MB-61368 NOVASX550InstructionBook EN Rev00

Technical Manual
1 NOVA SX 550
Compact solventless coating / laminating machine
Job Order: 61368
Translation of the original instructions
© BOBST 2023
NOVA SX 550
CONTENTS
0 FOREWORD ................................................................................. 1
0.1 Identification document of the “Technical Manual” .................... 2

0.2 Customer obligation re. the technical manual ............................. 3
0.3 Purpose .......................................................................................... 3
0.4 How to consult and use the Technical Manual ............................ 3
0.4.1 Technical Manual Composition ................................................................ 3
0.4.2 Care of the Technical Manual .................................................................. 3
0.4.3 Standard safety texts and symbols .......................................................... 4
0.5 Technical manual revision in the event of machine upgrades ... 4
0.6 Notes ............................................................................................... 5
Job order 61368 - rev.0 Contents III

NOVA SX 550
1 SAFETY......................................................................................... 1
1.1 CE label........................................................................................... 2
1.2 Technical/Maintenance service for the machine ......................... 3
1.3 General safety rules ....................................................................... 3
1.3.1 Definitions ................................................................................................ 3
1.3.2 Safety Manager ........................................................................................ 3
1.3.3 Operator classification .............................................................................. 4
1.3.4 Compulsory compliance with regulations ................................................. 5
1.3.5 User obligations ....................................................................................... 5
1.4 General accident prevention regulations ..................................... 6
1.5 Accident prevention symbols ....................................................... 7
1.5.1 Danger ..................................................................................................... 8
1.5.2 Prohibitions ............................................................................................ 10
1.5.3 Obligations ............................................................................................. 12
1.5.4 Symbols used in the Instruction Manual ................................................. 13
1.6 Notes............................................................................................. 14
IV Contents Job order 61368 - rev.0

NOVA SX 550
2 MACHINE SECTIONS .................................................................. 1
2.1 Machine .......................................................................................... 2

2.1.1 Materials to be handled ............................................................................ 3
2.1.1.1 Primary unwinder ................................................................................................. 3
2.1.1.2 Secondary unwinder ............................................................................................. 3
2.1.1.3 Rewinder .............................................................................................................. 3
2.1.2 Main processes ........................................................................................ 4
2.1.3 General operating description .................................................................. 4
2.1.4 Technical data of the machine ................................................................. 5
2.1.4.1 Web width ............................................................................................................. 5
2.1.4.2 Line speed ............................................................................................................ 5
2.1.4.3 Web tension range ............................................................................................... 5
2.1.4.4 Power supply voltage ........................................................................................... 5
2.1.4.5 Compressed air .................................................................................................... 5
2.1.4.6 Idle rollers for the web path .................................................................................. 6
2.1.4.7 Noise level ............................................................................................................ 6
2.1.4.8 Machine tropicalization ......................................................................................... 6
2.1.4.9 Foundations .......................................................................................................... 6
2.2 Main & Secondary Unwinders ....................................................... 7

2.2.1 Unwinder composition.............................................................................. 7
2.2.1.1 Web Guide systems ............................................................................................. 9
2.2.1.2 Unwind web tension control ............................................................................... 11
2.2.1.3 Unwinder outlet .................................................................................................. 11
2.2.2 Main technical data ................................................................................ 12
2.3 Coating Station ............................................................................ 13
2.3.1 General information on the coating station ............................................ 14
2.3.1.1 Doctor roller (1) .................................................................................................. 15
2.3.1.2 Metering roller (2) ............................................................................................... 16
2.3.1.3 Transfer roller (3) ................................................................................................ 17
2.3.1.4 Coating roller (4) ................................................................................................. 18
2.3.1.5 Impression roll (5) ............................................................................................... 19
2.3.1.6 Adhesive mixing and dispensing system ........................................................... 20
2.3.1.7 Cylinder washing system.................................................................................... 23
2.3.2.1 Temperature control units .................................................................................. 25
2.3.2.2 Transfer roller. .................................................................................................... 25
2.3.2.3 Nip roll ................................................................................................................ 25
2.4 Overhead Connection Crossbeam.............................................. 26

2.5 Laminator Group .......................................................................... 27
2.5.1 Laminator composition ........................................................................... 28
Job order 61368 - rev.0 Contents V

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2.6 Rewinder....................................................................................... 30
2.6.1 Rewinder composition ............................................................................ 31
2.6.1.1 Lay-on unit ..........................................................................................................33
2.6.1.2 Web Guide systems ...........................................................................................33
2.6.1.3 Rewind web tension control ................................................................................34
2.6.1.4 At inlet to the rewinder ........................................................................................35
2.7 Notes............................................................................................. 36
VI Contents Job order 61368 - rev.0

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3 COMMANDS AND CONTROLS ................................................... 1
3.1 Machine .......................................................................................... 2

