UserManual Tiratex 1600 V2 8 EN

Operating instructions
Tape extrusion line

tiraTex 1600
Read this manual before starting work!

Translation of original operating instructions
UserManual_tiraTex_1600_V2_8_EN.doc
Version 2.8
BSW Machinery s.r.o.

Service Department
Haj 374
79812 Kralice na Hané
Czech Republic
Tel.: +420 582 3050 10

Fax: +420 582 3050 33
office-cz@bsw-machinery.com
www.bsw-machinery.com
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i
1 General .................................................................................................................................. 1
1.1 Information on these instructions........................................................................................... 1
1.2 Explanation of symbols .......................................................................................................... 1
1.3 Limitation of liability ................................................................................................................ 2
1.4 Copyright ................................................................................................................................ 3
1.5 Warranty terms....................................................................................................................... 3
1.6 Declaration of conformity ....................................................................................................... 3
1.7 Customer Service .................................................................................................................. 3
2 Safety..................................................................................................................................... 4
2.1 Intended use .......................................................................................................................... 4
2.2 Risks....................................................................................................................................... 4
2.2.1 Occupational risks.................................................................................................................. 4
2.2.2 Electrical, pneumatic and hydraulic risks .............................................................................. 5
2.2.3 Mechanical risks..................................................................................................................... 6
2.2.4 Risks from high temperatures................................................................................................ 7
2.2.5 Risks from chemical substances ........................................................................................... 7
2.3 Responsibility of operating company..................................................................................... 7
2.4 Personnel qualification........................................................................................................... 8
2.5 Personal protective equipment .............................................................................................. 9
2.6 Safety devices...................................................................................................................... 11
2.7 Environmental protection ..................................................................................................... 13
2.8 Labelling ............................................................................................................................... 13
2.9 Spare parts........................................................................................................................... 15
3 Technical data .................................................................................................................... 16

3.1 Dimensional drawings.......................................................................................................... 16
3.2 General information ............................................................................................................. 18
3.3 Connection values ............................................................................................................... 19
3.4 Technical data of touchscreen............................................................................................. 21
3.5 Information on process data ................................................................................................ 21
3.6 Type plate ............................................................................................................................ 23
4 Structure and function ...................................................................................................... 24

4.1 Overview of entire system ................................................................................................... 24
4.2 Structure of tape extrusion line ............................................................................................ 25
4.2.1 Water bath............................................................................................................................ 25
4.2.2 Vibration drying .................................................................................................................... 31
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4.2.3 Longitudinal cutting unit ....................................................................................................... 32

4.2.4 Holding unit .......................................................................................................................... 36
4.2.5 Hot air oven .......................................................................................................................... 39
4.2.6 Stretching unit ...................................................................................................................... 41
4.2.7 Edge trim refeed................................................................................................................... 49
4.2.8 Tape exhaust ....................................................................................................................... 50
4.3 Control elements .................................................................................................................. 51
4.3.1 Control panel of tape extrusion line ..................................................................................... 52
4.3.2 Touchscreen of tape extrusion line...................................................................................... 54
5 Storage and transport ....................................................................................................... 56

5.1 Packaging ............................................................................................................................ 56
5.2 Storage ................................................................................................................................. 57
5.3 Transport and setup ............................................................................................................. 57
5.3.1 Setup of tape extrusion unit with crane ............................................................................... 57
5.4 Installing ............................................................................................................................... 59
5.4.1 Connecting electrical system............................................................................................... 60
5.4.2 Connecting pneumatic system ............................................................................................ 60
5.4.3 Connecting water ................................................................................................................. 61
6 Operation ............................................................................................................................ 64
6.1 Switching on ......................................................................................................................... 64
6.2 Checks and settings after switching on ............................................................................... 67
6.3 Switching off ......................................................................................................................... 68
6.4 Preparing production on machine........................................................................................ 69
6.4.1 Preparing dosing station ...................................................................................................... 69
6.4.2 Preparing automatic filter ..................................................................................................... 69
6.4.3 Feeding film web .................................................................................................................. 69
6.5 Procedure with production disturbance by winding on stretching unit or holding unit........ 69
6.6 Touchscreen operation ........................................................................................................ 71
6.6.1 Changing password ............................................................................................................. 71
6.6.2 Main menu ........................................................................................................................... 72
6.6.3 Performing general settings ................................................................................................. 72
6.6.4 Setting extruder parameters ................................................................................................ 74
6.6.5 Setting flat die parameters ................................................................................................... 76
6.6.6 Setting parameters of water bath/take up/holding unit........................................................ 78
6.6.7 Setting hot air oven/stretching parameters.......................................................................... 79
6.6.8 Setting stretching unit parameters ....................................................................................... 80
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6.6.9 Setting thermoCon parameters........................................................................................ 81

6.7 Activities during production .................................................................................................. 82
6.7.1 Preparation of production report .......................................................................................... 82
6.7.2 Thickness measurement (option) ........................................................................................ 83
6.7.3 Setting thickness measurement (option) ............................................................................. 85
7 Maintenance ....................................................................................................................... 87
7.1 Maintenance indicators ........................................................................................................ 88
7.2 Lubrication chart................................................................................................................... 89
7.3 Maintenance schedule ......................................................................................................... 91
7.4 Maintenance work ................................................................................................................ 92
7.4.1 Removing plastic residues ................................................................................................... 92
7.4.2 Changing screen tape.......................................................................................................... 92
7.4.3 Replacing knives of cutting mill ........................................................................................... 93
7.4.4 Hot air oven .......................................................................................................................... 95
7.4.5 Correcting belt tension ......................................................................................................... 99
7.5 Screw-tightening torques ................................................................................................... 101
8 Malfunctions ..................................................................................................................... 102

8.1 Malfunction indications....................................................................................................... 102
8.2 Malfunction table ................................................................................................................ 105
9 Disassembly and disposal .............................................................................................. 110

9.1 Disassembly ....................................................................................................................... 110
9.2 Disposal.............................................................................................................................. 111
10 Index .................................................................................................................................. 112
Annex 113
Alarm list ......................................................................................................................................... 114
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1 General 1
1 General
1.1 Information on these instructions

These instructions allow the safe and efficient use of the machine and must be kept for the entire
service life of the machine. The instructions are part of the machine and must be kept right next to
the machine and be accessible to personnel at any time.
In addition, the local accident prevention regulations and safety regulations for the application area
of the machine are applicable.
1.2 Explanation of symbols

Safety advices contained in these instructions are identified by symbols. The safety advices are
introduced by signal words that describe the extent of the risk.
DANGER!
This combination of symbol and signal word indicates an imminently hazardous
situation that will result in death or serious injuries if not avoided.
WARNING!
This combination of symbol and signal word indicates a possible hazardous situation
that can result in death or serious injuries if not avoided.
CAUTION!
that can result in minor or light injuries if not avoided.
NOTE!
that can result in damages to property and environment if not avoided.
To point out particular risks, the following symbols are used in safety advices:
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1 General 2
DANGER!
This combination of symbol and signal word indicates an imminently hazardous
situation due to electricity. Non-observance of an advice marked as such will result in
serious or fatal injuries.
Tips and recommendations
Loss of warranty
The manufacturer's warranty is void in the event of unauthorised use of spare parts.
Additional markings
Marking Explanation
1. Step-by-step guidelines
Result of action
Listings without specific sequence
1.3 Limitation of liability

All information and notes in these instructions were compiled under consideration of the applicable
standards and regulations, the present state of technology, as well as our many years of
knowledge and experience.
In the following cases the manufacturer will not accept liability for damages:
Non-observance of these instructions
Any use other than intended
Use of untrained personnel
Unauthorised conversions
Technical modifications
In case of customised versions, utilisation of additional order options, or latest technical

modifications, the actual scope of delivery can vary from the explanations and interpretations
described herein.
The commitments set out in the delivery contract, the general terms and conditions, as well as the
delivery conditions of the manufacturer and the regulations applicable at the time of contract
conclusion are in force.
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1 General 3
1.4 Copyright
The contents of these instructions are protected by copyright. Their use is permitted within the
scope of application of the device. Any other use is prohibited without the prior written permission
from the manufacturer.
1.5 Warranty terms

The warranty terms are included separately in the sales documents.
1.6 Declaration of conformity

The declaration of conformity is included separately in the provided documents.
1.7 Customer Service

Contact our Customer Service for technical information:
Address BSW Machinery Handels-GmbH
Technical Service
Triester Straße 10/1/122
2351 Wiener Neudorf
Österreich
Tel. +43 1 99 750 50-80
Fax +43 1 99 750 50-98
E-mail service@bsw-machinery.com
Internet www.bsw-machinery.com
To order spare parts, contact our Spare Parts Department:

Address BSW Machinery s.r.o.
Spare Parts
Haj 374
79812 Kralice na Hané
Czech Republic
Tel. +420 582 3050 22
Fax +420 582 3050 33
E-mail spareparts@bsw-machinery.com
Internet www.bsw-machinery.com
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2 Safety 4
2 Safety
This section provides an overview of all important safety aspects for the protection of people and
safe and trouble free operation. Additional task-related safety advice is included in the sections on
the individual life stages.
2.1 Intended use

The tiraTex 1600 Tape Extrusion Line is intended exclusively for the production of tapes made of
PP or PE.
Intended use also includes compliance with all the information contained in these instructions. Any
use other than the one intended is considered incorrect.
WARNING!
Risk due to incorrect use!
The incorrect use of the tiraTex 1600 Tape Extrusion Line can result in dangerous
situations.
- Do not use in potentially explosive area.
- During operation do not climb onto the machine.
- Do not reach into moving parts during operation.
2.2 Risks
The following section mentions residual risks that can be caused by the machine even when used
as intended.
To reduce the risks of personal injuries and damages to property and avoid hazardous situations, it
is essential that the safety advices listed here and the safety advices contained in the following
sections of these instructions are observed.
2.2.1 Occupational risks
WARNING!
Risk of injury from noise!
The noise level occurring in the workspace can cause serious hearing damage.
- Always wear hearing protection when performing work.
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2 Safety 5
WARNING!
Risk of injury due to strange noises or malfunction.
When strange noises occur, or in case of obvious defects or malfunctions, shut down
line immediately and notify the responsible supervisor.
- Restart is only permitted after fault has been corrected.
WARNING!
Risk of injury from tripping and slipping hazards!
Risk of injury from tripping over hoses, pipelines and power supply lines.
- Manufacturer and operating company must install hoses, pipelines and power
supply lines in such a way as to prevent the creation of trip hazard.
- Pick up and properly dispose of any leaked operating materials.
- Wear anti-slip safety shoes.
2.2.2 Electrical, pneumatic and hydraulic risks
DANGER!
Risk of fatal injury from electrical current!
Imminent risk of fatal injury from electric shock when coming in contact with live parts.
Damage to insulation or individual components could be life threatening.
- Any work on electrical system must be performed by authorized electricians.
- In case of damage to insulation, shut down power supply immediately and arrange
repair.
- Never attempt to bypass or deactivate fuses. When replacing fuses observe the
correct amperage.
- Protect live parts from humidity. This could cause a short circuit.
- Power supply cables must be properly installed.
WARNING!
Risk of injury from movement caused by pneumatic energy!
Due to stored residual energy, pneumatically operated components can move
unexpectedly and cause most severe injuries.
- Before starting work on the pneumatic system, remove all pressure. Release all
tension on accumulator and protect line against unintentional activation.
- Ensure that defective parts subject to pressure during operation are replaced
immediately by maintenance and service personnel.
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2.2.3 Mechanical risks
DANGER!
Risk of crushing from closing of hot air oven!
Crushing by hot air oven can cause serious injuries.
- Before closing the hot air oven, ensure that no people are in the danger zone.
CAUTION!
Risk of injury from blades of cutting unit!
The blades of the cutting unit are sharp and can cause cuts.
- Do not reach into the area of the blades.
GEFAHR!
Risk of injury from crushing and getting entangled by rotating rolls!
Accessible rotating rolls can entangle parts of clothing and long hair, or trap body parts
and cause most severe injuries.
- Do not reach into rotating rolls.
- Do not reach into gaps between rotating rolls.
- Before performing any work on the rolls, ensure that machine is stopped.
- Wear personal protective equipment in the work area.
CAUTION!
Risk of injury from cutting and scraping on moving film web and tape!
The movement of the film web and tape in the line poses a risk of cutting and scraping.
- Do not touch moving film web or tape.
WARNING!
Risk of injury from sharp blades!
- Risk of injuries from cuts when installing and changing cutting blades of knife
assembly due to incorrect handling.
- Wear protective gloves!
- Transport cutter bar only with protective device in place!
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2.2.4 Risks from high temperatures
WARNING!
Risk of injury from hot surfaces!
Surfaces of components on extruder, flat die, rollers, godets, hot air oven, drives and
tapes become very hot during operation. Skin contact with hot surfaces causes serious
burns to skin.
- Always wear heat-resistant protective clothing and gloves when working near hot
surfaces.
- Before starting any work ensure that all surfaces have cooled down to ambient
temperature.
2.2.5 Risks from chemical substances
WARNING!
Risk of injury from liquid plastics and vapours!
Plastic is melted in the extruder; this can cause burns. Liquid plastic can produce
vapours that can result in poisoning after being inhaled.
- During prolonged work on the extruder or near the flat die, wear respiratory
protection, protective clothing and protective gloves.
2.3 Responsibility of operating company

