Rewinder STD Extra5 GB01

OPERATING PROCEDURES AND ADJUSTMENTS
EXTRA 5 REWINDER
DO NOT CARRY OUT ADJUSTMENTS

It is forbidden to carry out adjustment interventions on the machine: these could reduce the safety of the
machine; it is especially forbidden to remove or modify the protections and/or the security and/or signaling
and/or control systems set up by the manufacturer.
Interventions on the program of the functioning logic of the machine (even if carried out by qualified
personnel) are also forbidden; in fact, carrying out said interventions could also result in serious
consequences for the safety of the operators.
Please note that the third-party and criminal liability of the manufacturer is forfeited with relation to the parts
of the machine that might be subject to alteration by the purchaser without the manufacturer’s authorization.
FABIO PERINI S.p.A. PROPERTY, EXTRA 5 REWINDER

UNAUTHORIZED REPRODUCTION, DISCLOSURE OR USE FORBIDDEN Copyright Fabio Perini S.p.A.
CONTENTS
DESCRIPTION .................................................................................................................... 4
EXTRA 5 REWINDER ......................................................................................................... 5
TECHNICAL CHARACTERISTICS ...................................................................................... 7
SPECIAL CHARACTERISTICS ........................................................................................... 8
PRODUCT CHARACTERISTICS ........................................................................................ 8
OPERATING PROCEDURES ............................................................................................. 9
WEB THREADING ......................................................................................................... 10
FILLING THE MACHINE WITH NEW CORES ............................................................... 14
CORE INTRODUCTION INTO THE MACHINE ............................................................. 16
PROCEDURE FOR ALIGNMENT OF THE WEB WITH THE CORE ................................. 18
PROCEDURE FOR AUTOMATIC ALIGNMENT OF THE WEB WITH THE CORE ....... 18
PROCEDURE FOR MANUAL ALIGNMENT OF THE WEB WITH THE CORE ............. 19
GLUEING UNIT ................................................................................................................. 21
GLUE LOADING/UNLOADING PROCEDURE .............................................................. 22
REFILLING THE GLUE TANK ....................................................................................... 23
STARTING PROCEDURES .............................................................................................. 25
REMOVING CORES FROM THE CORE FEEDING GUIDES........................................ 26
REMOVING CORES AND THE LOG WITHOUT DIATROL ........................................... 28
REMOVING CORES AND THE LOG WITH DIATROL .................................................. 29
MACHINE START .......................................................................................................... 30
RESET AFTER BREAKS DURING WORK .................................................................... 34
EMERGENCY RESET ................................................................................................... 34
CYCLE RESET .............................................................................................................. 34
OPERATING ADJUSTMENTS .......................................................................................... 35
PROCESSING OPTIMISATION ........................................................................................ 36
ADJUSTMENTS NEEDED FOR CORRECT WINDING ................................................. 36
ADJUSTMENT EMBOSSING PRESSURE ....................................................................... 40
PLY-BONDING PRESSURE ADJUSTMENT ................................................................. 41
REWINDER SPEED ADJUSTMENT ................................................................................. 42
LOWER WINDING ROLL DECELERATION ADJUSTMENT............................................. 43
SYNCHRONICITY ADJUSTMENT BETWEEN RIDER ROLL AND LOWER WINDING
ROLL ................................................................................................................................. 44
RIDER ROLL PRESSURE ADJUSTMENT........................................................................ 45
RIDER ROLL BACK PRESSURE ADJUSTMENT ............................................................. 46
LOG DIAMETER ADJUSTMENT WITHOUT DIATROL..................................................... 47
LOG DIAMETER ADJUSTMENT WITH DIATROL ............................................................ 48
WIDTH ADJUSTMENT OF THE GLUE LINE ON THE LOG TAIL..................................... 49
TAIL LENGTH ADJUSTMENT ........................................................................................... 50
PROPRIETÀ DELLA FABIO PERINI S.p.A.,
1 EXTRA 5 REWINDER
VIETATA LA RIPRODUZIONE, LA DIVULGAZIONE E L'USO NON AUTORIZZATI Copyright Fabio Perini S.p.A.
PAPER TENSION ADJUSTMENT ON THE EMBOSSER.............................................. 51
WEB TENSION CONTROL IN THE WINDING AREA ....................................................... 52
CHANGING THE PRODUCT WITH ONE NOT STORED IN THE MEMORY .................... 53
MECHANICAL ADJUSTMENTS ........................................................................................ 54
EMBOSSER UNIT ADJUSTMENTS .................................................................................. 55
EMBOSSING DEPTH ADJUSTMENT............................................................................ 55
DRIVE BELT TENSION ADJUSTMENT......................................................................... 56
PULLING BELT SUBSTITUTION IN VARIATORS WITH CONE PULLEYS .................. 57
RUBBER EMBOSSING ROLL REPLACEMENT ............................................................ 58
NIP ROLL ADJUSTMENT ................................................................................................. 62
PLY-BONDING UNIT ......................................................................................................... 63
AXIAL POSITION ADJUSTMENT OF THE PLY-BONDING WHEELS .......................... 64
PLY-BONDING PRESSURE ADJUSTMENT ................................................................. 65
AXIAL ADJUSTMENT OF THE PLY-BONDING ANVIL ROLL ....................................... 66
ADJUSTMENT OF THE SAFETY VALVES AT THE INFEED OF THE AIR HOSE ....... 67
PLY-BONDING WHEEL AND ANVIL ROLL LUBRICATION .......................................... 68
PLY-BONDING WHEEL INTERNAL RING REPLACEMENT ......................................... 69
PERFORATION UNIT ADJUSTMENTS ............................................................................ 70
PERFORATION UNIT ADJUSTMENTS ............................................................................ 71
PERFORATION LENGTH ADJUSTMENT WITH PREDEFINED RANGE......................... 71
NUMBER OF SHEETS ADJUSTMENT ............................................................................. 72
BLADE INTERFERENCE ADJUSTMENT ...................................................................... 74
ADJUSTMENT AND CALIBRATION OF THE PERFORATION ZERO SENSOR .......... 76
BLADE SUBSTITUTION ................................................................................................ 77
BLADE SUBSTITUTION ON THE FIXED ROLL ............................................................ 78
BLADE SUBSTITUTION ON THE ROTATING ROLL .................................................... 80
CHANGING PERFORATION LENGTH .......................................................................... 84
CHANGING PERFORATION LENGTH .......................................................................... 85
PERFORATOR UNIT INCLINATION ADJUSTMENT..................................................... 87
CORE FEED SYSTEM ADJUSTMENTS ........................................................................... 88
ADJUSTMENT OF THE CORE GUIDES ON THE CORE CONTAINING CHANNEL .... 88
ADJUSTMENT OF THE STOP GUIDES OF THE CORE CHANNEL ............................ 90
ADJUSTMENT OF THE CORE INTRODUCTION CHANNEL GUIDES ......................... 92
POSITION ADJUSTMENT OF THE CORE ELEVATOR DEVICE ................................. 93
CORE GLUING STATION ................................................................................................. 95
CORE GLUING .............................................................................................................. 95
POSITION ADJUSTMENT OF THE CORE GLUING UNIT ............................................ 96
GLUEING BLADE CLEANING ....................................................................................... 98
GLUE TANK CLEANING ................................................................................................ 99
INFEED UNIT ADJUSTMENTS ....................................................................................... 100
2 EXTRA 5 REWINDER
POSITION ADJUSTMENT OF THE BLADES SUPPORTING THE WAITING CORE .. 100
CORE ALIGNMENT BEFORE WINDING..................................................................... 101
ADJUSTMENT OF THE CYLINDER THAT BLOCKS THE CORES DURING GLUING
..................................................................................................................................... 102
ADJUSTMENT OF THE CORE INFEED UNIT ............................................................ 103
CORE INFEED PHASE ADJUSTMENT ....................................................................... 104
REMOVAL AND ADJUSTMENT OF THE ARMS OF THE INTRODUCING GRIPPERS
..................................................................................................................................... 105
ALIGNMENT OF THE INTRODUCING GRIPPERS ..................................................... 106
MAINTENANCE OF THE CORE INFEED UNIT GEARBOX ........................................ 107
ADJUSTMENT AND CALIBRATION OF INFEED ZERO SENSOR ............................. 108
SUBSTITUTION AND ADJUSTMENT OF THE CORE CRADLES .............................. 109
ADJUSTMENTS TO THE RIDER ROLL .......................................................................... 110
RIDER ROLL CHECK AND CALIBRATION ................................................................. 111
RIDER ROLL DIATROL ENCODER ADJUSTMENT.................................................... 116
RIDER ROLL COATING SUBSTITUTION ................................................................... 118
PROGRAMMING THE CONNECTING POINT WITH DIATROL .................................. 119
MAINTENANCE OF THE LOWER WINDING ROLL GEARBOX..................................... 120
POSITIONING THE LOWER WINDING ROLL IN RELATION TO THE UPPER
WINDING ROLL ........................................................................................................... 121
NOTES ON THE LOWER WINDING ROLL ................................................................. 123
ROLL OUTFEED TABLE ADJUSTMENT ........................................................................ 125

3 EXTRA 5 REWINDER
DESCRIPTION

4 EXTRA 5 REWINDER
EXTRA 5 REWINDER
The rewinder EXTRA 5 is an electronically controlled automatic model for the continuous winding
of toilet paper rolls and kitchen paper rolls on cardboard cores with gluing of the final sheet in the
machine.
It works according to the Perini three pope roller drums winding principle and combines the
advantages of complete flexibility deriving from electronics with the positive web interruption
system at the end of the winding through the concurrent insertion of the glued core and the
acceleration of the winding press.
It is possible to produce rolls with external diameters that vary from 90 mm / 3,543 inch to 140 mm
/ 5,511 inch, wound on cores with a diameter between 38 mm / 1,496 inch and 50 mm / 1,969 inch,
up to a maximum speed of 350 m/minute equal to 15 logs/minute.
The aforesaid exchange system allows strapping the web in correspondence to the selected
perforation, whatever it is, regardless of the angular position of the upper pope roller drum without
generating slackening in the web upstream from the winding zone.
The machine consists of the following main parts:
 Draw roll unit; its purpose is to drag the paper and adjust the tension according to the winding
requirements. A roll coated with a rough surface rubber tape is controlled by two pneumatic
cylinders that bring it close to another roll mounted in fixed position on the sides. The paper web
goes through the two rolls and is dragged to the next work stations.
 Perforation group; its purpose is to make on the moving web equidistant perforation lines
perpendicular to the paper feed shaft. It consists of two rolls, one fixed and equipped with a
toothed blade and the other turning and carrying one to four smooth blades opposite the fixed
roll blade. This group is characterized by the fact of being mounted on one side directly on the
machine bearing structure and on the other side on a plate that moves vertically to adjust its
inclination and keep the lines perforation perpendicular to the paper feed shaft. This group must
always be present on the machine, even for the production of non-perforated paper rolls only,
because at least one perforation line is necessary to obtain the breaking of the web at the end of
the winding; in this case the perforation group is made active for one perforation per roll only. By