3.1.1 Machine safety systems ........................................................................... 2
3.1.2 Protection from electric contacts .............................................................. 3
3.1.2.1 Safety instructions ................................................................................................ 3
3.1.2.2 Main isolator switch .............................................................................................. 4
3.1.2.3 Warnings for protection against direct electric contacts ....................................... 5
3.1.2.4 Warnings for protection against indirect electric contacts .................................... 5
3.1.2.5 Wiring ................................................................................................................... 5
3.1.3 Noise, hearing protection ......................................................................... 5
3.1.4 Protection from falling .............................................................................. 6
3.1.5 Impression rollers safety .......................................................................... 6
3.1.6 Transparent guards.................................................................................. 6
3.1.6.1 Lexan transparent parts ....................................................................................... 6
3.1.6.2 Polycarbonate transparent parts .......................................................................... 6
3.1.6.3 Antistaticity ........................................................................................................... 6
3.1.7 Emergency stop ....................................................................................... 7
3.1.8 Compressed air supply ............................................................................ 7
3.1.9 Electric supply: ......................................................................................... 8
3.1.10 Machine controls ...................................................................................... 9
3.1.11 Main control panel.................................................................................. 10
3.1.12 Supervisor .............................................................................................. 11
3.1.12.1 Structure of the main display pages ................................................................... 12
3.1.12.2 RECIPES 1 page (Recipes Management) ......................................................... 14
3.1.12.3 RECIPES 2 page (Modify / Create New Recipes) ............................................. 15
3.1.12.4 CONFIGURATION page .................................................................................... 16
3.1.12.5 MONITORING page ........................................................................................... 18
3.1.12.6 NOTIFICATIONS page....................................................................................... 20
3.1.12.7 SETTINGS page 1 ............................................................................................. 21
3.1.12.8 SETTINGS page 2 ............................................................................................. 22
3.1.12.9 MAINTENANCE page ........................................................................................ 23
3.1.12.10 CALIBRATION pages ......................................................................................... 25
3.1.12.11 REGULATORS + RAMPS page ......................................................................... 26
3.1.12.12 WASHING page ................................................................................................. 26
3.1.12.13 MOTORS Page .................................................................................................. 27
3.1.12.14 HALF-ARMS Page ............................................................................................. 27
3.1.12.15 WEB GUIDE page .............................................................................................. 28
3.1.12.16 RECIPES CALIBRATION 1 page ...................................................................... 28
3.1.12.17 RECIPES CALIBRATION 2 page ...................................................................... 29
3.2 Main & Secondary Unwinders ..................................................... 30

3.2.1 Unwinder safety ..................................................................................... 30
3.2.1.1 Safety condition ➔ Operative condition ............................................................ 31
Job order 61368 - rev.0 Contents VII

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3.2.1.2 Operative condition ➔ Safety condition ............................................................31

3.2.1.3 Unloading bars and/or electrostatic assist ..........................................................31
3.2.2 Commands on unwinder crossbeam ...................................................... 31
3.2.3 Misaligned roller adjustment................................................................... 32
3.2.4 Unwinder Touch Panel ........................................................................... 33
3.2.4.1 Start page ...........................................................................................................33
3.2.4.2 UNWINDERMAIN page ......................................................................................34
3.2.4.3 AUXILIARY EQUIPMENT page .........................................................................35
3.3 Coating Station ............................................................................ 36

3.3.1 Coating station safety ............................................................................. 36
3.3.1.1 E-Stop pull cord ..................................................................................................37
3.3.1.2 Risk of inhaling fumes and vapours....................................................................38
3.3.1.3 Particular risks of solventless coating.................................................................38
3.3.2 Controls on the coating station ............................................................... 39
3.3.2.1 Wash pedal .........................................................................................................40
3.3.2.2 Impression Roller pneumatic controls ................................................................41
3.3.2.3 Transfer roller pneumatic controls ......................................................................42
3.3.3 Coating Station’s touch panel................................................................. 43
3.3.3.1 COATING STATION LOGICS page ...................................................................44
3.3.3.2 COATING STATION ANALOGICS page ...........................................................45
3.4 Laminator Group .......................................................................... 46

3.4.1 Laminator unit safety .............................................................................. 46
3.4.1.1 Risk of inhaling fumes and vapours....................................................................47
3.4.2 Laminator unit controls ........................................................................... 48
3.4.2.1 Pneumatic controls of the laminator units ..........................................................49
3.5 Rewinder....................................................................................... 50
3.5.1 Rewinder safety ..................................................................................... 50
3.5.1.1 Safety condition ➔ Operative condition ............................................................50
3.5.1.2 Operative condition ➔ Safety condition ............................................................50
3.5.2 Controls of the rewinder ......................................................................... 51
3.5.2.1 Rewinder side control panel ...............................................................................51
3.5.2.2 Commands on rewinder crossbeam ...................................................................52
3.5.2.3 Rewinder pneumatic controls .............................................................................53
3.5.4 Rewinder Touch Panel ........................................................................... 54
3.5.4.1 REWINDER MAIN page .....................................................................................55
3.5.4.2 REWINDER SUB page .......................................................................................56
3.6 Notes............................................................................................. 57
VIII Contents Job order 61368 - rev.0

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4 MACHINE OPERATION ............................................................... 1
4.1 Using the machine ......................................................................... 2

