder via a pellet hopper.
The filter block with heating elements is equipped with filter tape which cleans the
plastic melt flowing through. It is positioned between the extruder and the wide-
slot die or feed block (optional).
4.8.1 Setting the extruder control

The electronic control for the zone heaters and cooling fans is located in the
switching cabinet on the extruder. Each zone heater is electrically safeguarded
separately according to the zone heater loads anticipated for the machine.
There is a built-in thermocouple cut-out. If the measurement circuit is broken, the
regulator responds and the heater remains switched off. A corresponding alarm is
shown on the display.
The set value for the zone heaters must be set on the display (see the
lamiTEC LX/CX display user manual).
4.8.2 Setting the speed of the extruder drive

The speed of the extruder drive is dependent on the speed of the coating unit.
The speed of the coating unit is adjusted on the display (see the lamiTEC LX/CX
display user manual).
4.8.3 Adjusting the melt filter on the extruder

The plastic plug (2) formed at the filter output (3) in the water-cooled area is
continuously under pressure. In the event of a filter change, the installed heating
elements soften the front of the plastic plug (2) at the filter output (3).
The filter tape (1) is clamped by this plastic plug (2). If the plastic plug becomes
softer due to heating, the filter tape (1) moves on and a change in the filter
surface (sieve change) is achieved.

4. SETTINGS
Fig. 4769/4038
1 Filter tape 3 Filter output

2 Plastic plug
Filter tape feed

The heat volume required for the filter tape feed is dependent on the material to
be processed and on the melt pressure.
If the filter tape feed is too low, the temperature must be increased. The filter tape
feed is set on the display (see the lamiTEC LX/CX display user manual).
Feeding in the filter tape
Fig. 4769/4039
1 Coarse filter tape 3 Filter input

2 Fine filter tape
The filter tapes (1) and (2) must be slid into the narrow gap at the filter input (3) –
the coarse tape on the die side and the fine tape on the extruder side. The filter
tape must protrude from the filter output by approx. 12 mm.

4. SETTINGS
Adjust the melt barrier at the filter input
NOTE!
Possible damage to property!
The melt barrier must only be adjusted when cold!
The melt filter must be cleaned beforehand (see Chapter 6.4.4)!
Fig. 4769/4040
1 Filter tape 5 Grub screw

2 Filter tape 6 Bolt
4 Nut 7 Melt barrier
Procedure
1. Loosen the bolts (6)
3. Adjust the grub screws (5) such that the filter tapes (1) and (2) touch
the melt barrier (7) lightly
4. Tighten the nuts (4)
5. Tighten the bolts (6)
4.9 Co-extruder (optional)

The co-extruder with melt filter is a part of the additional equipment for producing
fabric coated in OPP film. The melt filter of the co-extruder takes the form of a
manual sieve changer.

4. SETTINGS
In the co-extruder a screw transports the additional coating material through a

heated cylinder and on to the manual sieve changer. At the same time the
additional material is plasticised and homogenised. The co-extruder can be
moved in and out on the base frame together with the extruder. The metal
separator removes ferromagnetic impurities from the pellets, which pass into the
co-extruder via a pellet hopper.
The plastic melt flowing through is cleaned by the manual sieve changer. It is
positioned between the co-extruder and the transfer piece to the feed block.
4.9.1 Setting the co-extruder control

The electronic controls for the zone heaters and cooling fans are located in the
switching cabinet on the co-extruder. Each zone heater is electrically
safeguarded separately according to the zone heater loads anticipated for the
machine.
There is a built-in thermocouple cut-out. If the measurement circuit is broken, the
regulator responds and the heater remains switched off. A corresponding alarm is
shown on the display.
The set value for the zone heater load must be set on the display (see the
4.9.2 Speed of the co-extruder drive

The speed of the co-extruder drive is dependent on the speed of the coating unit.
The speed of the coating unit is adjusted on the display (see the lamiTEC LX/CX
4.9.3 Adjusting the melt filter on the co-extruder

The melt filter of the co-extruder takes the form of a manual sieve changer.
The manual sieve changer intermittently cleans the plastic melt in the co-extruder
as it flows through it.
It consists of replaceable sieves, which are held inside the housing by a sieve
plate holder. This is positioned between the co-extruder and corner piece to the
feed block. If a sieve change is necessary, the sieve is moved to sieve change
position by operating the ratchet.
For further information on the settings for the manual sieve

changer, see the manufacturer's documentation.

4. SETTINGS
4.10 Adjusting the melt pressure control valve
The machine must be switched on to adjust the melt pressure

control valve (see Chapter 5.4.1). The extruder and co-extruder
(optional) must be heated up to operating temperature. Pay
attention to all safety instructions, as during operation (see
Chapter 5.5).
Fig. 4769/4007
1 Bolt 2 Spindle
The melt pressure control valve is used to adjust the melt pressure upstream of
the melt filter. The melt pressure upstream of the melt filter is dependent on the
material to be processed.
To adjust, loosen the bolts (1) and rotate on the spindle (2):
 Rotating to the left reduces the pressure upstream of the melt filter
 Rotating to the right increases the pressure upstream of the melt filter
 The melt pressure upstream of the melt filter should be set to
approx. 100 bar with a screw speed of 100 rpm. The melt pressure
upstream of the melt filter is shown on the display (see the
4.11 Feed block (optional)

The feed block is a part of the additional equipment for producing fabric coated in
OPP film. The feed block allows for an additional coating film to be applied.
For further information on the feed block, see the manufacturer's

documentation.

4. SETTINGS
4.12 OPP unwinder (optional)

The OPP unwinder is a part of the additional equipment for producing fabric
coated in OPP film.
The settings described below must be performed in the same way on the single
unwinder and OPP double unwinder (optional). For certain tasks, however, a
different procedure is required. If this is the case, a notice will appear to this
effect.
CAUTION!
4.12.1 Adjusting the web edge control turning frame
CAUTION!
Risk of injury from using unsuitable climbing aids!
When performing adjustment work on the bridge, the ladder (2)
must be used (see Chapter 3.3.19, Fig. 4769/3054)!
When adjusting the web edge control on the turning frame, the
machine must be switched on. The same safety instructions are
applicable as during operation (see Chapter 5.5).
Adjusting the web edge control sensor

The web edge control sensor takes the form of an ultrasound sensor. It is fitted to
the turning frame on the bridge. The position of the sensor is dependent on the
width of the OPP film web. The position of the sensor is adjusted using the <Web
edge sensor to left/right> switch on the operating units of the coating unit (see
Chapter 5.2.12, Fig. 4769/5078).

4. SETTINGS
Fig. 4769/4060
1 OPP unwinder 3 Sensor

2 Edge of the OPP film web 4 Positioning drive
Procedure
1. Hold the <Web edge sensor to left/right> switch to the left or right
 The sensor (3) is moved in the appropriate direction by means of the
actuator (4).
 The sensor (3) should be positioned such that the edge of the OPP
film web (2) runs through it centrally.
 Pay attention to the mark on the sensor!
2. Release the <Web edge sensor to left/right> switch to confirm the
position
 The sensor is in position.
 The <Web edge sensor to left/right> switch is in the centre position.
Adjusting the position of the OPP unwinder

Once the web edge control sensor (3) has been adjusted, the position of the
unwinder must be checked and readjusted if necessary. The OPP unwinder must
be adjusted such that the OPP film web runs into the turning frame, and into the
coating unit, in the centre.

4. SETTINGS
For information on the single unwinder operating unit, see

Chapter 5.2.12, Fig. 4769/5055.
For information on the OPP double unwinder (optional) operating
unit, see Chapter 5.2.12, Fig. 4769/5056.
 Hold the <Unwinder to left/right> switch to the right

 The OPP unwinder is moved to the right.
 Hold the <Unwinder to left/right> switch to the left
 The OPP unwinder is moved to the left.
4.12.2 OPP unwinder (optional) web edge control

The web edge control ensures that the web of OPP film is fed precisely into the
coating unit at the bridge.
The settings for web edge control must be performed in the same way on the
single and OPP double unwinder (optional).
To adjust the web edge control, the machine must be switched on

and in manual mode (see Chapter 5.4.1). Pay attention to all
safety instructions, as during operation (see Chapter 5.5).

Fig. 4769/4053
For further information on the web edge control, see the

manufacturer's documentation. Follow the instructions of the
manufacturer!

4. SETTINGS
The machine must be switched on to calibrate the loadcell (see

Fig. 4769/4052
1 Calibration weight 5 - 25 kg 4 Deflection roller

3 Loadcell
Procedure
1. Remove the drawn-in OPP film in order to relieve the load on the
sensing roller (2)
3. Secure the calibration weight (1) to a rope (5) and thread in the rope (5)
on the OPP unwinder in accordance with the feed diagram (see
Chapter 5.3.5)
- Recommended weight: 5 - 25 kg (max. 30 kg)
4. Secure the rope (5) in the direction of the arrow in order to put a load on
the sensing roller (2)

4. SETTINGS
4.13 Register control (optional) for the OPP unwinder
The distance between the print marks on the front and back of the fabric web (4)
coated on both sides is determined by the print mark readers (1) and (2).
Depending on the deviation (print mark on the front leading or trailing the one on
the back), the register roller (3) is adjusted to the left or to the right (as seen from
the operating side). This compensates for the difference between the front and
the back and the placement of the two print marks coincides.
The print mark readers (1) and (2) for the register control are mounted on the
coating unit. The position of the print mark readers (1) and (2) is dependent on
the print mark being used for referencing.
The position of the print mark is taught in on the display (see the lamiTEC LX/CX
The colour of the print mark is taught in using the switch on the operating unit or
on the print mark reader itself.
The adjustment of the register roller (3) to the right is interrupted if the min. web
tension (default 5 kg) is not attained. The adjustment to the left is interrupted if
the max. web tension (default 90 kg) is exceeded.
Once the tension of the fabric web (6) which is coated on one side has been
equalised, register roller (3) adjustment proceeds, until the print marks coincide.
The machine must be switched on while the print mark readers of

the register control are being taught in and positioned. The same
safety instructions are applicable as during operation (see Chapter
5.5).

4. SETTINGS
Adjusting the print mark readers
Fig. 4769/4064
Fabric web with OPP film on both

1 Upper print mark reader 4
sides
2 Lower print mark reader 5 OPP film web
Fabric web with OPP film on one
3 Register roller 6
side
Teaching the colour of the print mark

The procedure described below must be performed in the same way on the
upper (1) and lower (2) print mark readers.
The colour of the print mark is taught in without the coating. The OPP film is
merely pressed onto the fabric web. The extruder unit must be in the
maintenance position (see Chapter 5.4.9).

4. SETTINGS
Procedure
1. Open the safety door on the operating side of the coating unit
 The door can be opened under the following conditions:
- Machine is stopped
- Speed of the coating unit is less than 7 m/min
2. Position the print mark readers with the <Move upper print mark reader
to left/right> switch and <Move lower print mark reader to left/right>
switch (see Chapter 5.2.12, Fig. 4769/5080)
3. Position the fabric web (4) with the <Inch mode> push button in such a
way that the print mark is approximately 20 mm in front of the print mark
reader
4. Press and hold the <Teach upper/lower print mark readers> switch
- To the left: to teach in the upper print mark reader (1)
- To the right: to teach in the lower print mark reader (2)
 The indicator on the print mark reader is illuminated with different
colours.
5. Use the <Inch mode> push button to inch the fabric web (4) forwards
until the indicator on the print mark reader is white.
6. Release the <Teach upper/lower print mark readers> switch
 The colour of the print mark is taught in for the selected side.
4.14 Wide-slot die
NOTE!
Possible damage to property due to improper handling of the
wide-slot die!
The die lips are chrome-coated and must, therefore, be handled
very carefully!
Even the most minor damage on the surface of the die lips, such
as chips, scratches or dents, can impact the quality of the coating
and therefore subsequently that of the product!
NOTE!
The operator must ensure that gases produced at the wide-slot
die are channelled outside and/or neutralised.

documentation.

4. SETTINGS
The heated wide-slot die applies the plastic melt to the fabric. The coating width
can be adjusted. Gases produced during this process are extracted via an
extraction device.
4.14.1 Adjusting the temperature

The temperature set value for the zone heater of the wide-slot die must be
adjusted on the display (see the lamiTEC LX/CX display user manual).
4.14.2 Adjusting the coating width

The plastic melt flowing out of the extruder is tapered at both ends of the melt
(see Fig. 4769/4068). This produces considerable thickening of both the edges of
the coated fabric web. This is known as the "neck-in" effect. This effect must be
considered when adjusting the coating width.
Fig. 4769/4068
The coating applied must be approx.15 - 20 mm wider than the fabric web on
each side. This is known as the cover coating. In the event that the width of the
fabric web to be coated changes, the coating width must be adjusted.
Depending on operational guidelines, the width of the cover coating may vary
compared to what we recommend here.
The setting must be identical on both sides.

4. SETTINGS
Fig. 4769/4058
1 Grub screw 3 Clamping plate

2 Holder 4 Sealing strip
Procedure
1. Loosen all grub screws (1)
2. Slide the bracket (2) with the clamping plate (3) and the sealing strip (4)
down and clean (see Chapter 6.4.4)
3. Clean the die lips (see Chapter 6.4.10)
4. Move the bracket (2) with the clamping plate (3) and the sealing strip (4)
to the desired width
 The width is dependent on the format of the fabric web being coated
and on the coating material used.
- Use a ruler to check the width against the intended setting
Fig. 4769/4066
5. Re-tighten the grub screws (1)

4. SETTINGS
4.14.3 Adjusting the die gap
The machine must be switched on to adjust the die gap (see

Chapter 5.4.1). The extruder and co-extruder (optional) must be
heated up to operating temperature. Pay attention to all safety
instructions, as during operation (see Chapter 5.5).
In the event of a product change it is recommended that the coating weight is

checked (see Chapter 5.5.10) and that the die gap is adjusted if necessary.
In addition, the die gap must also be adjusted if the coating is being applied
unevenly.
This will be indicated by:
 the irregular composition of the fabric roll on the winder
 bead formation on the edges of the fabric web
Adjustment
WARNING!
Hot surfaces and vapours!
Risk of injuries to the eyes and hands!
Wear protective gloves when working on the extruder and co-

extruder (optional)!
Wear eye protection when working on the extruder or co-extruder

(optional)!
Move the extruder unit to the maintenance position (see Chapter 5.4.9).

4. SETTINGS
Fig. 4769/4065
1 Allen key 3 Tested section of fabric

2 Bolt
Position the tested section of fabric (3) in relation to the wide-slot die. Apply the
Allen key (1) to the respective bolt (2) and adjust the die gap over the entire
width. The degree to which the die needs to be adjusted was determined when
you checked the coating weight (see Chapter 5.5.10).
Fine adjustment
CAUTION!
Fine adjustment must be performed with the utmost care!
Move the extruder unit to the working position (see Chapter 5.4.9).

4. SETTINGS
Fig. 4769/4009
1 Allen key 2 Bolt
Apply the long Allen key (1) to the respective bolt (2) and adjust the die gap over
the entire width. The degree to which the die needs to be adjusted was
determined when you checked the coating weight (see Chapter 5.5.10).
4.15 Coating unit

The coating process takes place in the coating unit (1). The fabric web is fed into
the coating unit to the pressure roller (2).
LX standard version
The plastic melt is joined to the fabric web between the pressure roller (2) and
chill roller (3). The coating unit (1) must be set up in such a way that the plastic
melt flows from the wide-slot die (4) on to the fabric web.
CX version (optional)
Between the pressure roller (2) and the chill roller (3), the fabric web and the
OPP-film web are brought together and joined with the plastic melt. The coating
unit (1) must be set up in such a way that the plastic melt flows from the wide-slot
die (4) on to the fabric web.

4. SETTINGS
Fig. 4769/4043
1 Coating unit 4 Wide-slot die

2 Pressure roller 5 Teflon tapes
3 Chill roller 6 Edge trimmer
The Teflon tapes (5) prevent the plastic melt (cover coating) extruded by the
fabric web from sticking to the pressure roller (2). Moreover, the Teflon tapes (5)
direct the cover coating along the chill roller (3), cooling it and the coating of the
fabric web.
The plastic melt flowing out of the extruder is tapered at both ends of the melt.
This produces considerable thickening of both the edges of the coated fabric
web. This is known as the "neck-in" effect.
The cover coating is separated and extracted after coating with the aid of an
edge trimmer (6).
4.15.1 Adjusting the temperature of the chill roller

The chill roller has a cooling water circuit (see Chapter 4.3). This ensures a
constant flow with minimum temperature difference over the entire length of the
chill roller. The cooling water volume is controlled according to the machine
output.
The set values for chill roller temperature are set on the display (see the lamiTEC
LX/CX display user manual).

4. SETTINGS
4.15.2 Adjusting the pressure roller
NOTE!
Possible deformation of the rubberised surface of the pressure
roller in the event of an extended machine stop!
When the machine is at a stop, the pressure roller must be lifted
off with the <Lift off/Position pressure roller> switch (see Chapter
5.2.12, Fig. 4769/5078)!
NOTE!
Possible damage to the rubberised surface of the pressure roller
from sharp objects!
Never use sharp objects when performing adjustment work on the
pressure roller!
Fig. 4769/4061
1 Pressure roller 3 Pneumatic cylinder

2 Chill roller 4 "Pressure roller" pressure gauge
The coating is applied to the fabric web between the pressure roller (1) and chill
roller (2). With the help of a pneumatic cylinder (3), the pressure roller (1) presses
the coated fabric web against the chill roller (2).
The pressure roller (1) is lifted off/positioned on to the chill roller (2) with the <Lift
off/position pressure roller> push button (see Chapter 5.2.12, Fig. 4769/5078).

4. SETTINGS
Adjusting the temperature

The temperature set values for the rollers are adjusted on the display (see the
The pressure roller (1) is connected to a cooling device via the cooling water
distributor (see Chapter 4.3). The water cooler in the inner steel jacket of the
pressure roller (1) prevents the rubberised surface from peeling off.
Destruction of the rubberised surface of the pressure roller (1)

through overheating, e.g. from direct contact with the plastic melt,
is not prevented by the water cooler!
Setting the contact pressure

At 5 bar, the linear pressure is approx. 78 N/cm, at 6 bar 93.7 N/cm. The setting
is made in the side box on the operating side at the pressure reducing valve. The
set pressure is indicated on the "Pressure roller" pressure gauge (4).
 The recommended contact pressure is approx. 5 - 6 bar.
Setting the infeed speed

Using the throttle valves located on the pneumatic cylinders (3) in each case, the
infeed speed can be set. The throttle valves must be set so that the retraction
and extension movements of the cylinders (3) are even.
 The recommended setting time value is approx. 2 - 3 secs.
4.15.3 Adjusting the chill roller and pressure roller

Horizontal and vertical adjustment must be selected such that the wide-slot die
does not come into contact with the chill roller.
Horizontal adjustment of the chill roller
NOTE!
Potential material damage!
Careless horizontal adjustment can cause damage to the chill
roller and wide-slot die!
When adjusting, note the position of the chill roller!

4. SETTINGS
Fig. 4769/4070
Adjustment of the frame in

1 Spindle +
the direction of the winder
Adjustment of the frame in
2 Tool -
the direction of the wide-slot die
Procedure
1. Attach a suitable tool (2), e.g. a spanner, to the spindle (1)
2. Turn the spindle (1)
 Turning the spindle in the "+" direction adjusts the frame in the
direction of the winder.
 Turning the spindle in the "-" direction adjusts the frame in the
direction of the wide-slot die.
 The horizontal distance between the chill roller and wide-slot die is
shown on the display (see the lamiTEC LX/CX display user manual).
Vertical adjustment of the chill roller

The <Raise/lower chill roller> switch (see Chapter 5.2.12, Fig. 4769/5041 and
Fig. 4769/5078) adjusts the vertical spacing of the chill roller in relation to the
wide-slot die.
The vertical distance between the chill roller and wide-slot die is shown on the
display (see the lamiTEC LX/CX display user manual).

4. SETTINGS
4.15.4 Adjusting the flow volume for the chill roller and pressure roller
The chill roller (1) and pressure roller (2) share a single cooling water circuit. The
flow volume is continuously adjustable, if required.
Fig. 4769/4044
1 Chill roller 5 Chill roller supply 2 lever

2 Pressure roller 6 Chill roller supply 1 lever
3 Pressure roller supply lever 7 Chill roller return 2 lever
4 Pressure roller return lever 8 Chill roller return 1 lever
Adjusting the pressure roller (2) flow volume

1. Open the doors on the drive side
2. Adjust the flow volume of the pressure roller (2) using lever (3)
3. Close the door on the drive side
Adjusting the chill roller (1) flow volume

The chill roller flow volume is adjusted on the cooling water distributor (see
Chapter 4.3).

4. SETTINGS
4.15.5 Positioning Teflon tapes

The Teflon tapes (1) prevent the plastic melt (cover coating) extruded by the
fabric web from sticking to the pressure roller (2).
Without Teflon tapes (1), beads of extracted plastic melt form on the rubberised
surface of the pressure roller (2). This can destroy the pressure roller (2),
preventing further coating of the fabric web.
The outer Teflon tapes (1) have a width of 20 mm and run under the fabric web to
be coated. The remaining 80 mm protects the pressure roller (2) from the
extracted plastic melt.
NOTE!
The Teflon tapes may be damaged when the machine is at a
standstill!
To position the Teflon tapes, the following conditions must be
fulfilled:
 The machine must be switched on (see Chapter 5.4.1).
 The machine must be in operation; the chill roller and pressure
roller must be turning
 The extruder and co-extruder (optional) must be heated up to
operating temperature.
 All safety instructions must be observed, as during operation
(see Chapter 5.5).

4. SETTINGS
Fig. 4769/4045
1 Teflon tapes 5 Handwheel for Teflon tape (B)

2 Pressure roller A Drive side
3 Handle B Operating side
4 Handwheel for Teflon tape (A)
Procedure
1. Fold out the handle (3) for the handwheel (4) or (5)
2. Turn the handwheel (4) or (5) in the respective direction
 Turning the handwheel in the "+" direction adjusts the Teflon tape for
a wide fabric.
 Turning the handwheel in the "-" direction adjusts the Teflon tape for
a narrow fabric.
3. Fold in the handle (3)

4. SETTINGS
4.15.6 Adjusting the speed of the coating unit

The speed of the coating unit is dependent on the following:
 Coating thickness
 Coating width
 Extruder output
 Type and quality of the fabric web to be coated
 Coating material
The operating parameters are calculated from the set values (fabric width,
coating weight, and cover coating) entered on the display (see the lamiTEC
LX/CX display user manual).
4.16 Adjusting the central cutter

For double-sided coating, the fabric webs - which run adjacent to one-another
and are joined together by a cover coating - are cut down the centre.
CAUTION!
Risk of cuts from the blade of the central cutter!