Operating company
Operating company is the party who operates the machine for industrial or economical purposes or
makes it available for use by third parties and who assumes the legal product stewardship during
operation for the protection of the user, the personnel or third parties.
Duties of operating company
The machine is used for industrial purposes. Hence, the operator of the machine is subject to the
legal obligations concerning occupational health and safety.
In addition to the safety advice contained in these instructions, the safety, accident prevention
guidelines and environmental protection regulations applicable at the site of implementation must
be complied with.
The following applies in particular:
Operating company must become familiar with applicable industrial safety
regulations and determine additional hazards that arise due to the specific working
conditions prevailing at the site where machine is implemented, in a risk analysis.
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2 Safety 8
This analysis must be implemented in form of work instructions for machine

operation.
The operating company must check throughout the machine's entire period of use
whether the operating instructions created by it satisfy current legislation, and adapt
the instructions if necessary.
The operating company must ensure that all people handling the machine have read
and understood these instructions. In addition, it must train the personnel on a semi-
annual basis and provide information on the hazards. Instructions or training must
be recorded in the log book, and confirmed by the persons receiving the
instructions.
The operating company must provide the personal protective equipment mentioned
below and order its use.
The operating company must ensure that the line area and its surrounding is free
from flammable and combustible substances.
The operating company must block the hazard zone to keep out unauthorized
persons and place easily visible prohibition signs in the line area.
The operating company must provide a fire extinguisher in an easily visible location,
and instruct personnel on how to use it.
The operating company must provide sufficient lighting of site.
The operating company is responsible for the installation of guards that detect
electrical short circuits and isolate all connection phases.
Furthermore, the operating company is responsible for keeping the machine in perfect technical
condition. Hence, the following applies:
The operating company must ensure that the maintenance intervals described in
these instructions are complied with.
The operating company must arrange regular checks of all safety devices to ensure
functionality and completeness.
2.4 Personnel qualification

The various tasks described in these instructions place different demands on the qualification of
the people appointed to perform these tasks.
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2 Safety 9
WARNING!
Risk due to inadequately qualified people!
Inadequately qualified people lack the ability to properly assess risks when handling the
machine and expose themselves and others to serious or fatal injuries.
- Use only qualified people to carry out any work.
- Keep inadequately qualified people away from work area.
Any work is only to be performed by people that are expected to be reliable. People with impaired
responsiveness, e.g. due to drugs, alcohol or medication, are not permitted.
These instructions list the qualifications of people for the various tasks as follows:
Operator
The operator has been trained by the manufacturer's specialists or the operating company about
the assigned tasks and possible hazards in case of incorrect behaviour. Tasks that exceed normal
operation may only be performed by the operator if mentioned in these instructions and if the
operating company has appointed him specifically.
Maintenance and service personnel

Any maintenance and troubleshooting shall only be performed by service personnel. Based on its
technical training in the mechanical or/and electrical field and experience/knowledge of relevant
regulations, maintenance and service personnel is able to perform assignments and independently
recognise and avoid possible risks.
Manufacturer's specialists
Certain types of work may only be performed by manufacturer's specialists. Any other personnel is
not authorised to perform this work. To arrange the associated tasks, please contact our Customer
Service.
2.5 Personal protective equipment

The purpose of personal protective equipment is to protect people against negative effects of
occupational safety and health. The personnel must wear the protective equipment referred to in
the individual sections of these instructions when working on and with the machine.
Below is an explanation of the personal protective equipment.
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2 Safety 10
When working, always wear:
Protective Description
equipment
Protective clothing
Protective clothing refers to close-fitting work clothes with low tensile
strength, close-fitting sleeves, and without protruding parts. It serves
primarily as protection against getting entangled in movable machine
parts.
Do not wear rings, necklaces and other jewellery.
Long hair must be tied back.
Safety shoes
Safety shoes protect the feet from crushing, dropping parts and slipping
on slippery floors.
Hearing protection
Hearing protection is used to prevent hearing damage.
Wear when performing specific tasks:

Special protective equipment is required when performing specific tasks. They are mentioned
separately in the individual chapters of these instructions. Below is an explanation of this special
protective equipment:
Protective Description
equipment
Hard hat
Hard hats protect the head against falling objects, suspended loads and
against impacts with fixed objects.
Protective gloves
Protect hands against friction, abrasion, punctures or deeper skin lesions
and contact with hot surfaces.
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2.6 Safety devices
WARNING!
Risk of fatal injury from non-functioning safety devices!
Non-functioning or disabled safety devices pose a risk of most severe injuries, and even
death.
- Before starting work, check to ensure that all safety devices are functional and
properly installed.
- Never disable or bypass safety devices.
- Ensure that all safety devices are accessible.
Emergency stop system

Figure 1 Shows the position of the emergency stop button of the tape extrusion line and the overall
line.
Figure 1: Emergency stop system, front view of line

1 Emergency stop pull-wire switch Positions of emergency stop buttons
Emergency stop button

Pressing the emergency stop button immediately disconnects the energy supply and thus shuts
down the machine. After pressing an emergency stop button it must be unlocked by turning to
allow switching on again.
Emergency stop pull-wire switch

Operating the emergency stop pull-wire switch shuts down the machine by immediately
disconnecting the energy supply.
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2 Safety 12
Master switch with emergency stop function

The master switch on the line's main switch cabinet is also designed as emergency stop switch.
Turning the master switch to "0" position shuts down the machine by immediately disconnecting
the energy supply, thus triggering an emergency stop.
Safety covers holding and stretching unit

Figure 2 shows the position of the monitored safety cover of the godet stretching unit (Figure 2/1).
Opening the safety cover triggers an alarm on the touch panel. After 60 sec. with open safety cover
at a 6-godet stretching unit, an automatic quick-stop of the line will happen. At a 8- or 10-godet
stretching unit, the quick-stop will happen after 120sec.
Figure 2: Monitored safety cover stretching unit
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2 Safety 13
2.7 Environmental protection
NOTE!
Risk to the environment from incorrect use of environmentally hazardous
substances!
Incorrect use of environmentally hazardous substances, particularly incorrect disposal,
can cause significant damage to the environment.
Follow the advice mentioned below on the use of environmentally hazardous
substances and their disposal.
- If environmentally hazardous substances are released into the environment, take
proper action immediately. If in doubt, report the damage to the responsible local
authorities and ask about suitable action to be taken.
The following environmentally hazardous substances are used:

Follow manufacturer's safety data sheets for the substances used.
Lubricants
Lubricants contain toxic substances. Do not allow them to enter the environment. Disposal must be
carried out by a professional disposal company.
Plastics
Plastics for extrusion are toxic substances for the environment. Use a professional disposal
company to dispose of residues from production or surplus plastic.
Cooling water mixture
Cooling water mixtures for the cooling water circuit are toxic substances for the environment.
Never let these substances escape into the environment; if necessary, use a professional disposal
company.
Batteries
Batteries contain environmentally harmful battery acid. Never dispose of with household waste but
by a professional disposal company.
2.8 Labelling
The following symbols and labels are located in the workspace. They refer to the immediate
surroundings in which they are attached.
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2 Safety 14
WARNING!
Risk due to illegible labels!
In the course of time, stickers and labels can become dirty or otherwise unrecognisable,
thus risks are not recognised and necessary instructions cannot be followed. This poses
a risk of injury.
- Keep all safety, warning and operating instructions in good legible condition.
- Replace damaged signs or labels immediately.
Symbol Description
Electrical voltage
In the area marked as such, only professional electricians are
allowed to work. Unauthorized people are not allowed to enter the
respectively marked workspaces, or to open the switch control box.
Moving machine parts
Maintenance work on open machines may only be performed by
specifically trained specialists. As long as the machine moves, there
is a risk of injury.
Risk of entanglement
Perform work on infeed sections only in shut-down condition. As long
as the machine moves, there is a risk of injury.
Hot surfaces
Hot surfaces, such as hot machine parts, containers or materials as
well as hot liquids, are not always perceptible. Do not touch them
without protective gloves.
Sharp blades
Sharp blades on cutting unit can cause severe injuries. Transport
cutter bar only with guard. Wear protective gloves during handling.
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2 Safety 15
2.9 Spare parts
WARNING!
Risk of injury when using incorrect spare parts!
The use of incorrect or defective spare parts can create hazards to personnel and
cause damages, malfunctions or total failure.
- Use only original parts from manufacturer or parts approved by manufacturer.
- In case of any questions, please contact manufacturer.
Loss of warranty
The manufacturer's warranty is void in the event of unauthorised use of spare parts.
The spare parts catalogue can be found on the included CD.
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3 Technical data
3.1 Dimensional drawings
Figure 3: Layout plan
„X“ depends on final customer design (see filaTex)

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Figure 4: Layout plan with melt pump (option)
„X“ depends on final customer design (see filaTex)
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3 Technical data 18
Use of an optional melt pump on the extruder or a godet holding unit downstream from
the water bath results in different dimensions. See appendix for additional information
on the changed dimensions.
3.2 General information

Dimensions and weight of entire system
Information Value
Length 44 m when using 324 winders
Width 5.4 m
Height 5.3 m
Weight (water bath, take up, holding unit, hot air ov en, stretching unit) 28.000 kg
Space requirement for operator in front 1.5 m
Working width 1.600 mm
Maximum speed 530 m/min
Capacity of water cooling 190.000 kcal/h
Noise
Information Value
Noise exposure > 70 dB
Ambient conditions
Information Value
Air temperature 16 – 45 °C
Relative humidity 60 – 95 %
Altitude above sea level up to 1.000 m
Any use above an altitude of 1.000 m requires modifications to the tiraTex Tape
Extrusion Line. For this purpose, contact manufacturer; contact data page 3.
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3 Technical data 19
Setup location requirements

Machine may not be exposed to direct sunlight or moisture.
The level difference is not to exceed 10 mm (0.4 inch) in relation to machine length and
machine width.
The space requirement for the operator is at least 1.5 m in front of the operator's side of the
line.
Information Value
Floor load capacity 2.500 kg/m²
Insulation resistance of floor > 108 ohm
3.3 Connection values

Electrical connection values
Information Value
Nominal voltage 3x365V – 445 V 50/60Hz
Fuse protection 630 A
Connection power 420 kVA
Additional information on electrical connections can be found in the electrical circuit

diagrams in the separate documents.
Pneumatic connection values
Information Value
Connection value ½“ (13 mm)
Nominal pressure 6 bar
Maximum oil concentration in compressed air 1 mg/m³
Maximum dew point 0.7 MPa at 3 °C
Connection values cooling-water
Information Value
Connection diameter 2x3“
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3 Technical data 20
Request to the water
Designation Value
Appearance colourless, clear
Changes in standstill no sediment
Aroma odourless
pH-value 7,5 – 8,5
Conductivity [in µS/cm] 100 – 150 µS/cm
m-value [in mval/l] max. 10 mval/l
Carbonate hardness [in °dH] 16 °dH
Ammonium [in mg/l] < 0,5 mg/l
Iron [in mg/l] < 0,2 mg/l
Manganese [in mg/l] < 0,2 mg/l
Zinc [in mg/l] < 1,0 mg/l
Chloride [in mg/l] > 30 mg/l
Nitrates [in mg/l] max. 30 mg/l
Total chloride + nitrates [in mg/l] max. 30 mg/l
Chlorine < 0,5 ppm
Sulfate [in mg/l] max. 50 mg/l
Potassium permanganate – value [in mg/l] max. 20 ml/l
Silicid acid [in mg/l] max. 20 ml/l
Bacteria count [count/ml] max. 10 count/ml
Carbonid acid CO2 < 10 ppm
Hydrogen sulphide H2S < 50 ppb
Fresh water connection values
Information Value
Nominal pressure 2-3 bar
Connection diameter ¾“
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3 Technical data 21
3.4 Technical data of touchscreen
Information Value
Voltage supply 24 VDC
Size 15" colour display
Ambient temperature up to 60 °C
Password levels
Password level Access
Production password 173
3.5 Information on process data

