Original Instructions

Translation of
Adhesive Station

LS 40 LS 80 LS 120
Cod. 4086527 ADHESIVE DX LS40

Instruction manual
Use and Maintenance
Version: 1.0
Year: 2017

Z- ITALIA S.r.l.
Via Brusche, 15
46014 Castellucchio (MN) • Italy
Tel. +39 0376 434611 • Fax +39 0376 434699
@mail: z-italia@z-italia.eu
 Introduction

FOREWORD
All rights reserved. No part of this instruction manual can be reproduced or transmitted by any electronic or
mechanical means, including photocopies, recordings or any other storage and data retrieval system, for any
purpose other than the exclusive personal use of the purchaser, without the express written consent of the
Manufacturer.
The Manufacturer is by no means liable for the consequences of incorrect operations performed by the user.

EDITOR'S NOTE
This documentation is expressly addressed to technicians. Therefore, information that can be easily retrieved
by reading these texts and analysing the drawings may not be explained further.
The Editor shall by no means be held responsible for the information and data referred to in this manual:
all the information included in it is supplied, controlled and approved on the premises after Manufacturer/
Representative’s verification.
The Editor shall by no means be held responsible for the consequences resulting from the user’s misuse of
the system.

GENERAL REMARKS
The machine was designed for labelling containers.
Any operational and maintenance instructions, as well as the recommendations described herein, shall be
complied with.
To ensure the best results, the Manufacturer recommends carrying out cleaning operations and maintenance
on a regular basis, in order to keep the system as efficient as possible.
It is very important that the personnel in charge of the machine are duly trained on its use, maintenance and
observance of the operating procedures and safety standards included in this manual.
LABELLING MACHINE

Edition: 2017
Version: 1.0

COPYRIGHT
© 2017 Z-ITALIA S.r.l.

CHAP. 0 Pag.2
Adhesive Station

TABLE OF CONTENTS

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.3CHAP. 0

 Introduction

1. Description...................................................................................................................................... pag.7

1.1. Technical data...........................................................................................................................pag.7

1.1.1. Main features....................................................................................................................pag.7
1.2. Description of operation.............................................................................................................pag.8
1.3. Main components....................................................................................................................pag.10
1.4. Overall dimensions..................................................................................................................pag.12
1.5. Adhesive station assembly......................................................................................................pag.12

2. Adhesive station setup................................................................................................................ pag.15

2.1. First coil and junction coil installation...................................................................................... pag.15

2.1.1. First coil installation.........................................................................................................pag.15
2.1.2. Junction coil....................................................................................................................pag.18
2.1.3. Adjusting the adhesive station position........................................................................... pag.20

3. Controls......................................................................................................................................... pag.25

3.1. Adhesive station controls.........................................................................................................pag.25

3.1.1. Control devices...............................................................................................................pag.25

4. Adhesive station panel................................................................................................................. pag.29

4.1. Operating pages......................................................................................................................pag.29

4.1.1. Home page......................................................................................................................pag.29
4.1.2. Operator menu................................................................................................................pag.30
4.1.3. Adhesive unit start-up.....................................................................................................pag.31
4.1.4. Recipe parameters..........................................................................................................pag.32
4.1.4.1. Movement recipe...................................................................................................pag.34
4.1.5. Setup page......................................................................................................................pag.35
4.1.6. Backup page...................................................................................................................pag.36
4.1.7. Diagnosis page...............................................................................................................pag.37
LABELLING MACHINE

5. Maintenance.................................................................................................................................. pag.41

5.1. Safety precautions...................................................................................................................pag.41

5.2. General maintenance information .......................................................................................... pag.42
5.3. Routine maintenance...............................................................................................................pag.42
5.3.1. Checks............................................................................................................................pag.43
5.3.2. Lubrication.......................................................................................................................pag.43
5.3.3. Cleaning..........................................................................................................................pag.44
5.3.3.1. Operator panel.......................................................................................................pag.44
5.3.3.2. Photocells..............................................................................................................pag.44
5.4. Safety devices check...............................................................................................................pag.45
5.5. Special maintenance...............................................................................................................pag.45
5.6. Recommended consumer products......................................................................................... pag.46