4.2 Switching on and off ...................................................................... 2
4.2.1 Switching the machine on ........................................................................ 2
4.2.2 Switching the machine off ........................................................................ 2
4.3 Starting and Stopping .................................................................... 3
4.3.1 Start or Run Modes .................................................................................. 3
4.3.2 Start sequence ......................................................................................... 3
4.3.3 Machine stop ........................................................................................... 3
4.3.3.1 Ordinary stop ........................................................................................................ 3
4.3.3.2 Emergency stop ................................................................................................... 3
4.4 Main & Secondary Unwinders ....................................................... 4

4.4.1 Access to the unwinder ............................................................................ 4
4.4.2 Preparing the unwinder ............................................................................ 5
4.4.2.1 Unloading the core ............................................................................................... 5
4.4.2.2 Loading a new reel ............................................................................................... 5
4.5 Coating Station .............................................................................. 9

4.5.1 Access to the coating station ................................................................... 9
4.5.2 Replacing the transfer roller sleeve........................................................ 10
4.5.3 Preparing for work.................................................................................. 16
4.5.4 Cleaning the coating zone ..................................................................... 19
4.6 Laminator Group .......................................................................... 22
4.6.1 Access to the laminator unit ................................................................... 22
4.6.2 Closing the laminating nip ...................................................................... 23
4.6.3 Removing the lamination impression roller ............................................ 24
4.7 Rewinder ....................................................................................... 26
4.7.1 Access to the rewinder........................................................................... 26
4.7.2 Preparing the rewinder........................................................................... 27
4.7.3 Rewinding modes .................................................................................. 28
4.7.3.1 Lay-on mode ...................................................................................................... 28
4.7.3.2 Constant tension / Taper tension ....................................................................... 28
4.8 Web threading .............................................................................. 30

4.9 Putting the web under tension through the machine ................ 31
4.9.1 Web tension tables ................................................................................ 31
4.9.1.1 Paper and cardboard (specific weight 0.8 kg/dm3) ............................................ 31
4.9.1.2 Cardboard (specific weight 0.8 kg/dm3) ............................................................. 32
4.9.1.3 Annealed aluminium foil, for printing and coating in flexible packaging (specific
weight 2.7 kg/dm3) .............................................................................................. 32
Job order 61368 - rev.0 Contents IX

NOVA SX 550
4.9.1.4 Hard tempered aluminium foil for lacquer coating machines (specific weight 2.7
kg/dm3)................................................................................................................33
4.9.1.5 Annealed aluminium foil for lacquer coating machines (specific weight 2.7 kg/dm 3)
............................................................................................................................33
4.9.1.6 Cellophane (specific weight 1.4 kg/dm3) ............................................................34
4.9.1.7 Polyester (specific weight 1.38kg/dm3)...............................................................34
4.9.1.8 Cast PP (specific weight 0.9 kg/dm3) .................................................................34
4.9.1.9 BOPP (specific weight 0.9 kg/dm3) .....................................................................35
4.9.1.10 Non-oriented nylon (specific weight 1.13 kg/dm3) ..............................................35
4.9.1.11 Bi-axially oriented nylon (specific weight 1.13 kg/dm 3) ......................................35
4.9.1.12 Soft PVC (specific weight 1.3/dm3) .....................................................................36
4.9.1.13 Semi-Rigid PVC (specific weight 1.35 kg/dm3)...................................................36
4.9.1.14 Rigid PVC (specific weight 1.4 kg/dm3) ..............................................................37
4.9.1.15 LDPE (specific weight 0.92 kg/dm3) ...................................................................37
4.9.1.16 LLDPE ................................................................................................................38
4.9.1.17 EVA (specific weight 0.95 kg/dm3) .....................................................................38
4.10 First job......................................................................................... 39

4.10.1 Setting the machine parameters ............................................................ 39
4.10.2 Preparing the machine for coating ......................................................... 39
4.11 Repeat Job ................................................................................... 39
4.12 Restarting after an emergency.................................................... 39
4.13 Job Changeover ........................................................................... 40
4.13.1 Routine checks....................................................................................... 40
4.13.2 General cleaning .................................................................................... 40
4.14 Extended periods of machine inactivity ..................................... 40
4.14.1 Short-term inactivity (from 3 or 4 weeks to 6 months) ............................ 40
4.14.2 Long-term inactivity (over 6 months) ...................................................... 40
4.15 Notes............................................................................................. 41
X Contents Job order 61368 - rev.0

NOVA SX 550
5 TROUBLE SHOOTING ................................................................. 1
5.1 Alarms............................................................................................. 2
5.1.1 General re. Alarms ................................................................................... 2
5.1.2 Legend of symbols used in the individual alarm sheets: .......................... 3
5.1.3 Summary of alarm description sheets ...................................................... 4
5.1.4 Alarm description sheets .......................................................................... 6
5.2 Messages ...................................................................................... 33
5.3 Notes ............................................................................................. 34
Job order 61368 - rev.0 Contents XI

NOVA SX 550
6 MAINTENANCE ............................................................................ 1
6.1 General safety recommendations ................................................. 2