5 EXTRA 5 REWINDER
adjusting the inclination of the turning perforation roll and interchanging the driving pulley it is
possible to vary the perforation length.
 Core gluing group; it is formed by a blade that, activated by a pneumatic cylinder, plunges in a
tank of glue and then comes out of it, applying at the core passage the right quantity of glue.
 Core introduction group; it consists of a set of guides that form an almost vertical track, where
the cores coming from an external collection container rest. Once they have reached the winding
zone, the cores enter between the pope roller drums at the right time by means of an
introduction mechanism.
 Control group; the motion of all components is performed by a DC main motor placed on the
left side of the machine, by means of a belt transmission and a set of servomotors. All
servomotors are equipped with encoders that send data to a central control unit, which
processes them and ensures the perfect operation of the machine.
 Winding roll group; its function is to wind the paper on the core. It consists of three rolls coated
with abrasive fabric and moving independently. The upper pope roller drum drags the paper,
while the lower pope roller drum concurs to the log making and support, and controls its position
from the start to the end of the winding; the independent electronic control system adjusts the
lower pope roller drum speed at every instant according to a model that can be preset and
adjusted and allows having the maximum control of the tension of the web being wound and of
the instantaneous position of the roll being formed; the third roll, called “nip roll”, has the double
function to control the growing of the log keeping it in the desired position by exercising on it the
necessary pressure, and to cause at the end of each winding the breaking of the web in
correspondence to the desired perforation line. It consists of a motor-driven roll supported by two
swinging arms with automatic angular control; at the end of each winding, the press roll,
supported by a servomotor, increases its speed to a preset value until the web breaks on the
perforation line.
 Core gluing and log sealing group; the glue is applied to the core by a pneumatic controlled
blade and allows both sealing the final sheet and paper grab at the start of the winding.
 Outfeed roll stopping group; it carries out three functions, simple but important to the
appearance of the finished roll: it receives the log exiting the winding, stops its movement
without damaging its surface and lets it slowly roll to the next stage. It is formed by a metal
component coated with soft material in the portion that is in contact with the log; it is also pivoted
and activated by a pneumatic cylinder that controls its lowering and lifting at specific times.

6 EXTRA 5 REWINDER
TECHNICAL CHARACTERISTICS

7 EXTRA 5 REWINDER
SPECIAL CHARACTERISTICS
Description Values
Operating type: peripheral winding
Material detachment: by means rider roll acceleration
Winding start-up: with line glue
Lower roll winding speed: manual adjustable
Glue feeding: with manually air pump
Spreading shaft: stationary
Core hopper: type EXTRA
Core feeding speed: max. 30 cores per minute
Diatrol: counterpressure with diameter control
Perforation adjustment: manually
Core gluing and tail: with removable blade
Stationary perforator: with1 toothed blade
Rotating perforator: with 4 smooth blades
Draw roll: coated in rough tape
Winding roll: coated in abrasive canvas
Deceleration control: Brushless servomotor
Core infeed control: Brushless servomotor
Rider roll acceleration control: Brushless servomotor
PRODUCT CHARACTERISTICS
Description Values
Tail length: adjustable with tolerance +/-10 mm / +/-0,394 inch on
log length
Winding length: minimum 9500 mm / 374,015 inch
Perforation length: predeterminated +/- 1%; with 4 blades from 110 mm /
4,331 inch to 140 mm / 5,511 inch; with 2 blades from
220 mm / 8,661 inch to 280 mm / 11,023 inch; with 1
blade from 440 mm / 17,323 inch to 560 mm / 22,047
inch; adjustment through flat pulley substitution
Number of sheets: one after the other without limits, up to reaching
maximum diameter
Core inside diameter min.: 38 mm / 1,496 inch
Core outside diameter max.: 50 mm / 1,969 inch
Required cores: weight 400 g/m2 with 2 strips; 300 g/m2 with 1 strip
Log diameter min.: 90 mm / 3,543 inch
Log diameter max:: 140 mm / 5,511 inch

8 EXTRA 5 REWINDER
OPERATING PROCEDURES

9 EXTRA 5 REWINDER
WEB THREADING
Follow the directions given in “SAFETY AND ACCIDENT PREVENTION” section. Follow
the safety procedures of the manufacturing company.
Machine status Procedure to enter the guard doors with the machine at a standstill
Authorized personnel Machine operator
Number of operators 1
Residual risks
PPE
ATTENTION! Do not touch the belts during jog run, drawing-in/trapping hazard!
EXTRA-5 Rewinder
Web threading
with Embosser
 Open all auxiliary units that may be on by the relative selector.

 Enter inside the machine enclosure following the steps necessary to work in conditions of
adequate safety;

10 EXTRA 5 REWINDER
1 Automatic web 3 Jog selector 4 Jog mode
threading belt switch push-button
2 Slits
 Press the JOG mode push-button until one of the slits on the automatic web threading belt
comes forward, paying attention not to touch any moving organs;
 Trim the reel and twist the web into a spiral, preparing a strong head;
 Introduce the head of the web thus prepared into the nearest slit on the automatic web
threading belt and lock the pulley on the paper guide roll by means of the clutch part placed
inside the machine under the perforation unit operator side;
 Press the JOG mode push-button, complete the first web threading cycle on the Rewinder unit.

11 EXTRA 5 REWINDER
WHERE AN EMBOSSER UNIT IS PRESENT, it is necessary to thread the web manually
proceeding as follows:
 Attach the paper web, completely stretched over the entire surface of the steel embossing roll,
with adhesive tape.
 Press the JOG mode push-button, turn the roll until the web is threaded up to area B;
 Now detach the web from the steel roll;
 Introduce the head of the web thus prepared into the nearest slit on the automatic web
threading belt and lock the pulley on the paper guide roll by means of the clutch part placed
inside the machine under the perforation unit operator side, then complete the passage;
 Raise the rider roll acting on the relevant lever provided on the operator side (if you are working
in backpressure mode), or on the relative template present in the Operator Panel (if the Diatrol
device is installed);
1 Steel embossing roll

2 Rider roll
3 Lever
4 Automatic web
threading belt
5 Slits

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 Press the JOG mode push-button until the web reaches the position of detachment in the log
exit area;
 Remove the web from the slit, unlock the pulley on the paper guide by means of the clutch part,
placed inside the machine under the perforation unit operator side, and run press the JOG mode
push-button until the web is completely stretched on the log exit table;
 Place one core manually on the lower and upper winding rolls under the web;
 Lower the rider roll acting on the relevant lever;
 Resume the normal run of the machine turning on again the necessary auxiliary units previously
disabled (opened).
1 Upper winding roll 4 Log outfeed zone

2 Lower winding roll 5 Core
3 Rider roll
Jog selector Jog mode

switch push-button

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FILLING THE MACHINE WITH NEW CORES
Residual risks
PPE
1 Conveyor belt
2 Core feed channel
3 Loading channel
4 Glue application point
Before starting normal processing, it is necessary to check the presence and level of cores on the
core feed channel.
The new cores, coming from the core elevator (outside the machine), are conveyed by a conveyor
belt up to the core feed channel and then through a loading channel up to the glue application
point.
In the case in which it becomes necessary to transport a certain number of cores from the core
elevator up to the feeding area, press CORE CALL in the Operator Panel in order to obtain
complete refilling.

14 EXTRA 5 REWINDER
1 Conveyor belt 5 Photocell 1
2 Gluing and infeed area 6 Photocell 2
3 Elevator device
4 Core feed channel
The level of cores in the core feed channel of the rewinder is controlled by a photocell 2 that,
once energized by the core, causes the core conveyor belt to stop.
On the core feed channel there is also installed a photocell 1 which, if energized, enables
operation of the elevator device with consequent loading of the core into the gluing and infeed
area.

15 EXTRA 5 REWINDER
CORE INTRODUCTION INTO THE MACHINE
Residual risks
PPE
1 Loading channel
2 Elevator device
3 Glue zone
4 Axial positioning cylinder
5 Introducing grippers
The cores, after passing through the core feed channel, position themselves in the waiting zone,
transiting through the guides of the loading channel.
The cylinder for axial positioning of the core (maintenance side) aligns the first one of the
loaded cores with the position of the paper by means of the limit stop.
The elevator device makes the first positioned core run in the gluing zone and stop in contact with
the introducing grippers. At this point, a relevant sensor detects the core presence and
commands the blade of the core gluing unit to rise.

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1 Pneumatic cylinder 4 Tank
2 Winding area
3 Introducing gripper
A series of pneumatic cylinders keeps the core in stable position at the moment of glue
application.
Core gluing is controlled by a system composed of a pan which contains a blade, actuated by a
pneumatic cylinder, which makes it rise at the moment of glue application and then go down
again.
Once terminating glue application, after a definite time set on the program, the introducing
grippers are activated to insert the core into the winding area.

17 EXTRA 5 REWINDER
PROCEDURE FOR ALIGNMENT OF THE WEB WITH THE CORE
PROCEDURE FOR AUTOMATIC ALIGNMENT OF THE WEB WITH THE CORE
Residual risks
PPE
1 Motor
Procedure from Operator Panel:

 Select the page relative to the Unwinder;
 Press the RH SIDE AXIAL ADJUSTMENT or LH SIDE AXIAL ADJUSTMENT template;
 Carry out the alignment of the reel, in the direction required, then check and adjust the tension of
the paper.
The movement of the two webs takes place by means of the relevant control motor.
In every case, it is necessary to verify the movement between the web or the webs aligned and the
fixed end of the core.

18 EXTRA 5 REWINDER
PROCEDURE FOR MANUAL ALIGNMENT OF THE WEB WITH THE CORE
Residual risks
PPE
1 Motor 2 Push-button for web

alignment on the Unwinder
In the Operator Panel press the relevant push-button in order to shift the ends of the two webs by
approximately 2 mm / 0,079 inch outside the fixed end of the core.
The movement of the two webs takes place by means of the relevant drive motor.

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1 Core
2 Web 1
3 Web 2
In every case it is necessary to verify the movement S between the web or the webs aligned and
the fixed end of the core.

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GLUEING UNIT
Personnel in charge 1
Residual risks
PPE
1 Delivery pipe
2 Suction tube
3 Flow regulator
4 Valve
5 Pressure regulator
IMPORTANT! Before proceeding to load/unload the glue, carefully read the instructions and
recommendations on the commercial glue drums!
PRECAUTIONS TO BE TAKEN WHEN USING GLUES

 Wear gloves when handling glue.
 Wear protection goggles during refilling/topping up operations. Avoid direct contact with
eyes and mucous membranes.
 Change contaminated clothes.

21 EXTRA 5 REWINDER
GLUE LOADING/UNLOADING PROCEDURE
Residual risks
PPE
1 Delivery valve
2 By-pass valve
IMPORTANT! Before proceeding to refill/empty the glue tank, carefully read information and
recommendations on the commercial bins!
PRECAUTIONS IN THE USE OF GLUES

Use gloves when handling.
Use protective goggles to refill. Avoid direct contact with eyes and mucous membranes.
Change contaminated clothes.
For substituting the glue bin to proceed as follows:

 Remove the glue delivery hose.
 Substitute the empty vessel with a new, full one.
 Reinsert the glue suction and delivery hoses.

22 EXTRA 5 REWINDER
REFILLING THE GLUE TANK
Residual risks
PPE
1 Delivery hose
2 Lever
3 Scoop hose
4 Pneumatic pump
Glue tank refilling is obtained by means of a pump (manual or semi-automatic).

To refill the glue tank through the manual pump it is necessary to:
 Close the tap used for draining glue from the tank.
 Act the lever to actuate the pneumatic pump which scoops the glue from the external tank
through the scoop hose.
 When the glue has reached the pump, it is transferred into the glue tank through the delivery
hose.
 Continue until the glue tank contains sufficient glue for gluing the core.