CHAP. 0 Pag.4
Adhesive Station

CHAPTER 1
Description

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.5

CHAP. 4
LABELLING MACHINE Description

CHAP. 4 Pag.6
Adhesive Station

1. Description

1.1. TECHNICAL DATA

1.1.1. Main features

NAME
TYPE Adhesive Station
MODEL LS 40 M - 80 M - 120 M

PRODUCTION
LS 40 M 40 metres/minute
HOURLY PRODUCTION LS 80 M 80 metres/minute
LS 120 M 120 metres/minute

MASS
LS 40 M 250 Kg
NET WEIGHT LS 80 M 250 Kg
LS 120 M 350 Kg

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.7

CHAP. 4
 Description

1.2. DESCRIPTION OF OPERATION

STAGE DESCRIPTION
1 The unwinding coil is installed on the unwinder.
Through a dancer roller (A) and a series of return rollers the tape label reaches a driving unit,
2
which ensures its progress.
3 Before detachment a photocell gives consent for its progress.
The detaching blade helps the detachment of the label from the supporting tape, allowing it to be
4
applied to the container.
The supporting tape, after the driving unit, reaches the winder through a series of return rollers
5
and a dancer system (A) (if present)
LS 40 LS 80
3 2 A 1
3 2 A 1

Cod. 4086524 ADHESIVE SX LS80

5
Cod. 4086526 ADHESIVE SX LS40
A 5

LS 120

3 2 A 1
LABELLING MACHINE

CHAP. 4 Pag.8
 Adhesive Station

6 Right hand Adhesive Station (clockwise)

LS 40 LS 80 LS 120

Cod. 4086527 ADHESIVE DX LS40

7 Left hand Adhesive Station (anticlockwise)

LS 40 LS 80 LS 120
04SL XD EVISEHDA 7256804 .doC

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.9

CHAP. 4
 Description

1.3. MAIN COMPONENTS

POS. ELEMENTO DESCRIPTION

This carries and unwinds the label tape coils.

1 UNWINDER COIL DISC Equipped with end of label sensor to notify when the labels are about
to run out.
A flexible element that distributes the tension along the label tape
2 UNWINDER DANCER
gradually for coil unwinding.
TRACTION ROLLER A flexible element applied to the label tape at the traction roller in feed
3
COMPENSATOR and out feed to avoid it from tearing during operation.
This applies traction to the tape label from the coil and retracts the
4 TRACTION ROLLER supporting tape from the detaching blade in case of impact with the
container.

5 STOP PHOTOCELL This detects the edges of the label to guarantee exact dispensing.

This detaches the label from the supporting tape during application on
6 DETACHING BLADE the container. The detaching blade can be fitted with a shock absorbing
element that supports the blade in case of impact with the container.
A flexible element that distributes the tension along the supporting tape
7 REWINDING DANCER
gradually for rewinding on the winders.

8 REWINDING DISC Disc collecting the supporting tape.

PRESSURE The regulators manage dancer pressure on the unwinder/rewinder and

9
REGULATORS therefore on the tape label tension.
10 CONTROL PANEL Touch-Screen panel to control operation.
11 TEST BUTTON Press to dispense a label.

POSITION The system that allows for the adjustment of the labelling station.
12
ADJUSTMENT SYSTEM Possible adjustments: vertical, horizontal, pitch, roll
LABELLING MACHINE

CHAP. 4 Pag.10
Adhesive Station

LS 40 LS 80
5 4 3 2 1
5 4 3 2 1

Cod. 4086524 ADHESIVE SX LS80

8
Cod. 4086526 ADHESIVE SX LS40
7 8

LS 120

8
5 4 3 2 1

7
LABELLING MACHINE

EC Regulation use and maintenance manual Pag.11

CHAP. 4
 Description

9 9

10

10

11

12

1.4. OVERALL DIMENSIONS

Note: For the specific layout of the labelling station, refer to the Spare Parts Catalogue.
LABELLING MACHINE

1.5. ADHESIVE STATION ASSEMBLY

The adhesive station must be assembled by Z-ITALIA S.r.l. authorised personnel.