4. SETTINGS
Fig. 4769/4016
1 Star knob 3 Blade

2 Star knob
Procedure
1. Release the star knob (1) and position the blade (3) horizontally
2. Release the star knob (2) and position the blade (3) vertically
 The setting of the blade (3) is dependent on the centre gap.
3. Re-tighten the star knobs (1) and (2)
4.17 Adjusting the turning device

The turning triangle (1) of the turning device turns the fabric web for coating on
both sides.
After the central cutter (2), the fabric web is guided to the turning triangle (1).
There the fabric web is turned and fed back through the hot air oven to the chill
roller in addition to the fabric web that has not yet been coated.
The brushes (3) tighten the fabric web.
In order to improve the turning process, the fabric web is charged with
compressed air from a side-channel compressor. You can switch it on or off on
the display (see the lamiTEC LX/CX display user manual).
After installation and modification work, the turning triangle (1) is positioned as
follows:

4. SETTINGS
Fig. 4769/4017
1 Turning triangle 5 Nut

2 Central cutter 6 Bolt
3 Brush 7 Brush bracket
4 Nut
Procedure
1. Loosen the nuts (4) on the operating and drive side
2. Horizontally position the turning triangle (1) by turning the nuts (4)
3. Re-tighten the nuts (4)
5. Vertically position the turning triangle (1)
6. Re-tighten the nuts (5)
7. Loosen the bolts (6) on the operating and drive side
8. Horizontally position the brush bracket (7)
9. Re-tighten the bolts (6)

4. SETTINGS
4.18 Edge trimmer
CAUTION!
Risk of cutting from the crush cut knives and the blades of the
edge trimmer!
The edge trimmer consists of two cutting units (2). They must be adjusted such
that a cover-coating surplus still remains on each edge of the fabric web.
If the blades cut right next to the edge of the fabric web, the surplus is not cut
properly at high speed and with low cooling, as warm (still soft) coating material is
difficult to cut.
The position of the cutting units (2) in relation to the width of the fabric web is
regulated by an optoelectronic web edge control.
4.18.1 Positioning the cutting unit
Fig. 4769/4020
1 Lever 2 Cutting unit

4. SETTINGS
Procedure
1. Loosen the clamp with the lever (1)
2. Positioning the cutting unit (2)
3. Engage the lever (1) again
4.18.2 Adjusting the web edge control
The machine must be switched on when adjusting the web edge

control (see Chapter 5.4.1). Pay attention to all safety instructions,
as during operation (see Chapter 5.5).
CAUTION!
Risk of injuries to the hands from cutting unit movements!
Never reach between the knife carriage and the mounting block!
When changing the colour of the coating material or the OPP film, material
calibration must be carried out.
Functional description
The control speed of the ECS (Edge Control System) is automatically adapted to
the speed of the coating unit. The faster the coating, the faster the reaction of the
ECS.
The teach process

The following calibration must be performed on both the operating and drive side.

4. SETTINGS
Fig. 4769/4019
1 Cover coating 4 Web edge

2 Fabric web A Cover coating position sensor
3 Sensor B Fabric web position sensor
Procedure
1. Pivot away the crush cut knives and raise the fixed blade
- on the display (see the lamiTEC LX/CX display user manual)
- or with the <Activate/Deactivate crush cut knives> switch
(see Chapter 5.2.12, Fig. 4769/5079)
2. Turn the <Stop/automatic cycle> switch anticlockwise
 The automatic cycle is stopped.
3. Press and hold the <Teach edge cut 1> or <Teach edge cut 2> push
button for at least 5 secs (see Chapter 5.2.12, Fig. 4769/5012)
 The <Teach edge cut 1> or <Teach edge cut 2> push button lights
up blue.
 The existing contrast values are deleted.
 The stepper motor is stopped.
4. Release the lever and position the cutting unit (see Chapter 4.18.1) on
the cover coating (1)
 Position the cutting unit such that only the cover coating (1) is
located between the sensor (3) (A).

4. SETTINGS
5. Confirm position (A) by pressing the <Teach edge cut 1> or <Teach
edge cut 2> push button
 The <Teach edge cut 1> or <Teach edge cut 2> push button flashes
blue.
6. Position the cutting unit on the fabric web (1)
 Position the cutting unit such that only the fabric web (1) is located
between the sensor (3) (B)
7. Confirm position (B) by pressing the <Teach edge cut 1> or <Teach
edge cut 2> push button
 The <Teach edge cut 1> or <Teach edge cut 2> push button does
not light up.
 Calibration is complete and the ECS can be started.
8. Turn the <Stop/automatic cycle> switch clockwise
 The stepper motor is enabled.
 The automatic cycle starts.
If calibration is successful, the sensor (3) should detect the web edge (4)
between the cover coating (1) and the fabric web (2).
As soon as the edge trimmer is switched on on the display, the carriage detects
the position of the web edge and follows it when operational (see the
4.18.3 Adjusting the edge trimmer with fixed blade

The sensor of the web edge control (see Chapter 4.18.2) detects the cover
coating area. A fixed blade is used to cut a strip off the cover coating along the
length of the fabric web. The cutting width is kept even during operation by the
stepper motor and the sensor.
Procedure
1. Loosen the clamping of the locking pin with the star knob (7) (see
Chapter 4.18.4, Fig. 4769/4018)
2. To adjust the blade (3), position the holder (8) with the star knob (7)
3. If the blade (3) is not required:
- Move the holder (8) upwards with the star knob (7) until the locking
pin (6) is resting on the cutting unit (2)
4. Engage the locking pin on the star knob (7)

4. SETTINGS
4.18.4 Adjusting the edge trimmer with crush cut knives
Fig. 4769/4018
1 Lever 5 Steel roller

2 Cutting unit 6 Locking pin
3 Blade 7 Star knob with locking pin
4 Crush cut knife 8 Holder
The two crush cut knives (4) are pressed against the hardened steel roller (5)
pneumatically. The crush cut knives (4) must be placed on the surface of the
hardened steel roller (5) slowly and steadily. Otherwise, the crush cut knives (4),
which are hard yet delicate, may be damaged.
The crush cut knives (4) are moved towards the hardened steel roller (5) or
pivoted away from it using the <Activate/Deactivate crush cut knives> switch (see
Chapter 5.2.12, Fig. 4769/5079). The crush cut knives (4) are moved towards the
steel roller as soon as the coating unit is started. The speed of the coating unit is
shown on the display (see the lamiTEC LX/CX display user manual).

4. SETTINGS
Feed motion pressure

The feed motion pressure for the crush cut knife (4) is set in the side box on the
operating side at the pressure control valve.
 The recommended feed motion pressure is approx. 2 - 2.5 bar.
Fig. 4769/4062
"Crush cut knives" pressure

4 Crush cut knife 9
gauge
Switch-on speed
The switch-on speed is set using the throttle valves at the pressure control valves
in the side box on the operating side.
4.19 Edge strip extractor
The machine must be switched on when adjusting the edge strip

extractor (see Chapter 5.4.1). Pay attention to all safety
The edge strip extractor operates in accordance with the injector principle. It
consists of a blower (1) and pipes (2). The trimmed edge strips are extracted into
the receptacle (3) through the exhaust pipe (5).
The edge strip extractor is activated on the display (see the lamiTEC MX display
user manual)
The position of the exhaust pipes (5) must be adjusted to the edge strips to be
extracted.

4. SETTINGS
Fig. 4769/4069
1 Blower 4 Lever
2 Piping 5 Exhaust pipe
3 Receptacle
Procedure
1. Release the lever (4)
2. Position the exhaust pipe (5)
3. Engage the lever (4) again
4.20 Adjusting the "process-control" edge strip return (optional)

The cut-off edge strips are fed back into the hopper of the extruder. The edge
strips are ground in a cutting mill and then conveyed to the extruder hopper via a
transport system.
The "process-control" edge strip return (return to the pellet hopper on the
extruder) is suited exclusively for use with detached sections of cover coating, but
not sections of fabric.
For further information on the settings for "process-control" edge

strip return, see the manufacturer's documentation.

4. SETTINGS
4.21 Adjusting the perforation system
CAUTION!
Risk of injury on the pin roller!
The perforation system produces a specific level of air permeability in the coated
fabric web for subsequent processing.
After the edge trimmer, the coated fabric web is directed through the pin roller (1)
and the counter roller (2).
The pin roller (1) is swivelled in and out (see Chapter 5.2.12, Fig. 4769/5079) with
the <Perforation off/on> push button.
The engagement depth of the pin roller is dependent on the fabric web to be
processed and must be adjusted when the width of the fabric web is changed.
Fig. 4769/4024
1 Pin roller 5 Grub screw

2 Backing roller 6 Holder

4. SETTINGS
Procedure
1. Loosen the grub screws (5)
2. Move the bracket (6) with the pin roller (1) lengthways
 Care must be taken to ensure that the pins of the swivelling pin
roller (1) are facing the grooves of the backing roller (2).
3. Tighten the grub screws (5)
Fig. 4769/4022
1 Pin roller 4 Bolt

2 Backing roller z Approx. 0.5 mm
3 Nut
4. Loosen the nut (3)

5. Lower the pin roller (1) using the <Perforation off/on> push button
6. Adjust the distance (z) with the bolt (4)
 Adjusting the distance (z).
7. Tighten the nut (3)

4. SET
TTINGS
S
4.22 Micro perforatin

p ng roller ((optional))
WARN NING!
Risk of
o being draawn in at the
e pin roller (1)
( and brussh roller (2)!
Do noot reach betw
ween the pin roller and d the brush roller!
CAUT TION!
Risk of
er!
Do noot touch the pin roller!
Wear protective g
gloves!
The micrro perforatin

ng roller rem
moves air bubbles
b from
m the coateed fabric we
eb. The
fabric weeb is pressed againsst a brush roller (2) by the pinn roller (1)), thus
perforatin
ng it.
Fig. 4769
9/4025
1 Piin roller 2 Brush

h roller
lamiTEC LX/CX DBE-04769D PA

AGE 140 / 341
Translatio
4. SETTINGS
4.22.1 Setting the contact pressure

The contact pressure of the pin roller (1) is set in the side box on the operating
side at the pressure control valve.
 The recommended contact pressure is approx. 2.5 - 3 bar.
Fig. 4769/4063
1 Pin roller 3 "Pin roller" pressure gauge

4. SETTINGS
4.22.2 Adjust the engagement depth and parallelism
Fig. 4769/4047
4 Bolts 7 Counter
5 Rod 11 Sign about engagement depth
6 Handwheel
Adjusting the engagement depth

1. Fold out the handle for the handwheel (6)
2. Turn the handwheel (6) in the respective direction
 When swivelling the pin roller (1) in, its pins must come into contact
with the brush roller (2).
3. Fold in the handle for the handwheel (6)
4. Select the type of perforation on the display
5. Check the adjustments by pressing the <Perforation off/on> button
(see Chapter 5.2.12, Fig. 4769/5079)

4. SETTINGS
Adjusting the parallelism

1. Undo the bolts (4)
2. Turn the rod (5)
 The pin roller (1) is adjusted on the operating side
3. Turn the handwheel (6)
 The pin roller is adjusted on both sides, parallel to the brush roller
Sign about engagement depth (11)
Fig. 4769/4059
Turning the handwheel anticlockwise increases the engagement depth,

1
and clockwise reduces it.
One turn of the handwheel (6) corresponds to 0.33 mm, or six units on
2
the counter (7)
Three turns of the handwheel (6) correspond to 1 mm, or 18 units on the
3
counter (7)

4. SETTINGS
4.22.3 Calibrating the gauge on the handwheel
Fig. 4769/4028
6 Handwheel 8 Ring
7 Counter
Procedure
1. Use the handwheel (6) to align the pin roller (1) to the brush roller (2)
(see Chapter 4.22, Fig. 4769/4025)
2. Loosen the bolt on the ring (8)
3. Turn the ring (8) until "00000" (zero) is displayed on the counter (7)
4. Re-tighten the bolt on the ring (8)
4.22.4 Adjusting the pin bushes
The outer edge of the first pin bush unit (10) must be located
approx. 10 mm inside of the coated edge of the fabric web.
NOTE!
Possible damage to the product due to incorrect positioning of the
pin bushes (10)!
Never perforate the cover coating!

4. SETTINGS
Fig. 4769/4029
9 Grub screw 10 Pin bush
Procedure
1. Loosen the grub screws (9)
2. Push the pin bushes (10) to the desired position
3. Re-tighten the grub screws (9)
NOTE!
Ensure the firm seating of the pin bushes (10)!
4.23 Positioning the spreader roller (optional)
The machine must be switched on to calibrate the spreader roller

(see Chapter 5.4.1). The extruder and co-extruder (optional) must
be heated up to operating temperature. Pay attention to all safety
The spreader roller smooths out the flat fabric in an outwards direction before
coating.

4. SETTINGS
Fig. 4769/4046
1 Spreader roller 2 Handwheel
Procedure
1. Fold out the handle for the handwheel (2)
2. Turn the handwheel (2) in the respective direction
 In the "+" direction, the spreader roller (1) is engaged.
 In the "-" direction, the spreader roller is pivoted out.
 Adjust the spreader roller such that all creases on the fabric web are
smoothed out.
3. Fold the handle for the handwheel (2) back in

4. SETTINGS
4.24 Winder
The winder is implemented in the form of a contact winder. The rotary motion of
the roll is produced by a powered contact roller (5).
The tension of the fabric web is regulated by a loadcell.
The contact pressure and web tension are adjusted on the display (see the
Fig. 4769/4049
1 Oscillator 6 Safety device

2 Cutting unit 7 Winding and depositing arm
3 Transfer device 8 Unwinding locking device
4 Insertion device 9 Pre-acceleration unit
5 Contact roller

4. SETTINGS
4.24.1 Adjusting the traverse

After setting the parameters for the fabric web on the display, the winder must be
adjusted to the corresponding fabric width (see the lamiTEC LX/CX display user
manual).
Fig. 4769/4050
1 Lever 4 Scale in mm
2 Rod 5 Max. value for flat fabric
Values for tubular fabric
3 Lever 6
(doubled over and laid flat)
Adjusting the width of the fabric web

 Adjust the width of the fabric web using the rod (2).
2. Apply the lever (1)
Adjusting the traversing path

 Adjust the traversing path using the scale (4)
2. Apply the lever (3)

4. SETTINGS
4.24.2 Setting the pressure
Fig. 4769/4034
Pressure control valve for

1 3 Blade
contact pressure
Pressure control valve for
2 4 Contact roller
cutting
The pressure that must be set in each case is dependent on the properties of the
fabric web and on the roll change speed and must be set accordingly.
Cutting unit
During a roll change, the fabric web is severed by a pneumatically powered
cutting unit. The speed of the cutting process is dependent on the pressure set at
the pressure control valve for cutting (2).
A pressure of 5 - 5.8 bar must be set at the pressure control valve for cutting (2).
NOTE!
Possible damage to property due to excessive pressure at the
pressure valve for cutting (2)!
The set pressure must not exceed 5.8 bar!

4. SETTINGS
Contact roller contact pressure

The contact pressure of the roll on the contact roller (4) in the transfer position is
adjusted at the pressure control valve (1).
When adjusting the contact pressure, the expansion shaft must be located in the
transfer device (see Chapter 5.5.8, Fig. 4769/5024).
The contact pressure is adjusted on the pressure control valve for contact
pressure (1). The operating pressure of the other valves is adjusted at the
maintenance unit (see Chapter 4.1).

Fig. 4769/4036
1 Calibration weight 5 - 25 kg 4 Infeed roller

3 Loadcell
Procedure
1. Remove the drawn-in web in order to relieve the load on the sensing
roller (2)

4. SETTINGS
3. Secure the calibration weight to a rope (5) and thread in the rope (5) in
accordance with the feed diagram (see Chapter 5.3.6)
- Recommended calibration weight: 5 - 25 kg (max. 30 kg)
4. Pull the rope (5) taut in the direction of the arrow in order to put a load
on the sensing roller (2)
4.24.4 Pre-acceleration unit

During a roll change, the expansion shaft is brought up to the speed of the
coating unit with assistance from the pre-acceleration unit. All of the necessary
parameters are calculated in the control unit.
4.24.5 Adjusting the ioniser

An ionising nozzle (11) reduces the electrostatic charge on the fabric, enabling
better winding.
The air pressure at the ionising nozzle (11) is material-specific and can be set to
approx. 0.8 - 2 bar using the pressure control valve (10).
Fig. 4769/4031
10 Pressure control valve 11 Ionising nozzles

5. COMMISSIONING AND OPERATION
5 COMMISSIONING AND OPERATION
5.1 Before initial commissioning

Before initial commissioning, the following tasks must be performed:
 Check the installation (see Chapter 3)
 Check all settings (see Chapter 4)
 On the gear motors and gearboxes, replace transport bolts with bleed
screws
 On the drive belts, check the belt tension and retension if required (see
Chapter 6.3.8 and 6.4)
 Check chain tension and re-tension if required (see Chapter 6.3.7)
 Check the chains and sprockets for alignment
 Check the lubricating points (see Chapter 6.1)
 Make sure that all electrical connections were performed in accordance
with the Circuit diagram
 Check all connection bolts and connection terminals on bus bars and
switchgear for firm seating and, if necessary, retighten them to the
specified tightening torque, per the manufacturer's specifications.
DANGER!
Danger from electric current!
Before work is done on connections bolts and on connection

terminals, all <Main switches> must always be set to OFF ("0"
position) and be safeguarded against being switched back on!
Before carrying out work on the connection bolts and connection

terminals on one of the <Main switches>, the supply line must be
de-energised!
 Have the condition and function of the safety switch, circuit breaker and
EMERGENCY STOP system checked by a qualified electrician (even
for modifications or retrofitting of machine parts)
 Check the direction of rotation of all of the motors (see arrow direction
on the motors)
 If air-conditioned switching cabinets or switching cabinet units are
installed, check the seal

 Make sure that all safety guards are properly attached

 Ensure that all safety doors are closed and locked
 Pneumatic system: check connections, pressure and function
WARNING!
Danger due to malfunction of the pneumatic system!
Do not reach into the danger area!
 Hydraulic system: check connections, pressure and function
WARNING!
Danger due to malfunction of the hydraulic system!
Do not reach into the danger area!
 Check the water connections
5.2 Controls and display elements
5.2.1 Overview
A number of controls and display elements can be found on the machine. The
<Main switch> on the machine is located on the switching cabinet. Central control
of the machine is achieved via a display in the operating area. In addition, there
are operating units in various locations on the machine, which provide the option
to intervene in the production process.

LX standard version
Fig. 4769/5076
Pneumatic operating pressure

1 Operating unit for double unwinder 7
gauge
2 Operating unit for base frame 8 <Main switch>
Operating unit (with display) for
3 9 <Crane system main switch>
coating unit
4 Operating unit for winder 10 Signal light on the coating unit
Operating units for extruder and
5 11 Operating unit for crane system
coating unit
6 Signal light for winder 13 Signal light for double unwinder

Overview of the CX version (optional)
Fig. 4769/5075
Operating unit for double unwinder,

1 11 Operating unit for crane system
drive side
Operating unit for the register control
2 Operating unit for base frame 12
(optional)
Operating unit (with display) for
3 13 Signal light for double unwinder
coating unit
Operating unit for OPP unwinder,
4 Operating unit for winder 14
operating side
Operating units for extruder and
5 15 <OPP crane system main switch>
coating unit
Operating unit for OPP crane
6 Signal light for winder 16
system
Pneumatic operating pressure Operating unit for OPP unwinder,
7 17
gauge drive side
8 <Main switch> 18 Signal light for OPP unwinder
Operating unit for double unwinder,
9 <Crane system main switch> 19
operating side
10 Signal light on the coating unit

5.2.2 EMERGENCY STOP command devices
WARNING!
Risk of injury when triggering an EMERGENCY STOP command
device if the specified working positions are not observed!
Before triggering an EMERGENCY STOP command device,
ensure eye contact with the second person!
Several EMERGENCY STOP command devices are located on the machine for
halting it in an emergency.
The precise layout of the EMERGENCY STOP command devices and their
method of operation is described in Chapter 5.7.
Fig. 4769/5040
1 <EMERGENCY STOP> push button for the crane system operating unit*
<EMERGENCY STOP> push button for the double unwinder operating
2
unit
3 <EMERGENCY STOP> push button for the double unwinder, drive side
4 <EMERGENCY STOP> push button for the coating unit, drive side
5 <EMERGENCY STOP> push button for the coating unit operating unit
<EMERGENCY STOP> push button for the coating unit operating unit,
6
operating side
7 <EMERGENCY STOP> push button for the winder operating unit
8 <EMERGENCY STOP> push button for the winder, operating side
9 <EMERGENCY STOP> push button for the winder, drive side
10 EMERGENCY STOP pull cord for the extruder unit
<EMERGENCY STOP> push button for the OPP unwinder, operating
11
side (optional)
* On the operating unit for shutting down the relevant crane system!

<EMERGENCY STOP> push button for the OPP unwinder, drive side
12
(optional)
<EMERGENCY STOP> push button for the OPP crane system
13
(optional) *
14 Safety light barrier
A Drive side
B Operating side
* On the operating unit for shutting down the relevant crane system!
DANGER!
Risk of injury!
The <EMERGENCY STOP> push button (1) and (13) for the
crane system only shuts down the relevant crane system!
Use one of the EMERGENCY STOP command devices to shut
down the machine!
Safety light barrier (14) on the winder

If the safety light barrier on the winder is interrupted during operation, am
EMERGENCY STOP is triggered. The safety light barrier (14) must be briefly
interrupted to check the roll quality (see Chapter 5.5.9).
5.2.3 Signal light for double unwinder

The signal light takes the form of a flashing light.
Signal Appearance
The set value shown on the display for the min. fabric roll diameter
Flashes yellow
has been reached.
5.2.4 Signal light on the coating unit
Signal Appearance
Fault
Lights up red  Do not start the machine
 Pay attention to the alarm on the display
Fault
Lights up yellow
 Pay attention to the alarm on the display
Lights up green Machine is ready for use
Lights up blue
Corona (optional) in operation
(optional)

5.2.5 Signal horn on the coating unit
Signal Description
 When automatic mode stops
1 Hz
 When the extruder unit is moved
During movements of the following components of the winder
2 Hz  Winding and depositing arm
 Insertion hook
5.2.6 Signal light for winder

The signal light takes the form of a yellow flashing light.
Signal Appearance
 When the insertion device is moved
Flashes yellow
 When the winding and depositing arm is moved
5.2.7 Signal light for the bagging station (optional)

The signal light takes the form of a blue flashing light.
Signal Appearance
One of the two containers is full. It must be removed and a new
Flashes blue
container hooked in (see Chapter 5.4.8).
5.2.8 Signal light for the OPP unwinder (optional)

The signal light takes the form of a blue flashing light.
Signal Appearance
The set value shown on the display for the min. roll diameter for the
Flashes blue
OPP film has been reached.
5.2.9 Display
The display for the central control unit is located at the operating unit on the
coating unit. It is used to set and view all parameters.
For further information on the individual functions of the display,

see the lamiTEC LX/CX display user manual.