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1 Delivery hose
2 Pump
3 Scoop hose
4 Selector switch
To refill the glue tank through the semi-automatic pump, it is necessary to:
 Close the tap used for draining glue from the tank.
 Rotate the specific selector switch to actuate the pump which scoops the glue from the external
tank through the scoop hose.
 When the glue has reached the pump, it is transferred into the glue tank through the delivery
hose.
 When the glue tank contains sufficient glue for gluing the core, act again on the selector switch
to stop the operation of the pump.

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STARTING PROCEDURES

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REMOVING CORES FROM THE CORE FEEDING GUIDES
Residual risks
PPE
1 Conveyor belt
2 Core feed channel
In the case in which there are defective cores in the core feed channel, remove them as follows:
 Verify that the core conveyor belt is at a standstill, then stop the machine and enter inside the
enclosure.

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1 Inspection door
2 Locking handle
 Turn the locking handle to free the inspection door of the core feed channel.
 Turn the door to open position.
 Carry out the operations desired and restore normal operating conditions.

27 EXTRA 5 REWINDER
REMOVING CORES AND THE LOG WITHOUT DIATROL
Residual risks
PPE
1 Rider roll 3 Pneumatic lever

2 Opening
WINDING AREA
Stop the machine in FAST STOP mode and enter inside the enclosure.
Act on the pneumatic lever provided on the machine operator side: the rider roll will rise to a
preset position.
Remove the log manually from the winding area acting from the rear of the Rewinder and then
stretch the web uniformly on the surface of the rolls.
Remove the cores one by one, manually, through the opening in the frame side of the Rewinder,
operator side, or from the exit side of the Rewinder.
Lower the rider roll, always using the relevant pneumatic lever on the operator side.
Verify that there are not more than one core waiting to be introduced.
WARNING! Now the machine is ready for executing the first transfer at slow speed, after
which it will be possible to operate normally.

28 EXTRA 5 REWINDER
REMOVING CORES AND THE LOG WITH DIATROL
Residual risks
PPE
1 Opening
2 Rider roll
3 Winding area
Stop the machine in FAST STOP mode and enter inside the enclosure.
Act on the relative control present on the Operator Panel, operator side: the rider roll will rise to a
preset position.
Remove the log manually from the winding area acting from the rear of the Rewinder and then,
stretch the web uniformly on the surface of the rolls.
Remove the cores one by one, manually, through the opening in the frame side of the Rewinder,
operator side, or from the exit side of the Rewinder.
Lower the rider roll always using the relevant selector switch on the operator side.
Verify that there are not more than one Core waiting to be introduced.
WARNING! Now the machine is ready for executing the first transfer at slow speed, after
which it will be possible to operate normally.

29 EXTRA 5 REWINDER
MACHINE START
Residual risks
PPE
1 Compressed air supply 2 Operator Panel 3 Main switch
The Rewinder starting procedures are the following:

 Turn on the main switch which commands the entire Rewinder Section by positioning it to on 1-
ON;
 Turn on the compressed air supply at a maximum of 6 bar / 87,023 psi;
 Turn on the auxiliary circuits acting on the relevant key-operated selector switch (where
provided);
 Automatically the Operator Panel comes on and prepares to make the machine ready for run,
by showing the home page;
 On the display there appear a series of instructions.

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1 Rider roll 3 Log RESET
2 Opening 4 Winding area push-button
 Before running the zero cycle, make sure that there is neither a log in the winding area nor a
core ready for introduction
 To remove the log from the winding area, act on the relevant lever on the machine operator
side; in this way, the rider roll will rise to a preset position in order to allow checking for and, if
necessary, removing logs;
 Open the appropriate door to remove cores manually through the opening on the operator side
of the Rewinder, or on the front of the Rewinder. In this way also cores with dry glue are
removed;
 Press the RESET push-button in the Operator Panel. This will reset all emergency circuits
tripped.
 The programme carries out a series of automatic operations to reset the servo-assisted axes to
their reference zero positions.
 During these operations, the display will show RESET CYCLE RUNNING; if the display area is
clear, it means that the above mentioned procedure has been carried out successfully and the
machine run may be resumed normally.

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1 Rider roll 3 Gluing unit RESET
2 Ply-bonding push-button
wheels
PRODUCT
OUTFEED SIDE
CHECK PRODUCT!
 Automatically the programme keeps in memory the last product run before the machine stop, so
at every power-on the programme will resume those values;
 Press the RESET push-button on the Operator Panel to reset all emergency circuits tripped;
 Press the RESET AXIS CONTROL push-button on the Operator Panel;
 Check that the rider roll is regularly in low position; if not, lower the rider roll acting on the
relevant lever on the machine, present on the operator side;
 Carry out the operations relative to the check of embossing depth to its adjustment (where
provided);
 Activate the Embossing unit required for normal processing (where provided), by the relevant
pneumatic control;
 Activate the ply-bonding wheel unit required for normal processing, by the relevant pneumatic
control;
 Check for correct operation of the glue pump on the gluing unit.

32 EXTRA 5 REWINDER
1 Nip roll 3 Start push-button Production
2 Revolving 4 Acoustic signal speed control
perforator roll
PRODUCT
OUTFEED SIDE
 Pressing the start push-button of the Rewinder Section for a first time, a specific acoustic
signal, lasting approximately 3 seconds, warns that the machine is ready to start normally. After
which, pressing the start push-button a second time within 6 seconds, comes on the warning
light of the push-button and the machine run is enabled at low speed, until the required speed is
reached.
 When the machine has started, activate the perforation unit by means of the relevant selector
switch;
 Activate the web threading protections in the Operator Panel; if these protections are not turned
on, the machine cannot exceed a certain safety speed threshold;
 Check that the rider roll touches the first log;
 Check the first log produced;
 Rotate the selector for speed adjustment until the desired production speed is set, verifiable in
the Operator Panel;
 Verify and check the normal operation of the machine and the product in course of processing.

33 EXTRA 5 REWINDER
RESET AFTER BREAKS DURING WORK
Follow the directions given in “SAFETY AND ACCIDENT PREVENTION” section.
Follow the safety procedures of the manufacturing company.
 Clean the machine after a web break, avoiding the use of very sharp metal knives to remove the
broken part of web.
 Press one of the Emergency Circuit Reset push-buttons.
 After clearing the jam, thread the web again through the machine and check all systems,
especially those involved in the transfer and winding phase.
 Reset protective circuits.
 Restart the machine normally.
EMERGENCY RESET
Follow these steps to reset the machine after an emergency stop or situation has occurred:
 eliminate the cause
 reset the protection circuits by pressing the RESET push-button,
 reset the machine cycle by the relevant push-button,
 when the whole system has been cleared, the machine is ready to start again.
CYCLE RESET
When it is necessary to restart the machine:

ZERO CYCLE OBLIGATION : The Axis Control executes a series of automatic operations to reset
all servo-controlled axes to their “zero" or starting position.
Make sure there are no logs in the winding area, otherwise remove them.
The system controls these sequences in order:

During automatic operations, a few messages will appear on the Operator Panel: ZERO CYCLE
OPERATIONAL and CYCLE RESET IN PROGRESS; when the display area is clear, this means
that the above-mentioned operations were carried out correctly and the machine may resume its
normal operating cycle.
Avoid pushing buttons throughout the above phases.

34 EXTRA 5 REWINDER
OPERATING ADJUSTMENTS

35 EXTRA 5 REWINDER
PROCESSING OPTIMISATION
ADJUSTMENTS NEEDED FOR CORRECT WINDING
Perfectly wound roll (log)
Before starting to produce logs, verify that all adjustments reported below have been correctly
carried out:
 Roll deceleration adjustment.
 Rider roll acceleration adjustment
 Core gluing adjustment.
At this point, it is possible to start producing logs in order to verify that they are wound in perfectly
uniform way as, based on the product wound, the following defects may appear and be more easily
noticed on soft products:
A. tight ring around the core for the first 1,5-2 mm / 0,059-0,079 inch of winding (radial).
B. 5-6 mm / 0,197-0,236 inch thick zone (radial) with slack winding.
C. Compact and uniform zone up to completion of the roll.

36 EXTRA 5 REWINDER
1 Detail 1
2 Detail 2
3 Detail 3
4 Detail 4
If we are producing rolls at a high speed up to the limit allowed by the machine, it is advisable to
reduce the speed, and to check for correct passage of the core between the winding rolls during
the building process, and for correct subsequent contact with the rider roll (sunk to its minimum
position).
a) If the beginning of winding shows a 1 mm / 0,039 inch or 2 mm / 0,079 inch thick zone of paper
wound tight around the Core (normal conditions), it is assumed that the log is being controlled
correctly in its initial winding phase (passage between upper and lower winding roll), therefore at
the moment it is not necessary to change the position of the cam which regulates deceleration.
a1) Verify that there is correct contact between the building roll and the rider roll (sunk to the
minimum position).
The correct position is the following:

The roll just exiting the winding rolls contacts the rider roll which, sunk to its minimum position,
starts rising followed by the roll itself.
If the minimum position of the rider roll is too high, the two surfaces, that is, the one of the rider roll
and the one of the new winding log, do not touch each other, thus the initial buildup of the log is
incontrolled.
Incontrolled initial buildup of the log leads to bulkier buildup than expected. For this reason, the
product will show a bulkier and loosely wound initial area.
If the above takes place, we have to change the minimum position of the rider roll as indicated in
section ADJUSTMENT OF THE RIDER ROLL MINIMUM POSITION.
In order to adjust the minimum position and, consequently restore the right contact between log
and rider roll, it is advisable to change the position of the latter, in small steps, checking every time
the improvement of the product until fully satisfactory.

37 EXTRA 5 REWINDER
b) Another problem can be the following:
winding shows an initial tightly wound area which then tends to slacken, with difficulty to reach the
required log diameter.
The above mentioned winding appears after the product change and is illustrated in detail no.4,
where two different zones are noticed:
A) one compact zone with a thickness of approximately 20-25 mm / 0,787-0,984 inch.
B) one loosely wound zone with difficulty to reach the desired diameter.
This because the rider roll is rising too slowly in relation to the diameter increase of the log.
(The rise of the rider roll commanded by a mechanical cam does not faithfully observe the real
buildup of the logs. Therefore a higher pressure is developed between rider roll and log which
leads to a more tightly wound area at the beginning of winding, for the first 20-25 mm / 0,787-0,984
inch, and to a very slackly wound area at the end of winding).
The defects mentioned above usually appear after a product change.
In this case, put the machine to low speed to realize how the contact between the roll and rider roll
takes place.
Change the minimum position of the rider roll by raising it in small steps and making trials, until the
product appears optimized.
Please note that, for good winding quality of the logs, it is necessary that all important parts be in
good condition, such as:
1) abrasive tapes on winding rolls.
2) Coating of the rider roll.
3) Core introduction.
3a) Contact position of the core with the winding rolls.
4) Glue distribution on the Core.
4a) Glue doctor blade.
4b) Correct and systematic cleaning of the glue tank (every 4-5 weeks).
5) All articulations and leverages of the rider roll.
Generally with these preventive checks it is possible to ensure that winding quality will be constant
in time.