The improper and incorrect assembly of the adhesive station, its part or components, may result in damage to
the adhesive station and give rise to risks for the operators; therefore it is advised to have this operation carried
out by specialist personnel named “INSTALLER”.

CHAP. 4 Pag.12
Adhesive Station

CHAPTER 2
Adhesive Station Setup

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.13

CHAP. 6
LABELLING MACHINE Adhesive Station Setup

CHAP. 6 Pag.14
Adhesive Station

2. ADHESIVE STATION SETUP

2.1. FIRST COIL AND JUNCTION COIL INSTALLATION

2.1.1. First Coil Installation

STEP ACTION

Ensure the machine is in "MACHINE STOP" mode

The paper path varies slightly from model to model.

Reference should be made to the figure on the cover of the feeder unit to know the path that the paper
has to follow

LS 40 SX LS 40 DX

LS 80 SX
Cod. 4086526 ADHESIVE SX LS40
LS 80 DX
04SL XS EVISEHDA 6256804 .doC

LABELLING MACHINE
LS 120 SX LS 120 DX

Remove the centring ring (A) by widening the

pins at the sides. A
1
Put the new coil on the disc and put the
centring ring firmly back in place.

Unwind about a meter and a half of paper and

2
remove the labels in this section.
Feed the paper on the return rollers and
3 adjust the position of the guide rings until it
touches the edge of the paper.

EC Regulation use and maintenance manual Pag.15

CHAP. 6
 Adhesive Station Setup

A
A

Lift the pins (A) to open the feeder unit and

4
insert the paper from the top.

Unwind the label tape on the peeler and

5
reinsert it into the feeder unit.

Remove the labels on the tape after the

peeler and attach the tape to the winder,
which, depending on the layout, can be two A B
types as shown in the illustration.
A: remove the centring ring, insert a core and
rewind the supporting tape attaching it to the
core.
6
Reposition the centring ring.
LABELLING MACHINE

B: Open the lever of the attaching system.

Insert the supporting tape in the rewinder.
Close the lever of the attaching system.

A
A

Close the feeder unit and lock with the pins

7
(A).

CHAP. 6 Pag.16
Adhesive Station

8 Check the vertical position of the sensor stop (A)

A
Using the test button (A), dispense some test
9
labels.

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.17

CHAP. 6
 Adhesive Station Setup

2.1.2. Junction Coil

STEP ACTION

Ensure the machine is in "MACHINE STOP" mode

The paper path varies slightly from model to model.

Reference should be made to the figure on the cover of the feeder unit to know the path that the paper
has to follow

LS 40 SX LS 40 DX

LS 80 SX
Cod. 4086526 ADHESIVE SX LS40
LS 80 DX
04SL XS EVISEHDA 6256804 .doC

LS 120 SX LS 120 DX
LABELLING MACHINE

x
x

1 Cut the existing coil near the unwinder.

Remove the centring ring (A) by widening the

pins at the sides. A
2
Replace the coil on the disc and put the
centring ring firmly back in place.

CHAP. 6 Pag.18
Adhesive Station

Join the edge of the new coil with the edge of

3
the old label tape.

A
Using the test button (A), dispense some
4
labels until the join has passed the peeler.

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.19

CHAP. 6
 Adhesive Station Setup

2.1.3. Adjusting the Adhesive Station Position

Note:The position values of the adhesive station are shown on the Format Change Cards attached to the
machine manual.