5.2.10 Pneumatic operating pressure gauge

The pressure gauge for the whole machine is located on the drive side of the side
box at the coating unit (see Chapter 4.1).
5.2.11 Hydraulic operating pressure gauge

The gauge for the current hydraulic operating pressure is located on the winder
operating unit (see Chapter 5.2.12, Fig. 4769/5082).
5.2.12 Operating units

In addition to the display, operating units are attached to the machine in various
locations.
Operating unit for the crane system and OPP crane system
The operating unit described below is identical on the crane system for the
double unwinder for the fabric web and for the OPP crane system (optional).
Fig. 4769/5003
1 <EMERGENCY STOP> push button

<Select load hook>
Top Drive-side load hook selected
2
Centre Both load hooks are selected
Bottom Move load hooks on both sides
<Move vertically upwards> push button
3 Position 1 Lifting speed 1.25 m/min
Position 2 Lifting speed 5 m/min

<Move vertically downwards> push button

4 Position 1 Lifting speed 1.25 m/min
Position 2 Lifting speed 5 m/min
<Move horizontally right> push button
5 Position 1 Travelling speed 5 m/min
Position 2 Travelling speed 20 m/min
<Move horizontally left> push button
6 Position 1 Travelling speed 5 m/min
Position 2 Travelling speed 20 m/min
DANGER!
Risk of injury!
The <EMERGENCY STOP> push button (1) for the crane system
only shuts down the relevant crane system!
Use one of the EMERGENCY STOP command devices to shut
down the machine (see Chapter 5.2.2)!
For further information on the individual functions of the electric

chain hoist control panel, see the manufacturer's documentation.
Operating units for the double unwinder, drive side

There is one push button at each pneumatic brake to allow the brake to be
switched on/off.
Fig. 4769/5005
1 <Brake 1 on/off> push button


Operating unit for the double unwinder for fabric, operating side
Fig. 4769/5077
1 Two-hand <Roll change> push button

<Roll change speed> push button
Lights up blue Roll change speed reached
3
Flashes blue Change to roll change speed
Not lit Coating unit speed reached
<Roll prepared> push button
4 Lights up white Roll prepared for automatic roll change
Not lit Roll not prepared or automatic roll change not possible
5 "Brake disc" pressure gauge
8 <Stop> push button

Operating unit for base frame
Fig. 4769/5041
<Raise/lower chill roller> push button

Anticlockwise Raise chill roller
1
Centre Chill roller in position
Clockwise Lower chill roller
<Start> push button
Lights up
2 Coating unit started
green
Not lit Coating unit stopped
<Extruder movement limited> switch
Anticlockwise Move extruder towards operating side
4
Centre Extruder in position
Clockwise Move extruder towards drive side

Operating unit for coating unit (with display)
Fig. 4769/5078
1 Central control unit display

<Move web edge sensor to left/right> switch
Move the sensor for the web edge control on the turning frame
Anticlockwise
to the left (towards the operating side)
2 Move the sensor for the web edge control on the turning frame
Centre
into position
Move the sensor for the web edge control on the turning frame
Clockwise
to the right (towards the drive side)
4 USB connection
5 Operating unit with display for web edge control on the OPP unwinder*
6
*Optional

<Start> push button

8 Lights up green Coating unit started
Not lit Coating unit stopped
9
10 <Fast operation> push button
11 <Slow operation> push button
<Lift off/position pressure roller> switch
Anticlockwise Lift off pressure roller
Centre Pressure roller in position
12
Clockwise Position pressure roller
Lights up blue Pressure roller positioned
Not lit Pressure roller lifted off
<Roll change speed> push button
13
<Start extruder> push button
14 Lights up green Extruder or co-extruder (optional) started
Not lit Extruder or co-extruder (optional) stopped
15 <Stop extruder> push button
16 <Open oven> push button
17 <Close oven> push button
<Reset EMERGENCY STOP> push button
18
Lights up yellow EMERGENCY STOP is active
<Reset fault> push button
19
Lights up red Pay attention to fault/alarm on the display
20 "Pressure roller" pressure gauge
21 "Crush cut knives" pressure gauge
22 "Pin roller" pressure gauge

Operating unit for the register control (optional)
Fig. 4769/5080
<Teach upper/lower print mark readers> switch

1 Anticlockwise Teach upper print mark reader
Clockwise Teach lower print mark reader
<Move upper print mark reader to left/right> switch
Anticlockwise Move upper print mark reader to the drive side
2
Centre Upper print mark reader in position
Clockwise Move upper print mark reader to the operating side
<Move lower print mark reader to left/right> switch
Anticlockwise Move lower print mark reader to the drive side
3
Centre Lower print mark reader in position
Clockwise Move lower print mark reader to the operating side
4 <Inch mode> push button

Operating units for extruder and coating unit
Operating unit on operating side
Fig. 4769/5079
<Perforation off/on> push button

Depending on the selection on the display, the
Lights up
perforation system and/or the micro perforating roller
1 green
(optional) is activated.
Perforation and the micro perforating roller (optional)
Not lit
deactivated.
<Activate/Deactivate crush cut knives> switch
2 Anticlockwise Crush cut knives are pivoted away from the steel roller
Clockwise Crush cut knives are moved towards the steel roller
<Stop/automatic cycle> switch
3 Anticlockwise Edge trimmer stopped
Clockwise Edge trimmer automatic mode

Operating unit on drive side
Fig. 4769/5044
1 <Stop extruder> push button

2
<Start extruder> push button
Lights up
3 Extruder or co-extruder (optional) started
green
Not lit Extruder or co-extruder (optional) stopped
4
<Stop/automatic cycle> switch
5 Anticlockwise Edge trimmer stopped
Clockwise Edge trimmer automatic mode

Controls for the cutting unit
Fig. 4769/5012
<Teach edge cut 1> push button

Lights up blue Drive-side teach process active
Flashes blue
First position taught, waiting for second position
1 slowly
Flashes blue
Teach process fault
quickly
Not lit Teach process complete
<Teach edge cut 2> push button
Lights up blue Operating-side teach process active
Flashes blue
First position taught, waiting for second position
2 slowly
Flashes blue
Teach process fault
quickly
Not lit Teach process complete

Operating unit for the bagging station (optional)
Fig. 4769/5081
<Activate/Deactivate> switch
Anticlockwise Bagging station not in operation
1 Clockwise Bagging station in operation
Lights up
Bagging station in operation
green
<Select left/right station> switch
The left bagging station - as seen from the operating
Anticlockwise
2 side - is filled (in manual mode)
The right bagging station - as seen from the operating
Clockwise
side - is filled (in manual mode)
<Auto/Manual mode> switch
Bagging station in automatic mode
Anticlockwise  Once the bag is full (the ground-up edge strips have
reached the rotating paddle switch), the flap box
3 automatically switches over to the second station
Manual mode
Clockwise  The active bagging station is selected with the
<Select left/right station> switch
NOTE!
Overfilling the bags in the bagging station may cause a
malfunction!
Empty the bags in the bagging station on a regular basis!

OPP unwinder (optional) operating units
OPP single unwinder, operating side
Fig. 4769/5055
1 <OPP brake on/off> push button

<Roll prepared> push button
2 Lights up white The diameter of the roll has been read
Not lit The diameter of the roll has not been read
<Move unwinder to left/right> push button
Anticlockwise Move OPP unwinder to left (to the drive side)
3
Centre OPP unwinder in position
Clockwise Move OPP unwinder to right (to the operating side)

OPP single unwinder, drive side
Fig. 4769/5046
1 <OPP brake on/off> push button

Operating unit for the OPP double unwinder (optional), operating side
Fig. 4769/5056
1 Two-hand <OPP roll change> push button

2 <OPP Brake 1 on/off> push button
<Roll 1 prepared> push button
3 Lights up white The diameter of Roll 1 has been read
Not lit The diameter of Roll 1 has not been read

<Move unwinder to left/right> switch

Anticlockwise Move OPP unwinder to left (to the operating side)
4
Centre OPP unwinder in position
Clockwise Move OPP unwinder to right (to the drive side)
<OPP roll change speed> push button
6
<Roll 2 prepared> push button
7 Lights up white The diameter of Roll 2 has been read
Not lit The diameter of Roll 2 has not been read
Operating unit for the OPP double unwinder (optional), drive side
There is one push button at each drive to allow the holding brake for the motors
to be switched on/off.
Fig. 4769/5063


Operating unit for winder
Fig. 4769/5082
<Start winder> push button

1 Lights up green Winder started
Not lit Winder stopped
<Light barrier> push button
3 Lights up yellow Light barrier on
Not lit Light barrier off
4 "Contact pressure" pneumatic pressure gauge
5 "Cutting" pneumatic pressure gauge
7 "Winding arm contact pressure" hydraulic pressure gauge
<Roll change> push button
The length-of-roll set value entered on the display has been
8 Lights up white
reached
Flashes white The join in the fabric web has passed the cutting device.
Not lit Roll not prepared
<Raise/lower rollers> push button
Anticlockwise Raise rollers
9
Centre Rollers in position
Clockwise Lower rollers
10 <Prepare for roll change> push button

5.2.13 Other operating units
Depending on the design of the machine, additional controls and display

elements will be present on the machine.
For further information on the control and display elements on the

volumetric dosing unit with feed station, see the Technical manual
for the voluTEC volumetric dosing unit with feed station.
graviTEC gravimetric batch dosing unit with feed station (optional)
For further information on the controls and display elements on

the gravimetric batch mixer, see the Technical manual for the
graviTEC gravimetric batch dosing unit with feed station
"Process-control" edge strip return (optional)
For further information on the control and display elements for

"process control" edge strip return, see the manufacturer's
documentation.

5.3 Infeed diagrams
5.3.1 Infeed diagram of the double unwinder and web accumulator
Fig. 4769/5069

5.3.2 Infeed diagram of the coating unit
Fig. 4769/5071
Infeed diagram of the turning triangle
Fig. 4769/5072

5.3.3 Infeed diagram with corona (optional)
Fig. 4769/5073
5.3.4 Infeed diagram with spreader roller (optional)
Fig. 4769/5074

5.3.5 Infeed diagram of the coating unit, CX version (optional)
Infeed diagram of the turning triangle, see Chapter 5.3.2, Fig. 4769/5072.
Single unwinder
Fig. 4769/5050
Infeed diagram of the OPP film from the single unwinder to

_________
the coating unit
Infeed diagram of the fabric web coated in OPP film from the
_ _ _ _ _
coating unit towards the winder
.......... Uncoated fabric web from the hot air oven to the coating unit

Register control (optional)
Fig. 4769/5083
1 Uncoated fabric web from the hot air oven to the coating unit
Return of the fabric web coated on one side with OPP film to the coating unit by
2
means of the register control
Infeed diagram of the fabric web coated in OPP film from the coating unit towards
3
the winder
4 Infeed diagram of the OPP film from the OPP unwinder to the coating unit

Double unwinder (optional) with web accumulator
Fig. 4769/5051
Infeed diagram of the OPP film from the double unwinder to the
_________
coating unit
Infeed diagram of the fabric web coated in OPP film from the coating
_ _ _ _ _
unit towards the winder
.......... Uncoated fabric web from the hot air oven to the coating unit

5.3.6 Infeed diagram of the winder
Fig. 4769/5088
5.4 Commissioning
NOTE!
Dirty coating material will cause malfunctions!
Only use coating material sorted by type!
The material must not contain foreign materials such as:
 Metal
 Wood
 Rubber
 Paper
The residual humidity in the material stipulated in the technical
specification must not be exceeded!
NOTE!
Characteristics and composition of the material to be processed
(coating material, fabric, OPP film) must be known in advance!

To ensure continuous operation of the machine, a large amount of

the material to be processed must always be available.
For information on the control unit, see the lamiTEC LX/CX

Commissioning can be subdivided into the following steps:

1. Switching on the machine (see Chapter 5.4.1)
2. Preparing the coating unit (see Chapter 5.4.2)
3. Preparing the melt filter (see Chapter 5.4.7)
4. Preparing the double unwinder (see Chapter 5.4.3)
5. CX version: Preparing the appropriate version of the OPP unwinder
(optional)
- OPP single unwinder (see Chapter 5.4.4)
- OPP double unwinder (see Chapter 5.4.3)
6. Ensuring that there is a supply of raw materials (see Chapter 5.4.6)
7. Preparing the winder (see Chapter 5.4.5)
8. Preparing the bagging station (optional) (see Chapter 5.4.8)
5.4.1 Switching on the machine
Procedure
1. On the maintenance unit, establish the air supply (see Chapter 4.1 and
the Layout plan)
2. On the switching cabinet, Turn on the <Main switch>
 The control system starts up.
 The display starts automatically.
 EMERGENCY STOP is active.
 The signal light on the coating unit lights up red.
3. On the crane frame for the double unwinder for the fabric web, turn on
the <Crane system main switch>
4. On the crane frame for the OPP unwinder (optional),
switch on the <OPP crane system main switch>
5. On the cooling water supply, open the water lines (see Chapter 4.3 and
the Layout plan)

NOTE!
Possible damage due to the heated parts overheating.
Turn on cooling water!
6. Unlock all EMERGENCY STOP command devices (see Chapter 5.2.2)

7. There must be no alarm shown on the display, rectify if necessary (see
the lamiTEC LX/CX display user manual)
5.4.2 Preparing the coating unit
WARNING!

Wear eye protection when working on the extruder or co-extruder

(optional)!
The controls listed are described in Chapter 5.2.12.

Procedure
1. Switch on the control voltage with the <Reset EMERGENCY STOP>
push button
2. If necessary, move the extruder unit to the maintenance position with
the <Extruder movement limited> switch (see Chapter 5.4.9)
 The wide-slot die must be positioned above the receptacle.
3. Open the levers and valves on the cooling water distributor (see
Chapter 4.3)
4. Switch on the cooling water pumps on the display
5. Prepare the melt filter (see Chapter 5.4.7)

6. Press one of the <EMERGENCY STOP> buttons

 The heater timer only works when the EMERGENCY STOP is
activated. After the EMERGENCY STOP is reset, the heater timer is
deactivated automatically.
 The heaters resume operation.
7. On the display, set the temperature for all zone heaters (extruder, melt
filter, adapter and wide-slot die)
 The heating-up phase starts.
 The actual values indication on the display turns red if the
temperature deviation exceeds the tolerance.
DANGER!
Hot machine parts. Highest fire and explosion hazard!
 Do not lay/put flammable objects or combustible fluids on hot
machine components!
 The machine must be monitored by an expert during the
heating-up phase!
For information on the wide-slot die and feed block (optional), see
the manufacturer's documentation.
8. After reaching operating temperature:

 The indicator on the display changes from red to green.
 The heating timer for heating up of all parts starts (approx. 30 mins).
9. Once the heating timer has elapsed, reset the EMERGENCY STOP
(see Chapter 5.7.2)
10. Prepare the machine components (see Chapter 5.4.3 to 5.4.8)
- Prepare the double unwinder
- Prepare the appropriate version of the OPP unwinder
- Prepare the winder
- Ensure there is a supply of raw materials
- Prepare the melt filter
- Co-extruder (optional): prepare the manual sieve changer (see the
- Prepare the bagging station (optional)

11. Extruder unit: all the fastening bolts on the melt filter, adapter and wide-
slot die and all the tightening points on all the heater elements must be
re-tightened to the max. specified tightening torque when the extruder is
in its heated state
NOTE!
Possible damage to property due to failure to adhere to the
specified tightening torques!
tightening torque!
 For the LX standard version, see Fig. 4769/5017
 For the CX version (optional), see Fig. 4769/5059
Follow the information from the manufacturer!
Fig. 4769/5017 Fig. 4769/5059

12. Co-extruder (optional): all the fastening bolts on the manual sieve
changer, feed block, corner piece and transfer piece as well as all the
tightening points on all the heater elements must be re-tightened to the
max. specified tightening torque when the co-extruder is in its heated
state
NOTE!
Possible damage to property due to failure to adhere to the
specified tightening torques!
tightening torque (see Fig. 4769/5037)! Follow the information
from the manufacturer!
Fig. 4769/5037
Symbol Meaning
Max. tightening torque in a cold state
Max. tightening torque in a heated state
NOTE!
If plastic melt escapes, observe the following:
 Do not tighten the nuts any further!
 Replace the squeeze-type gasket with a new one (see
Chapter 6.4.6 and Chapter 6.4.9)!
 Observe the specified tightening torques!

13. Remove material residue from machine

14. Check infeed diagram (see Chapter 5.3)
15. Set Teflon tapes to the coating width (see Chapter 4.15.5)
16. Adjust the blade for the central cutter (see Chapter 4.16)
17. Adjust the crush cut knives for edge trimming (see Chapter 4.18.4)
18. Adjust the position of the exhaust pipes on the edge strip extractor (see
Chapter 4.19)
19. Switch on the "process-control" edge strip extractor (optional) (see the
20. On the display, if necessary activate the extruder and the co-extruder
(optional)
21. Start the extruder with the <Start extruder> push button
 The extruder and the co-extruder (optional) are started.
 The cooling water pump is switched on.
22. Adjust the line speed (speed of the coating unit, speed of the extruder
and of the co-extruder (optional))
- using the <Slow operation> or <Fast operation> push button
- or on the display
23. Allow the extruder to run until the coating material (plastic melt) flows
evenly and cleanly out of the wide-slot die into the receptacle
 On a production run with a special coating material, instead of the
receptacle, the customer must place a box (2) underneath.
Fig. 4769/5066
1 Wide-slot die 2 Box

24. Stop the extruder and co-extruder (optional) with the <Stop extruder>
push button
25. Clean the die lips on the wide-slot die (see Chapter 6.4.10)
26. Re-start the extruder and co-extruder (optional) with the <Start
extruder> push button and check the plastic melt flowing out
27. Stop the extruder with the <Stop extruder> push button
28. Pull a copper scraper through the die lips on the wide-slot die (see
Chapter 6.4.10, Fig. 4769/6025)
29. Start the machine with the <Start> push button
5.4.3 Preparing the double unwinder or OPP double unwinder (optional)

The procedure described below for preparing the double unwinder and OPP
double unwinder (optional) must be performed in the same way on both. For
certain tasks, however, a different procedure is required. If this is the case, a
notice will appear to this effect.
The double unwinder is fitted with a roll of fabric, and the OPP double unwinder
(optional) with a roll of OPP film.
The safety instructions listed below must be followed on both the double
unwinder and OPP double unwinder (optional).
NOTE!
Risk of injury from load hooks (1) and (2) on the crane system!
If the load hooks (1) and (2) are not used, they must be placed in
the uppermost position!
CAUTION!
Risk of crushing from double unwinder movements!
Beware of double unwinder movements if standing in the area of
the double unwinder!
CAUTION!
CAUTION!
bearing caps!
Remaining under suspended loads while the roll and the

pneumatic tension shaft are moving is prohibited!
Do not enter the area where the movement is taking place!

Wear a hard hat!
Fig. 4769/5091
1 Load hook 3 Pneumatic expansion shaft

2 Load hook 4 Roll
Procedure
1. Transport a new roll (4) to the double unwinder
- Note the corresponding direction of the unwinding device
2. Fit the roll (4) using the pneumatic expansion shaft (3)
3. Insert the pneumatic expansion shaft (3) into the core (7) of the roll (4)

Fig. 4769/5092 Fig. 4769/5093
3 Pneumatic expansion shaft z Approx. 890 mm

4 Roll w Distance
7 Core
4. Double unwinder for fabric:

 If the fabric web is to be coated on one side, the roll (4) must be
clamped in the centre of the pneumatic expansion shaft (3).
Distance (w) must be equal on both sides (Fig. 4769/5093).
 If the fabric web is to be coated on both sides, the roll (4) must be
clamped at distance (z) on the expansion shaft (3) (Fig. 4769/5092).
5. OPP double unwinder (optional):
 Clamp the roll (4) of OPP film in the centre of the expansion
shaft (3). Distance (w) must be equal on both sides
(Fig. 4769/5093).
6. To tension, charge the pneumatic expansion shaft (1) with compressed
air (see Chapter 5.4.10)
7. Place a mark on the roll (4) (see Chapter 5.5.6, Fig. 4769/5067)

Fig. 4769/5015
1 Load hook 4 Roll

3 Pneumatic expansion shaft 5 Triangular pin
8. Hook in the load hooks (1) and (2) between the triangular pins (5) and
the pneumatic expansion shaft (3) on both sides
NOTE!
Do not exceed the max. load-bearing capacity!
If the max. loading capacity is exceeded, no movement of
the load is possible due to the friction clutch.
9. Lift the pneumatic expansion shaft (3) with the clamped roll (4) on it by
using the operating unit on the crane system and convey it to one of the
unwinding stations

Fig. 4769/5016
3 Pneumatic expansion shaft 6 Bearing cap

4 Roll
10. To open the bearing caps (6), pull opposite the direction of the arrow
CAUTION!
Risk of injuries to the hands when opening the bearing caps (6)!
bearing caps!
11. Lower and position the roll (4)

- To position level 1, press the <Move vertically downwards> push
button
- Position the triangular pins (5) of the pneumatic expansion shaft (3)
in the locking device of the bearing caps (6)
12. Once the triangular pins (5) are in the locking device of the bearing
caps (6), close the bearing caps (6) by pushing in the direction of the
arrow
13. Remove load hooks (1) and (2)
14. Move load hooks (1) and (2) to the highest position using the operating
unit of the crane system

15. Double unwinder for fabric: <Roll prepared> push button

 The <Roll prepared> push button lights up white.
- Press the <Roll 1 prepared> push button or <Roll 2 prepared>
push button
 The <Roll 1 prepared> push button or <Roll 2 prepared>
push button lights up white.
17. Feed the fabric web and OPP film web roll up to the web accumulator,
according to the infeed diagram (see Chapter 5.3.1)
18. Carry out steps 1 to 14 for the second roll
19. Feed in the fabric web and OPP-film web from the second roll in the
direction of the arrow, until the mark is located at the edge of the work
table (see Chapter 5.5.6, Fig. 4769/5068)
5.4.4 Preparing the OPP single unwinder (optional)
NOTE!
Risk of injury from load hooks on the OPP crane system!
If the load hooks of the OPP crane system are not used, they
must be placed in the uppermost position!
CAUTION!
Risk of crushing from single unwinder movements!
Beware of single unwinder movements if standing in the area of
the single unwinder!
CAUTION!
Trip hazard in the area of the single unwinder!
CAUTION!
bearing caps!


Wear a hard hat!
Fig. 4769/5053
1 Load hook 6 Bearing cap

2 Load hook 7 OPP crane system
3 Pneumatic expansion shaft 8 Winder
4 Roll 9 OPP single unwinder
Procedure
1. Transport (A) the new roll (4) between the winder (8) and the unwinding
locking device using a suitable lifting device
- Note the corresponding direction of the unwinder
2. Fit the roll (4) using the pneumatic expansion shaft (3)
 Clamp the roll (4) in the centre of the expansion shaft (3).

4. Lower load hooks (1) and (2) of the OPP crane system (7) with the
operating unit
Fig. 4769/5064
1 Load hook 4 Roll

3 Pneumatic expansion shaft 5 Triangular pin
5. Hook the load hooks (1) and (2) of the OPP crane system (7) to the
triangular pins (5) of the pneumatic expansion shaft (3) on both sides
(see Fig. 4769/5053)
NOTE!
6. Raise the roll (4) of the OPP crane system with the operating unit
7. Transport the roll (4) to the single unwinder (9)
8. To open the bearing caps (6), pull opposite the direction of the arrow
CAUTION!
Risk of injuries to the hands when opening the bearing caps (6)!
bearing caps!

9. Lower the roll (4) of the OPP crane system (7) with the operating unit
and position (B)
- To position level 1, press the <Move vertically downwards> push
button
- Position the triangular pins (5) of the pneumatic expansion shaft (3)
in the locking device of the bearing caps (6)
10. Once the triangular pins (5) are in the locking device of the bearing
caps (6), close the bearing caps (6) by pushing in the direction of the
arrow
11. Remove load hooks (1) and (2) of the OPP crane system (7)
12. Move load hooks (1) and (2) to the highest position using the operating
unit of the OPP crane system (7)
13. Feed in the OPP film up to the coating unit, in accordance with the feed
diagram (see Chapter 5.3.5, Fig. 4769/5050)
5.4.5 Preparing the winder
CAUTION!
Risk of injuries to the hands from machine movements!
Operating personnel are not permitted to enter the working zone
marked out on the floor during winder movements!
CAUTION!
Risk of cuts in the area of the cutting device
NOTE!
Each movement is indicated by the signal light on the winder (see
Chapter 5.2.1) and an audible signal.

Fig. 4769/5036
1 Pneumatic expansion shaft 3 Lifting rod

2 Core
Procedure
1. Move the insertion hooks (4) to the splitter rails (5) with the <Prepare
roll change> push button
2. Slide the lifting rods (3) left and right as far as the stop in the pneumatic
expansion shaft (1)
3. Slide the core (2) onto the pneumatic expansion shaft (1)
4. Lift the pneumatic expansion shaft (1) on to the insertion hooks (4)
using the lifting rods (3)
5. Remove the lifting rods (3) and store in the proper manner
6. Position the core (2) in the centre of the pneumatic expansion shaft (1)
and charge with compressed air (see Chapter 5.4.10)
7. Apply tape to the core (2)

Fig. 4769/5035
1 Pneumatic expansion shaft 6 Contact roller

2 Core 7 Transfer device
4 Insertion hook 8 Winding and depositing arm
5 Splitter rail
CAUTION!
Risk of injury when lifting the pneumatic expansion shaft (1)!
During lifting, operating personnel are not permitted to enter the
working zone marked out on the floor!
8. Press the <Prepare for roll change> push button

 The insertion hooks (4) transport the pneumatic expansion shaft (1)
to the transfer device (7).
 The locking plates on the transfer device (7) close.
 The insertion hooks (4) move upwards.
9. Only required on commissioning or material change:
- Draw the fabric from the coating unit to the pneumatic expansion
shaft (1) of the winder (for infeed diagram, see Chapter 5.3)
- Stick the fabric on to the core (2)

10. Start the winder by pressing the <Start winder> push button
 The pneumatic expansion shaft (1) with the core (2) for winding up
the coated fabric web is in the winding position.
 This web tension is regulated and the winder is ready for operation.
11. Press the <Stop> push button on the winder
12. Press the <Roll change> push button
5.4.6 Ensuring there is a supply of raw materials

The supply of raw materials from the chosen feed system must be ensured.
For further information on commissioning the volumetric dosing

unit with feed station, see the Technical manual for the voluTEC
graviTEC gravimetric batch dosing unit with feed station (optional)
For further information on commissioning the gravimetric batch

dosing unit, see the Technical manual for the graviTEC
gravimetric batch dosing unit.
Preparing the vacuum conveyor (optional)

 Switch on the blower

5.4.7 Prepare the melt filter
WARNING!
Wear protective gloves when working on the melt filter!
Wear eye protection when working on the melt filter!
Fig. 4769/5065
1 Filter tape 8 Filter output

2 Filter tape
If the melt filter is being used for the first time and the extruder and the melt filter
have reached operating temperature, the melt filter is filled with material at a low
speed on the extruder (5 rpm) until the plastic melt flows out of the filter output
side (8).
The extruder then stops and, after cooling, a solid plastic plug is formed which
fixes the position of the filter tapes (1) and (2) at the filter output (8) (takes
approx. 30 min.).
The process must be repeated until a uniform plastic plug has formed (no more
plastic melt emerges).