6.2 Routine maintenance ..................................................................... 3
6.2.1 Structure of maintenance sheets.............................................................. 3
6.2.1.1 Legend of sheet identification codes ....................................................................3
6.2.1.2 Legend of symbols used on the sheets ................................................................3
6.2.2 Summary of maintenance sheets ............................................................. 4
6.2.3 Maintenance sheets ................................................................................. 8
6.3 Extraordinary maintenance ......................................................... 95
6.3.1 Checking the tension of drive belts ........................................................ 95
6.3.2 Removing the coating station chrome plated cylinders .......................... 96
6.3.2.1 Removing the doctor blade roller ........................................................................96
6.3.2.2 Removing metering roller .................................................................................108
6.3.3 Repairs and actions on the pipe fittings of the cooling water system ... 112
6.3.3.1 Glued connections ............................................................................................112
6.3.3.2 Threaded joints .................................................................................................112
6.3.4 Rollers rubber covering (Rossini) ......................................................... 113
6.3.4.1 Print and lamination pressure rollers rubber sleeves .......................................114
6.3.4.2 POLYCOAT coverings (transfer roller) .............................................................114
6.4 Lubricants .................................................................................. 115

6.4.1 Grease lubrication ................................................................................ 116
6.4.1.1 Mechanical parts lubricated by grease .............................................................116
6.4.1.2 Greasing principles ...........................................................................................117
6.5 Internet sites of auxiliary equipment and sensor manufacturers

.................................................................................................... 118
6.6 Notes........................................................................................... 119
XII Contents Job order 61368 - rev.0

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7 TRANSPORT ................................................................................ 1
7.1 Safety precautions ......................................................................... 2

7.1.1 Preliminary operations ............................................................................. 2
7.1.2 Lifting the machine ................................................................................... 3
7.1.2.1 Eyebolts ................................................................................................................ 4
7.1.3 Machine Transport & Shipping ................................................................. 4
7.1.4 Storage .................................................................................................... 4
7.2 Notes ............................................................................................... 5
Job order 61368 - rev.0 Contents XIII

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8 INSTALLATION ............................................................................ 1
8.1 Foundations ................................................................................... 2

8.1.1 Tolerances of foundation building works .................................................. 2
8.1.1.1 Foundation works. Instructions for the customer ..................................................2
8.1.1.2 Settling on the foundation plinth, beams and plates.............................................2
8.2 Preparations for machine installation .......................................... 3

8.2.1 Preliminary activities for machine assembly ............................................. 3
8.2.2 Preparing the erection yard ...................................................................... 3
8.2.3 General handling instructions ................................................................... 4
8.2.4 Preliminary checks ................................................................................... 4
8.3 Machine erection and alignment................................................... 5
8.3.1 Analysis of hazards related to machine installation .................................. 5
8.4 Auxiliary systems .......................................................................... 7
8.4.1 Pneumatic system .................................................................................... 7
8.4.1.1 Technical recommendations for the compressed air line and its connection to
users .....................................................................................................................7
8.4.1.2 Technical recommendations about the installation of a compressed air generation
unit ........................................................................................................................7
8.4.2 Cooling water system ............................................................................... 8
8.4.2.1 Recommended products to treat the water circulating through chill rolls .............9
8.4.3 Installation of the machine’s electrical hardware .................................... 10
8.5 Machine systems position .......................................................... 11
8.5.1 Front View .............................................................................................. 11
8.5.2 Top view ................................................................................................. 12
8.5.3 Side View ............................................................................................... 13
8.6 Machine systems connection points .......................................... 14
8.6.1.1 Connection point A (laminator unit 1 exhaust fan) .............................................15
8.6.1.2 Connection point B (coating station 2 exhaust fan) ............................................15
8.6.1.3 Connection point A (corona treater exhaust – if supplied) .................................16
8.6.1.4 Connection point D (machine compressed air supply) .......................................17
8.6.1.5 Connection point E (machine temperature control water supply) ......................17
8.6.1.6 Connection point F (machine power supply) ......................................................18
8.6.1.7 Attachment point G (electric supply of BOBST MIX adhesives) ........................18
8.6.1.8 Attachment point H (BOBST MIX adhesive mixer compressed air supply) .......19
8.6.1.9 Attachment point I (electric supply of corona treater primary and secondary
unwinders - if supplied) .......................................................................................19
8.7 Start-up ......................................................................................... 20

8.7.1 Installation / configuration of the machine software ................................ 20
8.7.2 Adjustments and final web handling tests .............................................. 20
8.7.3 Hazard Analysis in machine testing ....................................................... 21
XIV Contents Job order 61368 - rev.0

NOVA SX 550
8.8 Notes ............................................................................................. 23
Job order 61368 - rev.0 Contents XV

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9 DISMANTLING .............................................................................. 1
9.1 General Rules ................................................................................. 2

9.2 Dismantling electric systems ........................................................ 2
9.3 Dismantling the pneumatic system and the utility systems of the
machine .......................................................................................... 2
9.4 Mechanical dismantling................................................................. 2
9.5 Packing ........................................................................................... 2
9.6 Notes............................................................................................... 3
XVI Contents Job order 61368 - rev.0

NOVA SX 550
10 SPARE PARTS ............................................................................. 1
10.1 Spare parts list ............................................................................... 2

10.1.1 Overview .................................................................................................. 2
10.1.2 Spare parts .............................................................................................. 2
10.2 Notes ............................................................................................... 3
Job order 61368 - rev.0 Contents XVII