STEP ACTION

Ensure the machine is in "MACHINE STOP" mode

A series of adjustments can be performed that allow the modification of the position of the labelling system
of the adhesive station.
Possible Adjustments:
- Vertical
- Horizontal
- Roll
- Pitch

STEP ACTION
A

To adjust the vertical position move the

adjustment nut shown (A).
Vertical Adjustment Use the digital indicator to check that
the required adjustment has been
achieved.
LABELLING MACHINE

To adjust the horizontal position, move

the adjustment nut shown (A).
Horizontal Adjustment Use the digital indicator to check that
the required adjustment has been
achieved.

To adjust the horizontal position, loosen

the locking handle (A) and move the
adjustment nut shown (B).
Use the digital indicator to check that
Roll Adjustment
the required adjustment has been
achieved.
Having completed the adjustment, B
tighten the locking handle.
A

CHAP. 6 Pag.20
Adhesive Station

To adjust the horizontal position, loosen

the locking handle (A) and move the
adjustment nut shown (B).
Use the digital indicator to check that
Roll Adjustment
the required adjustment has been
A
achieved.
Having completed the adjustment, B
tighten the locking handle.

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.21

CHAP. 6
LABELLING MACHINE Adhesive Station Setup

CHAP. 6 Pag.22
Adhesive Station

CHAPTER 3
Controls

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.23CHAP. 7

LABELLING MACHINE Controls

CHAP. 7 Pag.24
Adhesive Station

3. CONTROLS

3.1. ADHESIVE STATION CONTROLS

Commands Machine controls This machine is fully automatic, so when it is in regular production, it requires
only one operator for checks on safety and for the smooth operation of the machine itself.

CAUTION!
Using the machine for a different purpose to that intended by the manufacturer may
cause serious personal injuries and/or damage property and/or animals.
Z-ITALIA S.r.l. will not be held responsible for damage caused by improper use of the
machine.

Before using the machine it is important to know perfectly:

• the operator workstations;
• all of its controls and their main functions.
The control devices are, partly on the main electric switchboard and partly on the pushbutton panels, along
the plant's perimeter.
To locate the push buttons refer to the following page layout, where each number corresponds to a push button
panel.

3.1.1. Control Devices

According to the various layouts, the adhesive station can be supplied with the control devices described
below.

1 1

2 LABELLING MACHINE

POS. BUTTON FUNCTION

1 PRESSURE REGULATORS
2 OPERATOR PANEL
These are used to adjust the pressure on the dancers of the self-
adhesive unit.
This is used to set the operating parameters.
Note: for the description of the operator panel refer to the relevant
manual attached.

EC Regulation use and maintenance manual Pag.25CHAP. 7

LABELLING MACHINE Controls

CHAP. 7 Pag.26
Adhesive Station

CHAPTER 4
Adhesive Station Operator Panel

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.27CHAP. 7

LABELLING MACHINE Adhesive Station Operator Panel

CHAP. 7 Pag.28
Adhesive Station

4. ADHESIVE STATION PANEL

The various functions of the adhesive labelling machine station are carried out entirely by electronic equipment
with a touchscreen on which it is possible to vary the operating parameters.

4.1. OPERATING PAGES

4.1.1. Home page

POS. ELEMENT
1 Adhesive unit number
2 Current Recipe Number
At 100% the stepper motor of the feeder
unwinds the label tape at the same frequency
3 Speed % as the encoder positioned on the machine. If the
label tape is kept taut, increase by 5% until the
required speed is reached.
4 Delay (mm) Offset value end of label on the container (Ofine)
5 Activation button of the adhesive unit. Enabled (green), Disabled (red)
6 Button to access the menu RECIPE PARAMETERS
7 Button to access the machine’s parameters page, diagnostics...
8 Button that allows a label to be dispensed.
9 Counting the labels dispensed in real time
10 Speed of adhesive unit in real time. Value expressed in labels / minute.