38 EXTRA 5 REWINDER
POSSIBLE WINDING FAULTS
1 Detail 1
2 Detail 2
3 Detail 3
4 Detail 4
Detail 1: 10-15 mm / 0,394-0,591 inch thick slackly wound zone starting from the core,
Possible causes: Deceleration duration too long, see section ADJUSTMENTS.
Detail 2: Uniform zone - 5 mm / 0,197 inch thick loosely wound zone
Zona tight around the Core, the first 1-2 mm / 0,039-0,079 inch.
Possible causes: Deceleration duration too short, see section ADJUSTMENTS.
Detail 3: Paper tight around the Core for 1-2 mm / 0,039-0,079 inch (normal condition)
slack for approximately 5-6 mm / 0,197-0,236 inch.
Uniform zone
Possible causes: Rider roll minimum position too high, see section ADJUSTMENTS.
Detail 4: Compact zone 20-25 mm / 0,787-0,984 inch.
Slack zone with difficulty to reach the desired diameter
Possible causes: Rider roll minimum position too low, see section ADJUSTMENTS.

39 EXTRA 5 REWINDER
ADJUSTMENT EMBOSSING PRESSURE
Follow the directions in the “SAFETY AND ACCIDENT PREVENTION” section”.
2 Pneumatic valve
The Steel embossing roll is in a fixed position while the rubber embossing rolls can be moved close
to each other pneumatically by means of the appropriate cylinders, to allow paper threading and
adjustment of the embossing depth.
The pressure of the air supplied to the pneumatic cylinders of the embossing rolls is adjustable by
acting on the relevant pressure regulator, while movement of the embosser to working position is
commanded by the pneumatic valve.

40 EXTRA 5 REWINDER
PLY-BONDING PRESSURE ADJUSTMENT
2 Manometer
In order to adjust ply-bonding pressure, it is necessary that the paper be regularly fed through the
unit ply-bonding wheels.
By the pressure regulator and the relative manometer it is possible, first, to verify bonding of the
webs and, second, to stabilize the movement of the ply-bonding wheels.

41 EXTRA 5 REWINDER
REWINDER SPEED ADJUSTMENT
1 Selector switch
It is possible to adjust the speed of unwinding by the specific Selector switch, which permits
regulating the normal production speed of the machine; the speed value is displayed by means of
the relevant control template in the Operator Panel.

42 EXTRA 5 REWINDER
LOWER WINDING ROLL DECELERATION ADJUSTMENT
1 Rider roll
2 Lower winding roll
The deceleration of the lower winding roll is controlled by an electronic cam and the deceleration
parameters are settable on the specific page of the Operator Panel LOWER ROLL
DECELERATION PARAMETERS.
On changing one of these parameters, there changes also the mathematical curve reported on a
cartesian plane, which represents deceleration.
The adjustment is obtained directly pressing DECELERATION DURATION and DECELERATION
RETURN in the Operator Panel.
The deceleration of the lower roll causes, along with the acceleration of the rider roll, the ejection
of the finished log from the winding area and, at the same time, allows insertion of a new log
(intended as core with the first spirals of paper wound on it) between the winding rolls.

43 EXTRA 5 REWINDER
SYNCHRONICITY ADJUSTMENT BETWEEN RIDER ROLL AND LOWER WINDING
ROLL
1 Flat belt 4 Handle

2 Cone pulley
3 Mechanical belt shifter
During the normal log building cycle the speed of the lower winding roll must result slightly lower
than the speed of the upper winding roll in order to allow core advancement and correct winding.
The deceleration of the lower winding roll can be regulated by a mechanical speed variator
characterised by a mechanical belt shifter, which permits positioning the flat belt for connection
of the cone pulleys.
The position of belt shifter is varied via a handle installed outside the machine, on the drive side.
NOTE: The speed of the roll during the transfer phase is controlled by the Axis Control.

44 EXTRA 5 REWINDER
RIDER ROLL PRESSURE ADJUSTMENT
This adjustment is made by means of the relevant pressure regulator, placed on the operator side
frame, and serves to regulate the pressure of the rider roll on the paper roll at the moment of
transfer.
IMPORTANT: The rider roll pressure varies according to the roll diameter and sort of paper.

45 EXTRA 5 REWINDER
RIDER ROLL BACK PRESSURE ADJUSTMENT
1 Proportional valve
This adjustment permits adjustment of the back pressure of the air, with which the rider roll works
during the winding phase, by means of the proportional valve present on the machine.

46 EXTRA 5 REWINDER
LOG DIAMETER ADJUSTMENT WITHOUT DIATROL
1 Sensor
2 Handwheel
3 Cam
4 Lever
When no Diatrol unit is installed on the Rewinder, the log diameter adjustment is controlled by
means of a system comprising a cam and a sensor mounted on a lever, controlled with a
handwheel.
In order to adjust the log diameter, act as follows:
 With the machine at a standstill, rotate the pneumatic lever on the machine, present on the
operator side, in order to lift the rider roll to a preset position;
 Make a log of the desired diameter and lower the rider roll by the pneumatic lever;
 Turn the handwheel in order to bring the sensor to read the leading edge of the cam integral with
the rider roll;
 At this point, for the next logs, every time when the rider roll reaches the preset diameter,
regardless of the number of sheets, a transfer takes place.
IMPORTANT! By equal length of paper wound, the higher the diameter value of the finished
log, the less compact the roll and vice versa.

47 EXTRA 5 REWINDER
LOG DIAMETER ADJUSTMENT WITH DIATROL
1 Operator Panel
2 Diatrol
OPERATOR SIDE
When the Diatrol unit is mounted on the Rewinder, the adjustment of the log diameter is verified by
the Axis Control.
In order to adjust the log diameter, act as follows:
 from the Operator Panel home page, select WORKING PARAMETERS;
 in the FINISHED LOG DIAMETER template press SET and enter the new value;
 in the PARAMETERS CHANGE template press CONFIRM to confirm the new values, DATA
ACCEPTED message will be displayed. At this point the parameters are executable and the
next log will be produced with the new values shown on CURRENT in the FINISHED LOG
DIAMETER template;
 if, on the contrary, on the display there appear DATA NOT ACCEPTED and PARAMETERS
OUT OF RANGE it is necessary to reprogram new executable parameters.
IMPORTANT! By equal length of paper wound, the higher the diameter value of the finished
log, the less compact the roll and vice versa.

48 EXTRA 5 REWINDER
WIDTH ADJUSTMENT OF THE GLUE LINE ON THE LOG TAIL
1 Profile
2 Blade
The width of the glue line is fixed, so its adjustment is possible only by changing the blade with
one having a profile different from the previous one.

49 EXTRA 5 REWINDER
TAIL LENGTH ADJUSTMENT
1 Operator Panel
In order to adjust the length of the log tail, act as follows:

 from the Operator Panel home page, select CALIBRATIONS AND MAINTENANCE 2;
 in the ADVANCE CORE INTRODUCTION template press SET and enter the new value;
 in the PARAMETERS CHANGE template press CONFIRM to confirm the new values, DATA
ACCEPTED message will be displayed. At this point the parameters are executable and the
next log will be produced with the new values shown on CURRENT in the FINISHED LOG
DIAMETER template;
 if, on the contrary, on the display there appear DATA NOT ACCEPTED and PARAMETERS
OUT OF RANGE it is necessary to reprogram new executable parameters.
IMPORTANT! The longer the log tail, the shorter the internal fold of the same, this because
the length of the core is always the same.

50 EXTRA 5 REWINDER
PAPER TENSION ADJUSTMENT ON THE EMBOSSER
Follow the directions in the “SAFETY AND ACCIDENT PREVENTION” section”.
1 Mechanical belt shifter

2 Upper cone pulley
3 Flat belt
4 Lower cone pulley
1 Handle
The adjustment of speed for tensioning the paper between the embossing rolls and the ply-bonding
anvil roll is obtained by means of a mechanical speed variator which regulates the speed of the
ply-bonding unit and , consequently, of the winding rolls.
The speed variator is characterised by a mechanical belt shifter, which acts on the flat belt for
connection between the lower cone pulley, connected to the embossing rolls, and the upper cone
pulley, connected to the ply-bonding anvil roll.
Turning the handle, placed on the external enclosure, it is possible to increase or reduce the ply-
bonding speed according to the characteristics of the product in course of processing and to the
paper tension required in this unit.

51 EXTRA 5 REWINDER
WEB TENSION CONTROL IN THE WINDING AREA
1 Mechanical belt shifter 5 Handle

2 Flat belt
3 Upper cone pulley
4 Lower cone pulley
The adjustment of speed for tensioning the paper between the ply-bonding anvil roll and the
winding rolls is obtained by means of a mechanical speed variator.
The speed variator is characterised by a mechanical belt shifter, which acts on the flat belt for
connection between the upper cone pulley, driven by a transmission derived from the ply-bonding
anvil roll, and the lower cone pulley, which drives the winding area.
Turning the handle, it is possible to increase or reduce the speed of the winding rolls according to
the characteristics of the product in course of processing and to the paper tension required.
Adjust the speed of the two rolls in the winding area until the web tension appears visually correct.
WARNING!
WEB TENSION TOO HIGH: loss in diameter, and possible web breaks.
WEB TENSION TOO LOW: increase in diameter and possible side slipping of the web, with
development of creases.

52 EXTRA 5 REWINDER
CHANGING THE PRODUCT WITH ONE NOT STORED IN THE MEMORY
1 Operator Panel
Recall one of the pages of the Operator Panel LOWER ROLL DECELERATION PARAMETERS,
PROCESS AND PRODUCT CHANGE PARAMETERS or CALIBRATIONS AND MAINTENANCE
2.
Select one by one the new parameters and input the desired data; press PARAMETERS
CHANGE to confirm the new values.
If on the display there appear CHANGE IN PROGRESS and DATA ACCEPTED the parameters
are executable, the next log will show the characteristics of the new product.
If on the display there appear PARAMETERS OUT OF RANGE and DATA NOT ACCEPTED, it is
necessary to reprogram new valid parameters.
NB: At every new start of the machine there remain valid the parameters set before its stop.

53 EXTRA 5 REWINDER
MECHANICAL ADJUSTMENTS

54 EXTRA 5 REWINDER
EMBOSSER UNIT ADJUSTMENTS
EMBOSSING DEPTH ADJUSTMENT
Follow the directions in the “SAFETY AND ACCIDENT PREVENTION” section
Machine Status Procedure to enter the guard doors with the machine at a standstill
Authorized personnel Maintenance technician
Residual risks
PPE
1 Stop screw
2 Air cylinder
3 Steel embossing roll
4 Rubber embossing roll
This adjustment is described for one embosser assembly only; on machines provided with two, the
following procedure applies also to the second Embosser assembly.
The embossing depth adjustment is obtained by adjusting the specific stop screws.
Check and maintain the shafts of the two rolls perfectly parallel to each other. Check for uniform
impression on the sides and in the middle.
This ensures more uniform embossing, greater efficiency of the unit and longer life of bearings.
To regulate the embossing roll, proceed as described in the following:
 Interpose paper samples at the sides and in the middle.

 Move the embossing rolls close to each other.
 Run the machine in jogs.
 Check the impressions.
 Intervene as necessary.
If the width of the impressions taken at the sides is smaller than the one taken in the middle, it will
be necessary to increase the nip of the rolls at the sides; to do this, rotate the stop screws
accordingly.
If the width of the impressions taken at the sides is larger than the one taken in the middle, it will be
necessary to reduce the nip and increase the gap between the rubber embossing roll and the
steel embossing roll, always rotate the screws, but in reverse to what described previously.