NOVA SX 550
XVIII Contents Job order 61368 - rev.0

0 FOREWORD
NOVA SX 550
0.1 Identification document of the “Technical Manual”
CUSTOMER NIPCO
MACHINE NOVA SX 550
JOB ORDER 61368
DOCUMENT DISTRIBUTION
Q.ty of copies Given to
REVISION LIST
Rev. Description Date Chapter Checked
0 Issue
This Technical Manual is an integral part of the machine. The identification page of this Technical Manual ensures
traceability and keeps reference to subsequent updates by means of the revision index (Rev.) and its descriptions.
All rights relating to the reproduction and disclosure of the information contained in this Technical Manual and the
documentation quoted and/or attached are reserved. Copyright by Bobst.
This Technical Manual complies with the requirements of Machinery Directive 2006/42/EC.
2 Introduction Job order 61368 - rev.0

NOVA SX 550
0.2 Customer obligation re. the technical manual

The acceptance document contained in the attachment must be signed by the NIPCO as proof that the Technical
Manual has been received and read. A copy of this signed document is to be handed over to the Bobst test
engineer prior to machine start-up.
0.3 Purpose
The purpose of the Technical Manual is to provide the Customer and any personnel interacting with the machine
with all the necessary information for correct use and maintenance in the safest possible conditions.
0.4 How to consult and use the Technical Manual

The graphic elements in the manual (photographs and/or drawings) are an integration of the descriptive parts and
have the purpose of making the system understood.
Among the possible variables, account should be taken of the web direction on the machine (left to right, or right to
left, when looked at from the operator side).
0.4.1 Technical Manual Composition

The Technical Manual is made up of several volumes: Volume 1 is the Instruction Manual + Attachments; the other
volumes contain the Technical Documentation.
0.4.2 Care of the Technical Manual

This Technical Manual is to be preserved for the entire working life of the machine, even if the machine is
transferred or sold to third parties. To keep the Technical Manual in good condition:
• Use the manual taking care not to damage its contents; in particular, do not leave the manual around during
use and remember to return it to its proper place immediately after consultation;
• Do not remove, rip out or rewrite parts of the manual; any changes required must be referred to and
subsequently supplied by Bobst;
• Keep the manual in a safe place, away from damp, heat and other environmental agents which could damage
it;
• In case of loss or damage to all or part of this Technical Manual, the necessary documentation should be
requested from Bobst. Also the request for any additional copies should be addressed to Bobst.
• Use the physical support in order not to modify or damage the documentation inside it.
• Save the maintenance instructions into a USB flash drive/CD.
Job order 61368 - rev.0 Introduction 3

NOVA SX 550
0.4.3 Standard safety texts and symbols

Text containing descriptions of particular importance for personal safety or correct product use, including incorrect
procedures as well as obligatory and forbidden operations, is accompanied by the symbols listed in Chapter 1,
which must be read carefully. Text type is as follows:
• Safety notes
The bold texts refer to the signalling of risks to the operator and are marked by the symbol as indicated in
Chapter 1 (ref. Signs used in the Manual);
• Warning notes
Texts in CAPITAL LETTERS refer to warnings relating to operations of particular importance to ensure the
proper functioning of the product and are marked by the symbol as indicated in Chapter 1 (ref. Signs used
in the Manual);
• Highlighted text
Whenever necessary, parts of the text in bold highlight certain characteristics or technical information for a
specific feature.
0.5 Technical manual revision in the event of machine

upgrades
Ensure any revisions are applied immediately.
The revision implemented can be of the following type:

• Complete revision of the entire publication, in which case make sure that the old copy is immediately disposed
of to prevent the circulation of obsolete documentation which could present a safety hazard;
• Single revised pages (to be added or replaced), in which case ensure the old pages, documents or attachments
are removed and replaced with the new ones provided. The revision index is indicated in the inner margin of
each page, after the machine model. The most recent pages are those with the highest “Rev.” number.
Revision 0 indicates the first issue of the publication.
In conjunction with the updates, Bobst is responsible for providing the user with instructions for altering the existing
documentation.

NOVA SX 550
0.6 Notes
Job order 61368 - rev.0 Introduction 5

NOVA SX 550

1 SAFETY
NOVA SX 550
1.1 CE label
The metal label shown in Fig. 1.1 is applied to the door of the machine’s main control panel and contains the
following permanently marked data:
• Manufacturer’s name, address and logo;
• Year of manufacture;
• CE mark;
• Machine model;
• Job order number;
Fig. 1.1 : CE Mark Label
2 Safety Job order 61368 - rev.0

NOVA SX 550
1.2 Technical/Maintenance service for the machine

When service on the machine is needed, you should contact company Bobst, who will indicate you nearest service
centre. Manufacturer Bobst does not take a responsibility on service if this was requested to other companies or
persons who are not authorized by Bobst.
To avoid errors and/or delays in sending spare parts, please make your request using a copy of the form attached,
filling it in as completely as possible.
1.3 General safety rules