1 2

9 10
LABELLING MACHINE
3 4

5 6 7 8

THE SCREENS IN GERMAN TO BE EN-

TERED

EC Regulation use and maintenance manual Pag.29CHAP. 7

 INDICATE EVERYWHERE ON THE ADHESIVE UNIT, COLD
GLUE AND HOTMELT AND ROLLFED
Adhesive Station Operator Panel

4.1.2. Operator Menu

POS. ELEMENT
1 Access to ALARMS page
2 Access to SIMULATOR page (if intended)
3 Access to DIAGNOSIS page
4 Access to BACKUP page
5 Allows access to the HOME page
6 Allows access to the next menu page
1 2

5 6

3 4

POS. ELEMENT
1 Access to the FEEDER SETTINGS page
2 Access to the REWINDER page
3 Access to the PRE-UNWINDER page
4 Access to SETUP page
LABELLING MACHINE

5 Allows access to the previous menu page.

1 2

3 4

CHAP. 7 Pag.30
Adhesive Station

POS. NAME DESCRIPTION

1 FEEDER Roller that pulls the coil label
2 PRE-UNWINDER Unwinding system of the label coil
3 REWINDER Rewinding system
4 TEST Button to dispense a Test label

4.1.3. Adhesive Unit Start-up

Note: To install the label coil refer to the adhesive unit manual attached

PressReset on the machine to initialize the labelling machine.

Compressed air in the adhesive unit is enabled.

Press START

LABELLING MACHINE

The adhesive unit performs the initial setup (AUTOTEST).

Press the Test button to dispense some labels.

EC Regulation use and maintenance manual Pag.31CHAP. 7

 Adhesive Station Operator Panel

4.1.4. Recipe Parameters

On the home page press the RECIPES button.

POS. ELEMENT DESCRIPTION

By pressing the value of the label step,
it leads to a page where, by pressing
1 LABEL STEP the “AUTO” button, two labels are
dispensed from the adhesive unit to
automatically calculate the label step.

Defines how far the label protrudes

2 LABEL OFFSET
from the peeler.
Press “AUTO” for the motor to move
forward until the first front of the label
and then stops.
Press and hold the “AUTO” button until
the label reaches the correct “flag”.

Number of labels before the end of coil “Warning” is generated.

3 COIL END
The counter begins to count after the sensor detects the end of the coil.
Diameter of the bottle to label.
DIAMETER
4 It is used together with the carousel diameter to calculate the linear
BOTTLE
speed of the label tape.
MM used to accelerate. Typical value 10mm.
5 RAMP ON
Note: if too high the adhesive unit dispenses more labels.
MM used to decelerate. Typical value 10mm,
6 RAMP OFF
Note: if too high the adhesive unit dispenses more labels.
Offset in carousel encoder pulses, that
pass between the start of the adhesive
unit and the moment when the unit has
to dispense (Of).
Set a value over half the step, since the
LABELLING MACHINE

value of the fine adjustment “Ofine” is

7 START DELAY
then subtracted.
Pressing the value leads to the page
where pressing START allows a bottle
to enter.
Advance the label as far as the peeler
(half a step beyond the peeler), then
press STOP.

CHAP. 7 Pag.32
Adhesive Station

Typical value 1.
It determines the behaviour of the adhesive unit when there are no
labels on the coil.
8 START ALARM In fact in this case the adhesive unit gets more starts while it is still
dispensing because it has not seen the presence of the labels.
The parameter shows how many stats it can see before triggering and
alarm.
Typical value 0.
Not used.
9 STOP ALARM Number of stop impulses visible between 2 starts of the adhesive unit.
Only used when one wants to observe if the label tape is under tension.
For example the label is torn off the bottle.
Address of the other adhesive unit with which it works in “master” and
10 COMBINED STATION
“slave”.
RADIUS Threshold value beyond which an “unload rewinder coil” pre-alarm is
11
REWINDER generated.
Average speed used to correct dancer movement.
12 RW_MAX_SPEED
The higher the speed the more reactive the dancer is.
13 RECIPE Setting the recipe number
14 HOME Access to the main page
15 PAGE 1/2 - 2/2 Access to various pages

1
13
2
3

4 14

6 15
LABELLING MACHINE
7
13
8
9

10 14

11

12 15

EC Regulation use and maintenance manual Pag.33CHAP. 7

 Adhesive Station Operator Panel

4.1.4.1. Movement Recipe

Note: the movement recipe and the label recipe are disconnected from each other, therefore it is necessary to
manually change the recipe number.
POS. ELEMENT DESCRIPTION
1 RECIPE MA Recipe selection
2 HOME Access to the main page
2 PAGE 1-2-3 Access to various pages
13 SET POINT X,Y,Z (mm) Position value for the recipe selected.