55 EXTRA 5 REWINDER
DRIVE BELT TENSION ADJUSTMENT
Residual risks
PPE
1 Idlers
2 Timing belt
1 Timing belt
2 Locking nut
3 Eccentric pivot
Movement is transmitted to the rolls of the Embosser device by the timing belt, directly connected
to the stationary steel roll.
It is possible to adjust the tension of the belt via a stretching system composed of one or more
idler rolls.
The idler roll is supported by an eccentric pivot and by a locking nut.

56 EXTRA 5 REWINDER
PULLING BELT SUBSTITUTION IN VARIATORS WITH CONE PULLEYS
Residual risks
PPE
1 Belt shifter
2 Rollers
3 Flat belt
In the course of use, the flat belt tends to wear down as well as the rollers on the belt shifter
itself; substitute these components with original spares.
To substitute the belt, use the relevant tools: remove the worn belt, install the new one and stretch
it to the preset tension.

57 EXTRA 5 REWINDER
RUBBER EMBOSSING ROLL REPLACEMENT
Residual risks
PPE
1 Arms
2 Locking screws
3 Pneumatic cylinder

2 Arms
3 Locking screws
4 Pivot
5 Screws

58 EXTRA 5 REWINDER
To substitute the rubber embossing roll, it is advisable to detach the pivoting arms and to bring
away the roll complete with arms; to do this, it is necessary to:
 provide mechanical or hydraulic extractors to ease disassembly or installation of the bearings;

 sling the roll correctly with suitable means and equipment;
 remove the locking screws from the ball joints that secure the pneumatic cylinders to the
arms;
 oosen the screws that secure the arms on the frame supporting pivots ,
 loosen the locking screws and pull out the pivot;
 remove the assembly from the machine and bring it to a work zone.

59 EXTRA 5 REWINDER

Now it is necessary to dismount the bearings from the rubber embossing roll, acting as follows:
 loosen the locking screws 1-2 that fix the housings to both ends of the arm;
 Bend the washer that locks the ring nut in position, paying attention not to break it;
 Screw out the ring nut, paying attention not to force the bearings;
 Remove the pressure bushings, using a ring nut KM20;
 Remove the bearings.

60 EXTRA 5 REWINDER

1 Arms
2 Locking screws
Now the rubber embossing roll is free and it is possible to install the new roll onto the arms,
proceeding in reverse, paying attention, when installing the bearings, to restore perfect alignment
of the arms with the bearings to prevent damaging them. When tightening the pressure bushings,
leave 140 mm / 5,511 inch radial clearance on the bearing.
Lock the adjustment by means of the washer.
During installation of the new roll into the machine, we suggest substituting these elements if, on a
visual inspection, they show signs of deterioration:
 Bearings type 23218 CCK/W33, quantity 2.
 Pressure bushing AHX 3218, quantity 2.
 Washers MB 12, quantity 2.
 Ring nuts KM17, quantity 2.
 Oil guard ring 105/130/12, quantity 2.
During the installation phase, pay attention to centre the roll in the machine, observing dimensions.

61 EXTRA 5 REWINDER
NIP ROLL ADJUSTMENT
Residual risks
PPE
1 Ply-bonding anvil roll

2 Lock nuts
3 Nip roll
4 Stop screws
The distance between the anvil roll and the nip roll must be regulated in a way to guarantee
correct feeding of the webs, preventing them from side slipping.
Stop screws are provided in order to adjust the distance between the rolls in working position.
Attention:
Regulate the stop screws in a way that the rolls remain parallel to each other.
If the parallelism between the rolls is not respected, damage can be caused to the revolving
organs.
To adjust parallelism between the rolls, proceed as follows:
 Move the two rolls close to each other in working position.
 After loosening the lock nuts, turn the lateral stop screws, in a way to achieve a gap of 0,1 mm
/ 0,004 inch between the rolls. Make this measurement with a thickness gauge.
Rotate the stop screws in equal amounts in order to guarantee parallelism between the stop
screws, until the webs are correctly pulled.

62 EXTRA 5 REWINDER
PLY-BONDING UNIT
Residual risks
PPE
1 Stationary frame
2 Ply-bonding
3 Plies
5 Pneumatic membrane
The ply-bonding wheel unit has the task of joining the web plies by exerting a strong mechanical
pressure on them. This pressure is applied by a series of oscillating, knurled (that is, engraved)
steel wheels called ply-bonding wheels, that are pushed against the ply-bonding anvil roll when
an overhead pneumatic membrane, that counteracts with a stationary frame, is inflated with
compressed air.
According to the tissue web width and to the cutting pitch of the log saw, every single ply-bonding
wheel unit has to be positioned in a way that its range of action falls in the immediate vicinity of the
edges of each tissue paper roll when cut.

63 EXTRA 5 REWINDER
AXIAL POSITION ADJUSTMENT OF THE PLY-BONDING WHEELS
Residual risks
PPE
1 Ply-bonding wheel units

2 Support
3 Locking screws
4 Beam
According to the paper format and to the log saw roll cutting pitch, every single ply-bonding wheel
unit must be positioned in a way that its sphere of action may fall in immediate vicinity to the ends
of each cut roll. Generally, the ply-bonding wheels are arranged in a way to leave a margin of a few
mm (approximately 5 mm / 0,197 inch) per end of each paper roll.
To adjust the position of the ply-bonding wheel units, loosen the locking screw and slide the
support along the beam guide.
The ply-bonding wheels must be spaced equally along the beam guide and must be put in a
position so that the axis of the last wheel will be at a distance of approximately 20-25 mm / 0,787-
0,984 inch from the log edge; this dimension must coincide with the last trim on the pusher side of
the log saw.
In addition, the last ply-bonding wheel must be kept within the web margin.
N.B.: PREVENT THE PLY-BONDING WHEELS FROM WORKING OUTSIDE THE WEB
MARGINS, AS THIS WOULD CAUSE DAMAGE TO THE ANVIL ROLL AND TO THE PLY-
BONDING WHEELS THEMSELVES.

64 EXTRA 5 REWINDER
PLY-BONDING PRESSURE ADJUSTMENT
Residual risks
PPE
1 Nuts 3 Pressure gauge

2 Stop screws 4 Pressure regulator
1st Adjustment : Webs joining

1st Adjustment: 0,5-1,5 bar / 7,252-21,756 psi
2nd Adjustment : Stabilization

2nd Adjustment: 2,5-3 bar / 36,259-43,511 psi
To regulate this pressure, the web must be regularly threaded through the ply-bonding wheel unit,
proceed as follows:
 Loosen the stop screws.
 Making the machine run at low speed, make a first pressure adjustment, setting it to the
minimum necessary of approximately 0,5-1,5 bar / 7,252-21,756 psi by means of the pressure
regulator and pressure gauge, then check that the webs are joined together.
 When the webs are joined, stop the machine, bring the stop screws lightly to touch the relative
stops and lock the adjustment by means of the nuts.
 Make a second adjustment of the ply-bonding pressure, to stabilize the movement of the wheels,
increasing the pressure by 1-2 bar / 14,504-29,008 psi by acting on the pressure regulator and
pressure gauge. The maximum recommended pressure is 2,5-3 bar / 36,259-43,511 psi.

65 EXTRA 5 REWINDER
AXIAL ADJUSTMENT OF THE PLY-BONDING ANVIL ROLL
Residual risks
PPE

2 Stop screw
The ply-bonding anvil roll is provided with axial adjustment in order to compensate the wear
caused by the action of the ply-bonding wheels and always obtain a perfect contrast between the
anvil roll and the ply-bonding wheels.
This adjustment is needed mainly when fixed distances are used between the ply-bonding wheels,
resulting in localized wear in the same areas.
To regulate the axial position of the anvil roll:
 Loosen the appropriate stop screws present on the internal and external bearing housings.
 Position the anvil roll in correspondence of an unmarked surface.
 Tighten all component parts previously loosened.
The maximum axial movement allowed is 20 mm / 0,787 inch.

66 EXTRA 5 REWINDER
ADJUSTMENT OF THE SAFETY VALVES AT THE INFEED OF THE AIR HOSE
Residual risks
PPE
1 Air hose
2 Safety valve
The ply-bonding wheel unit and its anvil roll are both provided with one safety valve (calibrated at
6 atm).
On the ply-bonding wheel unit, the safety valve controls the air hose, preventing excessively high
pressure from building inside the hose itself and the consequences resulting there from.
For example:
 Excessive wear and consequent break of the ply-bonding wheels.
 Excessive marking of the ply-bonding anvil roll.
 Burst of the air hose.
The valve is delivered with calibration given by the manufacturer at assembly and the original
calibration value must never be altered.

67 EXTRA 5 REWINDER
PLY-BONDING WHEEL AND ANVIL ROLL LUBRICATION
Residual risks
PPE
1 Felt 5 Motor
2 Ply-bonding wheels 6 Boxes
3 Anvil roll
4 Felt
The ply-bonding wheels and the ply-bonding anvil roll are lubricated by means of rubbing with a
felt soaked in paraffin oil
This lubrication reduces friction between the wheels and the anvil roll, dissipates any heat
originated by friction and assists in the cleaning of the knurled surface.
Also the anvil roll is equipped with a felt for cleaning its surface.
The motor, controlled by the Operator Panel software and by a specific counter, regulates the oil
flow to the small boxes. The oil contained in the boxes is sprayed onto the felts by means of
appropriate spray nozzles. The felts absorb oil and, consequently, this is applied onto the knurled
surface of the wheels as they revolve on the anvil roll. The boxes are held on the unit by
appropriate brackets (one per side).
When the felts are no longer capable of carrying out a correct lubrication, they have to be
substituted. This check must be normally carried out at least once every 15 days, taking care to
verify the state of wear of the felts for lubrication of the ply-bonding wheels and anvil roll and the oil
level in the boxes.

68 EXTRA 5 REWINDER
PLY-BONDING WHEEL INTERNAL RING REPLACEMENT
Residual risks
PPE
1 O-Ring
Every two times when the ply-bonding wheels are substituted, it is necessary to substitute also the
internal O-Rings.

69 EXTRA 5 REWINDER
PERFORATION UNIT ADJUSTMENTS

70 EXTRA 5 REWINDER
PERFORATION UNIT ADJUSTMENTS
PERFORATION LENGTH ADJUSTMENT WITH PREDEFINED RANGE

2 Flat belt
3 Upper cone pulley
4 Lower cone pulley
The perforation length is determined by the size of the cone pulleys and by the number of blades in
use.
In every selected perforation range, it is possible to adjust the perforation length by a mechanical
speed variator characterised by a belt shifter which permits positioning the flat belt for
connection of the cone pulleys.
The position of belt shifter is varied by means of a control handle installed outside the machine,
drive side.
Turning the handle it is possible to increase or reduce the revolving speed of the perforation roll in
relation to the speed of advancement of the paper processed, determining a higher or lower
distance between the perforations made.
Setting of the value must be also carried out on the relative page on the Operator Panel (see
section relative).
In order to adjust the perforation length when flat pulleys are installed, it is necessary to
substitute the pulley with one valid for the new perforation length programmed.