Water bath
Approx. 30-40 °C textile behaviour
>45 °C Risk from vapour bubble formation
Temperature suggestions
For thin tapes 40-45 °C
For medium tapes 35-40 °C
For heavy tapes 30-35 °C
For very heavy tapes approx. 25 °C
Water temperature too low Too much strength; problems during stretching
Wrinkles in film; problems during cutting
Water temperature too high Vapour bubble formation in film, water starts to
boil when in contact with melt (trapped air)
Quick cool down Normally results in smaller, finer crystals, and

thus increased effort during stretching. Short
distance to water. Increased splitting tendency
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3 Technical data 22
Slow cool down Greater distance to water results in reduced,

larger crystals, and thus less effort during
stretching.
Minimum distance 10 mm (for container tape)
Water must not spray on die
Maximum distance 50 mm (for thin tapes)
Short distance More strength
More difficult during stretching in oven
More breaks in oven
Large distance Less strength
Better running characteristics in oven
For optimal tapes, replace knives approx.
every 150 hours Breaks increase, knives vibrate
Elongation, strength and knife quality are

decreasing
(depending on raw material used and CaCO3 content)
Hot air oven

PP 140-160 °C max. 180 °C
HDPE 90-140 °C max. 160 °C
Higher temperature Increased elasticity, shrink-resistant
Lower temperature For high-strength tape
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3 Technical data 23
Stretching ratio
Annealing < 5% Increased residual shrinkage, bad winding quality
Annealing 5-10% Low residual shrinkage, good winding quality
Final stretching < 1:4,5 Warning! Fish eye effect
Final stretching 1:5 – 1: 6 Medium strength, high elongation (regular web tape), low splitting
Final stretching 1:6 – 1:7 High strength, low elongation, higher splitting tendency (Warning!
Cold stretching).
NOTE!
The higher the production speed, the lower the final stretching selected.
Example:
300 m/min Stretching 1:6
400 m/min Stretching 1:5.7
480 m/min Stretching 1:5.5
3.6 Type plate

The type plate of the entire line (Figure 5) is
located on the take up beside the touch
panel and contains the following data:
CE marking
Manufacturer
Equipment number
Machine designation
Year of manufacture
Figure 5: Type plate
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4 Structure and function 24
4 Structure and function
4.1 Overview of entire system
Figure 6: Overview of entire system

1 Dosing station dosiTex 7 Hot air oven
2 Extrusion unit 8 Stretching unit
3 Main switch cabinet 9 Tape exhaust
4 Water bath 10 filaTex
5 Take up with vibration drying 11 Container
6 Holding unit
The dosing station (Figure 6/1) fills the extruder (Figure 6/2) with granules. The extruder extrudes
the granules to a film in the water bath (Figure 6/4), where the film is cooled down. After the water
bath, the film is dried via deflectors and vibration drying (Figure 6/5); then it is cut into tape with the
cutting unit and fed to the hot air oven (Figure 6/7) via the holding unit (Figure 6/6). The tapes are
drawn between holding unit and stretching unit (in the area of the hot air oven). Next the tapes are
wound onto bobbins with filaTex.
The main switch cabinet of the line (Figure 6/3) is located behind the extruder. The entire system is
controlled via the control panel.
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4.2 Structure of tape extrusion line
Figure 7: Overview of tape extrusion line

1 Extrusion unit 6 Hot air oven
2 Water bath 7 Edge trim refeed
3 Control panel of line 8 Tape exhaust
4 Take up with vibration drying 9 Stretching unit
5 Holding unit
4.2.1 Water bath

The solidify the film discharged from the flat die, it is cooled in the water bath. After the film web is
discharged from the water bath, the remaining water is removed by means of nip rollers and
vibration pressure.
During operation, the water in the container is continuously circulated by a pump. The water
temperature is maintained at a constant level by means of a tubular heat exchanger, with
connection possibility to an external cooling system or fresh water connection with a control.
After removal from the water, the film has cooled. This is directly followed by a pair of nip rollers. It
removes the remaining water drops.
The contact pressure of the rollers is produced by pneumatic cylinders. For feeding of the film, the
rubber roller can also be completely swung out. Swinging in and out takes place via s switch
located in front of the take up unit. The film web is transported by means of a steel take up roller
and a rubber-coated press cylinder with controlled drive.
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1. A setting wheel (Figure 8/1) is used to

adjust the overflow pipes (Figure 8/2).
Turning it counter clockwise makes water
level fall, and clockwise makes it rise.
Figure 8: Setting water level
Figure 9: high water level Figure 10: low water level
2. If necessary, the film can alternately be

guided over the guide rods (Figure 11/1).
To achieve a longer cooling zone in the
water, the film guide can be lowered when
necessary. Loosen screw (Figure 11/2) and
set the desired position via the longitudinal
opening (Figure 11/3). Next fasten screw
(Figure 11/2) again.
Figure 11: Setting film guide
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3. For heavy tapes, set the spraying direction

of the inlet nozzles (Figure 12/1) toward the
film web.
For light to regular tapes set spraying
direction away from film web.
Setting is performed manually directly on
the blow pipe, or by turning.
Figure 12: Setting inlet nozzles
Keep water circulation volume as high as possible as otherwise the cooling capacity decreases.
By adjusting the control valve, set maximum water volume in such a way that water does not well
up and cause a rough water surface. Large local temperature differences are to be avoided. The
temperature spread between forward and reverse should not exceed 3°C.
4. After discharge from the water bath, the

film web runs through two deflector bars
(figure 19/1).
It consists of two rubber lips which should
be positioned at a 45° angle to the film
web.
For replacement, loosen the screws (figure
19/2) and pull out lips. Then insert the new
lips and tighten screws again (figure 19/2).
Figure 13 Deflector bar
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4.2.1.1 Water circuit
Figure 14: Water bath

1 Emergency overflow 6 Fresh water connection
2 Water bath with overflow pipes 7 Circulation pump
3 Integrated overflow area 8 Heat exchanger and nozzle pipes
4 Shut-off valve for draining 9 Filter
5 Gate valve for cooling water inlet
Circulation is controlled by means of a gate valve (Figure 14/5) and must be set in such a way that
water does not well up.
The water bath is filled through the fresh water connection (Figure 14/6).
The heat exchanger must be connected with the chiller circuit.
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When a high water level is set it can

happen that the overflow pipe can no
longer discharge the water volume. In this
case the two additional overflows (Figure
15/1) can be opened.
This causes the water to flow into the
compensation tank (Figure 15/2).
Figure 15: Overflow - water bath
NOTE!
It is not permitted to block the emergency overflow!
During ongoing production, foam is formed

on the water surface (released paraffins)
which must be siphoned off. Otherwise this
will result in contaminated piping.
Figure 16: Contamination - water bath
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4.2.1.2 Temperature control water bath
A 3-way valve (Figure 17/1) automatically

controls the cooling water volume from
cooler to heat exchanger (Figure 17/2).
Setting is performed via the visual display.
Figure 17: Temperature control - water bath
4.2.1.3 Drain
To drain the water, pull out the two plugs

(Figure 18/1) from the bottom of the water
bath and open shut-off valve.
Clean drain sieve (Figure 18/2) in regular
intervals to prevent contamination.
Figure 18: Drain - water bath
NOTE!
Before draining the water bath ensure that the drain hose discharges into the channel.
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4.2.2 Vibration drying
To set, use button to open flap (Figure 19/3).

The film is set into vibration by air. The
moisture is blown off via blow pipes (Figure
19/1).
Pay attention to film tension!
The angle position is fixed with threaded pins.

When setting the exhaust pipes (Figure 19/2)
ensure that intake opening is on top.
Figure 19 Vibration drying
Vibration drying can be activated via the visual

display (see 6.6.6 Setting parameters of water
bath/take up/holding unit).
The adjustment angle of the unit can be set via
limit stops (Figure 20/2) on the pneumatic
swivel drive (Figure 20/3). The blow pipes
(Figure 20/1) must be manually set.
Figure 20 Setting blow pipes
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NOTE!
In case of contamination, the intake openings of the exhaust pipes must be cleaned with
a wire brush.
4.2.3 Longitudinal cutting unit

The cutting unit consists of cutter bar, knife spacers, as well as blades.
WARNING!
Risk of injury from sharp blades!
- Risk of injuries from cuts when installing and changing cutting blades of knife
assembly due to incorrect handling.
- Wear protective gloves!
- Transport cutter bar only with protective device in place!
To change the knives, loosen counter nut

(Figure 21/1), then unscrew the tensioning
screw (Figure 21/2). Now the knives (Figure
21/3) or blade spacers (Figure 21/4) can be
removed.
Depending on required tape width, the distance
between two knives can be set via the
corresponding blade spacers.
Tighten tensioning screw (Figure 21/2) only by
hand (without tools) since otherwise the blades
could become slanted.
Figure 21 Cutting unit - knife replacement
The cutter bar is designed in such a way that the blades can be used four times. First turn cutter
bar by 180° (second use).
Then remove blades, turn over, and re-insert (third use). Turn cutter bar once more by 180° (fourth
use).
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Cutting tension is set on the visual display. A

load cell (figure 32/1) measures the force
exerted on the deflection roll (figure 32/2).
The anti-breaking screw (figure 32/3) must be

clear from the load cell. There must be a
clearance of at least 0,6 mm.
Figure 22 Cutting tension
The longitudinal cutting unit can be swung out

and in via the pneumatic cylinder (Figure 23/1).
The blades should be assembled in the cutter
bar in such a way that at "Zero" position (middle
position) the blades are in the centre of the film.
If this is not the case, turn adjusting screw
(Figure 23/2) until desired position is reached.
Figure 23 Cross positioning
The film traversing causes the guide rods

(Figure 24/1), to move up and down, thus
ensuring uniform wear of the knives.
The drive takes place via a gear motor (Figure
24/2).
Switching on and dimension of the traversing
can be set via the visual display (see
6.6.6 Setting parameters of water bath/take
up/holding unit).
Figure 24 Film traversing
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Use of table for knife spacers for cutter bar:

Example:
Required tape width: 3 mm
Required stretching ratio: 1 : 5.7
Results in a spacer width of 7.00mm (= 1 x 3mm (orange) and 1 x 4mm (brown)) and 229
tapes or required winders.
Spacer width Spacer colour

1.25mm natural
3.00mm orange
3.50mm red
4.00mm brown
4.50mm grey
5.00mm black
5.50mm blue
6.00mm green
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Figure 25: Table for knife spacers
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4.2.4 Holding unit

Components of holding unit
Figure 26: Integrated holding unit

1 Suction hopper 4 Emergency stop pull-wire
2 Control elements 5 Edge trim refeed
3 Press cylinder 6 Deflector
Settings
The rollers are driven by a controlled gear motor. The press cylinder can be swung in and out
pneumatically. This takes place via a switch on the frame (Figure 26/2). The roller has a rubber
coated surface to prevent the tapes from slipping through. In contrast to the hard surface of the
steel rollers that allows removal of laps with knives, the press cylinder is not to touch the knives.
When line is shut down, lift press cylinder to prevent pressure marks. These pressure marks could
cause a permanent deformation and deviation of the material.
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Feed diagram
Figure 27: Feed diagram water bath with holding unit
Figure 28: Feed diagram water bath with holding unit and thickness gauge (option)
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Prior to initial commissioning

Check rotational direction of all motors (direction of arrow on motors)
Check pneumatic connections
Lubricate bearings of holding unit
Control elements
Figure 29: Control elements integrated holding unit

1 Emergency stop buttons 3 Emergency stop pull-wire
2 press cylinders up/down
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Deflector
May only by supported by its own weight

(without tension). Check slide lining with which
the deflector rests on roller at least once per
month for wear and replace in a timely manner;
otherwise it could cause damage to the roller
surface.
Reference value: < 0.5mm thickness
Figure 30: Deflector integrated holding unit
4.2.5 Hot air oven

Components of hot air oven
Figure 31: Hot air oven

1 Control panel 3 Motor 2 – M2
2 Motor 1 – M1

Check pneumatic connections
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Control elements
Figure 32: Control elements hot air oven

1 Close 5 Fault indication
2 Start hot air oven 6 Open
3 Stop hot air oven 7 Close
4 Emergency stop button
Fans M1 and M2 are activated by pressing the start button (Figure 32/2). The heating surfaces are
automatically switched on and off. The temperature is input via the touch panel on the take up.
When the hot air oven is open, it cannot be started. When opened during operation, the hot air
oven switches off. To open, press button "Figure 32/6" and hold. To close, press the two buttons
"Figure 32/1 and Figure 32/7" and hold. The fans are stopped by pressing the stop button (Figure
32/3).
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4.2.6 Stretching unit
Figure 33: Stretching unit