1
13
3

Once selected the recipe accesses the page that allows modifications to the positioning values of the adhesive unit.

POS. ELEMENT DESCRIPTION

1 SET POINT Value of the set point of the axes
2 POSITION Value of the current position of the axes
EMERGENCY
3 It enables the axes to be brought into set point position
MOVEMENT
4 RECTANGLE???? WHAT DOES IT DO???????
5 EXIT It allows you to quit the page
LABELLING MACHINE

1 2

5 4

CHAP. 7 Pag.34
Adhesive Station

4.1.5. Setup Page

Press the SETUP button on the page OPERATOR MENU 2.

POS. ELEMENT DESCRIPTION

1 ITALIAN Operator panel display language selection.
2 EXIT RUN TIME It exits the system
3 EXIT Access to the previous menu.

2
1

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.35CHAP. 7

 Adhesive Station Operator Panel

4.1.6. Backup Page

Note: All the recipe and configuration data resides on the CR-driver-traino (driver address is “00”).
ITcreates a copy of this data on the ESA panel, in order to quickly restore the machine in the event of a fault
on the CR-drive-Traino.

Press the BACKUP button on the page OPERATOR MENU 1.

POS. ELEMENT DESCRIPTION

It copies the data from the “CR Driver” onto the HARD DISK
1 BACKUP HD
(HD) of the ESA Panel.
It moves the data (previously copied) from the ESA panel (HD)
2 RESTORE BACKUP HD
to the “CR Driver”
It copies the backup data onto the USB device inserted at the
3 HD -> USB
back of the ESA panel
It copies the data from the USB device inserted in the back of
the ESA panel onto the panel HD.
4 USB <- HD
To use the data uploaded press the button “RESTORE
BACKUP HD” to copy the data from the ESA to the CR Driver.

4
LABELLING MACHINE

CHAP. 7 Pag.36
Adhesive Station

4.1.7. Diagnosis Page

Press the DIAGNOSIS button on the page OPERATOR MENU 1.

POS. ELEMENT DESCRIPTION

1 START Green led when the start signal is 24V.
2 STOP Green led when the photocell is obscured.
3 ENABLE When it is at 0v the adhesive unit is enabled.
4 COIL END Coil End Sensor.
5 IN1 Start with the button.
6 IN2 Free.
7 EXIT Access to the previous menu.

1
2
7 3
4

5
6

Note: the sensor must issue a high exit when it observes the label.

Note: Datalogic sensors SR23 To invert the exit press the SET button for 7 seconds until the two LEDs flash
simultaneously.
When the sensor is activated, the orange light must be ON in line with the label.

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.37CHAP. 7

LABELLING MACHINE Adhesive Station Operator Panel

CHAP. 7 Pag.38
Adhesive Station

CHAPTER 5
Maintenance

LABELLING MACHINE

EC Regulation use and maintenance manual Pag.39CHAP. 9

LABELLING MACHINE Maintenance

CHAP. 9 Pag.40
Adhesive Station

5. MAINTENANCE

5.1. SAFETY PRECAUTIONS

CAUTION!
As a general rule, maintenance, lubrication and repair operations on the adhesive
station while running and/or live, are prohibited.

If the person who is carrying out maintenance operations is not near the electric power disconnection, or if
people not acquainted with maintenance operations can start a cycle without recognising the presence of
persons inside the protections, it is necessary to place hazard signs indicating “MACHINE MAINTENANCE IN
PROGRESS” and press the emergency button.