All operator/machine interaction relating to the overall machine life cycle was carefully and thoroughly analysed by
Bobst during the design phase and the drafting of the Technical Manual. Nevertheless, it is understood that nothing
can substitute the experience and adequate training of those interacting with the machine.
Such requirements are therefore regarded as essential in every operating phase on the machine, as well as while
reading this manual.
The machine must be operated and maintained by qualified staff duly authorised by the Customer after receiving
training from Bobst engineers (refer to training records).
Failure to comply with safety precautions or with specific warnings given in the manual, improper use of all or part
of the machine, use of unauthorised spare parts and machine operation by inadequate personnel will infringe any
safety standard relative to drafting, manufacture and expected use of the machine. Such acts and omissions will
relieve Bobst of all liability in the event of damage to persons or property.
1.3.1 Definitions
Pursuant to “Machinery Directive” 2006/42/EC and later revisions, definitions given in this manual have the
following meanings:
Danger areas: any area inside and/or close to a machine where the presence of an exposed person constitutes a
hazard to personal safety and health.
Exposed person: any person or part of a person inside a danger area.
Operator: person or persons assigned to machine operation, adjustment, routine maintenance or cleaning.
User: company or person responsible for and/or owner of the machine.
1.3.2 Safety Manager

The user is to appoint a safety manager for the machine with the following duties:
• Ensure familiarisation and compliance with the safety standards and precautions indicated in the Instruction
Manual;
• Take responsibility for the machine selector keys and distribute them to authorised personnel for use;
• Check the machine is used by qualified personnel, as specified in the following paragraph.
Job order 61368 - rev.0 Safety 3

NOVA SX 550
1.3.3 Operator classification

The following classification has been adopted to define “operator” intervention and qualification.
Operator: qualified person authorised to perform production operations using the commands on the
control panels, with safety devices operational.
Specialised operator: qualified person duly authorised to perform or supervise job changeover
operations with safety devices partially disabled.
Mechanical maintenance engineer: authorised and qualified technician capable of installing, repairing
and performing extraordinary maintenance operations of a mechanical nature only.
Electrical maintenance engineer: authorised and qualified technician capable of installing, repairing
and performing extraordinary maintenance operations of an electrical nature only.
Mechanical BOBST engineer: for operations of a complex nature.
Electrical BOBST engineer: for operations of a complex nature.
The Bobst installation team will explain the preparation, start production and job changeover operations to
personnel during training.
Production operations refer to:

• Reel loading/unloading;
• Setting work parameters.
Job changeover operations refer to, for example:

• Cleaning the coating system;
• Web threading and tension setting in the various spans.

NOVA SX 550
1.3.4 Compulsory compliance with regulations

Before carrying out any type of operation, all personnel operating on the machine must consult and strictly comply
with the instructions and specific safety precautions given in this manual.
CAUTION: THE TYPE OF PERSONAL PROTECTIVE EQUIPMENT THAT PERSONNEL MUST WEAR IS
SHOWN ON THE MACHINE SIGNS.
1.3.5 User obligations

The employer must ensure the disclosure of this document to all personnel operating on the machine and full
compliance with the accident prevention regulations in the European Union and local legislation. Bobst cannot be
held in any way liable for malfunctions resulting from non-compliance with the instructions and safety precautions
listed in this Technical Manual.
The user must inform Bobst immediately of any safety system defects and/or malfunctions, as well as any situation
of presumed danger encountered.
It is strictly forbidden for the user and/or third parties (excluding duly authorised Bobst personnel) to make
modifications of any kind or extent to the machine or its functions (refer to general warranty) or to this technical
document. Refer any modifications required directly and exclusively to Bobst or an authorised representative.

NOVA SX 550
1.4 General accident prevention regulations
THE USER AND OPERATORS MUST STRICTLY COMPLY WITH ALL LOCAL OR COMPANY ACCIDENT
PREVENTION REGULATIONS, IN PARTICULAR:
• Personnel operating in the machine area must not be under the influence of sedatives, drugs or alcohol, nor be
overtired; furthermore, personnel must be perfectly familiar with machine operation.
• Do not smoke, do not cause sparks and do not light open flames on the premises where the machine is
installed.
• Operators must not wear long hair down or loose clothing, chains, bracelets and other objects which may catch
in moving machine parts. In particular, they should avoid wrapping around parts of their body foreign things
such as rags, tapes and the like.
• Personnel operating in the machine area must wear suitable work clothing.
• Operators must comply with all local and European Union regulations, especially accident prevention
regulations, and must comply with the safety symbols indicating the use of protective clothing and/or
accessories.
• Ensure the areas surrounding the machine always allow unhindered transit of operators.
• Follow the instructions given in the signs affixed close to danger areas.
• Operators are obliged to signal any deficiency and/or potentially dangerous malfunction immediately to a direct
superior.
• It is forbidden to touch any part of the machine in rotation or the web in its working position, unless otherwise
specified in this manual.

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1.5 Accident prevention symbols

Several labels carrying warning symbols are affixed to the machine. The location of every single label is shown in
lay-out drawing ”Accident prevention lay-out”, which is provided as an attachment.
Other signs must be applied in the work area around the machine; when particular operations are being carried out
(for example transport, installation or maintenance), additional signs must be put in place.