5.4.8 Preparing the bagging station (optional)
Fig. 4769/5087
1 Container (e.g. FIBC) 4 Pin

2 Container 5 Support
3 Loop
Procedure
1. Remove full container (1) or (2) if necessary
- Pull out the pin (4) by pulling out the red button
- Unhook all loops (3)
- Open the quick-lock clamping ring and pull the filler neck of the
container downwards
- Remove the full container (1) or (2) with a suitable lifting device
2. Hook in container (1) and (2)
- If necessary, position a suitable support (5) underneath the
container
- Pull out the pin (4) by pulling out the red button
- Hook all loops (3) onto the pin (4)
- Secure the filler neck of the container with a quick-lock clamping ring

3. Turn the <Deactivate/Activate> switch to the right (see Chapter 5.2.10):

 The bagging station is in operation.
 The switch is lit green.
4. Turn the <Auto/Manual mode> switch to the left
 The bagging station is in automatic mode.
5.4.9 Moving the extruder unit
WARNING!
Risk of crushing from extruder unit movements!
During movements, operating personnel are not permitted to enter
the working zone marked out on the floor!
CAUTION!
Risk of injuries to the hands from extruder unit movements!
WARNING!

Wear eye protection when working on the extruder and co-

Wear a hard hat when working on the extruder unit!
WARNING!

the magnetic field!

NOTE!
Possible damage to property due to improper installation of the
switch plate!
Before the extruder unit makes its initial movement, check the
position of the switch plate (see Chapter 3.3.7, Fig. 4769/3090)!
The <Extruder movement limited> switch is used to move the extruder unit. It is
located on the following operating units:
 Operating unit on the base frame (see Chapter 5.2.12, Fig. 4769/5041)
 Operating unit on the coating unit (see Chapter 5.2.12, Fig. 4769/5078)
 Operating unit on the coating unit, drive side (see Chapter 5.2.12,
Fig. 4769/5044)
Fig. 4769/5019
Extruder unit in maintenance

1 Extruder unit C
position
A Drive side D Extruder unit in working position
B Operating side

Moving extruder unit to maintenance position

1. Turn the <Extruder movement limited> switch clockwise
 The extruder unit (1) moves in the direction of the drive side (A).
 An audible signal (1 Hz) is issued by the signal horn.
 Holding in the <Extruder movement limited> switch switches from
setting speed to travel speed.
Fig. 4769/5020
1 Extruder unit 5 Limit switch

2 Bracket with stop buffer A Drive side
3 Switch plate B Operating side
4 Limit switch
2. Turn the <Extruder movement limited> switch clockwise and hold

- The limit switch (4) is actuated by the switch plate (3) on the drive
side (A)
 The speed is changed from the travel speed to the setting speed.
- The extruder unit (1) runs at the setting speed until the limit
switch (5) is actuated by the switch plate (3)
 The extruder unit (1) is in the maintenance position (C).
 The wide-slot die is positioned above the receptacle.
3. Move the <Extruder movement limited> switch to the middle position

Moving the extruder unit into working position

1. Turn the <Extruder movement limited> switch anticlockwise
 The extruder unit (1) moves in the direction of the operating side (B).
 An audible signal (1 Hz) is issued by the signal horn.
 Holding in the <Extruder movement limited> switch switches from
setting speed to travel speed.
2. Turn the <Extruder movement limited> switch anticlockwise and hold
- The limit switch (5) is actuated by the switch plate (3) on the
operating side (B)
 The speed is changed from the travel speed to the setting speed.
- The extruder unit (1) runs at the setting speed while you hold down
the <Extruder movement limited> switch
- If the limit switch (4) is actuated by the switch plate (3), the unit
stops automatically
3. Release the <Extruder movement limited> switch once the optimum
working position has been reached
 The switch is in the centre position.
 The extruder unit (1) is in the working position (D).
 The wide-slot die is positioned above the rollers on the coating unit.

5.4.10 Pneumatic expansion shafts

The pneumatic expansion shafts (1) should be fitted with an empty core (winder),
a fabric roll (double unwinder), or an OPP-film roll (OPP double unwinder),
depending on use.
Fig. 4769/5029
1 Pneumatic expansion shaft 4 Air gun

2 Roll 5 Clamping bars
3 Pressure gauge
 To tension, blow compressed air into the pneumatic expansion shaft (1)
with the air gun (4)
 The clamping bars (5) press outwards.
 Charge it with compressed air until a pressure of approx. 5 bar is
achieved.
 The needle in the pressure gauge on the air gun (4) should not
move any further.
 To release the clamp, push on the outer ring of the blow-in opening with
the air gun (4)
 The pneumatic expansion shaft (1) is bled via the valve.

5.5 Operation
If no problems occurred during start-up, the machine can be set into operation.
WARNING!
During operation, operating personnel are not permitted to enter
Before switching operating mode, ensure that you are in visual
contact with a second person!
Double unwinder and crane system
CAUTION!
Risk of crushing from double unwinder movements!
Beware of double unwinder movements if standing in the area of
the double unwinder!
CAUTION!
CAUTION!
bearing caps!
NOTE!
Risk of injury from load hooks on the crane system!
If the load hooks are not used, they must be placed in the
uppermost position!


Wear a hard hat!
WARNING!
Risk of injury if max. load-bearing capacity is exceeded!
Extruder unit and co-extruder (optional)
WARNING!
CAUTION!
Risk of injuries to the hands from extruder unit movements!
Wear a hard hat!
WARNING!

the magnetic field!
WARNING!


Wear eye protection when working on the extruder and co-

Corona (optional)
DANGER!
adhered to!
DANGER!
manual).
WARNING!

the magnetic field!

documentation.

Coating unit
WARNING!
Wear a hard hat!
WARNING!
Risk of being crushed by the rotating rollers!
Never reach between the rollers during operation!
CAUTION!
Trip hazard on the cooling water distributor and cable ducts!
Note the bracket for the cooling water supply and cable ducts!
CAUTION!
Risk of cutting from the crush cut knives and the blades of the
edge trimmer!
Wear protective gloves when working on the crush cut knives and
the blades of the edge trimmer!
WARNING!
Risk of hand injuries at the chill roller and pressure roller!
Never reach between the chill roller and pressure roller during
operation!
WARNING!
Risk of hand injuries at central cutter!
Never reach between the rollers and bracket during operation!
CAUTION!
Risk of injuries to the hands from cutting unit movements!
Never reach between the knife carriage and the mounting block!
WARNING!
Risk of hand injuries at the infeed roller before the winder!
Never reach between the fabric web and infeed roller during
operation!

5. CO
OMMISS
SIONING AND OPERA
ATION
Micro pe
erforating roller
r (optio
onal)
WARN NING!
Risk of
o being draawn in at pin
n roller and brush rollerr!
Do noot reach betw
ween the pin roller andd the brush roller!
CAUT TION!
Risk of
er!
Do noot touch the pin roller!
Wear protective g
gloves!
OPP unw
winder (opttional) and
d OPP crane system (optional)
The safe
ety instructio
ons lists app
ply to both version
v of th
he OPP unw
winder (the single
and doub
ble unwinde er).
CAUT TION!
Risk of
o crushing by movemeents of the OPP
O unwindder!
Beware of OPP uunwinder movements iff standing inn the area of
o the
OPP unwinder!
u
CAUT TION!
Trip hazard in the
e area of the OPP unw
winder!
Beware of the gu uide rails!
CAUT TION!
Risk of
o injuries to
o the hands when open ning the beaaring cap!
Neverr reach into the gap at the bearing
g caps whenn opening thhe
bearin
ng caps!
NOTE E!
Risk of
o injury from
m load hook
ks on the OPP crane ssystem!
If the load hooks are not use
ed, they must be placeed in the
upperrmost positioon!
Remaaining underr suspended d loads while the roll a nd the

pneum
matic tensioon shaft are moving is prohibited!
p
Do no
ot enter the area wheree the movemment is takinng place!

AGE 211 / 341
Translatio
Wear a hard hat!
WARNING!
Risk of injury if max. load-bearing capacity is exceeded!
Winder
CAUTION!
WARNING!
Risk of being crushed by the rotating rollers!
Never reach between the rollers during operation!
CAUTION!

5.5.1 Starting the machine
Procedure
1. Set the speed of the coating unit to at least 5 m/min. with the <Fast
operation> or <Slow operation> push button or on the display
2. Start the extruder with the <Start extruder> push button
 The extruder and the co-extruder (optional) are started.
 The cooling water pump is switched on.
3. Adjust the line speed (speed of the coating unit, speed of the extruder
and of the co-extruder (optional))
- using the <Slow operation> or <Fast operation> push button
- or on the display
4. Allow the extruder to run until the coating material (plastic melt) flows
evenly and cleanly out of the wide-slot die into the receptacle
5. Stop the extruder and co-extruder (optional) with the <Stop extruder>
push button
6. Remove plastic melt from under the wide-slot die using a brass scraper
7. Position the pressure roller at the coating unit with the <Lift off/position
pressure roller> push button
8. Check that the winder is ready for operation (see Chapter 5.4.5)
9. Move the extruder unit into the working position above the chill roller
with the <Extruder movement limited> switch (see Chapter 5.4.9)
10. As soon as plastic melt emerges at the fabric web, start the coating unit
with the <Start> push button
11. Adjust the working position of the extruder with the <Extruder
movement limited> push button
 Set the working position so that the cover coating is the same width
on both sides of the fabric web.
12. If necessary, switch on the edge strip extractor on the display
 This is switched on automatically when the coating machine starts.
13. To switch on edge trimming, turn the <Stop/automatic cycle> switch
clockwise
14. Guide the edge strips into the extractor
In order that the edge strips can be removed unimpeded, the start
of the strip must be fully sucked in. Edge strips must never be
allowed to form loops!

15. Select the type of perforation on the display

16. If necessary, activate the pin rollers of the perforation system or the
micro perforating roller (optional) with the <Perforation off/on> push
button
17. Set the speed of the coating unit with the <Fast operation> or <Slow
operation> push button or on the display
The coating thickness is produced by the extruder speed and the

coating unit speed (see the lamiTEC LX/CX display user manual)!
5.5.2 Stopping the machine

The following steps must be performed each time before stopping the machine
(interrupting automatic mode):
1. Reduce the coating unit speed to 5 m/min with the
<Slow operation> push button or on the display
2. Press the <Stop extruder> push button
 The extruder stops
3. Move the extruder unit to the maintenance position with the <Extruder
movement limited> switch (see Chapter 5.4.9)
4. Once the extruder unit reaches the maintenance position, press
the <Stop> push button
5. Turn the <Lift off/Position pressure roller> switch anticlockwise
 The pressure roller is lifted off.
 The <Lift off/position pressure roller> switch does not light up.
 The pin rollers on the perforation system and micro perforating roller
(optional) are swivelled out automatically.
 The edge strip extractor is switched off automatically.
5.5.3 Workstations
The main workstation is located at the operating unit on the coating unit.
In addition, the machine is equipped with several maintenance positions.
For further information on the workstations and maintenance

positions, see the Layout plan.

5.5.4 Operating modes

The machine has the following operating modes:
 Automatic mode
 Manual mode
 Roll change mode
Automatic mode
The machine is designed for two-person operation. In automatic mode, the
machine requires no intervention whatsoever. Operating personnel can read and
adjust all parameters on the display.
The settings are determined by the properties and condition of the following
materials:
 Coating material (viscosity, humidity, bulk weight, density, additives,
level of dirt)
 Fabric (quality and weight)
 CX version: OPP film (quality and weight)
The following tasks must be performed in automatic mode:

 Monitoring the processes on the machine
- Checking the cooling water supply
- Regular checking of the coating for evenness across the entire width
of the fabric web
- Regular checking of the cover coating
- Regular checking of edge strip extractor (no formation of loops)
- Troubleshooting (see Chapter 7)
- Determination of the coating weight (see Chapter 5.5.10)
- Checking the roll quality (see Chapter 5.5.9)
 Machine loading (see Chapter 5.5.6 to 5.5.7)
 Ensuring a supply of raw materials (see the corresponding technical
manual)
 Removal of the finished product (see Chapter 5.5.8)

Interrupting automatic mode

The machine must be stopped to interrupt automatic mode (see Chapter 5.5.2).
Switching to automatic mode

1. Start the winder with the <Start winder> push button
2. Start the extruder and co-extruder (optional) with the <Start extruder>
push button
3. Move the extruder unit into the working position with the <Extruder
movement limited> switch (see Chapter 5.4.9)
4. Start the coating unit with the <Start> push button
5. Set the speed of the coating unit with the <Fast operation> or <Slow
operation> push button or on the display
Roll change mode

 Automatic roll change on the double unwinder
 Manual roll change on the winder
 CX version (optional):
- Manual roll change on the OPP single unwinder
- Semi-automatic roll change on the OPP double unwinder (optional)
Under optimal conditions, the coating unit speed will be the same as the roll
change speed.
5.5.5 Tasks to perform on the machine
Monitoring the processes

The machine may only be operated under the supervision of trained persons. The
machine must be shut down immediately if its operating behaviour changes.
Malfunctions may only be corrected by authorised persons (see Chapter 7).

Machine loading
Depending on the model of the machine, machine loading can encompass the
following operations:
 Roll change on the double unwinder (see Chapter 5.5.6)
 Ensuring the supply of raw materials from the appropriate feed system
 CX version (optional):
- Roll change on the single unwinder (see Chapter 5.5.7)
- Prepare for the roll change on the OPP double unwinder (optional)
(see Chapter 5.5.6)
Removing the finished product

 Roll change on the winder (see Chapter 5.5.8)
Removing residue from the material

 Remove cooled plastic melt from the receptacle on a regular basis
 Empty the wire-mesh container for edge strips regularly
5.5.6 Roll change on the double unwinder for fabric and OPP film (optional)
Double unwinder for fabric

For the automatic roll change on the fabric double unwinder, one roll must always
be in operation and one complete roll at the ready. When one roll runs out, an
automatic roll change is performed. Then a new roll must be prepared.
Automatic roll change is active when the <Roll change> push button is lit
OPP double unwinder (optional)

For the roll change on the OPP double unwinder, one roll must always be in
operation and one complete roll at the ready. If the signal light on the OPP
unwinder flashes (see Chapter 5.2.1), the set value specified on the display for
min. OPP-film roll diameter has been reached, and a roll change must be carried
out on the OPP double unwinder.
Procedure
1. Hold down both two-hand <Roll change> push buttons
 The roll is severed by the corresponding cutting unit.
2. Once the new roll has been fed in, release the two-hand <Roll change>
buttons
3. Prepare for the roll change

Preparing for the roll change

The procedure described below for preparing the roll for a roll change must be
performed in the same way on the double unwinder for fabric and the double
unwinder for OPP film. For certain tasks, however, a different procedure is
required. If this is the case, a notice will appear to this effect.
The double unwinder is fitted with a roll of fabric, and the OPP double unwinder
(optional) with a roll of OPP film.
The safety instructions listed below must be followed on both the double
unwinder and OPP double unwinder (optional).
NOTE!
Risk of injury from load hooks on the crane system!
uppermost position!
CAUTION!
Risk of injuries to the feet from double unwinder movements!
CAUTION!

Wear a hard hat!

Procedure
1. Transport a new roll (4) to the double unwinder
- Note the unwinding direction of the roll (4) in question
Fig. 4769/5067
1 Pneumatic expansion shaft 6 Start of the fabric web

2 Triangular pin 7 Mark
3 Double-sided tape t Approx. 500 mm
4 Roll y Approx. 150 mm
5 Core
2. Hook in the load hooks on both sides between the triangular pins (2)
and the pneumatic expansion shaft (1) with empty core (5) (see also
Chapter 5.4.3, Fig. 4769/5015)
3. Lift the pneumatic expansion shaft (1) with the empty core (5) by using
the operating unit on the OPP crane system and carry it to the roll (4)
4. Bleed the pneumatic expansion shaft (1) (see Chapter 5.4.10)
5. Pull the empty core (5) off the pneumatic expansion shaft (1)
6. Fit the new roll (4) to the pneumatic expansion shaft (1), paying
attention to distance (z) (see Chapter 5.4.3, Fig. 4769/5091)

8. Make a mark (7) at a distance (t) from the start of the fabric web (6) or
the OPP film web
9. Double unwinder for fabric: attach 2 strips of double-sided tape (3) at
distance (y) from the start of the fabric web (6)
10. Double unwinder for OPP film: attach 1 strip of double-sided tape (3) at
distance (y) from the start of the OPP-film web
11. Hook the load hooks on both sides between the triangular pins (2) and
the pneumatic expansion shaft (3) (see also Chapter 5.4.3,
Fig. 4769/5015)
NOTE!
12. Raise the roll (4) of the OPP crane system with the operating unit
- Transport a new roll (4) to the double unwinder
- Make sure that the triangular pins (of the pneumatic expansion
shaft (1)) are firmly seated in the locking mechanism of the bearing
caps (see Chapter 5.4.3, Fig. 4769/5016)
CAUTION!
bearing caps!
13. Close the bearing caps (see Chapter 5.4.3, Fig. 4769/5016)
14. Remove the load hooks on both sides
15. Move both load hooks to the highest position using the operating unit of
the OPP crane system
16. Double unwinder for fabric: Press the <Roll prepared> push button
- Press the <Roll 1 prepared> push button or <Roll 2 prepared> push
button
 The <Roll 1 prepared> push button or <Roll 2 prepared> push
button lights up white.

Fig. 4769/5068
Fabric web or OPP film during

3 Double-sided tape 10
production
4 Roll 11 Lever
7 Mark 12 Holder with rubber lugs
8 Work table 13 Compressed air hoses
18. Press the <Brake 1 on/off> or <Brake 2 on/off> push button

 Double unwinder for fabric: the corresponding pneumatic brake is
released and the roll (4) can be unwound.
 OPP double unwinder: the corresponding holding brake of the motor
is released and the roll (4) can be unwound.
19. Feed in the fabric web and OPP-film web from the roll (4) and swivel the
lever (11) in the direction of the arrow (for feed diagram, see Chapter
5.3.1)
 The brackets with rubber lugs (12) are raised.
 The fabric web or OPP-film web is charged with compressed air via
the compressed air hoses (13).
20. Feed in the fabric web and OPP-film web from the roll (4) in the
direction of the arrow, until the mark (7) is located at the edge of the
work table (8)

CAUTION!
Risk of hand injuries when feeding in the fabric web and OPP-film
web!
Do not reach into the fabric web or OPP-film web while it is
running!
Fig. 4769/5070
8 Work tables 9 Thrust piece
During operation, both work tables (8) must be pivoted upwards.

The thrust pieces (9) must engage on both sides.
21. Swivel the lever (11) back

22. Adjust the holder with rubber lugs (12) for the prepared roll so that the
rubber lugs lightly touch the edges of the fabric web
 When the roll is in operation, the holder with rubber lugs (12) is
raised automatically.
23. Double unwinder for fabric: Press the <Roll prepared> push button
 The roll (4) is prepared for an automatic roll change.
24. Then a roll change must be performed on the winder (see Chapter
5.5.8)

5.5.7 Roll change on the single unwinder (optional)

When the set value shown on the display for the min. roll diameter for the OPP
film is reached, this is indicated on the display, and a roll change must be
performed on the OPP single unwinder.
NOTE!
Risk of injury from load hooks on the OPP crane system!
uppermost position!
CAUTION!
Risk of injuries to the feet from single unwinder movements!
CAUTION!
Trip hazard in the area of the single unwinder!
Do not linger under suspended loads during crane system

movements!
Wear a hard hat!
The roll change on the single unwinder can be subdivided into the following
steps:
1. Stop the machine (see Chapter 5.5.2)
2. Use a suitable tool to cut the OPP film
3. Hold the <OPP brake on/off> push button and, if necessary, wind up the
remaining OPP film by hand and secure with tape
4. During a product change, remove the OPP film on the single unwinder
and from the coating unit

5. Lower load hooks (1) and (2) using the operating unit for the OPP crane
system (7) (see Chapter 5.4.4, Fig. 4769/5053)
6. Hook load hooks (1) and (2) of the OPP crane system (7) on both sides
between the triangular pins (5) and the pneumatic expansion shaft (3)
(see also Chapter 5.4.4, Fig. 4769/5053)
7. Lift the roll with the operating unit for the OPP crane system and carry it
towards the winder
8. Set down the roll between the winder and the unwinding locking device
9. Unhook the load hooks of the OPP crane system from the pneumatic
expansion shaft
10. Move the load hooks into the uppermost position
11. Vent the pneumatic expansion shaft (see Chapter 5.4.10) and remove
from the roll
12. Carry the roll away using a suitable lifting device and deposit a new roll
between the winder and the unwinding locking device
13. Fit a new roll to the single unwinder (see Chapter 5.4.4)
14. Start the machine (see Chapter 5.5.1)
15. Then a roll change must be performed on the winder (see
Chapter 5.5.8)
5.5.8 Roll change on the winder
CAUTION!
CAUTION!
NOTE!
Each movement is indicated by the signal light on the winder (see
Chapter 5.2.1) and an audible signal.
The control elements listed are described in Chapter 5.2.12,

Fig. 4769/5082.

Fig. 4769/5024
1 Pneumatic expansion shaft 5 Roll

Transfer device in winding
2 Transfer device A
position
Transfer device in transfer
3 Winding and depositing arm B
position
4 Contact roller
The roll (5) with the pneumatic expansion shaft (1) is wound into the transfer
device (2) via the contact roller (A).
During winding, the transfer device (2) swings approx. 30° in the direction of the
winding and depositing arm (3).
Once the roll (5) in the transfer device (2) has reached the transfer diameter, the
transfer device (2) is swivelled in the direction of the winding and depositing
arm (3) (B).
Once the winding and depositing arm (3) has accepted the pneumatic expansion
shaft (1) with the roll (5), the transfer device (2) is swivelled back. The roll (5)
with the pneumatic expansion shaft (1) is wound using the winding and
depositing arm (3).
When the length specified on the display has been wound up, a roll change must
be performed (for max. diameter, see Chapter 2).