1 Suction hopper 6 Heated godets
2 Control panel 7 Emergency stop pull-wire
3 press cylinders 8 Cooled godets
4 Regular godet 9 Deflector
5 Protective hood
Settings
The stretching system consists of a stretching unit – 4 godets – and an annealing unit – 2 godets.
Stretching unit
The stretching unit operates at a speed that corresponds to the stretching ratio, i.e. at a
stretching ratio of 1:5.5 or 1:7 with 5.5-fold or 7-fold speed of the holding unit. This results in
intensive stretching of the tapes. The drive takes place via an adjustable gear motor with
belt drive. The flat belt drive prevents transfer of oscillations to the godets.
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Annealing unit
The annealing unit runs slower than the stretching unit and is used to stabilise the tapes
drawn in the stretching unit. It is always driven by a separately adjustable gear motor with
flat belt and consists of two godets that are equipped with a cooling water throughput. To
prevent calcification and contamination of the medium line within the godet, the cooling
water circuit must be closed.
In contrast to the hard surfaces of the godets that allow removal of laps with knives, the
pivoting rollers should not touch the knives. The drive takes place from the adjacent godet.
The contact pressure of the press cylinder

is set via a pressure regulator (Figure 34/1)
in the main supply – max. 3 bar. To prevent
pressure marks when line is shut down, lift
press cylinder. These pressure marks could
cause a permanent deformation and
deviation of the material.
Figure 34: Setting - contact pressure
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Feed diagram
Figure 35: Feed diagram stretching system - 6 godets

Check water, oil and pneumatic connections
Check tension and position of drive belts
Lubricate godet bearings
Control elements
Figure 36: Control elements stretching unit
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1 Press cylinder #1 up/down 7 Emergency stop button

2 Tape exhaust on/off 8 Press cylinder #2 up/down
3 Meter counter 9 Increase line speed
4 Increase annealing 10 Decrease line speed
5 Reduce annealing 11 Start stretching unit
6 Stop production line 12 Stop stretching unit
Use start button (Figure 36/11) to bring stretching unit to starting speed. Wait until this speed is
reached before lowering the rollers with buttons Press cylinder annealing unit up/down (Figure
36/1) and Press cylinder stretching unit (Figure 36/8).
Commissioning
During initial commissioning ensure that heated and cooled godets are not dry when started (must
be filled with oil and water). Allow godets to run while oil heater heats up to desired temperature.
The temperature must not exceed 120 °C since otherwise the tapes will stick to the godet.
After 100 operating hours re-grease godet bearings according to lubrication chart, then according
to the intervals indicated in the maintenance schedule.
Shutting down stretching unit
Reduce line to starting speed.

Cut off tapes at stretching unit (rest goes into exhaust).
Reduce temperate for heated godets to 80 °C.
Use "Stop line" button (Figure 36/12) to switch off the stretching unit.
Switch off oil heater.
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Godet installation
1. Clean inside of godet (bearing seat), remove preservative.
2. Clean and grease conical rings and insert into godet from both sides (pay attention to
direction of insertion; front facing inward).
3. Slide flange ring (Figure 37/1, Figure 38/1) onto godet bearing; pay attention to direction.
4. Slide conical ring (Figure 37/2, Figure 38/2) onto godet bearing (front facing bearing).
5. Instead of a screw, insert threaded rod (Figure 37/3, Figure 38/3) into flange ring (use
installation tool for centring).
6. Carefully slide godet (Figure 37/4, Figure 38/4) onto bearing via crane/lifting gear
7. Slide conical ring (Figure 37/5, Figure 38/5) onto shaft (always lubricate); next remove
threaded rod (Figure 37/3, Figure 38/3).
8. Slide flange ring (Figure 37/6, Figure 38/6) onto shaft.
9. Grease and screw in screws (Figure 37/7, Figure 38/7, Figure 39/1).
10. Tighten screws by hand (crosswise); start with bottom screws.
11. Remove crane and measure out-of-balance with dial gauges (in front and rear).
12. Set the largest deflection (on dial gauge) of godet upwards and tighten screws with 40
Nm. Start with bottom screws, top screw last.
13. Measure out-of-balance again. Set the largest deflection upwards again and tighten
screws with 50 Nm. Start again at bottom, top screw last.
14. Repeat this process up to 120 Nm in increments of 10.
15. At 120 Nm, maximum out-of-balance must not exceed 0.18 mm.
16. If out-of-balance is exceeded, remove godet again, turn flange ring by 120° and start from
the beginning.
17. Next insert oil or water distributor again (pay attention to washers).
The heated godets can be installed analogous to the regular godet. It is merely necessary to insert
and fasten the return pipe (Figure 38/8) with the oil distribution plate (Figure 38/9, Figure 39/2).
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Figure 37: Installation regular godet

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Figure 38: Installation heated/cooled godet
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Figure 39: Front view heated/cooled godet
1 Adjustment screw for concentricity of godet 2 Screws for fastening of oil distribution plate
NOTE!
Completely drain godets prior to removal.
During removal ensure that a vessel is in place to catch draining fluids (oil, water).
Oil heater
For description of oil heater, see attached operating instructions.
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4.2.7 Edge trim refeed
Figure 40: Edge trim refeed

1 Exhaust pipe 2 Cutting mill
The edge trim is conveyed via an exhaust pipe (Figure 42/1) to the cutting mill (Figure 42/2), where
it is shredded. Then it is directly blown into the cyclone via a high-pressure blower, and forwarded
to the extruder by means of a densifier.
Prior to activation of the cutting mill, the edge trim must be fed into the exhaust.
The waste material is plasticized again in the extruder for further processing.
4.2.7.1 Cutting mill

The cutting mill is only to be operated after the final production speed has been reached.
This is due to the fact that the film width is reduced as production speed increases. The edge trim
should be maximum 15-20mm wide on left and right side. If necessary, remove cutting blades in
edge zone. Width to be fitted with blades shall always be sufficiently smaller than film width.
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Figure 41: Cutting mill
WARNING!
Manipulation could result in severe injuries!
- The safety regulation must not be manipulated since this could result in severe
injuries.
4.2.8 Tape exhaust
Figure 42: Tape exhaust

1 Container 3 Exhaust pipe
2 Exhauster 4 Hopper
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Tapes that break at holding unit or stretching unit are extracted via the overhead hopper and
delivered into the container. This prevents laps on rollers or godets.
4.3 Control elements
Figure 43: Overview of control elements

1 Main control cabinet 4 Control panel of hot air oven
2 Control panel of tape extrusion line 5 Control panel of stretching unit
3 Control panel of holding unit
The line's master switch is located on the main control cabinet (Figure 43/1). The entire production
process is controlled via the control panel of the tape extrusion line (Figure 43/2). The holding unit
features a control panel (Figure 43/3) to move the press cylinder up and down.
The hot air oven has a separate control panel (Figure 43/4).
On the control panel of the stretching unit (Figure 43/5), individual parameters can be adjusted.
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4.3.1 Control panel of tape extrusion line

The control panel of the tape extrusion line is used to control the entire line. It is located in front of
the line at vibration drying.
Figure 44: Control panel of tape extrusion line
1 Touchscreen 7 Emergency stop button

2 Button "Line speed up" 8 Button "Move extruder"
3 Button "Line speed down" 9 Button "Extruder start"
4 Button "Take up start" 10 Button "Extruder stop"
5 Button "Take up stop" 11 USB connection
6 Button "Reset & control voltage on“
The operating panel is equipped with an emergency stop button (Figure 44/7). The "Reset" button
allows resetting of the emergency stop and switching on of the control voltage. On the touchscreen
(Figure 44/1) all settings for the process can be performed (description see chapter 6.6
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Touchscreen operation). Data import and export is carried out via the USB connection (Figure
44/11).
Control elements for line operation:

Button "Reset" switches on the control voltage of the line.
Button "Line Stop" (Figure 44/5) stops all line movements.
Button "Line speed up" (Figure 44/2) increases the process speed during operation.
Button "Line speed down" (Figure 44/3) decreases the process speed during
operation.
Button "Take up start"
Control elements for extruder:

Button "Extruder start" (Figure 44/9) starts the extruder.
Button "Move extruder" (Figure 44/8) moves extruder forward ( ) or backward ( ).
In 0-position extruder is not moved.
Button "Extruder stop" (Figure 44/10) stops the extruder.
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4.3.2 Touchscreen of tape extrusion line
Figure 45: Touchscreen

The start page of the touchscreen features the following buttons:
Position Button Function

number
1 Accesses the start page in each window
2 Opens the window "Report"
3 Opens the window "Setup"
4 Opens the window "Thickness

measurement - wall thickness
distribution" (option)

measurement - settings" (option)
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Pressing on the different line parts accesses the settings pages of the corresponding component:
Position Component Settings

number
6 Extruder see operating instructions Extruder
7 Water bath/take up/holding unit see 6.6.6 Setting parameters of water

bath/take up/holding unit
8 Hot air oven/stretching see separate instructions of hot air oven or

6.6.7 Setting hot air oven/stretching
parameters
9 Stretching unit see 6.6.8 Setting stretching unit parameters
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5 Storage and transport 56
5 Storage and transport
5.1 Packaging
The individual packages are packaged according to the expected transport conditions.
The packaging is to protect the individual components from transport damage, corrosion and other
damages until the time of assembly. Therefore do not destroy the packaging and remove only
shortly before assembly.
Symbols on packaging
The following symbols are found on the packaging. Pay attention to the symbols during transport.
The packages are packed for transport on
IPPC pallets (Figure 46/1) made of treated
lumber.
Figure 46: IPPC symbol
Do not transport packages (Figure 47/1)

with this marking via forklift.
Figure 47: Forklift
After unpacking dispose of packaging material in an environmentally sound manner.

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5.2 Storage
NOTE!
Damage to property due to incorrect storage!
Incorrect storage can cause damage to machine components.
- Protect packages against humidity and moisture.
- Never store packages outside.
- Remove packaging only shortly before assembly.
5.3 Transport and setup
Transport, setup and installation of the machine is performed by employees of the

manufacturer or by persons authorized by him.
5.3.1 Setup of tape extrusion unit with crane
WARNING!
Risk of fatal injuries from suspended loads!
During lifting, loads can swing out and drop. This can cause serious injuries, even
death.
- Never stay under or within the pivoting range of suspended loads.
- Move loads only under supervision.
- Use only approved and undamaged lifting gear and lifting accessories with sufficient
load-bearing capacity.
- Do not place lifting gear such as ropes and belts against sharp edges and corners,
do not knot and twist.
- When leaving the workplace, set down the load.
WARNING!
Risk of injury from falling or tilting packages!
The packages' centre of gravity can be off centre. Incorrect attachment can cause the
package to tilt and fall. Falling or tilting packages can cause severe injuries.
- Pay attention to markings and centre of gravity information on the packages.
- When using a crane for transport, attach crane hook in such a way that it is above
the package's centre of gravity.
- Lift package carefully and see if it tilts. If necessary, change attachment.
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NOTE!
Damage to property due to incorrect transport!
Incorrect transport can cause transported goods to fall or overturn. This can cause
considerable property damage.
- Ensure that unloading of transported goods at time of delivery, as well as internal
transport is only carried out by service personnel under supervision of
manufacturer's personnel.
- Ensure that unloading of transported goods at time of delivery, as well as internal
transport are performed carefully and that symbols and advice on packages is
observed.
- Protect transport goods against humidity and moisture.
- Avoid impact on machine components.
- Transport machine only in a closed transport system such as truck, train or
container.
Before transport with crane ensure the following:

Crane and lifting gear must be designed for the weight of the transport goods.
When using load hooks, do not exceed the maximum permitted opening angle of the
hook.
The operating company must be authorised to operate the crane.
Protective equipment: Hard hat
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Figure 48: Requirements on lifting gear

1 Reference line 3 Capacity depending on angle of spread (in
2 Angle of spread of bearer cables (angular percent)
degree) 4 Load reduction (in percent)
5.4 Installing
WARNING!
Risk of injury from improper installation and commissioning!
Errors during installation or initial commissioning can result in fatal situations or
considerable property damage.
- Ensure that installation and initial commissioning is performed by manufacturer's
employees or persons authorised by him.
- Consult manufacturer in case location is changed at a later time.
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5.4.1 Connecting electrical system
DANGER!
Contact with energised components can result in death. Activated electrical components
can move uncontrollably and result in most severe injuries, even death.
- Switch off electrical supply before performing any work and protect against
unintentional activation.
Personnel: Manufacturer's specialists

1. Ensure that electrical supply is disconnected prior to starting work and protected
against unintentional activation.
2. Proceed according to electrical circuit diagrams provided in the separate

documents.
5.4.2 Connecting pneumatic system
WARNING!
- Before switching on compressed air ensure that all pneumatically driven
components are installed correctly.