71 EXTRA 5 REWINDER
NUMBER OF SHEETS ADJUSTMENT
IMPORTANT! By increasing the sheet

count, log finished diameter being equal,
the compactness increases and vice versa.
From the Operator Panel home page, select

REWINDER.
Select REWINDER PRODUCT.
Press WORKING PARAMETER AND

PRODUCT CHANGE.
In the SHEET NUMBER template insert the

new set date in SET.
In the PARAMETER CHANGE template press

CONFIRM.
On template ACCEPTED DATA will be
display.
If message DATA NOT ACCEPTED or
PARAMETERS OFF RANGE, will be
displayed, it is necessary to carry out a new
program with executable parameters.

72 EXTRA 5 REWINDER
At this point the new parameters have been
set.
The next log will be produced with the new
values displayed in ACTUAL in the SHEET
NUMBER template.

73 EXTRA 5 REWINDER
BLADE INTERFERENCE ADJUSTMENT
Residual risks
PPE
1 Setting screws 3 Locking nuts

2 Rotating blades
Interference between the blades of the rotating and fixed perforator rolls must be set with the
machine in jog mode and with the paper threaded in the machine, following the procedure
described below:
 Loosen the locking nuts on both sides.
 Rotate the setting screws gradually and alternatively face to face and from side to side to
obtain a satisfactory perforation in correspondence of all rotating blades.
 Tighten the locking nuts on completed adjustment.
N.B.: Excessively noisy perforation is a symptom of bad adjustment: stop the machine and
verify.

74 EXTRA 5 REWINDER
1 Rubber
2 Blade supporting block
3 Bimetallic blades
The blade supporting blocks are mounted on three sectors along the entire width of the
perforation roll and are delivered with the rubber already glued on their lower surface, in order to
prevent blade damage; the blades are all bimetallic (both for the fixed and for the rotating roll).

75 EXTRA 5 REWINDER
ADJUSTMENT AND CALIBRATION OF THE PERFORATION ZERO SENSOR
Residual risks
PPE
1 Rotating perforator roll 5 Sensor

2 Zero position 6 Dowel
3 Fixed perforator roll
4 Cam
The adjustment of the perforation zero position is controlled by a sensor, which is integral with the
rotating perforator roll.
This sensor detects the position of the perforation; in fact, on its leading edge it detects the contact
of one blade of the rotating perforator roll with the blade of the fixed perforator roll: this is the
zero position.
In order to adjust the perforation zero position, it is necessary to:

 Once positioning the perforator rolls in a way to place the marked blade (master) in the position
of first contact between rotating roll and fixed roll, turn the cam in order to energize the sensor;
 Then, lock the cam in position by acting on the relative dowel.

76 EXTRA 5 REWINDER
BLADE SUBSTITUTION
1 Revolving perforator roll 2 Stationary perforator roll
Due to wear or breakage, it may become necessary to substitute the blades of the perforation
unit.
1 Revolving perforator roll 3 Tools

2 Stationary perforator roll
Due to wear or breakage, it may become necessary to substitute the blades of the perforation unit.
Please note that excessive wear is evinced when it is not possible to obtain a satisfactory
perforation in spite of most accurately setting the distance between the stationary perforator roll
and the revolving one.
Before acting on the unit, take all relevant precautions and ensure that no person or accidental
events may cause incidental activation of the unit.

77 EXTRA 5 REWINDER
BLADE SUBSTITUTION ON THE FIXED ROLL
Residual risks
PPE
ATTENTION: DO NOT REMOVE THE RUBBER STRIPS FROM THE BLADE SUPPORTING
BLOCKS, UNLESS THEY APPEAR DAMAGED; IN THIS CASE, PROCEED VERY
CAREFULLY.
1 Arm 4 Stop screw Selector switch

2 Key 5 Rotating perforator roll for opening
3 Fixed perforator roll perforation unit
To substitute the blade of the fixed perforator roll, act as follows:

 Rotate the selector switch to open the perforation unit, stop the machines in the safety
conditions prescribed and enter inside the enclosure;
 Rotate the stop screws in order to retract the fixed perforator roll from the rotating one;
 Screw out the key and, after inserting a lever into the hole, turn the roll bringing the blade to the
front.

78 EXTRA 5 REWINDER
1 Selector 1 Tools A
switch for 2 Tools B
closing 3 Screw
perforation
unit
 loosen the blade supporting blocks and remove the blade;

 clean the seat by means of air blasts or suction;
 prepare and install the new blade into the previously cleaned seat;
 tighten a few screws slightly;
 mount the blade flush into its seat by using the tools A.
IMPORTANT: During this phase, keep the tools aligned with the blade.
 to mount the blade perfectly into its seat by using the tools B and turning the screw;
 tighten all screws completely;
 reposition the roll by means of the lever and connect it with the arm using the key;
 leave the machine interior closing the guard door;
 press the RESET push-button and rotate the selector switch in order to load the rolls to each
other;
 screw in the stop screws gradually and alternatively from one to the other side of the machine,
until satisfactory perforation is obtained on the paper.

79 EXTRA 5 REWINDER
BLADE SUBSTITUTION ON THE ROTATING ROLL
Residual risks
PPE
Loosen the setting screws to retract the fixed

roll from the rotating one. Loosen the screws
on the blade locking segments.
Remove the blade from its seat.
Remove the locking segments.

80 EXTRA 5 REWINDER
If necessary, replace the HABASIT rubber
(width: 12 mm) and stick it onto the segment
with the appropriate adhesive.
If necessary, replace the POLIFIBRON rubber

(width: 8 mm) directly on the rotating
perforation roll.
ATTENTION:
Apply the rubber at a distance of 1 mm from
the blade seat.

81 EXTRA 5 REWINDER
ATTENTION:
Reposition each segment on its seat,
according to the reference numbers marked on
both the segments and the roll.
Assemble the locking segments on the roll by

means of the screws without tightening them
Round off the blade corners by means of a

grindstone and clean it with a degreasing
agent.
Lift the locking segments and insert the blade.

ATTENTION: the metallic part of the blade
must remain outside the rotating roll.

82 EXTRA 5 REWINDER
Push the blade manually up to a stop and
tighten the screws on each locking segment.
With the suitable tools, supplied with the

rewinder, tap the blade all over its length, in
order to ensure its correct contact and stop
against its seat on the roll.
Tighten the screws from the centre towards the

ends, by means of a dynamometric key
calibrated at 50 Newton.

83 EXTRA 5 REWINDER
CHANGING PERFORATION LENGTH
Residual risks
PPE
1 Handwheel
2 Screws
3 Clamping ring
4 Revolving perforator roll
5 Idler 1
6 Adjusting screw
7 Locking screw
8 Transmission belt
9 Idler 2
In order to change the perforation length when flat pulleys are installed, act as follows:
 Loosen the transmission belt by means of idler 1 and of the relevant adjusting screws.
 Rotate the screws of the friction clamping ring and dismount the pulley.
 Then, substitute the pulley with a new one valid for the new perforation length programmed.
 In this way, the speed of the revolving perforator roll is increased or reduced and,
consequently, the distance between sheets perforated on the web.
 Once substituting the pulley, set the new value in the PERFORATION LENGTH REQUIRED
template in the Operator Panel.
To change perforation length within the values admitted by the pulley installed, is obtained by
PERFORATION LENGTH REQUIRED template in the Operator Panel.
To adjust the inclination of the revolving perforator roll, a handwheel is mounted on idler 2, in
order to keep the pulling belt in its guide on changing inclination of the revolving perforator roll,
so as to maintain the centred position of the transmission belt.

84 EXTRA 5 REWINDER
CHANGING PERFORATION LENGTH
Residual risks
PPE

2 Flat belt
3 Upper cone pulley
4 Lower cone pulley
The machine, having a perforation roll with four blades, is preset for perforation lengths ranging
between 90 mm / 3,543 inch and 163 mm / 6,417 inch.
Substituting the cone pulleys results in two drive ratios which produce following perforation lengths:
Range A 90-133 mm / 3,543-5,236 inch
Range B 100-145 mm / 3,937-5,709 inch
Range C 115-163 mm / 4,527-6,417 inch
A, B and C are punched directly on the pulleys.

For each perforation ratio selected it is possible to adjust the perforation length by a mechanical
speed variator characterised by a mechanical belt shifter, which permits positioning the flat belt
which connects the cone pulleys.

85 EXTRA 5 REWINDER
1 Revolving perforator roll
2 Blade
The belt shifter position is varied by a handle installed outside the machine drive side.
The setting of the value must be carried out also on the relative page on the Operator Panel (see
section relative).
If perforation values over 163 mm / 6,417 inch are desired, it is necessary to remove the blades
from the revolving perforator roll symmetrically.
In the following table are indicated the lengths obtainable according to the number of blades
mounted:
PERFORATION LENGTHS
Blades n° Range A Range B Range C

4 90-133 mm / 3,543- 100-145 mm / 3,937- 115-163 mm / 4,527-
5,236 inch 5,709 inch 6,417 inch
2 180-266 mm / 7,087- 200-290 mm / 7,874- 230-336 mm / 9,055-
10,472 inch 11,417 inch 13,228 inch
1 360-532 mm / 400-580 mm / 460-672 mm /
14,173-20,944 inch 15,748-22,834 inch 18,110-26,456 inch

86 EXTRA 5 REWINDER
PERFORATOR UNIT INCLINATION ADJUSTMENT
Residual risks
PPE
1 Gib unit
2 Locking screw
3 Adjusting screw
4 Ring nut
In both cases mentioned above (see section CHANGING PERFORATION LENGTH), it is

necessary to reposition also the gib unit, which permits inclination of the perforator unit, according
to the new perforation length.
To do this, it is necessary to act as follows:
 Loosen the locking screws taking care to leave the system slightly tensioned.
 Loosen the ring nut.
 Rotate the adjusting screw of the gib unit in order to move the unit manually.
 Position the unit according to the new perforation length; to do this, this value must be indicated
by the index on the graded scale.
 On terminating the adjustment, tighten again the locking screws and lock the ring nut.

87 EXTRA 5 REWINDER
CORE FEED SYSTEM ADJUSTMENTS
ADJUSTMENT OF THE CORE GUIDES ON THE CORE CONTAINING CHANNEL
Residual risks
PPE
1 Core feed channel

2 Internal movable guide
3 Loading channel
4 Upper guide
5 External fixed guide
6 Lower fixed guide
In case of changing the diameter of the core in course of processing, the distance between the
internal movable guide and the external fixed guide, which build the core feed channel, and the
distance between the upper movable guide and the lower fixed guide, which build the loading
channel of the cores, must be regulated in order to allow smooth running and prevent simultaneous
access of more cores.

88 EXTRA 5 REWINDER
1 Internal movable guide
2 External fixed guide
3 Locking screws 2
4 Locking screws 1
5 Locking screws 3
6 Upper movable guide
7 Locking screws 4
8 Lower fixed guide
These adjustments are made to the internal guide of the core feed channel and tp the upper
movable guide of the loading channel as follows:
 Loosen the locking screws 1 and the locking screws 4 in order to adjust the height of the
internal guide and of the upper movable guide.
 Loosen the locking screws 2 and the locking screws 3 in order to adjust the width of the
internal guide and of the upper movable guide.
 Position the internal guide and the upper movable guide, according to the diameter of the
core, leaving 7-8 mm / 0,276-0,315 inch air in relation to the diameter of the core.
 On completed adjustment, tighten the locking screws of the internal guide and of the upper
movable guide previously loosened.