To change the roll (5) with or without a previous roll change on the double
unwinder for fabric (see Chapter 5.5.6), different procedures are required.
Fig. 4769/5027
1 Pneumatic expansion shaft 6 Pneumatic expansion shaft

2 Transfer device 7 Core
3 Winding and depositing arm 8 Unwinding locking device
4 Contact roller 9 Cutting unit
5 Roll

Procedure: roll change on the winder with previous roll change on the double
unwinder for fabric
1. Prepare the pneumatic expansion shaft (6) with an empty core (7) (see
Chapter 5.4.5, Fig. 4769/5036)
 The pneumatic expansion shaft (6) with empty core (7) is positioned
in the transfer device (2).
 The roll (5) with the pneumatic expansion shaft (1) is wound using
the winding and depositing arm (3).
 The pre-acceleration unit was lowered with the roll change on the
double unwinder for fabric, and subsequently the newly prepared
pneumatic expansion shaft (6) with the empty core (7) was
accelerated to the current speed of the coating unit.
CAUTION!
Risk of injury from the unwinding roll (5)!
During a roll change on the contact winder, operating personnel
are not permitted to enter the working zone marked out on the
floor!
 The pre-acceleration unit is pivoted away and the coating unit

accelerates.
 The coated fabric web is cut by the cutting unit (9).
 The coated fabric web is accepted by the newly-prepared pneumatic
expansion shaft (6) with empty core (7) and wound up.
3. Turn the <Raise/lower rollers> switch clockwise
 The full roll (5) is swivelled out by the winding and depositing
arm (3), deposited on the floor and rolled to the unwinding locking
device (8).
4. Turn the <Raise/lower rollers> switch anticlockwise until the winding
and depositing arm (3) is in the transfer position
5. Move the <Raise/lower rollers> switch to the centre position
6. Bleed the pneumatic expansion shaft (1) and pull out of the roll (5) (see
Chapter 5.4.10)
7. Remove the roll (5) with a suitable lifting device
8. As soon as the unwinding and depositing arm (3) has accepted the
roll (5) again, prepare the new pneumatic expansion shaft (6) with
empty core (7) (see Chapter 5.4.5, Fig. 4769/5036)

Procedure: roll change on the winder without previous roll change on the double
unwinder for fabric
1. Prepare the pneumatic expansion shaft (6) with an empty core (7) (see
Chapter 5.4.5, Fig. 4769/5036)
 The pneumatic expansion shaft (6) with empty core (7) is positioned
in the transfer device (2).
 The roll (5) with the pneumatic expansion shaft (1) is wound using
the winding and depositing arm (3).
CAUTION!
Risk of injury from the unwinding roll (5)!
During a roll change on the contact winder, operating personnel
are not permitted to enter the working zone marked out on the
floor!
 The newly prepared pneumatic expansion shaft (6) with the empty
core (7) is accelerated to the current coating unit speed by the pre-
acceleration unit.
3. Press the <Roll change> push button again
 The coated fabric web is cut by the cutting unit (9).
 The coated fabric web is accepted by the newly-prepared pneumatic
expansion shaft (6) with empty core (7) and wound up.
4. Turn the <Raise/lower rollers> switch clockwise
 The full roll (5) is swivelled out by the winding and depositing
arm (3), deposited on the floor and rolled to the unwinding locking
device (8).
5. Turn the <Raise/lower rollers> switch anticlockwise until the winding
and depositing arm (3) is in the transfer position
6. Move the <Raise/lower rollers> switch to the centre position
7. Bleed the pneumatic expansion shaft (1) and pull out of the roll (5) (see
Chapter 5.4.10)
8. Remove the roll (5) with a suitable lifting device
9. As soon as the unwinding and depositing arm (3) has accepted the
roll (5) again, prepare the new pneumatic expansion shaft (6) with
empty core (7) (see Chapter 5.4.5, Fig. 4769/5036)

5.5.9 Checking the roll quality (muting the safety light barrier)
CAUTION!
Risk of injury from machine movements!
During contact winder movements, operating personnel are not
permitted to enter the working zone marked out on the floor!
Standing in the marked area is only permitted for a short period
during operation, when inspecting the roll quality!
If an inspection of the roll quality must be performed on the contact winder during
operation, the safety function of the safety light barrier must be briefly interrupted
(muting). When the safety light barrier is active, the <Light barrier> push button is
lit yellow (muting indicator light).
Before performing the inspection, operating personnel must assume the following
positions:
 Position (E) for the first person, at the manual operating unit on the
contact winder
 Position (F) for the second person, at the roll (2) for inspecting the roll
quality
Fig. 4769/5021
1 Light barrier E Position of the second person

2 Roll F Position of the first person

Procedure
1. The first person at position (F) must press and hold the <Light barrier>
push button for min. 10 seconds
 The safety light barrier (1) is deactivated (muting is active).
 The <Light barrier> push button is no longer lit.
 During this period, the second person (E) must check the roll quality
by tapping on the roll (2) and then leave the working area again.
2. The <Light barrier> push button flashes after 5 secs
 Half of the time available has passed.
3. The <Light barrier> push button lights up again after a further 5 secs
 The safety light barrier (1) is activated again.
 If the <Light barrier> push button is released before the 10 seconds
have elapsed, an EMERGENCY STOP is triggered.
4. If an EMERGENCY STOP is triggered:
- Press the <Reset EMERGENCY STOP> push button
- Start the machine (see Chapter 5.5.1)

5.5.10 Determining the coating weight

To determine the coating weight, proceed as follows:
Inspecting the coated double-flat fabric:
Fig. 4769/5094
The arrows indicate the direction of production.

Slit section of fabric (both
1 Folded-over section of fabric 3
coated sides facing up)
2 Cut-off section of fabric B Operating side
1. On the roll being wound up by the contact winder, fold the fabric up so
that the inside of the section of fabric is on the outside (1)
2. Draw an arrow on the section of fabric on the operating side (B) facing
in the direction of production (2)
3. Slit the section of fabric on the left side and open it out so that the two
coated sides of the fabric web are facing upwards (3)
4. Set the section of fabric from the coated fabric web down on a clean,
smooth surface, with the two coated sides facing upwards

Fig. 4769/5095
The arrow indicates the production direction.
5. Use a circular knife (see Fig. 4769/5085) to cut out pieces of fabric of
equal size, starting from the centre at even intervals
 The number of circular cutouts is dependent on the width of the
fabric web.
6. Number the circles and position of the cutouts (see Fig. 4769/5095)
7. Use a suitable measuring instrument to determine the coating weight of
the individual circular cutouts
- Coating weight = Weight of the circular cutout - Gross weight of the
fabric
- Write down the result for the individual circular cutouts on the
section of fabric, next to the cutouts in question
 Move the section of fabric with the test results to the wide-slot die
(see Fig. 4769/5086) and set the die gap according to the
established coating weight (see Chapter 4.14.3).

documentation.

Inspecting the coated flat fabric:
Fig. 4769/5097
The arrows indicate the direction of production.

1 Folded-over section of fabric B Operating side
2 Cut-off section of fabric
1. On the roll being wound up by the contact winder, fold the fabric up so
that the coated inside of the section of fabric is on the outside (1)
2. Draw an arrow on the section of fabric on the operating side (B) facing
in the direction of production (2)
3. Set the section of fabric from the coated fabric web down on a clean,
smooth surface, with the coated sides facing upwards and the arrow on
the left
Fig. 4769/5085
4 Circular knife

Fig. 4769/5096
4. Use a circular knife (4) to cut out pieces of fabric of equal size, in the
running direction at uniform intervals
 The number of circular cutouts is dependent on the width of the
fabric web.
5. Number the circles and position of the cutouts (see Fig. 4769/5096)
6. Use a suitable measuring instrument to determine the coating weight of
the individual circular cutouts
- Coating weight = Weight of the circular cutout - Gross weight of the
fabric
- Write down the result for the individual circular cutouts on the
section of fabric, next to the cutouts in question
 Move the section of fabric with the test results to the wide-slot die
(see Fig. 4769/5086) and set the die gap according to the
established coating weight (see Chapter 4.14.3).

documentation.

Fig. 4769/5086
2 Wide-slot die 3 Strip
5.5.11 Special functions on the contact winder
CAUTION!
During contact winder movements, operating personnel are not
permitted to enter the working zone marked out on the floor!
CAUTION!
NOTE!
Each movement is indicated by the signal light on the contact
winder (see Chapter 5.2.1) and an audible signal.


The control elements listed are described in Chapter 5.2.12,

Fig. 4769/5082.
Fig. 4769/5028
1 Insertion hook 5 Winding and depositing arm

2 Locking plate 6 Blade
3 Transfer device A Drive side
4 Auxiliary feed B Operating side
Operation with auxiliary feed

 Select the auxiliary feed function on the display
 If the auxiliary feed (1) is required to support winding (depending on
the web specification), this will be lowered.
 If the fabric web is to be trimmed, the cutting blade (6) will move
from the operating side (B) to the drive side (A).
 The auxiliary feed (1) then lifts and the blade (6) moves back to the
operating side (B).
Operation with faulty insertion hook

1. Select the function on the display
2. Fit the pneumatic expansion shaft with core and charge with
compressed air (see Chapter 5.4.10)

3. Manually insert the pneumatic expansion shaft into the transfer

device (3)
 The locking plate (2) closes automatically.
CAUTION!
Risk of hand injuries when inserting the pneumatic expansion
shaft manually!
Do not reach into the transfer device while inserting the shaft!
4. Press the <Start winder> push button

 The pneumatic tension shafts lowers towards the contact roller.
Manually moving the transfer device

The corresponding function should be selected on the display.
Requirements for swivelling the transfer device (3) into a vertical position:
 Pneumatic expansion shaft in the transfer device (3) and locking
plate (2) closed
 No pneumatic expansion shaft in the transfer device seating (3) and
locking plate open or closed
Requirements for opening the locking plate (2):

 Pneumatic expansion shaft in the transfer device (3) and
- winding and depositing arm (5) in the winding position
- upper transfer device (2)
- pneumatic expansion shaft in the winding and depositing arm (5)
- transfer device (3) tilted to the winding and depositing arm (5)
 No pneumatic expansion shaft in the transfer device seating (3)
- opening is always possible
Closing the locking plate (2) is always possible.

Requirements for swivelling the transfer device into the transfer position:
- locking plate (2) closed
- no pneumatic tension shaft in the winding and depositing arm (5)
 No pneumatic tension shaft in the transfer device (3) and
- no pneumatic tension shaft in the winding and depositing arm (5)
If the transfer device (3) cannot be swivelled, an automatic stop

will be triggered for the machine.
In order for the alarm to be reset or the contact winder to be
restarted, the pneumatic expansion shaft must be removed from
the transfer device (3). A new pneumatic expansion shaft with
empty core must then be lifted into the transfer device (3).
Requirements for raising the transfer device (3):

 Pneumatic expansion shaft in the winding and depositing arm (5)
- transfer device (3) swivelled or in undefined positioned
- locking plate (2) open
- put the transfer device (3) into the vertical position
 No pneumatic tension shaft in the winding and depositing arm (5)
- raising is always possible
If the transfer device (3) was lowered with the <Roll change> push button, it can
be raised again as follows:
1. Press the <Stop> push button
2. Press the <Prepare for roll change> push button
Requirements for lowering the transfer device (3):

 Pneumatic expansion shaft for transfer device (3) and locking plate
closed
 Lowering is possible at all times when there is no pneumatic expansion
shaft in the transfer device (3)

5.6 Switching off the machine
Before switching off the machine each time, the following tasks must be
performed:
1. Stop the machine (see Chapter 5.5.2)
2. Switch off the zone heaters on the display
3. Switch off the hot air oven via the display
4. If necessary, move the load hooks of the crane system to the highest
position using the operating unit
5. Turn off the crane system with the <Crane system main switch> (see
Chapter 5.2.1)
6. Turn off the OPP (optional) crane system with the <OPP crane system
main switch> (see Chapter 5.2.1)
7. Switch off the supply of raw materials from the appropriate feed system
- Volumetric dosing unit with feed station
For further information on switching off the volumetric dosing unit

with feed station, see the Technical manual for the voluTEC
- graviTEC gravimetric batch dosing unit with feed station (optional)
For further information on switching off the gravimetric batch

dosing unit, see the Technical manual for the graviTEC
gravimetric batch dosing unit with feed station.
- Switch off the blower vacuum conveyor (optional)

8. Switch off the "process-control" edge strip return (optional)


9. Switch on the cooling system on the display

10. Switch off the machine after approx. 30 mins with the <Main switch> on
the switching cabinet
11. Shut off the compressed air on the maintenance unit (see Chapter 4.1
and the Layout plan)
The machine must always be switched off at the main switch. The <Main switch>
is located on the switching cabinet and provides an EMERGENCY STOP
function.
Fig. 4769/5023 Fig. 4769/5054
Rotating the <Main switch> to the "0" position immediately interrupts the power
supply and shuts down the machine.
DANGER!
Risk of serious injury!
Before starting the machine up it must always be ensured that this
cannot place anyone at risk.
In order to prevent the accidental start-up of the machine, the
<Main switch> must be secured against being switched back on
(e.g. during adjustment and maintenance work).
For further information on the control system, see the lamiTEC

LX/CX display user manual.

5.7 Shutting down the machine

In accordance with EN ISO 13850:2006, each person is required to trigger an
EMERGENCY STOP if doing so could avert the risk of personal injury, damage
to the machine or risks to ongoing work or existing danger can be lessened.
DANGER!
The EMERGENCY STOP must NEVER be used to shut down the
machine for maintenance work!
When performing maintenance on the machine, the <Main
switch> must always be set to OFF ("0" position) and be
safeguarded against being switched back on!
5.7.1 EMERGENCY STOP command devices

The machine is equipped with several EMERGENCY STOP command devices,
which can be found on the machine at various locations (see Overview in
Chapter 5.2.2). Actuating an EMERGENCY STOP command device shuts down
the machine or the associated area.
EMERGENCY STOP push button
Fig. 4769/5058
<Reset EMERGENCY STOP> push button

The <Reset EMERGENCY STOP> push button is located at the manual
operating unit on the coating unit. The signal from the indicator light provides
information on the operating status of the machine. The signals are explained in
the following table.
Signal Meaning
Off Fault-free operation
Lights up EMERGENCY STOP active or unlocked but not yet reset

Fig. 4769/5026
1 EMERGENCY STOP pull cord 3 <Reset push button>

2 Appearance
The <Reset push button> has the same design as the <EMERGENCY STOP>
push button. This must be pulled out for the EMERGENCY STOP on the pull cord
to be acknowledged.
Appearance Meaning
 EMERGENCY STOP pull cord active
Yellow
 Cord broken
Green  The EMERGENCY STOP pull cord is ready for operation
5.7.2 Method of operation
Triggering an EMERGENCY STOP

 Press the <EMERGENCY STOP> push button or pull the
 The EMERGENCY STOP is active.
 The machine is shut down.
 The power supply for the drives is interrupted.
 The 24V control voltage is maintained.
 The indicator on the EMERGENCY STOP pull cord changes from
green to yellow.
 The EMERGENCY STOP is indicated on the display.

Cancelling an EMERGENCY STOP

1. Rectify the cause of the EMERGENCY STOP
2. Unlock <EMERGENCY STOP> push button or pull
<Reset push button> on the EMERGENCY STOP pull cord
3. Reset the EMERGENCY STOP by pressing the <Reset EMERGENCY
STOP> push button
 The machine is ready for operation again.
4. Move the extruder unit to the maintenance position with the <Extruder
movement limited> push button (see Chapter 5.4.9)
5. Start the machine (see Chapter 5.5.1)

6. MAINTENANCE
6 MAINTENANCE
In order to ensure the full functionality and performance of the machine, all
instructions pertaining to maintenance work on the machine must be complied
with to the letter. All maintenance tasks carried out must be recorded in a system
logbook and identify the respective number of operating hours.
DANGER!
Before lubrication and maintenance work is performed on the
machine, the <Main switch> must always be set to OFF ("0"
WARNING!
Before carrying out work on the pneumatic system, it is vital that
you depressurise the system!
WARNING!
Before performing work on the hydraulic system, it is vital that you
depressurise the system!
WARNING!
NOTE!
When carrying out servicing and maintenance tasks, unless
otherwise stated, the extruder unit must be in maintenance
position (see Chapter 5.4.9).
NOTE!
Potential for damage to property through failure to comply with the
stipulated lubrication and maintenance intervals!
Ensure that the lubrication and maintenance intervals listed on the
display are complied with (see the lamiTEC LX/CX display user
manual)!
Confirm on the display which work was carried out!

6. MAINTENANCE
6.1 Lubrication
In order to achieve optimum performance and largely eliminate operational faults,
the machine must be lubricated using suitable lubricants (see lubrication chart in
Chapter 6.2) at regular intervals.
NOTE!
Potential for damage to property from inadequate lubrication!
Mixing different oils and greases must be avoided at all costs!
The specified lubricant amounts are recommended amounts. The

decisive measure of the amounts to be used are the marks on the
respective component (sight glass, dipstick, etc.).
Special instructions on the proper lubrication of purchased

components can be found on the respective type plates or in the

6. MAINTENANCE
6.1.1 Double unwinder
Fig. 4769/6002
Lubrication point Lubricant DIN 51502 Quantity Interval

1.1 Bearing cap Grease KP 2 K-20 - Monthly
1.2 Gearbox - - - Lifetime lubricated
Shaft mounting on
1.3 - - - Lifetime lubricated
stepper motor
1.4 Linear guides - - - Lifetime lubricated
Ball-type linear drive Every 1,000
1.5 Grease KP 2 K-20 -
for web edge control operating hours

6. MAINTENANCE
6.1.2 Crane system and OPP crane system (optional)

The listed lubrication points are identical on the crane system for the double
unwinder for the fabric web and for the OPP crane system (optional). The same
applies to the running gear of each.
Fig. 4769/6003

Check annually,
2.1 Gearbox Gear oil CLP 220 0.25 litres perform gear oil
change if necessary
Hook flange and
2.2 Grease KP 2 P-30 - Once annually
hook block
2.3 Chassis Grease KP 2 P-30 - Once annually

6. MAINTENANCE
6.1.3 Web accumulator

The listed lubrication points are identical on the web accumulator for fabric and
on the OPP web accumulator (optional).
Fig. 4769/6004

CLP HC Every 25,000
3.1 Gearbox Gear oil 2.6 litres
320 operating hours
Petamo 133 N Every 25,000
3.1 Motor roller bearing - -
from Klüber operating hours
3.2 Linear guides Grease KP K-20 - Every 3 - 6 months

6. MAINTENANCE
6.1.4 Extruder unit
NOTE!
When carrying out work on the extruder unit, the ladder on the
upright must be used (see Chapter 3.3.16, Fig. 4769/3047).
When not being used, the ladder (9) must be stored on the upright
(see Chapter 3.3.16, Fig. 4769/3047).
Fig. 4769/6005

Every 8,000
4.1 Extruder gearbox Gear oil CLP 220 18 litres operating hours
(or every 18 months)
Every 8,000
Gearbox roller
4.1 Grease K 3 K-20 - operating hours
bearing
(or every 18 months)

6. MAINTENANCE
6.1.5 Coating unit
Fig. 4769/6066

Every 500 back and
Pendulum nut,
5.1 Grease KP 2 K-20 - forth cycles, at least
spindle lifting gear
every 2 years
Every 500 back and
Spindle
5.2 Grease KP 2 K-20 - forth cycles, at least
vertical adjustment
every 2 years
5.2 Lift gears - - - Lifetime lubricated
Every 25,000
CLP HC operating hours,
5.3 Gearbox Gear oil 0.5 litres
320 at least every
3 years
Every 25,000
Grease
operating hours,
5.3 Roller bearing Petamo 133N - -
at least every
from Klüber
3 years
Klüberlub Every 8,000 operating
Chill roller
5.4 BE41-542 from K 2 N-20 - hours,
pillow block bearing
Klüber at least annually

6. MAINTENANCE

Every 4,000 operating
Self-aligning ball Klüberlub
hours,
5.5 bearings for BE41-542 K 2 N-20 -
at least every
pressure roller from Klüber
6 months
Barrierta
At least every 2,000
5.6 Rotor connections L55/2 - -
operating hours
from Klüber
Threaded spindles
for
5.7 Grease K 2 N-20 - Weekly
Teflon tape
adjustment
Linear ball bearing Klüberlub Every 8,000 operating
5.8 for BE41-542 - - hours,
edge trimmer from Klüber at least annually

6. MAINTENANCE
6.1.6 Winder
Fig. 4769/6007

First oil change after
50 operating hours
and subsequently
6.1 Hydraulic unit Hydraulic oil HLP 46 25 litres
every 2,000 operating
hours (at least every
12 months)
6.2 Gearbox for oscillator - - - Lifetime lubricated

6. MAINTENANCE

Every 25,000
Gearbox for feed operating hours, at
6.3 Gear oil CLP HC320 2.2 litres
roller least every
3 years
Klüberlub Every 8,000 operating
Flange bearing for
6.4 BE41-542 - - hours,
contact roller
from Klüber at least annually
Every 25,000
Petamo GHY
Roller bearing for operating hours, at
6.5 133 N - -
feed roller motor least every
from Klüber
3 years
Every 25,000
Gearbox for lifting operating hours, at
6.6 Gear oil CLP HC320 0.4 litres
device least every
3 years
Every 25,000
Petamo GHY
Roller bearing for operating hours, at
6.6 133 N - -
lifting device least every
from Klüber
3 years
Check annually,
Chains for lifting
6.7 Grease KP 2 K-20 relubricate if
device
necessary
Check annually,
Sprockets for lifting
6.8 Grease KP 2 K-20 relubricate if
device
necessary
Toothed rack for
6.9 Grease KP 2 K-20 Monthly
transfer device

6. MAINTENANCE
6.1.7 Co-extruder (optional)
NOTE!
When carrying out work on the co-extruder, the supplied ladder
must be used.
(see Chapter 3.3.16, Fig. 4769/3047).
Fig. 4769/6036

7.1 Co-extruder gearbox Gear oil CLP 220 10 litres hours (or every 18
months)
Gearbox roller
7.1 Grease K 3 K-20 - hours (or every 18
bearing
months)

6. MAINTENANCE
6.1.8 OPP single unwinder (optional)
Fig. 4769/6037

Every 25,000
Shaft-mounted
8.3 Gear oil CLP HC 320 2.1 litres operating hours, at
helical gearbox
least every 3 years

6. MAINTENANCE
6.1.9 OPP double unwinder (optional)
Fig. 4769/6038

Every 25,000
Shaft-mounted
9.3 Gear oil CLP HC 320 2.1 litres operating hours, at
helical gearbox
least every 3 years

6. MAINTENANCE
6.1.10 Register control (optional)
Fig. 4769/6047

Spindle lifting
10.1 - - - Lifetime lubricated
gears
Every 500 operating
hours (at least every
10.2 Ball screw drive Grease KP 2 K-20 2 ml
5 years, full cleaning with
subsequent lubrication)
Every 500 operating
10.3 Linear guides Grease KP 2 K-20 -
hours
10.4 Toothed belt axle - - - Lifetime lubricated

6.. MAINT
TENANCE
6.2 Lubrica
ation cha
art
The folloowing tabless provide innformation about whicch lubricants
ts are suitable for
lubricatin
ng the mach b used if thhey are sho
hine. Otherr lubricants may only be own to
have simmilar propertties.
6.2.1 Oils
Labelling in
n
accordance with
w Lubricant
DIN 51502
Veloccite Oil
HL 10 Hydraulic oil
o ----------- Hyspin AW
WS 10 ----------- Morlina
a S2 BL 10
Noo. 6
HL 32 Hydraulic oil
o ----------- Hyspin AW
WS 32 ----------- DTE O
Oil Light Tellus S2 M 32
HL 46 Hydraulic oil
o ----------- Hyspin AW
WS 46 ----------- DTE Oil Medium Morlina
a S2 B 46
Energool
HLP 32 Hydraulic oil
o Hyspin AW
WS 32 LAMORA HLP 32 DTE
E 24 Tellus S2 M 32
HLP HM 32
Energool
o Hyspin AW
WS 46 LAMORA HLP 46 DTE
E 25 Tellus S2 M 46
HLP HM 46
Energool
o WS 68
Hyspin AW LAMORA HLP 68 DTE
E 26 Tellus S2 M 68
HLP HM 68
Energool
o Hyspin AW
WS 100 ----------- DTE
E 27 Tellus S2 M 100
HLP HM 1100
Energool Mobil Hyddraulic Oil

HLPD 32 Hydraulic oil
o Hyspin DS
SP 32 ----------- Tellus S2
S MA 32
HLP D 332 HLPPD 32

o Hyspin DS
SP 46 ----------- Tellus S2
S MA 46
HLP D 446 HLPPD 46

o Hyspin DS
SP 68 ----------- ----------
HLP D 668 HLPPD 68
Bartrann
HVLP 32 Hydraulic oil
o Hyspin AWH-M 32 ----------- Mobil S
SHC 524 Tellus S2 V 32
HV 322
Bartrann
HV 466
Bartrann
HV 688
Gear oil, Energool Klübe

eroil Mobiilgear
CLP 68 ALPHA SP
S 68 a S2 G 68
Omala
mineral-oil ba
ased GR-XP 668 GEM 1--68 N 600 X
XP 68

eroil Mobiilgear
CLP 100 ALPHA SP 100 Omala S2 G 100
ased
mineral-oil ba GR-XP 1 00 GEM 1-100 N 600 X
XP 100

eroil Mobiilgear
mineral-oil ba
ased GR-XP 1 50 GEM 1-150 N 600 X
XP 150

eroil Mobiilgear
mineral-oil ba
ased GR-XP 2220 GEM 1-220 N 600 X
XP 220
Gear oil, Energool eroil