1. Ensure that compressed air supply is disconnected prior to starting work and
protected against unintentional activation.
2. Establish pneumatic connections; proceed according to pneumatic diagrams

provided in the separate documents.
3. Set operating pressure to 6 bar at pressure regulator.
4. Check operating pressure on pressure gauge at the rear end of the switch cabinets.
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5.4.3 Connecting water

1. Ensure that water supply is disconnected prior to starting work and protected
Figure 49: Water distributor stretching unit
1 Feed from chiller 9 Connection from drive 13 kW (annealing

2 Connection to cooled godet unit)
3 Connection to cooled godet 10 Connection from drive 19 kW (stretching
4 Connection to drive 26 kW (stretching unit) unit)
5 Connection to drive 19 kW (stretching unit) 11 Connection from drive 26 kW (stretching
6 Connection to drive 13 kW (annealing unit) unit)
7 Connection to water distributor extruder, 12 Connection cooled godet
etc. 13 Connection cooled godet
8 Connection from water distributor extruder, 14 Return to chiller
etc.
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Figure 50: Water distributor extruder - water bath
1 Feed from chiller (Figure 49/7) 8 Connection from control panel

2 Connection to heat exchanger water bath 9 Connection from air-water heat exchanger
3 Connection to extruder (switch cabinets)
4 Connection to thermoCon 10 Connection from air-water heat exchanger
5 Connection to air-water heat exchanger (switch cabinets)
(switch cabinets) 11 Connection from main drive extruder
6 Connection to air-water heat exchanger 12 Connection from thermoCon
(switch cabinets) 13 Connection from heat exchanger water
7 Connection to control panel bath
14 Return to chiller (Figure 49/8)
Rust damage from water cooling

If water cools down below 20°C, the feed section of the extruder and the screw can start
to rust due to condensation.
Add 25 % ethylene glycol antifreeze to water
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thermoCon:
The thermoCon is only available in
conjunction with a torque motor.
1 Connector from distributor (Figure 50/4)

2 Connector to distributor (Figure 50/13)
Abbildung 51: Scheme thermoCon

Display of lamps:
Green lamp lights = thermoCon is in operation
Green lamp is flashing= thermoCon is ready for operation
Red lamp lights = an alarm is present; see the alarm on the touchscreen
1 Inlet motor
2 Inlet frequency inverter

3 Inlet from chiller (chiller to
thermoCon)
4 Return to chiller (thermoCon to

chiller)
5 Return motor
6 Return frequency inverter
Abbildung 52: Connection thermoCon
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6 Operation 64
6 Operation
WARNING!
Risk of injury from improper operation!
Improper operation can cause serious injuries.
- Perform all steps according to information and notes contained in these instructions.
- Before starting operation ensure that all covers and safety equipment are installed
and function properly.
- Ensure that no persons are in the danger zone.
- Never disable or bypass safety equipment during operation.
- Do not remove insulation hoods of cylinder cooling during operation.
- Wear personal protective equipment.
DANGER!
Risk of injury from getting entangled by godets on stretching unit!
and cause most severe injuries or can result in death.
- Do not reach between tapes and rotating rolls.
- Keep away from immediate danger zone in stretching unit.
NOTE!
Production failure due to improper operation!
Improper operation can cause damage to the line.
- Always keep heating elements in stock.
- Switch on cooling water circuit immediately after switching on line.
6.1 Switching on
WARNING!
Risk of injury from noise!
The noise level occurring in the workspace can cause serious hearing damage.
- Always wear hearing protection when performing work.
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6 Operation 65
DANGER!
- Do not reach into rotating rolls.
- Do not reach into gaps between rotating rolls.
Personnel: Operator
Switching on for production

1. Ensure that all emergency stop buttons are unlocked.
2. Switch on master switch on main switch cabinet of line.
3. Switch on cooling water circuit.
4. Extruder: Check whether screen is inserted in filter.
Check measuring lines for thermal sensor, melt temperature and melt pressure, plus
connection cables for all heaters.
5. To heat up, enter the desired temperature into the visual display of extruder,
automatic filter, static mixer and flat die.
When all temperatures are within the tolerances, the heating timer is started.
The waiting period is 60 min. During this time the extruder cannot be started.
6. If necessary retighten all fastening screws during initial commissioning in heated

state on automatic filter, static mixer, flat die and on all tensioning points of the
heating elements.
Pay attention to screw-tightening torque.
7. Pull a film web from the guide rolls through the water bath, take up and holding unit.
8. Switch on extruder via the visual display.

Wait until the melt is uniformly discharged from the die.
9. Move extruder carriage until it is approx. 100 mm in front of end position and start
extruder with a base speed of approx. 10 rpm.
10. When the melt discharged from the die touches the film, start take up and holding
unit and advance extruder to end position. Then the melt is bonded to the film and
pulled through to the holding unit over the longitudinal cutting unit. Close nip rollers
and press cylinders and switch on water pump.
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6 Operation 66
11. Next, film web is manually wound by operating personnel.
12. Cut off film and pull through hot air oven.
13. Start stretching unit drive and place film on godets. Switch on exhaust, guide film
into exhaust die. As a result, the film web is sucked into the container.
14. Lower press cylinders on stretching and annealing unit.
15. Check film web after it is discharged from water bath to see if it is free of defects;
swing longitudinal cutting unit into place. Cut off edge trim and convey to exhaust in
holding unit.
16. After the stretching unit at the exhaust die, the tapes are picked up in bundles by the
suction gun and then placed onto the winding unit.
17. Increase line speed to 100 m/min.
18. Check tapes
Width of tapes.
If necessary, correct stretching ratio until proper tape width is achieved.
Check titer.
If necessary, correct extruder speed until titer is reached.
Check quality.
19. After checking the line speed, slowly increase to production speed.
In the process, check all parameters (cutting tension, annealing on stretching unit,
gradually increase oven temperature, oil heater).
20. Check tapes again.
21. Switch on cutting mill of edge trim refeed on visual display. The width per edge trim
should not exceed 10mm.
22. In case of production change, check die gap and reset if necessary.
Checks during production
Material supply.
Cooling water supply.
Pre-set parameters.
Drives running in specified load range.
Empty waste container immediately after all tapes are placed on winder.
Cutting unit: Ensure that film is not displaced by the blades in the cutting area.
Film drying.
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6 Operation 67
Process check
Width of tapes.
Strength of tapes.
Cold stretching Yes/No.
Visual assessment of film for specks, streaks, colour distribution, surface.
Wall thickness distribution
6.2 Checks and settings after switching on

1. Check rotational direction of all motors according to arrows on motors.
2. Check tension and position of drive belts.
3. Ensure that screen tapes are inserted in automatic filter.
4. Move cut off edge trims of exhaust into lattice box.
5. Ensure that rotational direction of

extruder screw in production direction always
runs counter clockwise (Figure 53).
Figure 53: Rotational direction of extruder screw
After production process is switched on, the cut off edge trims must be fed to the exhaust lines.
06.11.2015
6 Operation 68
1. Feed edge trim 2x (Figure 54/1) of edges to

the corresponding exhaust lines.
Figure 54: Setting up exhaust
6.3 Switching off

Switching off in normal operation
Personnel: Operator
1. Reduce line speed to about 80 m/min.
2. Cut off tapes at exhaust of stretching unit.
3. Press button "Stop line" – switch off all drives.
4. Switch off circulation pump and hot air oven.
5. Switch off components.
6. Clean off liquid plastic residue from flat die.
7. If necessary, switch off water and compressed air supply.
8. If standstill is planned for an extended period of time, also switch off machine's
master switch.
NOTE!
In the event of machine downtime, swing press cylinder away from holding unit and
stretching unit, since otherwise deformation of the silicone layer can occur.
Emergency shutdown
1. Operate emergency stop device.
06.11.2015
6 Operation 69
6.4 Preparing production on machine
6.4.1 Preparing dosing station

See operating manual of dosing station.
6.4.2 Preparing automatic filter

See operating manual of extruder.
6.4.3 Feeding film web

Feed film web according to feed diagram as described in chapter 4.2.6 Stretching unit.
6.5 Procedure with production disturbance by winding on stretching

unit or holding unit
DANGER!
Risk of injury from getting entangled by godets on stretching unit/holding unit!
- Do not reach between tapes and rotating rolls.
- Keep away from immediate danger zone in stretching unit.
- Keep safety cover closed during operation.
In the case of a winding formation through torn tapes on stretching unit or holding unit, the
machine must be stopped and the winding are removed with a knife at stillstand of the machine!
Personnel: Operator
1. Stop the machine!
2. Open safety cover.
3. Remove the winding with a knife at standstill.
4. Close safety cover.
5. Start the machine as described.
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6 Operation 70
During the operation it is strictly forbidden to remove a winding and to rise to the stretching
unit or to get into the stretching unit !!!
Figure 55: PROHIBITION Figure 56: PROHIBITION
To feed the film to suction hopper after the stretching unit, the knife bar must be swung out AND
the safety cover must open max. 50m/min. If the safety cover is closed and the knife bar is
swung in, the line can be brought to production speed.
If the safety cover is open for reloading of tapes during the production, it is indicated by a light
signal. Is the safety cover not closed after 60 sec. at a 6-godet stretching unit and 120 sec. at a 8-
or 10-godet stretching unit, an automatic quick-stop is initiated.
Special inrunning nips are indicated in the following figure with arrowas.
Do not touch the inrunning nips!
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6 Operation 71
Figure 57: Inrunning nips
6.6 Touchscreen operation
NOTE!
The touchscreen shall only be operated by fingers.
Do not use any sharp objects!
6.6.1 Changing password
1. To open the "Settings" window, press the (left)

button in the start window.
2. Access password entry.

A numeric keypad appears for entry.
3. Enter new password and confirm.
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6 Operation 72
6.6.2 Main menu
Figure 58: Window "Overview screen"
1 Accesses the start page in each window
2 Opens the window "Report"
3 Opens window "Setup"

measurement - wall thickness
distribution" (option)

measurement - settings" (option)
6.6.3 Performing general settings

Make desired settings on touchscreen in "Setup" (Figure 59) window.
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6 Operation 73
Figure 59: "Setup" Window
1 Setting time and date 15 Entry titer

2 Indication of drop at which line speed will 16 Entry number of tapes
be reduced 17 Entry edge trim cutting width
3 Annealing unit On/Off 18 Entry tape width
4 Stretching unit 8 or 10 godets On/Off 19 Indication knife spacer width
5 Stretching unit On/Off 20 Entry total stretching ratio
6 Holding unit On/Off 21 Indication actual total stretching ratio
7 2nd take up On/Off (Option) 22 Indication actual stretching ratio
8 Melt pump On/Off 23 Indication calculated extruder speed
9 Oil heater On/Off 24 Setting tolerance that when exceeded will
10 Switch heating zone Z27 + Z28 On/Off trigger alarm
11 Switch between left and right oriented 25 Switching automatic heating on and off at a
design certain time
12 Open window "Status messages converter" 26 Indication temperatures of switch cabinet,
13 Thickness measurement On/Off cooling water and main drive
14 Setting touchscreen display language 27 Entry password
28 Entry production parameters
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6 Operation 74
6.6.4 Setting extruder parameters

1. In start window of line overview screen press on extruder.
2. Enter parameters on display in "Extruder" (Figure 60) window.
Figure 60: "Extruder" window
1 Entry effective extruder output 9 Indication duty cycle as ratio between

2 Entry material change pause time and heating time (green)
3 Indication operating hours 10 Indication melt pressure in front of flat die
4 Heater On/Off 11 Indication melt pressure in front of
5 Entry heating time automatic filter
6 Entry target line speed 12 Entry target temperature of feed zone
7 Entry target temperature heating zone cooling
(blue) 13 Status indication of drive
8 Indication melt temperature
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6 Operation 75
Figure 61: "Extruder" window - with melt pump (option)
1 Entry maximum pressure. The extruder 3 Indication power input

controls the speed correspondingly. 4 Indication torque
2 Entry melt pump speed
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6 Operation 76
6.6.5 Setting flat die parameters

1. In start window of line overview screen press on flat die.
2. Enter parameters on display in "Flat die" (Figure 62) window.
Figure 62: "Flat die" window
1 Entry target line speed 4 Entry heating intervals in minutes

2 Entry extruder screw speed 5 Entry target temperature of heating
3 Switching automatic filter on and off cartridge
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6 Operation 77
Figure 63: Window "Flat die with melt pump" - (option)
1 Entry maximum pressure. The extruder 3 Indication power input

controls the speed correspondingly. 4 Indication torque
2 Entry melt pump speed
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6 Operation 78
6.6.6 Setting parameters of water bath/take up/holding unit

1. In start window of line overview screen press on water bath.
2. Enter parameters on display in window "Water bath/take up/holding unit" (Figure

64).
Figure 64: Window "Water bath/take up/holding unit" - integrated holding unit
1 Entry extruder screw speed 8 Entry film tension between holding unit and
2 Entry water exhaust On/Off take up
3 Indication power input and speed of take 9 Entry target line speed
up #2 10 Entry tape oscillation On/Off
4 Indication power input and speed of take 11 Entry lifting height of tape oscillation in mm
up #1 12 Entry duration of lifting height. Duration of
5 Entry preload take ups. Ratio take up #2 dwell time at set lifting height in minutes.
and take up #1. The value set is the value 13 Entry water pump On/Off
by which the speed of take up # 1 is 14 Entry water bath temperature
reduced
6 Entry vibration drying On/Off
7 Entry edge trim refeed On/Off
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6 Operation 79
6.6.7 Setting hot air oven/stretching parameters