89 EXTRA 5 REWINDER
ADJUSTMENT OF THE STOP GUIDES OF THE CORE CHANNEL
Residual risks
PPE
1 Deflector 6 Core conveyor belt

2 Holes
3 Frame
4 Locking screws
5 Adjusting slots
When changing the length of the core in course of processing, it is necessary to change the
position of the deflector and of the core limit stop lateral guides.
When adjusting the stop plates, pay attention that the core be aligned with the opposite side of the
roll exit from the log saw.
In order to adjust the position of the deflector, it is necessary to proceed as follows:
 Loosen the locking screws.
 Move the deflector along the relevant slots or move the entire body to the other holes present
on the frame of the conveyor belt.
 Tighten the locking screws.

90 EXTRA 5 REWINDER
1 Locking screw
2 Tubular support
3 Lateral limit stop guide
4 Cores
In order to adjust the position of the lateral limit stop guide, it is necessary to act as follows:
 Loosen the locking screws of the limit stop guide.
 Shift the limit stop guide along the tubular support and position it according to the core length,
leaving a clearance of approximately 10-15 mm / 0,394-0,591 inch between the sheet metal
plate and the core end.
 Tighten the locking screws of the limit stop guide.

91 EXTRA 5 REWINDER
ADJUSTMENT OF THE CORE INTRODUCTION CHANNEL GUIDES
Residual risks
PPE
1 Lower infeed guide

2 Core positioned in
gluing zone
3 Locking screw 1
In case of change of the diameter of the core in course of processing, the lower infeed guide of
the cores must be adjusted in order to allow smooth running and prevent simultaneous access of
more cores to the gluing zone.
This adjustment is done as follows:
 Loosen the locking screws of the lower guide.
 Move the front part of the lower guide closer to or away according to the diameter of the core, so
that a single core will be positioned correctly over the gluing blade in order to ensure correct glue
application and next pick-up of the cores.
 Tighten the locking screws.

92 EXTRA 5 REWINDER
POSITION ADJUSTMENT OF THE CORE ELEVATOR DEVICE
Residual risks
PPE
2 Spherical joint
3 Screw
4 Core elevator guides
5 Ratchet
6 Elevator table
A pneumatic cylinder moves the elevator table which, going up, pushes up the cores between
the core elevator guides and, at the same time, prevents the next core from advancing to the
lifting position.
The core, pushed by the lifting table, moves the ratchet, which acts as a limit stop for the column
of cores present between the core elevator guides, in order to prevent the cores themselves from
falling back.
On the core feeding and elevating unit, it is necessary to adjust the limit of the upstroke of the
elevator table according to the diameter of the core .
This adjustment is necessary to allow the core, positioned at the top of the column between the
core elevator guides, to be correctly unloaded into the downstream gluing zone.
In order to adjust the position of the elevator table, it is necessary to act as follows:
 Loosen the screw.
 Slide the spherical joint of the cylinder along the slot.
 On completed adjustment, tighten the screw.
Shifting the spherical joint of the cylinder toward the fulcrum, the stroke of the elevator table is
increased, shifting its toward the opposite side the stroke of the elevator table is reduced.

93 EXTRA 5 REWINDER
The stroke of the pneumatic cylinder must allow the elevator table to make a movement little
greater than the core diameter.
The ratchet can be mounted in two different positions according to the diameter of the core:
 Position (low) for cores with diameters up to 42 mm / 1,653 inch.
 Position (high) for cores with diameters from 43 mm / 1,693 inch to 50 mm / 1,969 inch.

94 EXTRA 5 REWINDER
CORE GLUING STATION
CORE GLUING
1 Blade 3 Pneumatic cylinder

2 Tank
The gluing system of is composed of a blade, driven by a pneumatic cylinder, which scoops the
glue from a tank and, through its vertical movement, applies it onto the core coming from the core
bin.
The exit of the blade from the gluing unit can be adjusted also in the Operator Panel; the software
increases the duration of glue application by 0,1 seconds every 100 m/1’ of machine speed.

95 EXTRA 5 REWINDER
POSITION ADJUSTMENT OF THE CORE GLUING UNIT
Residual risks
PPE
In the case of change of the core diameter it is necessary to adjust the height and /or depth of the
core gluing unit so that the glue my be correctly applied to the core surface.
VERTICAL ADJUSTMENT (HEIGHT)
1 Slots 3 Adjusting nut

2 Positioning
screws
In order to adjust the vertical position of the core gluing units, act as follows:
 Loosen the positioning screws which tighten the bearing frame, provided with slots;
 Turn the adjusting nut in order to make the gluing unit rise or sink according to need;
 Once finding the right position for the new diameter of the core, tighten the positioning screws.

96 EXTRA 5 REWINDER
HORIZONTAL ADJUSTMENT (DEPTH)
1 Core gluing unit

2 Positioning screws
3 Slots
4 Adjusting nut
In order to adjust the horizontal position of the core gluing units, act as follows:
 Loosen the positioning screws which tighten the bearing frame, provided with slots;
 Turn the adjusting nut in order to move the gluing unit forward or backward according to need;
 Once finding the right position for the new diameter of the core, tighten the positioning screws.

97 EXTRA 5 REWINDER
GLUEING BLADE CLEANING
Residual risks
PPE
1 Glueing blade
2 Tank
In order to clean the blade of the gluing unit, act as follows:

 Bring the blade to gluing position;
 Lock the machine in safe condition and clean the blade by means of a spatula and /or a brush.

98 EXTRA 5 REWINDER
GLUE TANK CLEANING
Residual risks
PPE
1 Fitting 6 Locking nut 9 Tank

2 Pump 7 Pin 10 Locking screw
3 Delivery hose 8 Pneumatic cylinder
4 Ball valve
5 Glue tank drain
The glue tank can be cleaned inside the machine or outside the machine after removing it from
the side frames as follows:
 Disconnect the glue delivery hose from the pump by the fitting;
 Empty the tank by the ball valve;
 Disconnect the cylinder that actuates the gluing blade by the relevant lock nut and remove the
pivot;
 Loosen and remove the locking screws from the tank in order to be able to remove it;
 Accurately clean the whole after removing the tank.
To reinstall the glue tank, act in reverse.

99 EXTRA 5 REWINDER
INFEED UNIT ADJUSTMENTS
POSITION ADJUSTMENT OF THE BLADES SUPPORTING THE WAITING CORE
Residual risks
PPE
1 Core in waiting position

2 Core in gluing position
3 Holding blade
4 Locking screws
5 Slotted support
The holding blade, which is located upstream of core introduction between the winding rolls, must
be regulated according to the diameter of the core, in order to hold up the core before the gluing
phase.
In fact, incorrect positioning of the blades causes early introduction of the core, thus compromising
the correct operation of the machine in the phase of introduction and transfer.
To make this adjustment, it is necessary to bring a core to the gluing position.
After loosening the locking screws, shift the holding blades mounted on the slotted supports,
until reaching the minimum pressure necessary to hold the core in the gluing zone.
On completed adjustment, tighten the locking screws.

100 EXTRA 5 REWINDER
CORE ALIGNMENT BEFORE WINDING
Residual risks
PPE
1 Beam
2 Locking screw 2
3 Support
4 Positioning cylinder
5 Locking screw 1
6 Plate
7 Core
The correct position of the core before its introduction into the gluing zone is obtained through a
positioning cylinder which, by means of the plate, pushes the core against the fixed limit stop
existing on the other side of the machine.
In case of notable variations in length and diameter of the core, it is necessary to change also the
position of the positioning cylinder.
In order to adjust the position of the positioning cylinder according to the length of the core, it is
necessary to loosen the locking screws 2 and move the cylinder support along the beam; on
completed adjustment, tighten the locking screws 2.
In order to adjust the position of the positioning cylinder according to the diameter of the core, it
is necessary to loosen the locking screws 1 and move the cylinder along the relevant slots of the
support; on completed adjustment, tighten the locking screws 1.

ADJUSTMENT OF THE CYLINDER THAT BLOCKS THE CORES DURING GLUING
Residual risks
PPE
1 Glue tank
3 Support
4 Locking screw
5 Plate
Blocking of the core before its gluing is obtained through the pneumatic cylinder which, by means
of the plate, pushes the core against the glue tank.
In case of notable variations in the diameter and length of the core, it is necessary to change also
the position of the locking cylinder.
In order to adjust the locking cylinder, it is necessary to act as follows:
 loosen the locking screws;
 move the cylinder support along the beam;
 tighten the locking screws on completed adjustment.

ADJUSTMENT OF THE CORE INFEED UNIT
Residual risks
PPE
1 Infeed unit 4 Locking screws

2 Cradles 5 Adjusting nuts
3 Gluing unit
The core infeed unit serves to push the cores, after a glue line has been applied onto them, into
the winding area.
The core infeed system needs adjusting in the case in which the diameter of the core in use and
the position of the gluing unit are changed.
With this adjustment one regulates both the height of the grippers and interference of the cradles.
In order to adjust the position of the core infeed unit act as follows:
Loosen the locking screws;
Turn the adjusting nuts in order to make infeed unit rise or sink according to need;
Once finding the right position of the gluing unit, tighten the locking screws.

CORE INFEED PHASE ADJUSTMENT
Residual risks
PPE
1 Upper winding roll 4 Cam

2 Introducing gripper 5 Infeed axis
3 Cradle 6 Toothed belt
7 Sensor
Introduction of the core between the upper winding roll and the cradles takes place by means of
a series of introducing grippers.
The axis, on which the series of introducing grippers is coupled, is moved thanks to a
transmission toothed belt, driven by the servomotor which moves the infeed unit.
The correct timing for core infeed is the one in which the introducing grippers bring the core into
pressure between the upper winding roll and the cradles, when the sensor reads the leading edge
of the relevant cam, keyed on the infeed axis.
The movement of the introducing grippers to the above-mentioned position takes place by means
of the joint fitting, which permits disengaging the infeed axis from the drive pulley.
The movement of the infeed axis is manual, by the drive pulley.
On completed adjustment, correctly tighten the joint fitting previously loosened.

REMOVAL AND ADJUSTMENT OF THE ARMS OF THE INTRODUCING GRIPPERS
Residual risks
PPE
1 Introducing grippers 4 Locking screws 7 Pin

2 Upper winding roll 5 Fixed part 8 Elastic ring
3 Gripper holding shaft 6 Movable part
Gripper unit for core Gripper unit for core

diameter 35 mm / 1,378 inch diameter 50 mm / 1,969 inch
For correct operation, the core introducing grippers must be adjusted according to the range of
diameters of the cores to be used.
In order to adapt the grippers to a different core diameter, it is necessary to act as follows:
 Remove the locking screws and substitute the fixed part with the new one relative to the new
core diameter.
 Tighten the screws removed previously to connect the new fixed part of the gripper to its own
body.
 Dismount the movable part of the gripper by removing the elastic ring from the pin on which it
revolves and removing the pin itself.
 Mount the movable part relative to the new core, reinserting the pin on which it revolves.
 Reinstall the elastic ring removed previously.
If necessary, proceed to reposition the entire gripper holding shaft in relation to the upper
winding roll.

ALIGNMENT OF THE INTRODUCING GRIPPERS
Residual risks
PPE
1 Introducing gripper
2 Upper winding roll
3 Infeed axis
4 Joint fitting
To align the introducing grippers, act as follows:

 Loosen the joint fittings, which connect the introducing grippers to their axis, until they
become movable only if subjected to a force applied on the grippers themselves.
 Place a tube of correct diameter in the grippers.
 Force all grippers to bring the core, carried by them, into uniform contact with the upper
winding roll.
 Tighten the joint fittings, which connect the grippers with the axis, paying attention not to shift
them from the position found.