NOVA SX 550
1.5.1 Danger
The following symbols warn the exposed person of danger and are located close to machine danger areas.
Some danger signs indicate residual risk areas i.e. those areas, due to the nature of the machine, presenting a risk
even if the devices and guards outlined in the accident prevention standards were correctly installed and
operational.
GENERIC DANGER
CRUSHING DANGER
It warns of a crushing hazard between moving parts that are approaching each other, leaving a gap < 120 mm.
CRUSHING DANGER
It warns of a risk of crushing between the two rolls, specially at their lead-in side.
CRUSHING DANGER
It warns of the risk of getting caught between the web and its transport rollers.
DANGER: HIGH TEMPERATURES
It warns that parts near the sign (or inside the enclosure that carries the sign) have a higher temperature than
50°C.
This danger may persist even after disconnection from the energy sources, during the time the specific heated
device is cooling down.

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DANGER: LIVE EQUIPMENT
It warns of the presence of live electric equipment.

The danger ceases after the power supply is cut by engaging the main isolator switch, with the exception of
those devices which are still powered even with the main Isolator Switch open and which are identified by
shielding over them and by the orange colour of the supply cables.
DANGER: OVERHANGING LOADS
It warns of the presence of overhanging loads.
DANGER OF FALLING
It warns residual risk of falling from a height.
CAUTION AT THE SIDE SURFACE OF ALL IDLE ROLLERS
It warns on the shearing risk in the area between the end of idle rollers and the machine side frame.
DANGER: LASER PRODUCT
This label is associated to a class 2 laser device. Don’t stare at the laser beam.
There is a risk of physiological damage when staring directly at the laser beam.

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1.5.2 Prohibitions
The following symbols, where applied, signal prohibitions to be complied with in full by exposed persons present in
the danger areas.
NO UNAUTHORISED PERSONNEL ALLOWED BEYOND THIS POINT
DO NOT START THE MACHINE IF THE GUARD IS NOT FITTED
It prohibits starting the machine in the absence of guards which protect against the risk of pinching at pressure
points.
DO NOT START THE MACHINE IF THE GUARD IS NOT FITTED
It prohibits starting the machine in the absence of guards against the risks associated with power transmission
elements. It also prohibits removing such guards while the machine is running.
DO NOT LUBRICATE OR ADJUST MOVING PARTS
It prohibits any sort of intervention on moving parts.

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ACCESS PROHIBITED TO MORE THAN ONE PERSON AT A TIME
No other person may enter the area shown by the sign, if somebody is already there.
- NO ACCESS! –
THE CABLE CHANNEL MAY NOT BE STEPPED ON OR HIT
- NO ACCESS! –
ACCESS IS PERMITTED ONLY IF THE MACHINE IS AN EMERGENCY STATUS
- NO ACCESS! –
ACCESS IS PERMITTED ONLY WHILE THE SAFETY PUSHBUTTON IS PRESSED

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1.5.3 Obligations
The following symbols indicate the obligations to which operators must comply in the zones displaying the symbol.
PROTECTIVE GLOVES COMPULSORY (CUT AND HEAT RESISTANT)
Location: Near hot parts of the machine which are subject to adjustment and maintenance operations, or in points
with cutting hazards.
The operator must wear protective gloves with the characteristics indicated in the accident prevention standards.
PROTECTIVE FOOTWEAR COMPULSORY
Location: Near machine parts where there is a risk of having one’s feet crushed by heavy mobile objects (for
example the reels when loading/unloading them).
The operator must wear protective footwear with the characteristics indicated in the accident prevention standards.
GOGGLES COMPULSORY
Location: Near all intervention points where there is a risk of irritating liquids coming in contact with the eyes.
It indicates the need to wear goggles whenever approaching or doing any work at that point.
OBLIGATION TO USE THE INDICATED HOISTING POINTS ONLY
Location: Near all hoisting points.

It indicates the obligation to use the hoisting points only identified by this sign.

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1.5.4 Symbols used in the Instruction Manual

This instruction manual uses the following symbols:
DANGER
Accompanies a warning which, if not complied with in full, could constitute a HAZARD to personnel safety;
CAUTION
Accompanies a warning which, if not complied with, could cause damage to the machine or production.

NOVA SX 550
1.6 Notes

2 MACHINE SECTIONS
NOVA SX 550
2.1 Machine
Coating / Laminating Line NOVA SX 550 1350/450
2 Machine sections Job order 61368 - rev.0

NOVA SX 550
2.1.1 Materials to be handled
2.1.1.1 Primary unwinder
Material Min. Max.
BOPP 12 µm 80 µm
PET 10 µm 30 µm
OPA 12 µm 20 µm
PE 30 µm 200 µm
CPP 30 µm 150 µm
Nylon cast 30 µm 80 µm
Aluminium 6,35 µm 40 µm
Paper/Laminates 40 g/m2 150 g/m2
2.1.1.2 Secondary unwinder
Material Min. Max.
BOPP 12 µm 80 µm
PET 8 µm 30 µm
PE 20 µm 200 µm
CPP 20 µm 150 µm
Nylon cast 20 µm 80 µm
Aluminium 6,35 µm 40 µm
Paper/Laminates 40 g/m2 150 g/m2
Other suitable materials that can be processed within the envisaged web tension range.
2.1.1.3 Rewinder
Rewinding of laminates up to a maximum weight of 250 g/m²
Job order 61368 - rev.0 Machine sections 3