Klübe Mobiilgear
mineral-oil ba
ased GR-XP 3320 GEM 1-320 N 600 X
XP 320
Gear oil, Energool eroil

Klübe Mobiilgear
mineral-oil ba
ased GR-XP 4460 GEM 1-460 N 600 X
XP 460

eroil Mobiilgear
mineral-oil ba
ased GR-XP 6680 GEM 1-680 N 600 X
XP 680
Syntheticc Enersynn Alphas

syn Klübers
synth
CLPPG 150
0 Glygooyle 22 Omala S4
S WE 150
gear oil SG-XP 1 50 PG 15
50 GH 6--150
Syntheticc Enersynn syn

Alphas synth
Klübers
CLPPG 220
0 Glygooyle 30 Omala S4
S WE 220
gear oil SG-XP 2220 PG 22
20 GH 6--220

AGE 258 / 341
Translatio
6.. MAINT
TENANCE
Labelling in
n
accordance with
w Lubricant
DIN 51502

syn Klübers
synth
CLPPG 320
0 Glygoyyle 320 Omala S4
S WE 320
20 GH 6--320

syn Klübers
synth
CLPPG 460
0 Glygoyyle 460 Omala S4
S WE 460
60 GH 6--460
Syntheticc Enersynn syn

Alphas synth
Klübers
CLPPG 680
0 Glygoyyle 680 ----------
80 GH 6--680
Syntheticc Enersynn Klübers

synth
CLPHC 150
0 Alphasyn HTX
H 150 C Gear 150 Omala S4
Mobil SHC S GX 150
gear oil HTX 1550 GEM 4-150 N

synth
CLPHC 220
0 Alphasyn T 220 C Gear 220 Omala S4
Mobil SHC S GX 220

synth
CLPHC 320
0 Alphasyn T 320 Mobil SHC
C Gear 320 Omala S4
S GX 320
Syntheticc Enersynn synth

Klübers
CLPHC 460
0 Alphasyn T 460 Mobil SHC
C Gear 460 Omala S4
S GX 460
CGLP 220 Track oil Maccurat D 220 Magnaglide

e D220 LAMORA
A D 220 Vactra O
Oil No. 4 Tonna S2 M 220
6.2.2 Greases
s
Labelling in
n
accordance with
w Lubricant
DIN 51502
Energreaase SPHEER
ROL
K 2 K-20 Grease CENTOP
PLEX 2 Mobiluux EP 2 Gadus S2
S V100 2
LS 2 EP 2
Energreaase Olista
a RAGS
STABUR
K 3 K-20 Grease Mobiluux EP 3 Gadus S2
S V100 3
LS 3 Longtim
me 3 N 12
Energreaase Optim
mol Klüberrplex
KP 1 K-20 Grease Mobiluux EP 1 Gadus S2
S V220 1
LS-EP 1 Longtime PD 1 BEM 411-141
CENTOPLEX
KP 2 K-20 Grease Energreasee LZ ALV
V Mobiluux EP 2 Gadus S2
S V220 2
2 EP
Energreaase Optim
mol Klüberrplex
KP 2 K-30 Grease Mobilith S
SHC 220 Nature
elle EP 2
LS-EP 2 Longtime PD 2 BEM 411-132
Energreaase SPHEER
ROL RAGS
STABUR
K 3 G-20 Grease Mobiilux 3 Gadus S2
S V100 3
LS 3 AP 3 N 12
Olista
a RAGS
STABUR
K3N Grease ----------- Unireex N3 Gadus S2
S V100 3
Longtim
me 3 N 12
Klüberrplex
GP 00 G-20
0 Grease ----------- CLS Gre
ease Mobiluxx EP 004 Gadus S2
S V220 00
GE 11-680

AGE 259 / 341
Translatio
6. MAINTENANCE
6.3 Maintenance overview

The following table provides information about maintenance work to be carried
out and the corresponding maintenance intervals.
DANGER!
Before performing maintenance on the machine, the <Main
switch> must always be set to OFF ("0" position) and be
safeguarded against being switched back on!
The machine must remain switched on for certain tasks. If this is

the case, a notice to this effect will appear in the document.
WARNING!
Before performing maintenance work on the pneumatic system, it
is vital that you depressurise the system!
WARNING!
Before performing maintenance work on the hydraulic system, it is
vital that you depressurise the system!
WARNING!
WARNING!
Risk of injury from forgotten objects!
Ejected objects can cause serious injuries and property damage.
After maintenance work:
 Remove tools from the machine
 Ensure there are no foreign objects in the machine

6. MAINTENANCE
CAUTION!
Risk of injury due to unsuitable tool!
 Observe the instructions on the use of special tools
 Only use tools that are in a flawless condition
 Remove tools after work is complete and store them properly
NOTE!
Damaged hoses can cause property damage!
Never kink, crush, rupture, pull or drive over hoses!
Refer to the manufacturer's documentation for special instructions

on the proper maintenance of purchased components.
6.3.1 Daily maintenance tasks

 Inspect the machine for coarse soiling and clean as necessary
 Inspect fans of motors and fan filters for dirt and clean them as
necessary
 On the hydraulic unit, Check the oil level
 Maintain the wide-slot die (see Chapter 6.4.10)
 Check the fill level in the edge strip receptacle, and empty if necessary
 Maintain the feed block (optional) (see the manufacturer's
documentation)
 Maintain the coating unit (see Chapter 6.4.11)
 Check the condition of the blade on the winder and replace if necessary
 Check the condition of the blades on the OPP double unwinder
(optional), replace if necessary (see Chapter 6.4.12)
6.3.2 Weekly maintenance tasks

 On the gearbox and gear motors, check the oil level
 Inspect switching cabinets for dust and dirt and vacuum out as
necessary
 Inspect cable ducts for dirt and infestation by small animals,
clean as necessary
 Clean the floor under the machine
 Maintain the hot air oven (see Chapter 6.4.3)

6. MAINTENANCE
 Check the metal separator on the extruder and co-extruder (optional) for
dirt and clean the magnetic discs if necessary (see Chapter 6.4.7)
 Check the condition of the heating sleeves and replace if necessary
(see Chapter 6.4.8)
 Clean the bagging station (optional)
6.3.3 Monthly maintenance tasks

 Check smooth running of all cylinders and rollers; pay attention to any
running noises
 Check safety doors and protective guards for completeness; replace if
necessary
 Check safety stickers are intact; replace if necessary
 Have the condition and function of the safety switch, circuit breaker and
EMERGENCY STOP system tested by an electrician
For further information, see the Circuit diagram.
 Check the function of the lamps and the signal alarm

 Clean piping
 Clean light barriers and reflectors with a dry, lint-free cloth
 Check the belt tension and belt run on the extruder unit and re-tension if
necessary (see Chapter 6.4.6)
 Check the belt tension and belt run on the web accumulator and OPP
web accumulator (optional) and re-tension if necessary (see Chapter
6.4.2)
 Check the chain tension and chain run on the contact winder and
re-tension if necessary (see Chapter 6.4.13)
6.3.4 Quarterly maintenance tasks

 Check cooling water circuit

6. MAINTENANCE
6.3.5 Six-monthly maintenance tasks

 Check cables and protective sleeves for damage
 On switching cabinets:
- Seal the cable ducts and cable entry points
- Clean fans and filter mats (only for switching cabinets with air
cooling)
 Check the silicon sealing strips on the hot air oven for damage and
incorrect impermeability and replace if necessary (see Chapter 6.4.3)
6.3.6 Annual maintenance tasks

 Clean the extruder screw (see Chapter 6.4.6)
 Clean the extruder cylinder (see Chapter 6.4.6)
 Extract the extruder screw of the co-extruder (optional)
(see Chapter 6.4.9)
 Clean the extruder screw of the co-extruder (optional)
(see Chapter 6.4.9)
 Clean the wide-slot die (see Chapter 6.4.10)
6.3.7 Chain drives
Cleaning
The chains must be continuously supplied with free-flowing oil over their whole
surface, i.e. links and plates must be permanently moistened with oil.
NOTE!
Possible damage to the chain due to hydrogen embrittlement!
Cleaning must be performed exclusively with paraffin
derivatives:
 Diesel oil
 Paraffin spirit
 White spirit
Under no circumstance should cold cleaners, corrosive or acidic
substances, or steam jets be used!

6. MAINTENANCE
If dirt on the chain becomes so heavy that penetration of the lubricating oil is no
longer guaranteed, the chain must be cleaned.
1. Remove coarse dirt deposits with a wire brush
2. Rinse the chain using a suitable agent
3. If the internal parts are soiled: Immerse the chain in a suitable agent for
24 hrs and move back and forth several times
4. Check the chain for noises
 The movement of the chain links should not produce any noise.
Other maintenance work

 Check chain tension:
- before initial commissioning
- after a run-in period of roughly 1 week
- then after no longer than 6 months (depending on load and
temperature)
 At each lubricating interval, check chains and sprockets:
- for wear (unless otherwise instructed)
- for proper alignment (unless otherwise instructed)
 Check the secure attachment of the sprockets once a year
 In the case of heavy wear, replace the chains and sprockets without
delay
6.3.8 Belt drives
Cleaning
Belt drives must be free of dirt and oil. Regular cleaning and care increases the
service life of the belts.
NOTE!
The belt may be damaged by improper cleaning.
Only use compressed air for cleaning!
Do not use sharp-edged or pointed objects!

6. MAINTENANCE
Other maintenance work

 Check belt tension:
- before initial commissioning
- after a run-in period of roughly 1 week
- then every 1,000 operating hours
 Check belts and belt pulleys every 3 - 6 months (depending on the type
of belt and on the loading):
- for damage and unusual wear patterns (unless otherwise instructed)
- for proper alignment (unless otherwise instructed)
- for heat build-up; temperature must not exceed the specified limit
values during operation
 Check the secure seating of the belt pulleys once a year
 In the case of heavy wear, replace the belts and belt pulleys without
delay
Belt tension measuring device

The belt tension is checked with a measuring device, which measures the
resonant frequency of the vibrating belt.
Fig. 4769/6048
1 Measuring head 2 Readout in [Hz]
Always take the measurement at the specifically indicated

measuring point on the span (a free, non-supported section of the
belt being measured).
The stated values apply exclusively to this measuring point!

6. MAINTENANCE
Information on testing the belt tension with a belt tension measuring device
For information on the precise procedure for testing and

tensioning the respective belt, see Chapter 6.4.
Fig. 4769/6050
3 Belt F Force
x Measuring point
To achieve the optimum measuring result with a belt tension measuring device,
note the following:
 Use a blunt object to start the belt (3) being measured vibrating:
- Tap gently on the belt (3) in the direction of the arrow (F)
NOTE!
Failure to carry out the check in the proper way can cause
damage to the belt (scratches, blind spots)!
Do not use any sharp or sharp-edged objects, such as:
 Scrapers
 Razor blades
 Putty knives

6. MAINTENANCE
 In order to ensure a correct measuring result, the belt (3) must be

allowed to vibrate freely during the measurement process. It must not
strike the measuring head (1) or parts of the machine.
 The measuring head (1) must be held at the specified measuring
point (x), a distance of approx. 1 cm away.
 If the distance from the measuring point (x) is too far, no readout (2)
is shown on the measuring device.
 If the distance from the measuring point (x) is too near, there is a
risk of the vibrating belt hitting the measuring head (1).
 The measurement must be performed at least 3x / measuring point (x).
The average of the three measuring results must be taken.
6.3.9 Electrical system

Extended, scheduled shut-downs of the machine can also be used as an
opportunity to check all connection bolts and connection terminals on bus bars
and switchgear. In any case, this check should be performed at least once a
year, in order to avoid possible damage to the electrical equipment.
DANGER!
Danger from electric current!
Before work is done on connection bolts and on connection

terminals, the <Main switches> must always be set to OFF ("0"
Before carrying out work on the connection bolts and connection

terminals on one of the <Main switches>, the supply line must be
de-energised!
 Check all connection bolts and connection terminals on bus bars and
switchgear for firm seating and, if necessary, retighten them to the
specified tightening torque, per the manufacturer's specifications.
6.3.10 Safety switch

A defective safety switch (2) or a defective actuator (4) is indicated on the display
as an alarm. The safety switch must be replaced by a qualified electrician, and
then its condition and proper functioning should be checked.
For further information on troubleshooting, see the Display user

manual.

6. MAINTENANCE
Fig. 4769/6065
1 Bolt 3 Sensor plate

2 Safety switch 4 Actuator
Procedure
1. Terminate the cables
2. Remove the safety switch (2) or actuator (4)
3. Mount the new safety switch (2) or actuator (4) on the sensor plates (3)
4. Attach the safety switch (2) or actuator (4) to the sensor plates (3) and
make the electrical connections (see the Circuit diagram)
NOTE!
The locks must always be attached to the actuator (4) properly, in
accordance with the manufacturer's documentation!
NOTE!
When installing the safety switch (2) or the actuator (4), use only
new bolts!
For further information on fitting the safety switch, see the

manufacturer's documentation and the Circuit diagram.

6. MAINTENANCE
6.3.11 Pneumatic system
WARNING!
Before performing maintenance work on the pneumatic system, it
is vital that you depressurise the system!
 Check the pneumatic lines once a week for leak-tightness, damage and
wear, and replace if necessary
 Check for proper fastening
 On the maintenance unit:
- Empty the water separator once a week
- Clean the filter once a week and replace if necessary
6.3.12 Hydraulic system
WARNING!
Before performing maintenance work on the hydraulic system, it is
vital that you depressurise the system!
 At each oil change of the hydraulic unit, check the filter for dirt and
replace if necessary
 Check that hydraulic hose lines are in an operationally safe condition
before initial commissioning and at least once per year under normal
conditions.
The operational lifetime of hydraulic hose lines is limited!

Under normal conditions, hydraulic hose lines must be replaced
every 6 years!
6.3.13 Water circuit

 Check water circuit and cooling function of the air/water heat exchanger
 Perform a visual check of water pipelines for separated lagging, kinks,
dents or weak points.

6. MAINTENANCE
 Check water connections for possible leaks

 Check soiling of the dirt traps (1), (2), and (3) on a weekly basis, and
replace the filter if necessary
Fig. 04769/6072
1 Dirt trap 4 Position of the dirt trap filter

Detail: dirt trap with flow
2 Dirt trap A
direction
3 Dirt trap (optional)
6.3.14 Plastic glazing

Plastic glazing must always be free of dirt, and must be cleaned with a suitable
cleaning agent at regular intervals.
NOTE!
Surface damage (scratches, blind spots) may be caused by
improper cleaning!
Only use mild plastic cleaning agents!
 Never use glass cleaners or abrasive cleaners!
 Do not use any pointed or sharp-edged objects, such as
scrapers, razor blades, putty knives, etc.!

6. MAINTENANCE
1. Rinse off the surfaces with running water

2. Prepare warm water in a suitable container
3. Mix in a small amount of a mild plastic cleaner
4. Clean surfaces with a soft, lint-free cloth
6.4 Specific maintenance tasks

Individual maintenance tasks are explained in detail in the following chapter. The
same safety instructions provided in the maintenance overview apply here.
Specific hazards are addressed individually.
6.4.1 Servicing the double unwinder

The following maintenance tasks must be carried out on the double unwinder:
 Check the condition of the brake on a daily basis, and replace the brake
pads if necessary
NOTE!
Potential for damage to property from inadequate lubrication!
Do not lubricate the brake if running noises occur!
Once the brake pads reach a minimum dimension of 5 mm,
replacement is necessary!
For further information on maintenance of the brake, see the

6.4.2 Maintaining the web accumulator and OPP web accumulator (optional)
The procedure described below for tensioning the belt must be performed in the
same way on the web accumulator for fabric and on the OPP web accumulator
(optional).
The belt tension and belt run must be checked on the two web accumulators on a
monthly basis, and if necessary they the belt should be retensioned. Pay
attention to the general maintenance instructions for the belt drives (see
Chapter 6.3.8)
Checking the belt tension
The machine must be switched on to check the belt tension (see


6. MAINTENANCE
WARNING!
While one person is performing the check, the second person
must take up a position next to an EMERGENCY STOP command
device!
Maintain visual contact with the second person while performing
the check!
Fig. 4769/6052
1 Cover 4 Spring cotter

2 Cover 5 Holder
3 Pin 6 Positioning unit
Procedure
1. The machine must be stopped (see Chapter 5.5.2)
2. Remove fabric from the web accumulator
3. Move the web accumulator into the top limit position manually using the
display.
4. Remove the cover (1) and (2)
5. Remove the pin (3) from the holder (5) on each side and insert into the
hole
6. Secure the two pins (3) with the spring cotter (4)
7. Move the web accumulator up to the pins manually using the display.

6. MAINTENANCE
8. Release the brake on the display

 The brake of the drive is released; the positioning unit (6) rests on
the pins (3).
Fig. 4769/6051
7 Toothed belt x Measuring points

8 Toothed belt
9. Check the tension of the toothed belts (7) and (8)

- Put the toothed belts (7) and (8) in vibration
- Using a belt tension measuring device, measure the resonant
frequency of the toothed belts (7) and (8) at the measuring points (x)
(see Chapter 6.3.8)
 Measure at two measuring points (x) on each toothed belt in the
centre of the divided side
 The frequency with a tensioned belt must be 30 - 35 Hz.
 If the measured frequency does not match the specified value,
the toothed belt (1) must be tensioned or loosened.

6. MAINTENANCE
Tensioning the toothed belt
Fig. 4769/6053
7 Toothed belt 11 Nut

9 Nut 12 Bolts
10 Nut 13 Nut
Procedure
3. Turn the nut (13) clockwise
 The toothed belt (7) is tensioned.
4. Using a belt tension measuring device, measure the resonant frequency
of the toothed belts at the measuring points (x) (see Fig. 4796.6051)
5. Adjust the nut (13); tighten nuts (13) and (11) in opposite directions
7. Repeat the process for toothed belt (8) (see Fig. 4769/6053)
Fully tightening the bolts changes the belt tension. The belt
tension must be checked again after tensioning.

6. MAINTENANCE
Once all work is complete (checking and tensioning), proceed as follows:

1. Apply the brake on the display
2. Move the positioning unit (6) manually upwards on the display
(see Fig. 4769/6052))
3. Pull out the two spring cotters (4) and remove the pins (3)
4. Store the two pins (3) with the spring cotter (4) in the holder (5)
5. Fit the covers (1) and (2)
6.4.3 Maintaining the hot air oven

The following maintenance work must be performed on the hot air oven:
 Check the condition of the circulator wheel on a weekly basis and
 Check the condition of the heating surfaces on a weekly basis and
 Check the condition of the silicon sealing strips for damage and
incorrect impermeability on a 6-monthly basis and replace if necessary
WARNING!
Risk of burns
Wear protective gloves when working on the hot air oven!
Wear eye protection when working on the hot air oven!

6. MAINTENANCE
Replacing the circulator wheel
Fig. 4769/6010
1 Circulator wheel 3 Heating unit cover plate

2 Retaining screw 4 Motor cover plate
Procedure
1. Remove the motor cover plate (4)
2. Remove the heating unit cover plate (3) and the ring heater
3. Remove the motor and the circulator wheel (1)
4. Remove the retaining screw (2)
5. Pull the circulator wheel (1) off the motor shaft with the hub and cooling
disc.
 If the circulator wheel (1) is stuck on the motor shaft, you can lift it off
motor shaft by screwing a M12 x 200 set screw into the hub of the
circulator wheel (1).
6. Replace the circulator wheel (1) and hub
 When fitting the circulator wheel (1), ensure that the spring and
groove on the motor shaft and on the new hub engage without
problems.
7. Reassemble all parts in reverse order

6. MAINTENANCE
Replacing the heating surface
Fig. 4769/6011
1 Circulator wheel 4 Motor cover plate

3 Heating unit cover plate 5 Bolt
Procedure
1. Disassemble the T-piece from the extruder frame. Remove the motor
cover plate (4)
2. Remove the heating unit cover plate (3)
3. Remove the motor and the circulator wheel (1)
4. Remove the cover from the terminal box
5. Disassemble the cable
6. Loosen the counternut
7. Switch off the terminal box
8. Remove the counternut and bush on the leadthrough tube of
the heating surface
9. Remove the bolts (5) from the heating surface
10. Remove the heating surface

6. MAINTENANCE
Replacing the silicon sealing strip
Fig. 4769/6012
6 Sealing strip with base
Procedure
1. Remove old sealing strip (6)
2. Remove any remnants of plastic
3. Trim the new seal (6) to the length of the channel and remove 50 mm of
the base on both sides
4. Apply a thin layer of silicone paste in the crevice and at both ends of the
hot air oven
5. Fit the new sealing strip (6)
6. Keep the hot air oven open until the silicon adhesive has fully dried
6.4.4 Cleaning parts coated in plastic melt
WARNING!
NOTE!
In order to prevent damage, a suitable mat should be laid on the
assembly table. After the mat is used, all dirt particles must be
removed.

6. MAINTENANCE
Wear eye protection!
Tools and cleaning materials required
Fig. 4769/6013
1 Brass or aluminium scraper 3 Copper wool

2 Die soap 4 Silicone oil
Further equipment includes:

 Polishing paste
 High-temperature thread paste (Molykote HSC)
 Cylinder cleaning brush
Important note
 The parts to be cleaned must be brought up to operating temperature or
at least 10 - 20 °C above the melt point of the particular plastic.
 Aluminium scrapers and brass brushes must be used exclusively in
order to prevent scratching to the sensitive surfaces and sealing faces,
most of which are polished.
- Remove any thick layers of stuck-on material with scrapers
- Remove finer residue with a brush and copper wool
- Fine plastic residue should be rubbed off hot parts using a cloth
soaked in silicone oil

6. MAINTENANCE
CAUTION!
Potential for damage to the airways or chemical burns to the skin!
Never use petrol for cleaning!
Ensure that there is good ventilation.
 Areas of the polished surfaces that have become dull must be re-
polished with a commercially-available polishing paste.
 The material-transporting surfaces of the cleaned parts must be
sparingly sprayed or rubbed with silicone oil, in order to avoid oxidation
of the polished surfaces during the heating phase.
This silicone oil must be rinsed out as quickly as possible during

the start-up procedure, so that there is no risk of harmful effects
from the separating effect of the silicone oil.
CAUTION!
Potential material damage!
Normal machine oil must not be used under any
circumstances for rubbing on the parts, as it will burn and char at
high temperatures, rendering the parts unusable.
 Parts that are subjected to very high temperatures must be thinly coated
with a high-temperature thread paste (Molykote HSC) prior to
installation!
- All fitted surfaces
- All screw/bolt threads
 In order to assure the leak-tightness of threaded connections between
parts carrying melt, tighten all bolts to the prescribed tightening torques
and retighten after approx. 10 min. Unless otherwise stipulated use the
tightening toques specified in chapter 8.
6.4.5 Replacing the silicone hose on the corona (optional)
DANGER!
adhered to!

6. MAINTENANCE
DANGER!
manual).
WARNING!
The corona produces a strong magnetic field!

the magnetic field!

documentation.
Fig. 4769/6027
1 Silicon hose 4 Opening for removal device

2 Removal device 6 Roller
3 Hose clamp

6. MAINTENANCE
Procedure
1. Remove the roller (6)
2. Remove the silicon hose (1) from the roller (6) with a suitable cutting
tool
CAUTION!
Risk of injury due to improper handling of the cutting tool!
3. Pull a new silicone hose (1) on to the roller (6)

4. Attach the silicon hose (1) to the winding-up mechanism (2) with
the hose clamp (3)
5. Blow air into the opening (4)
 The hose (1) is expanded
6. Pull silicone hose (1) over the entire roller (6)
6.4.6 Maintaining the extruder unit

The following maintenance tasks must be carried out on the extruder unit:
 Check the metal separator for dirt on a monthly basis and clean the
magnetic discs if necessary (see Chapter 6.4.7)
 Check the condition of the heating sleeves each week and replace if
 Check the belt tension and belt run on a monthly basis and retension if
necessary
 Pay attention to the general maintenance instructions for the belt drives
(see Chapter 6.3.8)
 Clean the extruder screw and extruder cylinder on an annual basis
WARNING!
Wear protective gloves when working on the extruder!