MAINTENANCE OF THE CORE INFEED UNIT GEARBOX
Residual risks
PPE
1 Gearbox 2 Vent cap

3 Level cap
4 Drain cap
In the event of having to dismount or substitute the gearbox of the infeed unit, during the
assembling phase it is necessary to check for perfect concentricity of the axes. Maximum
admissible tolerance: +/-0,03 mm / +/-0,0012 inch.
During coupling, pay attention that the counter flange adheres perfectly to the gearbox flange.
Verify the oil level (quantity 0,28 litres) on a monthly base.
Substitute the oil a first time after 50-60 hours of operation (running in), next changes every 1000
hours of operation along with cleaning of the magnetic caps.
Refilling, level check and draining shall be carried out according to design indications and with
vent caps and drain caps in vertical position.

ADJUSTMENT AND CALIBRATION OF INFEED ZERO SENSOR
Residual risks
PPE
1 Pulley 2 Introducing gripper 5 Cam

3 Upper winding roll 6 Sensor
4 Gluing unit
To calibrate the zero sensor for core introduction, it is necessary to proceed as follows:
 Put the Rewinder in Emergency mode;
 Place the core in the introducing gripper, which takes it from the gluing unit toward the upper
winding roll;
 Move the core close to the winding area by turning the pulley manually.
 Interrupt the rotation of the pulley as soon as the core touches the rolls and the cradles (zero
position);
 Loosen the locking screw of the cam;
 Turn the cam, now free to move, until the sensor reads the leading edge of the cam itself.
At this point, the calibration of the zero sensor for core introduction is concluded.

SUBSTITUTION AND ADJUSTMENT OF THE CORE CRADLES
Residual risks
PPE
1 Screw 2 (fulcrum)
2 Infeed cradle
3 Screw 1
The core infeed cradles are designed in specific sets to suit a well specific core diameter.
If, for production needs, it is wished to change the core in progress of production, it becomes
necessary to substitute the infeed cradles .
To substitute the cradles, it is necessary to rotate the screws 1 and 2, remove the old cradles and
install the new ones for the core diameter required; verify during installation that the cradles are
well aligned with one another and that they do not hit against the lower winding roll; for this reason,
the cradle allows a certain adjustment by means of the screw 2, which acts as a fulcrum.

ADJUSTMENTS TO THE RIDER ROLL

RIDER ROLL CHECK AND CALIBRATION
Residual risks
PPE
With the closed doors and reset machine, from

RIDER ROLL CALIBRATION page, in the
CALIBRATION template press REQUEST.
Enter the PASSWORD and confirm.
The message ENABLE VERIFICATION ONLY
will be displayed. The rider roll moves toward
the zero point.
Turn the selector to enable the door opening

and enter the central zone of the operator side
rewinder.
Insert the alignment index in the specific hole.

Verify whether the roll index corresponds to
that inserted on the side frame; in the positive
the VERIFICATION procedure is finished.
Remove the index from the hole and place it in
its proper place.
Exit the machine, close the door, turn the

selector switch and press the RESET push-
button.
In the CALIBRATION template press OFF.
In the negative, that is if the two index do not

coincide, pull lightly the index from the hole go
on with the procedure.

In the CALIBRATION template press ENABLE
CONFIRMATION.
Press the ZERO cycle push-button.
When in the template will be displayed the

message ON the nip roll is in calibration.
With the closed doors and the reset machine,

in the RIDER ROLL POSITION template press
UP or DOWN to align index.
Any time the template is pressed, the roll
moves by an established value.

In the CALIBRATION STEP template select
the order of magnitude to which the roll shall
move: the greatest precision is obviously
achieved if small values are set.
Turn the selector to enter and verify the

alignment of the index.
NOTE: This will require more entries inside the

machine, because the movement of the rider
roll is only allowed with the doors closed, while
to verify the alignment of the indexes you must
enter inside the guard.
Once alignment has been remove from the

hole the reference index and replace it in its
seat on the side frame of the machine.
Exit the machine, close the door, turn the

selector switch and press the RESET push-
button.

In the RIDER ROLL POSITION template press
RIDER ROLL CONF. ON INDICATOR, the
message DONE will be displayed.
In the CALIBRATION template press OFF.
Press the ZERO cycle push-button to start up

the machine.

RIDER ROLL DIATROL ENCODER ADJUSTMENT
Residual risks
PPE
1 Rider roll
2 Cam
3 Zero Zero encoder position
4 Upper limit with horizontal rider roll
In the event of a failure or breakdown of a servomotor or encoder, the faulty part shall have to be
changed or adjusted.
Then, for the regulation the rider roll again, an index is provided, which corresponds to the rider
roll in horizontal position.
When turning on the machine, the rider roll moves at high speed in the direction indicated by the
sensor; the front A of the cam rotates toward the zero and upper limit sensors, until the zero
sensor is engaged by the cam.
The dimming of the zero sensor commands the start of its low speed movement in search of the
zero position, toward direction B.
The upper limit proximity microswitch serves exclusively as maximum limit of excursion of the
rider roll.
The zero encoder has to be regulated in a way to make the relevant index correspond to the rider
roll arms in horizontal position and to make the cam advance approximately 10 mm / 0,394 inch
past the zero proximity microswitch.

RIDER ROLL COATING SUBSTITUTION
Residual risks
PPE
1 Abrasive tape
2 Rider roll
The rider roll is coated with abrasive tape; it is necessary to substitute the tape with an equal
one, if damaged or broken, winding it spirally on the surface of the roll, on which double sided
adhesive tape has been previously applied.
It is obligatory to keep the original thicknesses in order not to change the roll speed.

PROGRAMMING THE CONNECTING POINT WITH DIATROL
1 Rider roll 3 Motor

2 Diatrol unit
Inside view - Operator side Outside view - Operator side
The Diatrol unit controls the buildup of the log; for this reason, it is necessary for the rider roll
always to stay as long as possible in physical contact with the building log.
For every product, the minimum position of the rider roll (point of connection with Diatrol) is
calculated by the system; it is possible to intervene on this datum in the WINDING PARAMETERS
template.

MAINTENANCE OF THE LOWER WINDING ROLL GEARBOX
Residual risks
PPE
1 Gearbox 2 Vent cap

3 Level cap
4 Drain cap
In the event of having to dismount or substitute the gearbox of the lower winding roll, during the
assembling phase it is necessary to check for perfect concentricity of the axes. Maximum
admissible tolerance: +/-0,03 mm / +/-0,0012 inch.
During coupling, pay attention that the counter flange adheres perfectly to the gearbox flange.
Verify the oil level (quantity 0,28 litres) on a monthly base.
Substitute the oil a first time after 50-60 hours of operation, next changes every 1000 hours of
operation along with cleaning of the magnetic caps.
Refilling, level check and draining shall be carried out according to design indications and with
vent caps and drain caps in vertical position.

POSITIONING THE LOWER WINDING ROLL IN RELATION TO THE UPPER WINDING
ROLL
Residual risks
PPE

The above adjustment is made as follows and with the machine at a standstill in FAST STOP
mode:
N.B. It is important that the lower winding roll be parallel to the upper winding roll.
To position the lower winding roll to the correct distance from the upper winding roll, use steel
thickness gauges, supplied with the machine.
These thickness gauges must have the outside diameter calibrated to the size needed (core
diameter minus desired interference, for ex., 2 mm / 0,079 inch for bath tissue rolls; core diameter
plus 2 mm / 0,079 inch for kitchen towel rolls).
To set the distance between the two rolls, place the thickness gauge first at one end of the roll,
approximately 200 mm / 7,874 inch before its journal, then at the opposite side.
N.B. Above-mentioned values are not absolute and may vary according to the specific
product made by the Purchaser; in this case, the corresponding thickness gauges will be
fabricated during the machinery final test.

1 Nuts
3 Locking screws
4 Lock nut
5 Adjusting screws
Approach the lower winding roll to the upper winding roll loosening, but not removing, the
locking screws on both sides of the machine, then rotate the adjusting screws, after releasing
the relative lock nuts, until the thickness gauges force lightly.
Make this adjustment at both ends of the roll, as described previously, and, once making it, tighten
the nuts and locking screws in succession.
The roll supports are pivoted on the sides; this makes it possible to move the lower winding roll
towards the upper winding roll.
In this way, it is possible to make a fine adjustment, maintaining and positioning the two rolls
perfectly parallel.

NOTES ON THE LOWER WINDING ROLL
1 Tissue wound 3 Servomotor

2 Rider roll
Thanks to its speed variation, the lower winding roll commands the output of the finished log and
the insertion of a new core between the two winding rolls.
The roll surface is suitably coated in order to improve its effect on the log being wound.
The power transmission to the lower winding roll is obtained directly from the main transmission of
the machine via timing belts and cone pulleys.
During the decelerated phase, controlled via the Axis Control central computer, the servomotor is
accelerated to a certain speed.
This value is such as to obtain the required deceleration in the surface speed of the lower winding
roll, variable and adjustable acting on a specific parameter in the Operator Panel.
The Axis Control central computer has the capability to check and correct the speed of each single
servomotor up to 200 times per second.
This guarantees at any given moment that control and adjustment of motor speed values
are maintained as programmed in the Axis Control memory during the machine work cycle.

1 Rider roll 4 Servomotor
The deceleration of the lower winding roll causes the ejection of the finished log from the upper
winding roll and the insertion of a new log (the core with the first loops of tissue wound), between
the two winding rolls.
The tear-off and ejection of the log, in this case, are determined by the acceleration of the rider
roll.
After transfer, the speed of servomotor initially decreases rapidly, then more and more gradually.
The speed of the lower winding roll tends gradually to return to normal: this happens only at about
the end of the cycle.

ROLL OUTFEED TABLE ADJUSTMENT
Residual risks
PPE

2 Locking screw
3 Roll outfeed table
When the distance between the upper winding roll and the lower winding roll is varied notably, it
is necessary to adjust the position of the roll outfeed table.
To do this, act as follows:
 Loosen all locking screws;
 Shift the roll outfeed table to the new position required;
 Tighten all locking screws.


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OPERATING PROCEDURES AND ADJUSTMENTS

DO NOT CARRY OUT ADJUSTMENTS

FABIO PERINI S.p.A. PROPERTY, EXTRA 5 REWINDER

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

 Open all auxiliary units that may be on by the relative selector.

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

1 Steel embossing roll

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

1 Upper winding roll 4 Log outfeed zone

Jog selector Jog mode

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

Procedure from Operator Panel:

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

1 Motor 2 Push-button for web

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PRECAUTIONS TO BE TAKEN WHEN USING GLUES

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PRECAUTIONS IN THE USE OF GLUES

For substituting the glue bin to proceed as follows:

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

Glue tank refilling is obtained by means of a pump (manual or semi-automatic).

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

1 Rider roll 3 Pneumatic lever

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

1 Compressed air supply 2 Operator Panel 3 Main switch

The Rewinder starting procedures are the following:

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

When it is necessary to restart the machine:

The system controls these sequences in order:

Avoid pushing buttons throughout the above phases.

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

Perfectly wound roll (log)

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

The correct position is the following:

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

PROPRIETÀ DELLA FABIO PERINI S.p.A.,

1 Flat belt 4 Handle