Maintenance operators must wear the personal protective equipment (gloves, goggles, overalls, etc.) necessary
to perform the procedure.

Key locks or padlocks on switches are installed to:

• avoid unexpected starting of the adhesive station during the operations;
• avoid unexpected movements of the components;
• eliminate the danger of electrical shock and electrocution;
• prevent the machine operator or unauthorised personnel from starting the machine during maintenance.

During maintenance operations, unauthorised staff must stay outside the working area; if it is foreseen to
remove the protection, isolate the area with barriers and place warnings signs prohibiting the access to any
person not working on the maintenance.

LABELLING MACHINE
Carry out the maintenance operations and before commissioning the adhesive station, it is necessary to:
• make sure that replaced parts and/or tools used to carry out maintenance operations have been removed
from the machine;
• carefully inspect the adhesive station before starting it and make sure that all the guards have been
properly installed and secured in their seat.

CAUTION!
Some fixed protections are not interlocked, therefore, the adhesive station may
operate even when the protections are not repositioned, thus, creating serious risk
conditions.
Before starting the machine and machining operations, all protection casing must
be installed as foreseen by the manufacturer.

Before restarting the adhesive station, make sure that there are no persons present in the danger area.

CAUTION!
Non-observance of these safety precautions may cause serious injury to persons,
the adhesive station, the product and the objects.

EC Regulation use and maintenance manual Pag.41CHAP. 9

 Maintenance

5.2. GENERAL MAINTENANCE INFORMATION

Maintenance of the adhesive station includes the operations that are necessary following normal use.
The operations involve mechanical and electrical parts.

For a good maintenance:

• Only use original spare parts, suitable tools for the purpose and in good condition.
• Respect the frequency of intervention indicated in the scheduled maintenance (preventive and periodical)
manual. The distance (indicated in time or in working cycles) between operations has to be understood as
the maximum acceptable, so it must not be exceeded; however, it can be shortened.
• A good preventive maintenance requires constant attention and continuous monitoring of the machine.
Check immediately the cause of any abnormalities such as excessive noise, overheating, fluid leakage,
etc and solve it.
• A timely removal of the any causes of anomaly or malfunctioning avoids further damaging the equipment
and guarantees operator safety.
• In case of doubt, it is forbidden to operate. Contact the manufacturer for necessary details.

For maintenance operations, always refer to the attached documents, such as:
• functional diagrams of equipment and machinery attached to the manual;
• schedule of the components with the data necessary to order spare parts;
• list of possible malfunctions and recommended solutions (see Alarms).

From an operational point of view, the adhesive station maintenance operations are divided into two
main categories:

ROUTINE All those operations that the operator must carry out proactively to ensure good
MAINTENANCE efficiency over time.

MAINTENANCE All the operations the operator must perform when the machine requires them
SUPPLEMENTARY (breakage, malfunction ...).
LABELLING MACHINE

5.3. ROUTINE MAINTENANCE

To ensure an efficient operation of the adhesive station, carry out periodical and preventive checks and
maintenance operations, following the tables and complying with the frequency indicated.
Failure to observe this warning exempt the manufacturer from liability from the effects of the warranty.

The regular scheduled maintenance includes inspections, controls and operations to prevent stops and
damages, by systematic controlling:
• the mechanical conditions and, particularly, service switches;
• the state of lubrication.

The frequencies indicated in the schedule refer to normal working conditions, i.e. those that are compliant with
the conditions for use provided for and set forth by the contract.