6. MAINTENANCE
Wear eye protection when working on the extruder!
NOTE!
When carrying out work on the extruder unit, the ladder on
the upright must be used to access the operating platform.
(see Chapter 3.3.16, Fig. 4769/3047).
NOTE!
A suitable ladder must be used for all work on the extruder unit
which cannot be performed from the operating platform!
Move the extruder unit to the standby position before carrying out maintenance
work (see Chapter 5.4.9).
Removing the melt discharge unit

In addition to the safety instructions in the maintenance overview, the same
safety instructions apply to removal as for installation (see Chapter 3.3).
The melt discharge unit must be removed for the following maintenance work:
 Cleaning the extruder screw
 Cleaning the extruder cylinder
Before removing the melt discharge unit, the extruder and co-
extruder (optional) must be heated up to operating temperature.
Pay attention to all safety instructions, as during operation (see
Chapter 5.5).

6. MAINTENANCE
Fig. 4769/6071
1 Wide-slot die 4 Melt pressure control valve

2 Melt mixer 5 Melt filter
3 Adapter 6 Bracket
Procedure
1. Switch off the heaters via the display
2. Remove the thermocouples
3. Remove the wide-slot die (1)
4. Loosen the screws on the adapter (3)
5. Remove the melt mixer (2) with melt pressure control valve (4) and
adapter (3)
6. Remove the melt filter (4)
After the maintenance work is complete, reassemble all parts in reverse order.
NOTE!
to installation! All bolts must be tightened evenly and in a diagonal
pattern, until the part being fitted is entirely flush!
Pay attention to the correct tightening torque! (see Chapter 5.4.2).

6. MAINTENANCE
NOTE!
If melt escapes, observe the following:
 Do not tighten the nuts any further!
 Replace the squeeze seal with a new one!
 Observe the specified tightening torques (see Chapter 5.4.2)!
Extracting the extruder screw

The removal of the extruder screw with the extraction device must be carried out
at 10 - 20 °C above the melt point of the plastic in question (coating material)
Fig. 4769/6056
1 Spindle guide 4 Extruder gearbox

2 Bush 9 Extruder screw
3 Bolt

6. MAINTENANCE
Procedure
1. Insert the bush (2) into the spindle guide (1)
2. Fit the spindle guide (1) using the bolts (3) to the extruder gearbox (4)
Fig. 4769/6057
1 Spindle guide 7 Push-rod

2 Bush 9 Extruder screw
4 Extruder gearbox 10 Bolt
5 Clamp 11 Cylindrical pin
3. Insert the clamp (5) into the spindle guide (1)

4. Coat the push-rod (7) with a high-temperature thread paste
(Molykote HSC)
5. Insert the push-rod (7) into the spindle guide (1) and through the
clamp (5)
6. Screw the push-rod (7) into the extruder screw (9)
7. Move the clamp (5) along the push-rod (7)
8. Insert the cylindrical pin (11) into the holes on the clamp (5) and
the push-rod (7), or secure the clamp (5) with the bolts (10)

6. MAINTENANCE
Fig. 4769/6058
1 Spindle guide 7 Push-rod

4 Extruder gearbox 12 Bushes
9 Extruder screw 13 Push-rod
6 Spindle
9. Insert the bushes (12) into the spindle (6)

10. Coat the spindle (6) with a high-temperature thread paste (Molykote
HSC)
11. Screw the spindle (6) with the bushes (12) into the spindle guide (1) up
to the clamp (5)
12. Coat the second push-rod (13) with a high-temperature thread paste
(Molykote HSC)
13. Screw the second push-rod (13) into the push-rod (7)

6. MAINTENANCE
Fig. 4769/6059
4 Extruder gearbox 7 Push-rod

9 Extruder screw 13 Push-rod
6 Spindle
14. Turn the spindle (6) clockwise

 The spindle (6) pushes the clamp (5) with the push-rods (7) and (13)
through the extruder gearbox (4) towards the extruder screw (9).
 The extruder screw (9) is extracted.
- Turn the spindle (6) until the clamping piece (5) is positioned at the
extruder gearbox (4)
15. Turn the spindle (6) back to the left to the end of the spindle guide (1)
16. Loosen the bolts (10) on the clamping piece (5) (see Fig. 4769/6057) or
pull out the cylindrical pin (11)
17. Move the clamp (5) back along the push-rod (7) to the end of the
spindle guide
18. Insert the cylindrical pin (11) into the clamp (5) and the push-rod (7) into
the following holes, or tighten the bolts (10)

6. MAINTENANCE
19. Turn the spindle (6) clockwise

 The spindle (6) again pushes the clamp (5) with the push-rods (7)
and (13) through the extruder gearbox (4) towards the extruder
screw (9).
 The extruder screw (9) is extracted.
- Turn the spindle (6) until the clamping piece (5) is positioned at the
extruder gearbox (4)
20. Repeat steps 13 to 19 until approximately half of the extruder screw has
been removed from the extruder cylinder, then it can be pulled out of
the cylinder extruder and subsequently cleaned (see Chapter
4769/6054)
Cleaning the extruder screw

After removing the extruder screw, it must be cleaned using one of the following
authorised procedures:
 Pyrolytic cleaning in an appropriate oven
 Cleaning by dry ice blasting
 Mechanical cleaning when hot
- After removal, the extruder screw must be laid down on a suitable
base and cleaned whilst hot (see Chapter 6.4.4)
- Remove any thicker layers of stuck-on material with scrapers
- Remove finer residue with a brash brush
- The fine layers of plastic are then rubbed off with a rag soaked in
silicone oil
CAUTION!
Potential for damage to the airways or chemical burns to the skin!
Never use petrol for cleaning!
Ensure that there is good ventilation.

6. MAINTENANCE
After cleaning, coat the splined shaft (1) with a high-temperature thread paste
(Molykote HSC). Spray the extruder screw (2) with silicone oil.
Fig. 4769/6054
1 Splined shaft 2 Extruder screw
Cleaning the extruder cylinder

After the extruder screw has been removed, the extruder cylinder must be
cleaned.
Fig. 4769/6019
1 Extruder flange
1. Insert the cylinder cleaning brush at the front at the extruder flange (1)
and clean the extruder cylinder

6. MAINTENANCE
Fig. 4769/6020
Splined shaft hub of the extruder

2 Extruder gearbox bore hole 3
screw
2. Blow out the residual plastic particles in the extruder cylinder towards
the front with compressed air:
CAUTION!
Risk of injury while working with compressed air!
Personal protective equipment must be worn in all machine
operating conditions where compressed air is utilised!
Compressed air must not be directed towards people!
- Hold the compressed air hose (2) in the bore holes of the extruder
cylinder
NOTE!
The splined shaft hub (3) for the splined shaft of the extruder
screw in the transmission shaft must not be dirty!
Once the extruder screw and extruder cylinder have been cleaned and refitted, all
removed parts must be refitted and adjusted.

6. MAINTENANCE
Replacing the squeeze seals

If plastic melt escapes from one of the following points, the sealing faces must be
inspected and the squeeze seals replaced:
 between the adapter (2) and the melt pressure control valve (5)
 between the melt pressure control valve (5) and the melt mixer (7)
Fig. 4769/6021
1 Squeeze-type gasket 5 Melt pressure control valve

2 Adapter 6 Squeeze-type gasket
3 Melt filter 7 Melt mixer
4 Extruder die flange
Procedure
3. Remove the wide-slot die
4. Remove the melt mixer and (7) the die flange
5. Remove the extruder die flange (4) from the melt mixer (7)
6. Remove the melt pressure control valve (5)
7. Check and clean the sealing surfaces (see Chapter 6.4.4)
8. Insert new squeeze seals (1) and (6)
9. Re-assemble all parts
- Tighten all bolts to the prescribed tightening torque
(see Chapter 5.4.2, Fig. 4769/5017 or Fig. 4769/5059)

6. MAINTENANCE
NOTE!
Pay attention to the correct tightening torque!
NOTE!
Only fit the thermocouples once operating temperature has been
reached!
Tensioning the toothed belt
Fig. 4769/6022
1 Bolt 4 Toothed belt

2 Nuts D 20 Nm
3 Bolt
Procedure

6. MAINTENANCE
3. Turn the bolt (1)

 Tension the toothed belt (4) such that crossways sagging is
prevented.
 If the extruder unit is on the operating side, the toothed belt (4) must
not allowed to twist on the drive side by more than 90°.
4. Engage the nuts (2)
Installation instructions for the clamping device

The belt pulley is fastened to the shaft by means of a Taper Lock clamping bush.
The clamping bush bolt must be tightened for torque transmission to the
prescribed tightening torque of 20 Nm (D).
6.4.7 Cleaning the metal separator

The procedure described below for cleaning the metal separator must be
performed on a weekly basis, in the same way on the extruder unit and the co-
extruder (optional).
WARNING!
Strong magnetic field around the metal separator!

the magnetic field!
NOTE!
upright must be used to access the metal separator via the
operating platform.
When not being used, the ladder must be stored on the upright
(see Chapter 3.3.16, Fig. 4769/3047).

6. MAINTENANCE
Fig. 4769/6064
1 Star knob 3 Magnetic discs

2 Inspection window 4 Housing
Procedure
1. Undo the star knobs (1)
2. Remove the inspection window (2), with the magnetic discs (3) fitted,
using the handles
3. Clean the magnetic discs (3) with compressed air
CAUTION!
4. Clean the sight glass (2) (see Chapter 6.3.14)

5. Insert the inspection window (2) with fitted magnetic discs (3) into the
housing (4) and re-fit with the star knobs (1)
6.4.8 Replacing the heating sleeves
WARNING!
Risk of sustaining burns on hot surfaces!

6. MAINTENANCE
Wear protective gloves when working on the extruder!
Wear eye protection when working on the extruder!
NOTE!
upright must be used to access the heating sleeves via the
operating platform.
When not being used, the ladder must be stored on the upright
(see Chapter 3.3.16, Fig. 4769/3047).
Fig. 4769/6015
1 Heating sleeves 4 Retaining strap

2 Tensioning bolt 5 Insulating hood
Body to be heated
3
(e.g. extruder cylinder)

6. MAINTENANCE
Procedure
1. Lift the insulating hood (5)
2. Remove the faulty heating sleeve (1)
3. Install new heating sleeve (1)
- Tighten the tensioning bolts (2)
4. Close the insulating hood again (5)
NOTE!
If the heating sleeve (1) is unevenly positioned, there is a risk of
local overheating, which can lead to the heating resistor burning
out.
The heating sleeve (1) can only give off heat reliably if the
retaining straps (4) press it evenly onto all of the objects to be
heated (3).
Tighten the tensioning bolts (2) for the retaining strap (4) evenly!
Heating causes elongation of the retaining strap (4).
Re-tighten the tensioning bolts (2) again after heating up!
When replacing a heating sleeve, the following points must be noted:

 If the heating sleeve is laid over parts which feature large interruptions
in the load-bearing surface (e.g. screw/bolt holes), then the following
points should be noted:
- Lay a heat-conducting plate 1 - 3 mm thick under the heating
sleeve (1)
NOTE!
There is a risk of the heating sleeve (1) burning out over a hole!
Use a heat-conducting plate!
 In order to prevent loss of production due to faulty heating sleeves, we

recommend keeping at least one unit of each heating sleeve design in
stock.
The size and heating power of the heating sleeve should be checked when
replacing defective heating sleeves.

6. MAINTENANCE
6.4.9 Maintaining the co-extruder (optional)

The following maintenance work must be performed on the co-extruder:
 Check the metal separator for dirt on a monthly basis and clean the
magnetic discs if necessary (see Chapter 6.4.7)
 Check the condition of the heating sleeves each week and replace if
 Clean the extruder screw and the extruder cylinder of the co-extruder
annually
WARNING!
Wear protective gloves when working on the co-extruder!
Wear eye protection when working on the co-extruder!
NOTE!
upright must be used to access the operating platform.
(see Chapter 3.3.16, Fig. 4769/3047).
NOTE!
A suitable ladder must be used for all work on the co-extruder
which cannot be performed from the operating platform!

6. MAINTENANCE
Replacing the squeeze seals

If plastic melt escapes from one of the following points, the sealing faces must be
inspected and the squeeze seals replaced:
 Between the transfer piece (2) and the feed block
 Between the transfer piece (2) and the corner piece (3)
Before removal, the extruder and co-extruder (optional) must be

Fig. 4769/6040
1 Squeeze-type gasket 4 Squeeze-type gasket

2 Transfer piece 5 Manual sieve changer
3 Corner piece
Procedure
3. Remove the transfer piece (2)
4. Check and clean the sealing surfaces (see Chapter 6.4.4)
5. Insert new squeeze seals (1) and (4)
- Tighten all bolts to the specified tightening torque
(see Chapter 5.4.2, Fig. 4769/5037)

6. MAINTENANCE
NOTE!
Observe the specified tightening torques!
NOTE!
Only fit the thermocouples once operating temperature has been
reached!
Extracting the extruder screw of the co-extruder
Fig. 4769/6060
1 Extruder screw of the co-extruder 3 Thread adapter

2 Extruder gearbox 4 Bolts
Procedure
1. Remove the transfer piece and corner piece (see Fig. 4769/6040)
2. Remove the manual sieve changer (see the manufacturer's
documentation)
3. Fit the thread adapter (3) with the bolts (4) to the extruder gearbox (2)

6. MAINTENANCE
Fig. 4769/6061
Extruder screw of the co-

1 5 Pressure piece
extruder
2 Extruder gearbox 6 Threaded rod
3 Thread adapter 7 Nuts
4. Fit the pressure piece (5) to the threaded rod (6)

5. Coat the pressure piece (5) and threaded rod (6) with a high-
temperature thread paste (Molykote HSC)
6. Fit the nuts (7) on the other end of the threaded rod (6) and tighten
in opposite directions
7. Screw the threaded rod (6) into the thread adapter (3) as far as
the extruder screw of the co-extruder (1)

6. MAINTENANCE
Fig. 4769/6062
1 Extruder screw of the co-extruder 7 Nut

6 Threaded rod
8. Apply an appropriate tool to the nut (7)

9. Turn the threaded rod (6) clockwise
 The threaded rod is pushed towards the extruder screw of the co-
extruder (1).
 The extruder screw of the co-extruder (1) is extracted.
- Turn the threaded rod (6) until the nuts (7) are positioned at the
thread adapter (5)
10. Pull the extruder screw of the co-extruder (1) out of the extruder
cylinder and clean (see Chapter 6.4.6, Fig. 4769/6054)

6. MAINTENANCE
Cleaning the extruder cylinder of the co-extruder

After removing the extruder screw of the co-extruder, the cylinder must be
cleaned.
Fig. 4769/6042
Splined shaft hub for the extruder

1 Co-extruder cylinder flange 3
screw of the co-extruder
2 Hole
Procedure
1. Insert the cylinder cleaning brush at the front at the flange of the co-
extruder (1) and clean the extruder cylinder
2. Blow out the residual plastic particles in the extruder cylinder towards
the front with compressed air:
CAUTION!
- Hold the compressed air hose (2) in the bore holes of the cylinder

6. MAINTENANCE
NOTE!
The splined shaft hub (3) for the splined shaft of the extruder
screw of the co-extruder in the transmission shaft must not be
dirty!
Once the extruder screw and extruder cylinder of the co-extruder have been
cleaned and refitted, all removed parts must be refitted and adjusted.
6.4.10 Maintaining the wide-slot die

The following maintenance tasks must be carried out on the wide-slot die:
 Check the condition of the wide-slot die on a daily basis, and clean if
necessary
 Check the condition of the die lips on the wide-slot die on a daily basis,
and clean if necessary
 Drain the condensate in the pipes for the die extractor on a daily basis
 Clean the wide-slot die
WARNING!
Wear protective gloves when working on the wide-slot die!
Wear eye protection when working on the wide-slot die!
NOTE!
Possible damage to property due to improper handling of the
wide-slot die!
The die lips are chrome-coated and must, therefore, be handled
very carefully!
Even the most minor damage on the surface of the die lips, such
as chips, scratches or dents, can impact the quality of the coating!
Follow the instructions of the manufacturer!

documentation.

6. MAINTENANCE
Cleaning the die lips

At each start-up, allow the extruder to run until the plastic melt is emerging evenly
and cleanly from the wide-slot die and flowing into the receptacle. Then stop the
extruder again and clean the wide-slot die.
The machine must be switched on for cleaning of the die lips (see
Chapter 5.4.1). The extruder and co-extruder (optional) must be
Procedure
Fig. 4769/6023
1. Scrape off the black deposits on the discharge side with a brass or
aluminium scraper

6. MAINTENANCE
Fig. 4769/6024
2. Clean the die lips with copper wool and then with a cloth soaked in
silicone oil
 Applying silicone oil prevents plastic melt from sticking to the die lip
again!
3. Start the extruder with the <Start extruder> push button and allow
the plastic melt to flow into the receptacle until it is free from dirt
Fig. 4769/6063

6. MAINTENANCE
4. Stop the extruder with the <Stop extruder> push button
Fig. 4769/6025
5. Insert a brass or aluminium scraper in the die gap and pull though
Cleaning the wide-slot die

The wide-slot die should be cleaned and removed while it is warm.
Fig. 4769/6055
1 Suction nozzle 4 Seal

2 Cover 5 Die adapter
3 Bracket

6. MAINTENANCE
Procedure
2. Remove the suction nozzles (1)
3. Remove the covers (2)
4. Remove the die lip cover and bracket (3)
5. Remove the side seals (4) from the wide-slot die
6. Hold the wide-slot die with a suitable lifting device
7. Remove the fastening bolts and centring pins from the die body
8. Carefully lift off the front half of the die
9. Clean both halves of the die with brass scrapers or brushes
CAUTION!
When cleaning, take care not to damage the sealing surfaces on
the halves of the die!
10. Spray the sealing surfaces with silicon oil

11. Before the assembly procedure, coat the fastening bolts and centring
pins with a high-temperature thread paste (Molykote HSC)
- For tightening torques, see the manufacturer's documentation
- Use a torque wrench
12. Fit all covers
6.4.11 Maintaining the coating unit

The following maintenance tasks must be carried out on the coating unit:
 Check the silicone hose on the corona (optional) for damage on a daily
basis and replace if necessary
 Check the condition of the blade for the central cutter on a daily basis
and replace if necessary (coating on both sides only)
 Check the condition of the crush cut knives or blades for the edge
trimmer on a daily basis and replace if necessary
 Check the condition of the Teflon tapes on a daily basis and replace if
necessary

6. MAINTENANCE
Replacing the Teflon tape
Fig. 4769/6028
1 Teflon strip 3 Self-adhesive Teflon tape

2 Pressure roller A 45°
Procedure
1. Cut a strip of Teflon tape (1) at a 45° angle with a width of 100 mm and
length of approx. 3,200 mm (A)
2. Place the Teflon tape (1) around the pressure roller (2)
3. Lay the angled ends flush together
4. Then stick the two ends together with the 50 mm-wide, self-adhesive
Teflon tape (3) (length 170 mm).
5. Turn down the ends of the self-adhesive Teflon tape (3) and stick to the
back

6. MAINTENANCE
Fig. 4769/6067
1 Teflon tapes 4 Chill roller

2 Pressure roller 5 Pulley
6. Guide the Teflon tape (1) around the pulley (5) and the chill roller (4) in
the machine

6. MAINTENANCE
Replacing the blade for the central cutter
CAUTION!
Risk of cuts in the area of the blade (1)!
Fig. 4769/6029
1 Blade 2 Bolts
Procedure
2. Replace the blade (1) with a new one

6. MAINTENANCE
Replacing the blade for the edge trimmer

When replacing the blade, the whole bracket (3) must be removed along with the
blade (4).
CAUTION!
Fig. 4769/6030
1 Locking pin 4 Blade

2 Locking pin with star knob 8 Knife carriage
3 Holder 9 Stop
Procedure
1. Pull out the stop bolt (1), rotate slightly and allow to engage
2. Pull out the locking pin (2), rotate slightly and allow to engage
3. Pull out the holder (3) with the blade (4)

6. MAINTENANCE
Fig. 4769/6068
1 Locking pin 6 Clamping plate

2 Locking pin with star knob 7 Pins
4 Blade 9 Stop
5 Knurled bolt
4. Unscrew the knurled bolt (5)

5. Remove the clamping plate (6)
6. Replace the blade (4) with a new one
7. Insert a new blade (4) onto the pins (7)
8. Fit the clamping plate (6) with the knurled bolt (5)
9. Push the edge trimming unit as far as the stop (9) in the knife carriage
groove (8)
10. Allow the locking pin with star knob (2) to engage again
11. Allow the locking pin (1) to engage again

6. MAINTENANCE
Resharpening crush cut knives
CAUTION!
Risk of cuts in the area of the blade!
With both new and sharpened crush cut knives, the knives' behaviour in the initial
hours of operation must be carefully monitored. The high specific contact
pressure of the crush cut knives on the hardened steel roller causes structural
compression, which causes the occurrence of a flat area instead of the rounded–
off blade.
This flat area must be removed by a fine whetstone, with a radius of 0.1 - 0.2 mm
having to be maintained.
It is recommended that you then polish the crush cut knife blade with an emery
cloth.
Fig. 4769/6032

6. MAINTENANCE
Tensioning the toothed belt on the chill roller drive
Fig. 4769/6049
1 Toothed belt 5 Bolts

2 Sign x Measuring point
3 Bolts D 31 Nm
4 Nuts
Procedure
1. Open the door on the operating side and remove the covers
2. Loosen all four bolts (3)
4. Turn each bolt (5) an equal amount clockwise in succession
 The toothed belt pulley is pushed in the direction of the arrow to
tension the toothed belt (1).
5. Check the tension on the toothed belt (1)
- Set the toothed belt (1) in vibration
frequency of the toothed belt (1) at the measuring points (x)
(see Chapter 6.3.8)
 The frequency for a tensioned toothed belt (1) is stated on the
sign (2).

6. MAINTENANCE
6. If the measured frequency does not match the specified value,

7. Tighten the nuts (4) and bolts (3)

The toothed belt pulley is fastened to the shaft by means of a Taper Lock
clamping bush. The clamping bush bolts must be tightened for torque
transmission to the prescribed tightening torque of 31 Nm (D).
Belt tensioning instructions sign (2) (example)

The sign (2) gives information on the test data (frequency, deflection, etc.) which
the belt in question must exhibit in a tensioned state.
Fig. 4769/6044
A Test force with new belt C Deflection

B Test force with used belt
The values shown in the illustration are example values.

6. MAINTENANCE
6.4.12 Replacing the OPP double unwinder (optional) blade

The procedure described below for replacing the blade must be performed in the
same way on both cutting units of the OPP double unwinder (optional).
CAUTION!
Fig. 4769/6043
1 Bolts 5 Cylindrical pin

2 Holding plate 6 Cover
3 Blade A Drive side
4 Cylindrical pin

6. MAINTENANCE
Procedure
1. Open the cover (6)
3. Remove the holding plate (2)
4. Remove the worn out blade (3)
5. Insert a new blade (3)
- The right hole in the blade (3) in the cylindrical pin (4)
- Slide the blade (3) up against the cylindrical pin (5)
6. Fit the holding plate (2) with the bolts (1)
7. Close the cover (6)
6.4.13 Servicing the winder

The following maintenance work must be performed on the contact winder:
 Check the condition of the blade on a daily basis, and replace if
necessary
 Check the chain tension and chain run of the chains on a monthly basis
and re-tension if necessary
 Pay attention to the general maintenance instructions for the chain
drives (see Chapter 6.3.7)
Replacing the blade
CAUTION!
Risk of cuts in the area of the blade!