1. In start window of line overview screen press on hot air oven.
2. Enter parameters on display in "Hot air oven/stretching" (Figure 65) window.
Figure 65: Window "Hot air oven/stretching" - integrated holding unit
1 Entry extruder screw speed 6 Indication ratio between annealing unit and
2 Indication power input and speed of take stretching unit.
up #2. 7 Indication ratio between stretching unit and
3 Indication power input and speed of take holding unit.
up #1. 8 Entry target temperature of hot air oven
4 Entry target temperature of oil heater 9 Indication of power input, speed and torque
5 Entry total stretching ratio. Ratio between of holding unit.
annealing unit and take up #2.
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6 Operation 80
6.6.8 Setting stretching unit parameters

1. In start window of line overview screen press on stretching unit.
2. Enter parameters on display in "Stretching unit" (Figure 66) window.
Figure 66: "Stretching unit" window

1 Entry temperature oil heater 3 Meter counter – count down from set value
2 Entry speed of annealing unit to 0
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6 Operation 81
6.6.9 Setting thermoCon parameters
1. In start window of line overview screen press on thermoCon-button.
2. Enter parameters on display in "thermoCon" (Figure 66) window.
Figure 67: "thermoCon" window
1 Indication Mixing valve open/close 7 Entry min. flow rate-extruder alarm

2 Indication pump ON/OFF 8 Entry min. flow rate-chiller Alarm
3 Indication flow rate motor 9 Indication threshold alarm
4 Entry Target-Temp. motor 10 Indication flow rate chiller
5 Indication Actual-Temp. motor 11 Indication temp. chiller
6 Entry time after the alarms are displayed
After the extruder was stopped, the thermoCon runs after 5 minutes.
The operating time of the mixing valve from minimum to maximum is 150 seconds (2,5 min).
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6 Operation 82
6.7 Activities during production
6.7.1 Preparation of production report
1. In start window, press button (left).

The window „Report“ (Figure 68) opens up.
Figure 68: "Report" window

2. To prepare a new report, press Figure 68/1.
3. To open an existing report, press Figure 68/2.
4. To delete an open report, press Figure 68/3.
5. To save an open report under a new name, press Figure 68/4.
6. To save an open report as HTML file on a USB stick, connect USB stick and press
Figure 68/5.
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6 Operation 83
6.7.2 Thickness measurement (option)

The window „Report“ (Figure 68) opens up.
Figure 69: Window "Wall thickness distribution in %"
1 Entry measure of scale in % 3 Entry control parameters

2 Switch to view of wall thickness distribution
in µm
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6 Operation 84
Figure 70: Window "Wall thickness distribution in µm"
1 Entry measure of scale in µm 3 Entry control parameters

2 Switch to view of wall thickness distribution
in %
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6 Operation 85
6.7.3 Setting thickness measurement (option)
Figure 71: "Thickness measurement –Settings" window
1 Move to parking position Yes/No 5 Status messages to wall thickness

2 Measurement On/Off measurement
3 Calibration On/Off 6 Entry parameters
4 Extruder control with wall thickness 7 Wall thickness distribution in %
measurement 8 Wall thickness distribution in µm
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6 Operation 86
Figure 72: "Thickness measurement –parameters
1 Entry minimum reversal point 7 Entry set thickness

2 Entry maximum reversal point 8 Longitudinal profile average values
3 Entry fix position of measuring head 9 Edge trim width
4 Speed at automatic setting 10 Film width adjustment
5 Manual speed 11 Width of hysteresis
6 Slow speed 12 Periodic calibration
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7 Maintenance 87
7 Maintenance
NOTE!
Perform work on or in the line only when shut down. Before recommissioning, install all
covers, fittings and guards according to directions and check for proper function.
NOTE!
- Do not use flammable solvents when cleaning the line!
- Do not clean with high-pressure cleaner.
DANGER!
can move uncontrollably and result in most severe injuries.
- Switch off electrical supply before performing any maintenance work and protect
WARNING!
Risk of injury from improper maintenance!
Improper maintenance can cause incorrect operation of the line and thus life-
threatening situations and severe property damage.
- Replace crush seals on automatic filter and static mixer after each removal.
- Always pay attention to the correct tightening torque.
DANGER!
- Exercise caution when working on rolls.
06.11.2015
7 Maintenance 88
WARNING!
7.1 Maintenance indicators

Required maintenance work is indicated on the touchscreen of the water bath/take up/holding unit.
If increased wear is noticed during regular checks, shorten the required maintenance intervals
according to actual wear and tear.
If you have questions concerning maintenance work and intervals, contact manufacturer; see
contact data page 3.
Accessing "Maintenance work" window

The window "Maintenance work" (Figure 73)
opens up.
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7 Maintenance 89
Figure 73: "Maintenance work" window
1 Reset maintenance work button 3 Maintenance work to be performed

2 Indication of current operating hours 4 Indication of maintenance intervals
2. Perform indicated maintenance work (Figure 73/3).
3. If necessary, perform maintenance work as listed in maintenance schedule.

Observe instructions on maintenance work (7.4 Maintenance work).
4. After completion of maintenance work press button Figure 73/1 to reset

maintenance intervals.
7.2 Lubrication chart

Personnel: Maintenance personnel
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7 Maintenance 90
Interval Lubrication point Lubricant

(operating
hours)
Take up
25000, at Oil change - gearbox CLP HC 320

least every 3 Mounting position E: 4.6 l
years Mounting position F: 2.5 l (left
hand execution)
6000, at least Flanged bearing SKF LGWA2 / SKF LGMT2

once per
year
1000 Grease and retighten chain for traversing Aralub HL 2

Boil 1 x per year in chain lubricant
4 x per year Betacontrol carriage DIN51825 K2K
Integrated holding unit
25000, at Oil change - gearbox Aral Degol 320

least every 3 5.2 l
years
6000 Flanged bearing Klueber Petamo GHY 441

110 ccm/Pos
Cutting mill
1000 Cutting mill bearings SKF LGWA2 / SKF LGMT2
Stretching unit
2500 Regular godets on stretching unit Klueber Petamo GHY 441

110 ccm/Pos
1500 Heated godets on stretching unit Klueber Petamo GHY 441

110 ccm/Pos
6000, at least Cooled godets on annealing unit Klueber Petamo GHY 441
once per 110 ccm/Pos
year
8000 Oil change – gearbox 3x Aral Degol BG220

6l
1200 Heated godet connecting parts Klueber Barrierta L55/2

Rotary feedthrough 555 18 g
16000 Cooled godet connecting parts Klueber Petamo GHY 441

Rotary feedthrough 555 18 g
06.11.2015
7 Maintenance 91
Interval Lubrication point Lubricant

(operating
hours)
7000, at least Oil heater – oilchange, replace oil filter BP Transcal N or

every 2 years Castrol Perfecto HT5 or
Mobil Mobiltherm 605 or
Agip Alaria 3 or
Shell Heat Transfer Oil S2
Specific instructions in terms of proper maintenance and lubrication are indicated on the type
plates or in the supplier documentation, and must generally be complied with.
Mixing of different oils and/or greases must be avoided at all costs.

Concerning specific instructions in terms of proper lubrication and
maintenance, the information on the type plates or the provided supplier
documentation have priority and must generally be followed.
7.3 Maintenance schedule

In addition to the maintenance indicated in the line control, the following maintenance schedule
applies.
Interval Maintenance Personnel
Daily Clean machine, if necessary use compressed air Operator

Check flow meters for cooling system of switch cabinet; if Maintenance
necessary, clean screen in dirt trap. personnel
If needed Clean extruder screw

Replace screen tape of automatic filter
Maintain cutting mill
Water bath
Weekly Clean intake openings of exhaust pipes with a wire brush Maintenance
personnel
If needed Clean scale on nip rollers with descaler
In case of exterior contamination, clean pump.
Keep impeller clean.
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7 Maintenance 92
Interval Maintenance Personnel
Integrated holding unit
Weekly Clean rollers with a soft cloth. When doing so, use cleaning Operator
agents or wire brushes
2 years Perform inspection of roller bearings Maintenance

personnel
Hot air oven
If needed To prevent a decrease in the air and temperature accuracy Operator

of the oven, the material duct and the metal lattice must be
kept free from material clumps and the like.
The seal strips between the oven parts must be replaced Maintenance
when they no longer seal properly. personnel
Stretching unit
Weekly Check belt tension. One week after initial commissioning, Maintenance
then every 1000 hours personnel
Clean godets with a soft cloth
2 years Perform inspection of godet bearings
7.4 Maintenance work
7.4.1 Removing plastic residues

See operating manual extruder.
7.4.2 Changing screen tape

See operating manual extruder.
06.11.2015
7 Maintenance 93
7.4.3 Replacing knives of cutting mill

WARNING!
Risk of injury from knives of cutting mill!
Stator knives and rotor knives of cutting mill can sever fingers and cause serious cuts.
- Never bypass safety switch.
- Wear protective gloves.
- Always use caution.
Making knives accessible

1. Switch off cutting mill via control panel (Figure
64/7 “Edge trim refeed off”).
The safety switch (Figure 74/1) opens 15 s after
mill is switched off.
2. Unscrew star-knob screws (Figure 74/3) and

remove inlet flange (Figure 74/2).
3. Loosen and remove screws (Figure 74/arrows),

remove cover (Figure 74/4).
Figure 74: Opening cutting mill
4. Remove nut (Figure 75/3) and spacer sleeve

(Figure 75/2).
5. Attach stop screws (Figure 75/1) all the way on

top.
6. Pull out rotor (Figure 75/4).
7. Dismantle and sharpen knives.
Figure 75: Removing rotor
06.11.2015
7 Maintenance 94
NOTE!
Property damage from incorrect regrinding!
The cutting angles of the stator and rotor knives can shift during regrinding and impair
cutting action of cutting mill.
- Regrind cutting angle of stator knives to 13.5°.
- Regrind cutting angle of rotor knives to 30°.
- Ensure that all rotor knives weigh the same after grinding.
Mounting knives
1. Mount both stator-knives.
2. Push rotor without knives onto motor shaft.
3. Attach spacer sleeve and tighten with nut.

Correct tightening torque 380 Nm.
4. Set the six rotor stop screws (Figure 76/1) to a

minimum.
5. Mount the three rotor knives (Figure 76/2)

through the lateral inlet opening and hand-
tighten.
6. Mount cover (Figure 74/4)
7. Adjust the rotor knives to the stator knife (Figure

76/3) by unscrewing the stop screws (Figure
76/1).
8. Spin empty to ensure that there is no contact.

Check cutting action with a piece of paper.
It should not cut directly, just to see creasing
along of knife/knives. Because in operation the
rotor with knives is expanded.
Fix knives with screws (Figure 76/4).
9. Also perform setting for the two other rotor

knives.
Figure 76: Mounting knives
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7 Maintenance 95
10. Adjust upper stator knife (Figure 77/1) to rotor

knives by shifting the pressure screws (Figure
77/2) on top.
11. Close inlet flange.
12. Check adjustment. Switch on cutting mill via

control panel. Edge trim tapes have to be cut to
small pieces (2-3 mm). If not or bad sound from
cutting mill, go back to point 5.
Figure 77: Setting stator knives
NOTE!
Cutting mill can be turned on only when the extruder is turned ‘ON’.
7.4.4 Hot air oven

WARNING!
WARNING!
Risk of injury from hot surfaces!
Component surfaces on hot air oven can become very hot during operation. Skin
contact with hot surfaces causes serious burns to skin.
- Always wear heat-resistant protective clothing and gloves when working near hot
surfaces.
- Before starting any work ensure that all surfaces have cooled down to ambient
temperature.
06.11.2015
7 Maintenance 96
DANGER!
Risk of crushing from closing of hot air oven!
Crushing by hot air oven can cause severe to deadly injuries.
- Before closing the hot air oven, ensure that no people are in the danger zone.
- Before performing work in the hot air oven, lock pneumatic cylinders with safeguard
2x (Figure 79/arrow).
Replacement of circulator wheel and heating coil
Figure 78: Replacement of circulator wheel and heating coil
1. Remove screws 16x (Figure 78/1) in circular arrangement.
2. Remove drive motor incl. motor cartridge.
3. Remove screw (Figure 78/2) and pull off impeller wheel (Figure 78/3).
4. Loosen screws on heating coil bracket and replace heating coil (Figure 78/4).
5. Installation occurs in reverse order.
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7 Maintenance 97
Replacement of sealing strip and Kevlar cloth

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7 Maintenance 98
WARNING!
Risk of injury from crushing!
- Before entering the hot air oven, fold down the safety levers (Figure 79/arrow).
1. Remove old seals and residues.