CHAP. 9 Pag.42
Adhesive Station

5.3.1. Checks

Start and end

ELEMENT INSPECTION

Quarterly
Monthly
Weekly
shift

Six
TRANSMISSION Check that there is no label or glue residue present
ROLLERS and that they turn freely
◘
Check that there is no label residue on the peeler
PEELER
blade.
◘

FIXED GUARDS Check the integrity of the guards on the feeder unit ◘

PHOTOCELLS Clean photocells with a dry or slightly damp cloth ◘

SHEET OF Check and lubricate as described on the appropriate
LUBRICATION lubrication card.
◘
◘ Frequency of intervention

5.3.2. Lubrication

Control from
TYPE
operator
POINT DESCRIPTION

TYPE*2
HOW*1
2000 h
1000 h
GREASE
panel

200 h
600 h
50 h

Adhesive station positioning

LUB 101 A x 1 1
screws

CHECK * 1 AND * 2 IN THE FOLLOWING TABLES

LABELLING MACHINE
*1 DESCRIPTION

1 Apply to the surface.

2 Use the specific grease fitting.

3 Replace the cartridge.

4 Remove and fill the gearbox. Reset the lubricant level.

*2 LUBRICANT

1 TRIBO STAR SYNTH 1 EP TYPE A GREASE

EC Regulation use and maintenance manual Pag.43CHAP. 9

 Maintenance

LUB 101

LUB 101

LUB 101

5.3.3. Cleaning

ROUTINE LUBRICATION
LABELLING MACHINE

Daily Weekly Monthly Quarterly Yearly

OPERATION SCHEDULE

OPERATOR PANEL ◘
PHOTOCELLS CLEANING ◘

Find below the cleaning modes of different components.

CAUTION!
Cleaning must be carried out with plant switched off.
Emergency button pressed and main switch "0/1" at "0".

5.3.3.1. Operator panel

The operator panel must be cleaned:

• using a damp cloth to eliminate dust and dirt.
5.3.3.2. Photocells

The photocells must be cleaned:

• using a microfiber cloth and compressed air.

CHAP. 9 Pag.44
Adhesive Station

5.4. SAFETY DEVICES CHECK

ROUTINE LUBRICATION 50 100 300 600 800 1000 1500

OPERATION SCHEDULE hours hours hours hours hours Hours Hours

GUARDS STABILITY FEEDER ROLLER ◘

◘ Frequency of intervention

5.5. SPECIAL MAINTENANCE

CAUTION!
Extraordinary maintenance and repair operations must be dealt with exclusively by
qualified, skilled and authorised technicians, hired by the manufacturer or by the
authorised service centre.
These procedures require a thorough and specialist knowledge of equipment,
necessary operations, related risks and correct procedures to work safely.

Operations, not included in the “routine maintenance” list, are considered extraordinary maintenance operations.
Should any exceptional circumstance occur, for which extraordinary maintenance is necessary, maintenance
operators shall follow this procedure:
• check damaged or out-of-phase components;
• if the operations to be executed are not provided for in this manual, send the manufacturer a report of the
event occurred, along with the outcome of the inspection and any comments;
• send the report of the event occurred, along with the outcome of the inspection and any possible comments
to the address shown on the form.

The manufacturer or the authorised service centre will consider, case by case, the situation.
Therefore, they will decide, together with ordinary maintenance operators, the type of intervention to be

LABELLING MACHINE
performed choosing the most appropriate solution among those listed below:
• the manufacturer sends a skilled technician who is trained and authorised to perform the necessary
operations;
• or the manufacturer authorises the user's routine maintenance engineers to perform the procedures,
sending any supplementary instructions.

CAUTION!
Please contact Z-ITALIA S.r.l. to order spare parts.
If the customer does not use original spare parts or pieces authorised in writing by
the manufacturer, the latter shall not be responsible for the machine operation and the
operators’ safety.
Authorisation and/or instructions must always be given in writing. It is forbidden to
operate the machine without written permission and the manufacturer disclaims all
responsibility.

EC Regulation use and maintenance manual Pag.45CHAP. 9

 Maintenance

5.6. RECOMMENDED CONSUMER PRODUCTS

TYPE DESCRIPTION
PRODUCT FOR CLEAN- Slightly soapy tepid water
ING PAINTED PARTS

STEEL CLEANING Non-aggressive products for cleaning steel

PRODUCT
LABELLING MACHINE

CHAP. 9 Pag.46