6. MAINTENANCE
Fig. 4769/6034
1 Blade 3 Holding plate

2 Bolt
Procedure
2. Remove the holding plate (3)
3. Insert a new blade (1)
4. Fit the holding plate (3) with the bolts (2)

6. MAINTENANCE
Fig. 4769/6070
1 Nut 4 Bolt
2 Nut J Measuring point
3 Chain
Tensioning the lifting device chain

The lifting device chain must be tensioned evenly on the operating side and drive
side.
Procedure
1. Loosen both bolts (4)
3. Turn the nut (1) clockwise
 The chain (3) is tensioned.
 The chain is adequately tensioned if it can be pushed in by approx.
25 mm at the measurement point (J).
4. Adjust the nut (2)

6. MAINTENANCE
Tensioning the toothed belt on the contact roller drive
Fig. 4769/6069
1 Toothed belt 6 Pulley

2 Sign E 92 Nm
3 Bolts F 49 Nm
4 Bolts x Measuring point
5 Nuts
Procedure
1. Open the right door on the drive side
2. Loosen all four bolts (3)
4. Turn each bolt (4) an equal amount clockwise in succession
 The pulley is pushed in the direction of the arrow to tension
the toothed belt (1).
5. Check the tension on the toothed belt (1)
- Set the toothed belt (1) in vibration
frequency of the toothed belt (1) at the measuring point (x)
(see Chapter 6.3.8)
 The frequency for a tensioned toothed belt (1) is stated on the
sign (2).

6. MAINTENANCE
6. If the measured frequency does not match the specified value,

7. Tighten the nuts (5)

The toothed belt pulleys are fixed onto the shaft by means of TaperLock clamping
bushes. The clamping bush bolts must be tightened for torque transmission to the
prescribed tightening torques of 92 Nm (E) and 49 Nm (F).
Belt tensioning instructions sign (2) (example)

The sign (2) gives information on the test data (frequency, deflection, etc.) which
the belt in question must exhibit in a tensioned state.
Fig. 4769/6045
A Test force with new belt C Deflection

B Test force with used belt
The values shown in the illustration are example values.

7. TROUBLESHOOTING
7 TROUBLESHOOTING
All troubleshooting tasks which are performed must be recorded in a system

logbook, including the respective number of operating hours.
For further information on troubleshooting, see the lamiTEC

LX/CX display user manual
For further information on troubleshooting the volumetric dosing

unit with feed station, see the Technical manual for the voluTEC
For further information on troubleshooting the gravimetric batch

dosing unit with feed station (optional), see the Technical manual
for the graviTEC gravimetric batch dosing unit with feed station.

7. TROUBLESHOOTING
7.1 Entire machine
Machine cannot be started

Causes Remedy
Check the supply voltage and connect it if
No supply voltage necessary (see the Layout plan and
Circuit diagram)
Fuses have tripped Test fuses
Check the compressed air supply and
No compressed air supply connect if necessary (see Chapter 4.1
and the Layout plan)
 Check alarms on the display
 Rectify the fault
Machine fault
 Acknowledge the alarms (see the
lamiTEC LX/CX display user manual)
 Rectify the cause of the
EMERGENCY STOP
 Reset the EMERGENCY STOP
EMERGENCY STOP active: (see Chapter 5.7.2)
The <Reset EMERGENCY STOP> push  Reset the safety switch for thee
button lights up yellow. EMERGENCY STOP pull cord
 Check supply voltage
cables and wires in accordance
with the Circuit diagram
Safety doors not closed Close the safety doors
Safety switch not properly adjusted Check the adjustment:
7.2 Hot air oven
Circulators do not start to move after start

Causes Remedy
Switch on line safety switch in switching
Line safety switch not switched on
cabinet (see Circuit diagram)
Frequency converter fault

Causes Remedy
Motor protection has tripped See Chapter 7.10.2
Frequency converter not ready See Chapter 7.10.3

7. TROUBLESHOOTING
Hot air oven cannot be set into operation

Causes Remedy
Close the hot air oven with the <Close
Hot air oven not closed
oven> push button
7.3 Double unwinder
Fabric web running off course

Causes Remedy
Check the web edge control and readjust
Web edge control misaligned
if necessary (see Chapter 4.4.1)
Web tension fluctuates

Causes Remedy
Brake pads worn Check and replace if necessary
Perform calibration again (see Chapter
Calibration of loadcell not performed
4.4.2 and the lamiTEC LX/CX display user
correctly
manual)
Poor roll quality Change the roll (see Chapter 5.5.6)
7.4 Extruder
Extruder cannot be started

Causes Remedy
Fault on extruder drive Check extruder drive (see Chapter 7.10)
Adjust the filter tape feed (see the
Pressure before the melt filter is too high
Temperature outside tolerance at zone Check the set temperature values (see
heaters the lamiTEC LX/CX display user manual)
Wait the time entered on the display (see
Heater timer is active

7. TROUBLESHOOTING
Extruder stops during production

Causes Remedy
 See Chapter 7.10.1
Motor temperature too high  If the pressure in the system
increases, reduce the chill roller feed
(see Chapter 4.3)
Melt pressure upstream of melt filter or Check temperature release (see the
wide-slot die too high lamiTEC LX/CX display user manual)
 Adjust the filter tape feed (see the
Filter tape extremely dirty lamiTEC LX/CX display user manual)
 Check the material
Clean the wide-slot die and feed block
Wide-slot die or feed block (optional) are (see Chapter 6.4.4 and Chapter 6.4.10
heavily soiled and the corresponding manufacturer's
documentation)
 The extruder is not drawing in
Melt pressure upstream of the melt filter material. Ensure that the infeed zone
or wide-slit die / feed block (optional) is cooling system is operational, reduce
too low the temperature if necessary
 Check the pressure sensor (7.11.2)
Thermocouple faulty (extruder stops after Check the thermocouple and replace if
15 mins) necessary (see Chapter 7.11.3)
Jolting, thrusting movement in the pellet feed line

Causes Remedy
Blockage due to heavy material-air Check the transport path (pipelines and
mixture hoses) of the pellets
Temperature increases at infeed zone cooling system

Causes Remedy
Thermocouple defective Check thermocouple (see Chapter 7.11.3)
Dirty water filter Clean water filter
Check cooling water temperature, reduce
Cooling water temperature too high
if necessary

7. TROUBLESHOOTING
Pressure before the melt filter is too high

Causes Remedy
 Clean melt filter (see Chapter 6.4.4)
 Adjust the filter tape feed (see the
Melt filter dirty
Melt pressure control valve closure too Check melt pressure control valve and
wide adjust if necessary
7.5 Co-extruder (optional)
Co-extruder cannot be started

Causes Remedy
Check the drive of the co-extruder
Fault with the co-extruder drive
(see Chapter 7.10)
Pressure upstream of melt filter of the co- Replace the sieve (see the manufacturer's
extruder too high documentation)
Check the set temperature values
Temperature of the zone heaters outside
(see the lamiTEC LX/CX display user
tolerance
manual)
Wait the time entered on the display (see
Heater timer active
Co-extruder stops during production

Causes Remedy
 See Chapter 7.10.1
Motor temperature too high  If the pressure in the system
increases, reduce the chill roller feed
(see Chapter 4.3)
 Replace the sieve (see
Heavy soiling of the sieve on the melt filter the manufacturer's documentation)
of the co-extruder
Clean the wide-slot die and feed block
Wide-slot die or feed block are heavily (see Chapter 6.4.4 and Chapter 6.4.10
soiled and the corresponding manufacturer's
documentation)
Thermocouple faulty (extruder stops after Check the thermocouple and replace if
15 mins) necessary (see Chapter 7.11.3)

7. TROUBLESHOOTING
Temperature increases at infeed zone cooling system

Causes Remedy
Thermocouple defective Check thermocouple (see Chapter 7.11.3)
Dirty water filter Clean water filter
Check cooling water temperature, reduce
Cooling water temperature too high
if necessary
Pressure upstream of melt filter of the co-extruder too high

Causes Remedy
 Replace the sieve (see the
Sieve of the melt filter on the co-extruder manufacturer's documentation)
dirty
7.6 Coating unit
Coating unit cannot be started

Causes Remedy
Winder has not started Start the winder (see Chapter 5.4.5)
Check motor circuit breaker (see Chapter
Motor circuit breaker fault
7.10.2)
Chill roller drive not ready for operation Check the drive (see Chapter 7.10)
Start/Stop system fault Check wiring against the Circuit diagram
Vertical adjustment of the chill roller not working

Causes Remedy
Motor protection has tripped See Chapter 7.10.2
Sensor fault See Chapter 7.11.1
Coating material on pressure roller

Causes Remedy
Readjust the Teflon tapes
The Teflon tapes have moved
Replace the Teflon tapes
The Teflon tapes have been torn off
(see Chapter 6.4.11, Fig. 4769/6028)

7. TROUBLESHOOTING
Cover coating cut poorly or not at all

Causes Remedy
Cover coating is cut off too close to the
Maintain a protruding edge of 5 mm
sheet material
Blade blunt Replace blade (see Chapter 6.4.11)
Grind crush cut knifes, replace if
Crush cut knife blunt
Crush cut knife not pressed against steel Check the pressure, adjust if necessary
roller (see Chapter 4.18.4)
 Check the position of the ball valves
Chill roller temperature too high  Check cooling water temperature
 Reduce chill roller set temperature
Edge strips not being extracted

Causes Remedy
Blower faulty Check blower
Exhaust pipe blocked Clean exhaust pipe
Reduce the volume by:
Volume of edge strips being extracted too  reducing edge trimming
high  adjusting the chill roller vertically
7.7 Perforation system
Pin roller does not swing in or out

Causes Remedy
 Check the compressed air supply
(see the Chapter 4.1 and the Layout
No compressed air supply plan)
 Check the pneumatic hoses for
damage and replace if necessary
Speed of the coating unit must be
Speed of the coating unit too high reduced to below 60 m/min to enable
pivoting in or out

7. TROUBLESHOOTING
7.8 OPP unwinder (optional)
OPP-film web running off course

Causes Remedy
Check the web edge control on the
turning frame
Web edge control misaligned
and readjust if necessary
Tension of the OPP-film web fluctuates

Causes Remedy
Perform calibration again (see Chapter
Calibration of loadcell not performed
4.12.3 and the lamiTEC LX/CX display
correctly
user manual)
Change roll (see Chapter 5.5.7 for single
Poor roll quality unwinder and Chapter 5.5.6 for optional
OPP double unwinder)
Double unwinder (optional)
OPP-film web is not being cut

Causes Remedy
Blade in the cutting unit is blunt Replace blade (see Chapter 6.4.12)

7. TROUBLESHOOTING
7.9 Winder
Winder cannot be started

Causes Remedy
Check the main contactor for the winder in
EMERGENCY STOP active
accordance with the Circuit diagram
Check frequency converter and motor
Contact roller drive not ready for operation
Motor fault in oscillator or hydraulic Check motor circuit breaker (see Chapter
system 7.10.2)
Reference the winder (see the lamiTEC
Winder not referenced
LX/CX display user manual)
Start/Stop system fault Check against the Circuit diagram
 Check the oil level and top up if
Oil level in hydraulic unit too low
 Check the hydraulic hoses for damage
and replace if necessary
Dirty oil filter Replace melt filter
Oil temperature too high Check hydraulic system
 Check compressed air supply
 Check the set pressure on the
maintenance unit and adjust if
Pneumatic pressure too low
necessary (see Chapter 4.1)
 Check the pressure setting
at the coating unit (> 5 bar)
No oscillation during operation

Causes Remedy
Check motor circuit breaker
Motor circuit breaker fault
Set longer oscillating path
Oscillating path too short
Check the adjustment of the traverse
One of the clamping levers is loose and firmly apply the clamping lever
Roll becoming too soft

Causes Remedy
Increase contact pressure or winding
Contact pressure or winding tension too
tension (see the lamiTEC LX/CX display
low
user manual)

7. TROUBLESHOOTING
Roll becoming too hard/creasing occurring in front of contact roller

Causes Remedy
Reduce contact pressure or winding
Contact pressure or winding tension too
tension (see the lamiTEC LX/CX display
high
user manual)
Fabric web running off course on spreader roller

Causes Remedy
Reduce the winding tension (see the
Winding tension too high
Correct position (see the lamiTEC LX/CX
Winder not in centre of web
Core not adequately clamped by the Repeatedly blow compressed air into the
pneumatic expansion shaft (pressure too pneumatic expansion shaft (see
low) Chapter 5.4.10)
Fabric web not being cut

Causes Remedy
Blade blunt Replace blade (see Chapter 6.4.13)
Fabric web being wound up unevenly

Causes Remedy
 Clean the wide-slit die and die lips
Uneven distribution of the coating material (see Chapter 6.4.10)
at the wide-slot die
 Adjust the gap (see Chapter 4.14.3)
7.10 DC drives
7.10.1 Checking the DC drive for overheating
Procedure
1. Allow motor to cool down
2. Check mechanism for ease of movement
3. Check gearbox and maintain as necessary
- Check the oil level
- Check the bearing

7. TROUBLESHOOTING
4. If a motor fan is fitted:

- Check if the fan cover is dirty, and clean if necessary
- Check that the fan blades are intact, and replace if necessary
5. For motors with forced ventilation:
 The fan is powered by its own motor.
- Check the motor protection and power supply
On motors with forced ventilation, the motor fan only runs under
the following conditions:
 The safety covers or doors are closed
 EMERGENCY STOP is not active
 Motor temperature > 65°C
6. If a water-cooled motor is fitted:

- Check water screen for dirt and clean as necessary
- Check the solenoid valves for functionality and permeability and
7. If the motor is soiled, clean the following parts:
- cooling fins
- if applicable, the filter
8. Check if the ambient temperature is too high
9. Check the loom parameters
7.10.2 Determining the cause that triggered the motor protection
Procedure
1. Compare set current value on the triggering device with the value on
the motor type plate
2. Check power supply
3. Check cable connection
4. Check motor temperature
5. Check mechanism for ease of movement
6. Check gearbox and maintain as necessary
- Check the oil level
- Check the bearing
7. Check direction of rotation

7. TROUBLESHOOTING
8. Check the motor for short-circuit/short-circuit to earth and other

malfunctions
9. Perform maintenance (see the manufacturer's documentation)
7.10.3 Checking the frequency converter
Procedure
1. Note down the alarm number as well as the alarm text, and
acknowledge the alarm on the display (see the lamiTEC LX/CX display
user manual)
 This activates the reset input on the frequency converter.
2. Check the diagnostics menu for of the drive
4. Check wiring
5. Look-up the fault displayed on the frequency converter in the
manufacturer's documentation
6. Switch off the machine (see Chapter 5.6) and switch on again after
30 secs (see Chapter 5.4.1)
7. Check the bus connection
8. Compare programming
9. Check the motor for short-circuit/short-circuit to earth and other
malfunctions
10. Check parameters
11. Shut off motor and switch on again
 If the fault occurs even without the motor: replace the frequency
converter
 If the fault does not occur without the motor: check the motor
7.10.4 Checking the rotary encoder
Procedure
1. Note down the alarm number as well as the alarm text, and
acknowledge the alarm on the display (see the lamiTEC LX/CX display
user manual)
2. Check cable connection
3. Remove the plugged connections in a de-energised state and reconnect
4. Press one of the <EMERGENCY STOP> push buttons (for overview
see Chapter 5.2.2)

7. TROUBLESHOOTING
5. Check shielding
- Check shield connection and cable ties
- Check the shielding braid and wire for corrosion
- Check that the motor cable is shielded on both sides and that the
shielding is fully tightened (check the shield connection points for
electrical conductivity)
- Check top-hat rail for earth connection
- Check that the earth connection is attached to the shielding plate
of the frequency converter
- Check that the connections are made properly (pay attention
to the electrical conductivity of the shield connection points)
6. If necessary, replace the cable of the rotary encoder
7. If necessary, replace the rotary encoder
8. If necessary, replace the motor
7.11 Sensors
7.11.1 Checking proximity switches

Inductive proximity switches (e.g. limit switches) trigger a signal when
approached by metal objects (e.g. aluminium, brass or steel), while capacitive
proximity switches (e.g. fill level sensors) trigger a signal when approached by
non-metal materials (e.g. plastic, glass or liquids).
Every sensor has a given detection area for steel, which is reduced by half with
aluminium or brass. The accuracy of the signal depends on the positioning of the
sensor and any fine adjustment.
Procedure
1. Check sensor for mechanical damage
2. Check the switching distance (see the manufacturer's documentation)
3. Reposition the sensor if necessary
- Unplug connector
- Undo nut (sensor is freed)
- Set the distance between the sensor and the object with a feeler
gauge
- Check the connector
- Tighten the nuts (see manufacturer's information for tightening
torques)
- Check function

7. TROUBLESHOOTING
4. Trigger the sensor with a suitable object and check the LED on the
control system input (see the Circuit diagram)
6. Check wiring
7. Measure output signals
8. If necessary, replace the sensor
 If the new sensor does not function, replace the input card
7.11.2 Checking the pressure sensor

A pressure sensor converts the physical pressure variable (force per area) into
an electrical output variable as a dimension for the pressure.
Procedure
1. Check voltage supply (see the circuit diagram and lamiTEC LX/CX
2. Measure the output signals and check the value on the display
3. Check wiring
4. Check the plug connections
5. Remove the sensor (when it is heated up, as the sensor may be stuck
in the plastic melt, if removed in a cold state, and could break off), and
inspect for physical damage, particularly on the diaphragm
- If the new sensor does not function, replace the input card
7.11.3 Checking the thermocouple

The thermocouples are used to measure temperatures. At the free ends of the
two connected conductors, if there is a temperature difference along the
conductors, an electrical voltage is generated due to the Seebeck effect.
The connection point for the two conductors must also have a different
temperature than the reference point. The receiver modules provide automatic
temperature compensation to adapt to the ambient temperature. This makes
calibration unnecessary on these thermocouples.

7. TROUBLESHOOTING
The connection is made via a terminal head or a compensating line made of one
of the following alloys (acc. to IEC 751 or EN 60751):
Type Colour coding acc. to IEC Alloy

Green
K NiCr-Ni
White
Black
J Fe-CuNi
White
Type Colour coding acc. to EN Alloy

Red
L Fe-CuNi
Blue
To avoid deviations in the measured values from thermocouples

 The terminal units must be made from the same alloy as the
compensating lines
 No cable end sleeves may be used on compensating lines
Procedure
2. Adjust the spring on the bayonet coupling so that the sensor is pushed
against the surface being monitored
3. Check and tighten terminal connections where required, observe
polarity
4. Check wiring
5. Check sensor:
- For sensors with a connecting head, disconnect and twist
the connection line
- For potted sensors, connect a new sensor or a twisted
compensating line to the input
 The ambient temperature is displayed on the screen:
The sensor is faulty.
 The ambient temperature is not displayed on the screen:
The control input is faulty.
- If the new sensor does not function, replace the temperature control
or input card

7. TROUBLESHOOTING
7.11.4 Checking the light barrier

A light barrier registers the interruption of a light beam by an object. Light barriers
exist in the following two types:
 Through-beam light barriers: with a transmitter and receiver
 Reflection light barriers: with a transmitter and reflector
Procedure
1. Check the transmitter and receiver or reflector for mechanical damage
2. Clean the transmitter and receiver or reflector
4. Measure output signal
5. Check the alignment of the transmitter to the receiver or reflector
6. Replace the reflector with another of the same type
7. If necessary, replace the cable
8. If necessary, replace the transmitter and receiver or reflector
 If the new transmitter or receiver does not function, replace the input
card.
7.11.5 Checking the ultrasound sensor

Ultrasound sensors measure the distance to objects based on the transit time of
emitted soundwaves, and can initiate switching procedures if specific threshold
values are reached.
Procedure
2. Remove soiling (on the ultrasound surfaces, this may distort the
measurement results)
3. Check installation position (in the case of distance measurements,
the ultrasound beam should be positioned centrally, and ideally at a 90°
angle to the object being measured)
4. Keep heat sources away from ultrasound sensors (hot objects cause air
turbulence, which could distort the measurement results)
5. Check voltage supply (see the circuit diagram and lamiTEC LX/CX
6. Check wiring (check the shielding on measuring ultrasound sensors)
7. Measure output signals

7. TROUBLESHOOTING

 If the new transmitter or receiver does not function, the input card
must be replaced

8. ENCLOSURES
8 ENCLOSURES
Tightening torques
The maximum permissible tightening torques in the table are based on VDI 2230
and apply to:
 Hex bolts, ISO 4014-4018
 Hex socket head cap screws, ISO 4762
 Bolts with analogous head rigidity and head bearing surfaces of
strength categories 8.8-12.9
at a 90% utilisation of the yield point ReL/0.2%-yield strength Rp0.2.
NOTE!
The tightening torques in the following table are permissible
maximum values and do not incorporate any safety factors!
Only use them where no other tightening torques are specified
(see particularly the information from the manufacturer)!
Strength categories in accordance with ISO

Width across 898/1
Thread
flats
M 8.8 10.9 12.9
s
Max. tightening torque (Nm)
M4 7 2.6 3.9 4.5
M5 8 5.2 7.6 8.9
M6 10 9 13.2 15.4
M8 13 21.6 31.8 37.2
M10 17 43 63 73
M12 19 73 108 126
M16 24 180 264 309
M20 30 363 517 605
M24 36 625 890 1,041
M30 46 1.246 1.775 2.077
M36 55 2.164 3.082 3.607

8. ENCLOSURES
NOTES
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Doc. no..: DBE-047

Warranty and liability

lamiTEC LX/CX DBE-04769D PAGE 2 / 341

ABOUT THIS DOCUMENT ................................................................................................ 9

lamiTEC LX/CX DBE-04769D PAGE 3 / 341

3.3.27 Installing the vacuum conveyor (optional) .................................................. 91

lamiTEC LX/CX DBE-04769D PAGE 4 / 341

4.15.3 Adjusting the chill roller and pressure roller ............................................. 123

lamiTEC LX/CX DBE-04769D PAGE 5 / 341

5.2.11 Hydraulic operating pressure gauge ........................................................ 159

lamiTEC LX/CX DBE-04769D PAGE 6 / 341

6.1.1 Double unwinder ...................................................................................... 246

lamiTEC LX/CX DBE-04769D PAGE 7 / 341

6.4.11 Maintaining the coating unit...................................................................... 308

lamiTEC LX/CX DBE-04769D PAGE 8 / 341

ABOUT THIS DOCUMENT

Notation Representation Example

lamiTEC LX/CX DBE-04769D PAGE 9 / 341

Indicator word Meaning

Risk of foot injury

lamiTEC LX/CX DBE-04769D PAGE 10 / 341

Warning: magnettic field

Do not excceed the max. load-bearing capaccity!

lamiTEC LX/CX DBE-04769D PAGE

Do not linger under suspended loads!

Transporting personnel is prohibited!

Do not stand on surface!

Wear protective gloves!

Hearing protection mandatory!

Wear a hard hat!

Wear eye protection!

Switch off before performing work!

Pay attention to the operating instructions!

This document contains additional pictograms with various purposes. The

lamiTEC LX/CX DBE-04769D PAGE 12 / 341

Reference to further information

Terms and abbreviations

lamiTEC LX/CX DBE-04769D PAGE 13 / 341

1.1 Area of application and intended use

Tasks to perform on the machine

The machine is designed for two-person operation.

1.2 Method of operation

lamiTEC LX/CX DBE-04769D PAGE 14 / 341

1.3 LX standard version

lamiTEC LX/CX DBE-04769D PAGE 15 / 341

The following figure provides an overview of the position of the individual

1 Crane system 5 Extruder unit with wide-slot die

Web edge control

lamiTEC LX/CX DBE-04769D PAGE 16 / 341

Pneumatic braking device

Pneumatic expansion shaft

Volumetric dosing unit with feed station

For further information on the volumetric dosing unit with feed

Hot air oven

Chill and pressure roller

lamiTEC LX/CX DBE-04769D PAGE 17 / 341

lamiTEC LX/CX DBE-04769D PAGE 18 / 341

Melt pressure control valve

For information on the wide-slot die, see the manufacturer's

Edge strip extractor

lamiTEC LX/CX DBE-04769D PAGE 19 / 341

Pneumatic expansion shaft