2. Cut the new seal (Figure 81/1) to duct
length.
3. Apply a thin coat of silicone glue to
adhesive surface.
4. Install new seal.
5. Close top part and do not open until

silicone glue is dry.
Figure 81: Replacement of sealing strip
1. Remove guard plate (Figure 80/1).

2. Remove protective angles (Figure 82/1+2).
The cloth (Figure 82/3) is loose.
3. Unthread both chains (Figure 82/4) and
thread into new cloth.
4. Rivet inner protective angle (Figure 82/1) to
one side of the cloth.
5. Rivet the outer protective angle (Figure
82/2) to the other side of the cloth.
6. Install guard plate (Figure 80/1) again.
Figure 82: Replacing cloth fabric
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7 Maintenance 99
7.4.5 Correcting belt tension

Correct belt tension on stretching system - stretching unit
Belt tension: max. 4.5mm/ 500 mm (0.9%)
Figure 83: Stretching unit drive
NOTE!
When tightening the clamping elements, no MoS2 add-ons are allowed on screws and
clamping elements.
Slightly oil shaft and hub of belt pulley!

The surface of the belt pulley must be free of oil!
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7 Maintenance 100
Correct belt tension on stretching unit - annealing unit
Belt tension: max. 4.25mm/ 500mm (0.85%).
Figure 84: Belt tension annealing unit
Loosen or tighten belt tensioner via hexagon

screw (use extension to reach the screw).
Figure 85: Adjusting clamping element
06.11.2015
7 Maintenance 101
7.5 Screw-tightening torques

The table shows the maximum permissible screw-tightening torques to reach the maximum
permitted preload for screws.
The specified screw-tightening torques apply to:
Screw connections of untreated surfaces, lubricated with MoS2 paste
Lightly oiled or non-oiled galvanically cadmium-plated surfaces
Property classes according to ISO 898/1
Size 8.8 10.9 12.9
M8 18 Nm 26 Nm 30 Nm
M10 35 Nm 51 Nm 60 Nm
M12 60 Nm 89 Nm 104 Nm
M14 96 Nm 140 Nm 165 Nm
M16 148 Nm 217 Nm 255 Nm
M18 212 Nm 303 Nm 354 Nm
M20 299 Nm 426 Nm 498 Nm
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8 Malfunctions 102
8 Malfunctions
DANGER!
- Before starting disassembly, switch off electrical supply and ensure that it is definitely
disconnected.
DANGER!
- Exercise caution when working on rolls.
8.1 Malfunction indications

Malfunctions are indicated on the touchscreen of the tape extrusion line.
Accessing alarm list
1. On touchscreen, press on line Figure 86/1.

The window "Alarm list" (Figure 87) opens
up.
Figure 86: Accessing fault list
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8 Malfunctions 103
The alarm list (Figure 87/1) shows all active alarms.
Figure 87: "Alarm list" window
2. To access older fault messages, press button Figure 87/2.

When receiving frequency converter fault messages, observe status messages of
the frequency converter.
3. To correct fault messages, check the attached alarm list table.
4. For other causes of malfunctions and their correction refer to the malfunction table
(see chapter 8.2 Malfunction table).
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8 Malfunctions 104
Accessing status messages of frequency converter

1. In "Setup" window, press button (left).
The "Frequency converter" (Figure 88) window
opens up.
The "Frequency converter" windows show details of the frequency converters (Figure 88 + Figure
89).
Figure 88: "Frequency converter 1" window
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8 Malfunctions 105
Figure 89: "Frequency converter 2" window
2. To acknowledge a fault message for a frequency converter, press the corresponding

button in column Figure 88/1.
3. To access the last 16 fault messages, press button Error-Log (Figure 88/3).
8.2 Malfunction table

The following chapter describes possible causes for malfunctions and what needs to be done to
correct them. If malfunctions occur more frequently, shorten maintenance intervals according to
actual load. If malfunctions cannot be corrected by using the following information, contact
manufacturer; see contact data, page 3.
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8 Malfunctions 106
Malfunction Cause Correction Personnel

description
Error on drive Frequency converter Check mains supply Maintenance

motors in front of 1st not ready Note fault indication personnel,
and 2nd take up of (number/LED) professional
water bath electrician
Press corresponding
reset button
Switch converter off and
after 5 minutes back on
Measure input voltage/
target value/ release/
output voltage
Compare programming
Error on drive Motor protection has Compare set current Maintenance

motors of circulation triggered value on triggering device personnel,
pump - water bath with value on motor type professional
plate electrician
Check mains supply
Check motor temperature
Check motor for free
movement (bearing)
Pay attention to rotational
direction
Check motor power cable
Measure voltage/current
Excessive Overflow pipes not Set overflow pipes Maintenance

movement of water parallel to water personnel
level level
Settling bar not in Set

contact
Water escapes on Mechanical seal Replace mechanical seal

circulation pump faulty
Film has holes or Damp granules Remove damp granules and Operator
forms bubbles fill in fresh granules
Suction power for Faulty exhauster Check exhauster Maintenance

extracting residual personnel,
moisture not professional
available electrician
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8 Malfunctions 107

description
Exhaust pipe twisted Set Maintenance

personnel
Openings of exhaust Clean openings with brush
pipe blocked
Press cylinders Pneumatics Check pneumatic cylinder and

cannot be swung in fittings
Film tape is not cut Dull blades Turn cutter bar by 180° or
straight replace blades
Cutter bar Check

misaligned
Film traversing Check

misaligned
Fault on drive Frequency converter Check mains supply Maintenance

motors of integrated not ready Note fault indication personnel,
holding unit (number/LED) professional
electrician
Press corresponding reset
button
Switch frequency converter
off, wait 5 min and switch
on again
Measure input voltage,
release and output voltage
Compare programming
Rollers are not Faulty toothed Check toothed wheels Maintenance

driven by integrated wheels personnel
holding unit
Faulty drive Check drive Maintenance
personnel,
professional
electrician
Press cylinder does Press cylinder not Swing in press cylinder Operator
not turn swung in
Laps on rollers Tape break Remove laps Operator
Godets are not Belt is torn Replace belt Maintenance

driven personnel
Insufficient belt Tighten belt
tension

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8 Malfunctions 108

description
personnel,
professional
electrician
Faulty drive motors Frequency converter Check mains supply Maintenance

of stretching unit not ready Note fault indication personnel,
(number/LED) professional
electrician
Press corresponding reset
button
Switch frequency converter
off, wait 5 min and switch
on again
Measure input voltage,
release and output voltage
Compare programming
Godets are not Belt is torn Replace belt Maintenance

driven personnel
Insufficient belt Tighten belt
tension

personnel,
professional
electrician
Faulty drive motors Motor protection has Compare set current value Maintenance
of edge trim refeed triggered on triggering device with personnel,
value on motor type plate professional
Check mains supply electrician
Check motor temperature
Check motor for free
movement (bearing)
Pay attention to rotational
direction
Check motor power cable
Measure voltage/current
Edge trims are not Faulty exhauster Check suction power of Maintenance
extracted exhauster personnel
Exhaust pipe Remove edge trims from Operator

clogged exhaust pipes
Mill develops loud Dull knives in mill Sharpen knives Maintenance
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8 Malfunctions 109

description
noise personnel
Circulators of hot air Faulty motors Check motors Professional

oven do not work electrician
Overload or short Check motor and heating
circuit of motor and surface
heating surface
Oven does not reach Faulty heating Check heating surface

target temperature surface
Incorrect entry of Check target temperature Operator

target temperature
Oven cannot be Faulty cylinder Check cylinder Maintenance

opened / closed personnel
No compressed air Check compressed air or
available compressed air connection
06.11.2015
9 Disassembly and disposal 110
9 Disassembly and disposal

After the end of useful life is reached, the machine must be disassembled and disposed of in an
environmentally friendly way.
9.1 Disassembly
DANGER!
- Before starting disassembly, switch off electrical supply and ensure that it is
definitely disconnected.
WARNING!
Risk of injury from improper disassembly!
Stored residual energies, sharp-edged components, points and corners on and in the
line or on the required tools can result in injuries.
- Before starting work, ensure that there is enough space.
- Observe partially high net weight of the components. If necessary, use lifting gear.
- Secure components against falling and overturning.
- In case of any questions, please contact manufacturer.
Before beginning disassembly:

1. Turn off machine and secure against unintentional activation.
2. Physically separate entire power supply from the machine; discharge stored residual
energy.
3. Remove operating and auxiliary materials, as well as residual processing materials

and dispose of in an environmentally safe manner.
4. If necessary, properly clean assemblies and components.
5. Disassemble assemblies in compliance with applicable local occupational health

and safety and environmental protection regulations.
06.11.2015
9 Disassembly and disposal 111
9.2 Disposal
Provided no return or disposal agreements exist, recycle disassembled parts:
Scrap metal.
Recycle plastic elements.
Dispose of remaining components sorted by material characteristics.
NOTE!
Risk to the environment from incorrect disposal!
Incorrect disposal can cause risks to the environment.
- Arrange disposal of electrical waste, lubricants and other auxiliary materials by
authorised professional companies.
- In case of doubt contact local municipal authorities or accredited waste
management operators for advice.
06.11.2015
10 Index 112
10 Index
Contact ...........................................................3 chemical substances .................................. 7
Contact data ...................................................3 Crushing ..................................................... 6
Customer Service...........................................3 Electricity .................................................... 5
Explanation of symbols ..................................1 Emergency stop system........................... 11
Oil heater ......................................................48 Entanglement ............................................. 6
Protective equipment Heat ............................................................ 7
Hard hat ....................................................10 Labelling ................................................... 13
Hearing protection ....................................10 Pneumatics................................................. 5
Protective clothing ....................................10 Spare parts................................................... 15
protective gloves.......................................10 Spare parts order ........................................... 3
Safety shoes .............................................10 Table for knife spacers................................. 34
Safety thermoCon .......................................62, 63, 81
06.11.2015
0 Annex 113
Annex
Alarmlist
Lubrication chart
06.11.2015
Alarm list Page 114
Alarm list
Alarm ID Fault message [EN] Cause Troubleshooting
AlarmGroup Battery discharged Battery of control is discharged Replace battery
[SystemAlarms]
.ID[7]
0 EMERGENCY STOP Emergency-stop activated Unlock emergency stop and restart line
1 Fault fan heater extruder Fan heaters for zone 1 to 6 have Check motor protection switch
reported a fault
2 Fault B&R - FC Group alarm for drive of take up, Based on this alarm, a second alarm appears
holding unit (HW), stretching unit a. that gives detailed information on what
annealing unit happened
3 Fault extruder drive Fault frequency converter extruder ID number of converter error is indicated; refer
to separate manual for frequency converter
4 Warning pressure before filter Excessive melt pressure before filter; Slide filter !
> 280 bar screen contaminated Check pressure sensor and signal
5 Warning pressure before pump Excessive melt pressure before
> 130 bar pump, screen contaminated
6 Warning pressure before die Excessive melt pressure before die Check pressure sensor and signal
> 250 bar
06.11.2015
Alarm list Page 115
7 Alarm pressure before filter Excessive melt pressure before filter, Slide filter !
> 320 bar critical value of 320 bar exceeded, Check pressure sensor and signal
screen contaminated
8 Warning pressure before pump Excessive melt pressure before
> 150 bar pump, critical value of 150 bar
exceeded, screen contaminated
9 Alarm pressure before die > 280 bar Excessive melt pressure before die, Check pressure sensor and signal
critical value of 280 bar exceeded.
10 Temp. alarm cylinder 1 Over- or under-temperature zone 1-6 Check whether temperature setting is OK; if
11 Temp. alarm cylinder 2 necessary, replace heating tape, check fuse
12 Temp. alarm cylinder 3

16 Temp. alarm screen Over- or under-temperature Check temperature setting heater
automatic filter Check automatic filter, check fuse
17 Temp. alarm screen tape Over- or under-temperature heating Check temperature setting heating cartridge
cartridge screen tape of automatic Check automatic filter, check fuse
filter
06.11.2015
Alarm list Page 116
18 Temp. alarm melt pump Over- or under-temperature melt Check temperature setting, heater
pump Check melt pump, check fuse
19 Temp. alarm mixer Over- or under-temperature static Check temperature setting, heater
mixer Check static mixer, check fuse
20 Temp. alarm melt Melt temperature before flat die not Check temperature
plausible
21 Temp. alarm die 1 Over- or under-temperature die zone Check temperature setting,
22 Temp. alarm die 2 1-6 Check heater flat die,
23 Temp. alarm die 3 Check fuse
24 Temp. alarm die 4

27 Temp. alarm feed section Over- or under-temperature feed Check cooling water temperature
zone
28 Temp. alarm water bath Over- or under-temperature water
bath
29 Alarm hot-air oven Fault on hot-air oven
30 Temp. alarm oil heater Over- or under-temperature oil Check oil heater
heater
06.11.2015
Alarm list Page 117
31 Temp. alarm switch control box Message switch control box

temperature above 45°C
32 Safety cover open Safety cover mill open Check safety covers and close if necessary
33 Fault fan drive take up and pump Failure of external fan drive take up, Check motor protection switch
melt pump
34 Fault fan drive annealing and Failure of external fan holding unit
holding unit drive
35 Fault fan drive stretching unit Failure external fan drive stretching
unit, annealing unit
36 Fault water pump Fault water pump drive
37 Edge trim refeed open Cutting mill is open Check cutting mill
38 Fault exhauster edge trim refeed Fault exhaust of edge trim refeed Check edge trim refeed
39 Fault cutter drive edge trim refeed Fault cutter drive of edge trim refeed Check motor protection switch
40 Fault film oscillating unit
41 Fault water exhauster
42 Fault vibration dryer
43 Fault motor edge trim screw Fault edge trim screw
44 Fault blower tape wiper
06.11.2015
Alarm list Page 118
45 Fault vacuum exhauster Fault tape exhaust

46 Alarm material empty in hopper Level sensor in hopper detects no Plant speed is automatically reduced by half
material Check feeding and dosing station
47 Fault extruder cart drive Fault extruder cart drive Check frequency converter
48 Alarm edge trim blocked Blocking in edge trim refeed Remove blocking in edge trim refeed
49 Fault take up drive 1 Fault take up drive 1 Pay attention to details of alarm message
50 Fault take up drive 2 Fault take up drive 1
51 Fault drive holding unit Fault holding unit drive
52 Fault drive stretching unit 26kW Fault stretching unit drive 26kW
53 Fault drive stretching unit 19kW Fault stretching unit drive 19kW
54 Fault drive annealing unit Fault annealing unit drive
55 Fault drive melt pump Error drive melt pump
56 Overload linespeed drive (>90%) Message drives reach a critical Check drive
57 Overload stretching unit drive 19kW motor torque range. When 100% are
(>90%) exceeded 60 seconds, line switches
off
58 Overload stretching unit drive 26kW

(>90%)
59 Overload holding unit (>90%)
60 Overload take up 2 (>90%)
06.11.2015
Alarm list Page 119
61 Overload take up 1 (>90%)

62 Overload melt pump (>90%)
63 Overload extruder drive (>90%)
64 Warning cutting tension Web tension on film cutting station Check setting of web tension
too high or too low
65 Temp. alarm oil heater 2 Over- or under-temperature oil Check oil heater
heater 3
66 Temp. alarm oil heater 3 Over- or under-temperature oil Check oil heater
heater 3
67 Undervoltage DC-BUS Supply voltage interrupted or briefly Check power supply at operating company
dropped
68 Material empty ramp down line Level sensor indicates low material Check material feeding
speed to 50% level, line speed reduced by half Check dosing station
69 Falling pressure -> extruder stop!! Material flow in the cylinder Start extruder <10rpm, if there is no increasing
temporarily interrupted resulting in of pressure (flow of material added) pull
rapid pressure drop screw
70 Connection fault betaControl Connection problem to layer Check wiring
thickness measuring device
71 Receive fault betaControl No data traffic to layer thickness
measuring unit
72 Temp. alarm chiller (>18°C) Cooling water temperature of Check chiller
06.11.2015
Alarm list Page 120
operating company above 18°C

73 Temp. alarm CMG (>83°C) Temperature CMG drive above 83°C Check drive
74 Temp. CMG (>88°C) -> ramp down CMG drive above 88°C, line speed
line speed to 50% reduced by half
75 Fault drive stretching unit 2 ; 26kW Fault stretching unit drive 2 26 kW Pay attention to details of alarm message
76 Overload stretching unit drive 2; Message drives reach a critical Check drive, e.g. faulty bearing
26kW (>90%) motor torque range. When 100% are
exceeded 60 seconds, line switches
off
77 Temp. alarm die 7 Over- or under-temperature die zone Check temperature setting,
7 or 8 Check heater flat die,
Check fuse
79 MAINTENANCE WORK Maintenance interval is indicated Perform maintenance work
80 Fault flow cooling water main drive Insufficient cooling water flow for Water valve does not open or is contaminated
extruder drive
81 Fault flow cooling water FC-main Insufficient cooling water flow for
drive frequency converter extruder drive
82 FAULT Blower Hot air oven Fault frequency converter blower Check blower, frequency converter, Pay
attention to details of alarm message
83 Overload Blower Hot air oven Excessive current draw Check blower, frequency converter
[I>33A]
06.11.2015
Alarm list Page 121
84 Warning CMG cooling water > 30°C Extruder cooling water > 30°C Check temp. of cooling water, flow rate
85 Temp. cooling water extruder drive Extruder cooling water > 35°C
to high ramp down line speed to >> Linespeed to 50%
50%
86 Temp. cooling water extruder drive Extruder cooling water > 40°C
to high LINE STOP! >> Line Stop
87 CMG cooling water level to low Extruder Motor water level too low Check cooling water level, refill if necessary
88 Fault drive fibrillator Fault frequency converter fibrillator Pay attention to details of alarm message
89 Overload fibrillator (>90%) Critical motor torque range Check fibrillator drive
90 HW fault thermoCon Fault hardware modules of control Check hardware modules of contol unit
unit thermoCon
91 Low water folw chiller Flow rate of chiller circuit is lower Check chiller circuit
than the adjusted minimum value
92 Cooling water flow extruder drive to Flow rate of secondary circuit is Check secondary circuit of thermoCon
low -> ramp down line speed to 50% lower than the adjusted minimum
value
93 Alarm Temp. thermoCon Actual temperature of secondary Check thermoCon system
circuit deviates by more than the set
temperature tolerance from the
nominal value
06.11.2015
Alarm list Page 122
94 Motor-protection Pump thermoCon Motor protection tripped Check pump and motor protection
aktiv
95 Cooling water flow extruder drive to Flow rate of secondary circuit is Check secondary circuit of thermoCon
low -> LINESTOP! lower than the adjusted minimum
value – 2 l/min.
96 HW FAULT thermoCon Fault hardware modules of control Check hardware modules of contol unit
unit energy monitoring
97 LOW water-flow chiller Too low supply voltage Check supply voltage
98 FAULT B&R HW-MODUL EXH Fault hardware modules of control Check hardware modules of contol unit
cabinet unit heating cabinet
99 FAULT B&R HW-MODUL SPS Fault hardware modules of control Check hardware modules of contol unit
cabinet cabinet
06.11.2015
Nr. Schmierstoff AGIP ARAL BP CASTROL DEA ESSO KLÜBER MOBIL SHELL TEXACO
Getriebe- Autol Aralub Energrease Glissando Beacon Microlube Mobilplex Spezial- Multifak
1 Grease CLS
Fließfett GP 00 Fließfett ZSA FDP 00 HT-EP00 6833 EP00 EP 0 GB 00 EP 004 Getriebefett H EP 0
Getriebe- Autol Energrease Glissando Getriebe- Syntheso Glygoyle Tivela
2 ------ Grease CLS ------
Fließfett GP 00 Fließfett ZSA ZS 00 6833 EP00 Fließfett S 420 D 220 EP GREASE 00 Compound A
Getriebeöl Degol Energol Falcon Spartan Mobilgear Meropa
3 Blasia 220 Alpha SP 220 Lamora 220 Omala oil 220
CLP 220 BG 220 GR-XP 220 CLP 220 EP 220 630 220
CLP 100 BG 100 GR-XP 100 CLP 100 EP 100 629 100
Getriebeöl Degol Enersyn Polydea Umlauföl Syntheso
5 Blasia S 220 ------ Glygoyle 30 Tivela oil WB ------
PGLP 220 GS 220 SG-XP 220 PGLP 220 S 220 D 220 EP
Maschinenöl Vitam GF Energol Astron Lamora Rando
6 Radula 68 Hyspin SP 68 Nuto H 68 DTE 26 Tellus oil 68
CLP 68 68 HLP-D 68 HLP 68 HLP 68 HDC 68
Energrease Spheerol Glissando
7 Lagerfett 2 GRMU 2 Aralub HL 2 Beacon 2 Centoplex 3 Mobilux 2 Alvania R2 Multifak 20
LS 2 EPL 2 20
Energrease Glissando Staburags
8 Lagerfett 3 GRMU 3 Aralub HL 3 Grease LMX Beacon 3 Mobilplex 47 Alvania R3 Multifak 30
LS 3 30 NBU 8 EP
Hydrauliköl Vitam Energol Astron Lamora Rando
9 OSO 32 Hyspin SP 32 Nuto H 32 DTE 24 Tellus oil S 32
HLP 32 GF 32 HLP-D 32 HLP 32 HLP 32 HDA 32
Maschinenöl Dural Energol Crucolan Vactra oil
10 Radula 100 Magna 100 Sera 100 Nuto 100 Vitrea oil 100 Omnis 100
C 100 MR 100 CS 100 100 heavy
Getriebeöl Enersyn Polydea Syntheso Glygoyle HE
11 Blasia S 460 ------ ------ ------ Tivela SD ------
PGLP 460 SG-XP 460 PGLP 460 D 460 EP 460
Getriebeöl Rotra HY DB Gear oil Gear oil Gear oil Deagear Gear oil Mobilube Spirax Geartex
12 Lamora 100
APIGL4 SAE 80W EP 80 EP SAE 80 EP 80 EP-A SAE 80W GP-D 80W GX 80W-A EP 80W EP-A 80W
Getriebeöl Degol Enersyn Polydea Spartan Syntheso
13 Blasia S 150 ------ Glygoyle 22 Tivela oil WA ------
PGLP 150 GS 150 SG-XP 220 PGLP 150 Synthetic EP 150 D 150 EP
Hydrauliköl Vitam Energol Hyspin Astron Lamora Rando
14 OSO 46 Nuto H 46 DTE 25 Tellus oil S 46
HLP 46 GF 46 HLP-D 46 AWS 46 HLP 46 HLP 46 HDB 46
CLP 320 BG 320 GR-XP 320 CLP 320 EP 320 632 320
16 Blasia 150 Alpha ZN 150 Lamora 150 Omala oil 150
CLP 150 TU 150 GR-XP 150 CLP 150 EP 150 629 150
CLP 460 BG 460 GR-XP 460 CLP 460 EP 460 634 460

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Operating instructions

Tape extrusion line

Read this manual before starting work!

BSW Machinery s.r.o.

Tel.: +420 582 3050 10

3 Technical data .................................................................................................................... 16

4 Structure and function ...................................................................................................... 24

4.2.3 Longitudinal cutting unit ....................................................................................................... 32

5 Storage and transport ....................................................................................................... 56

6.6.9 Setting thermoCon parameters........................................................................................ 81

8 Malfunctions ..................................................................................................................... 102

9 Disassembly and disposal .............................................................................................. 110

10 Index .................................................................................................................................. 112

Alarm list ......................................................................................................................................... 114

1.1 Information on these instructions

1.2 Explanation of symbols

Tips and recommendations

Listings without specific sequence

1.3 Limitation of liability

In case of customised versions, utilisation of additional order options, or latest technical

1.5 Warranty terms

1.6 Declaration of conformity

1.7 Customer Service

To order spare parts, contact our Spare Parts Department:

2.1 Intended use

2.2.1 Occupational risks

2.2.2 Electrical, pneumatic and hydraulic risks

2.2.3 Mechanical risks

2.2.4 Risks from high temperatures

2.2.5 Risks from chemical substances

2.3 Responsibility of operating company

This analysis must be implemented in form of work instructions for machine

2.4 Personnel qualification

Maintenance and service personnel

2.5 Personal protective equipment

When working, always wear:

Wear when performing specific tasks:

2.6 Safety devices

Emergency stop system

Figure 1: Emergency stop system, front view of line

Emergency stop button

Emergency stop pull-wire switch

Master switch with emergency stop function

Safety covers holding and stretching unit

Figure 2: Monitored safety cover stretching unit

2.7 Environmental protection

The following environmentally hazardous substances are used:

2.9 Spare parts

The spare parts catalogue can be found on the included CD.

3.1 Dimensional drawings

Figure 3: Layout plan

„X“ depends on final customer design (see filaTex)

Figure 4: Layout plan with melt pump (option)

„X“ depends on final customer design (see filaTex)

3.2 General information

Length 44 m when using 324 winders

Space requirement for operator in front 1.5 m

Working width 1.600 mm

Maximum speed 530 m/min

Capacity of water cooling 190.000 kcal/h

Noise exposure > 70 dB

Altitude above sea level up to 1.000 m

Setup location requirements