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2.1.2 Main processes

a) Unwinding of one of the materials listed above (main unwinder);
Coating with solventless adhesive;
Bond lamination with one of the materials listed above (secondary unwinder);
Rewinding.
2.1.3 General operating description

The web to be coated is unwound by the main single-position unwinder (1).
The web coating is carried out by the solventless coating station (2).
Then the web is transferred to the next section by the overhead connection crossbeam (3), using a series of idle
rollers.
The second web, to be laminated to the coated web, is unwound by the secondary single position unwinder (4).
The laminator (5) joins the two webs (main and secondary) together;
The single-position rewinder (6) rewinds the laminated web (duplex laminated).
Fig. 2.1.3: Main units of the machine

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2.1.4 Technical data of the machine

The machine and all systems provided by Bobst are designed to operate in an environment having a temperature
between 5 and 40°C, up to an altitude of 1,000 m.
The relative humidity of the installation site must be between 50 and 95%, without condensation.
2.1.4.1 Web width
• Max. web width: 1330 mm

• Max. coating width: 1320 mm
• Min. web width: 600 mm
with materials within the specified weight range
2.1.4.2 Line speed
• Maximum mechanical speed: 450 m/min
Maximum operating speed diversified according to the production processes, the materials and
adhesives used.
• Minimum operating speed: 50 m/min
2.1.4.3 Web tension range
• Main unwinder: from 2,5 to 38 daN

• Secondary unwinder: from 2,5 to 38 daN
• Rewinder: from 3 to 40 daN
2.1.4.4 Power supply voltage

• Machine power supply: 400 V ±10% 3Ph + PE without neutral
• Frequency: 50 Hz ± 2%
2.1.4.5 Compressed air

• Necessary supply pressure to the machine: 6-10 bar
• Air flow rate 100 Ndm3/h
Characteristics of the air

• Solid particles, class 5 (dimension): <40 micron
• Water content, class 4 (dew point): +3°C
• Oil content, class 3 (concentration): <1 mg/m3

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2.1.4.6 Idle rollers for the web path

• Made of special corrosion-free aluminium alloy;
• Ground and balanced;
• Running on sensitive bearings;
• Adequately grooved based on the web materials.
2.1.4.7 Noise level
• The level of sound pressure is within: 85 dB(A)
It is measured under the following conditions:

• According to the measurements indicated in standard EN ISO 11202 (with reference to EN 13023 for machine
classification) for background noise and influence on the surroundings;
• At a speed equal to 80% of the maximum operating speed;
• With a web width equal to 0.8:1 of the max. web width;
• Under steady operating conditions (i.e. excluding acceleration and deceleration phases);
• In the middle of the unwinder and rewinder, on the reel side, at a distance of 500 mm from the reel and at a
height of 1600 mm above the floor;
• In front of the main control panel, at the centre of it, at a distance of 500 mm and at a height of 1600 mm off the
floor.
2.1.4.8 Machine tropicalization
The electrical equipment is made with additional protection measures to deal with harmful environmental effects.
2.1.4.9 Foundations
The machine is placed and secured to steel pillars attached to the floor using dowels using synthetic resin
anchorings.

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2.2 Main & Secondary Unwinders
The unwinder is the section of the machine in which the web to be coated is unwound. The shaftless single-
position unwinder is capable of unwinding the roller in two directions (from bottom or from the top) without using
expanding shafts.
2.2.1 Unwinder composition

The unwinder consists of:
• Two half-arms (operator side and drive side) equipped with 3" or 6" aluminium conical chucks for locking the
reel core (locking by penetration).

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• A piston for the movement of the operator side half-arm for locking / unlocking the reel core.
The half-arms slide on four steel guides (two per drive side / operator side) which are integral with the
unwinder frame.

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• An AC motor (installed on the drive side half-arm) to control the rotation of the reel core.
2.2.1.1 Web Guide systems

The unwinder is equipped with an a.c. motor which rotates a worm drive connected to the drive side half-arm.
In this way both halves of the arm (simultaneous movement) can move axially to maintain belt alignment.

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A linear sensor mounted on the drive side half-arm controls the axial movement of the half-arms.
Transverse misalignments of the web are detected by an ultrasonic sensor mounted on an adjustable
fork.

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2.2.1.2 Unwind web tension control

Web tension (and possibly its breakage) in this section is controlled by a dancer roller which is loaded pneumatically
according to the set tension.
2.2.1.3 Unwinder outlet

At the unwinder outlet, the following are present:
• An adjustable roller, to correct any remaining transversal misalignments of the web.
• A corona treater to improve the adhesion of the coating. The unit is equipped with a dedicated transport roller,
with ceramic surface, whose rotation is driven by an a.c. motor.
The machine's current configuration does not include the corona treater unit at the exit from the primary
unwinder (only arrangement for future installation).

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An ionizing static eliminator bar is located at the outlet of the unwinding zone: it eliminates any charges of
electrostatic energy that may be present in the web.
2.2.2 Main technical data

• max. reel diameter: 1020 mm
• max. reel weight: 1000 kg
• inside core diameter: 3” / 6“ (76 / 152 mm)
• core type: cardboard / metal / plastic
• side stroke of web guide ±5 mm

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2.3 Coating Station
The coating station is the section where the adhesive is coated onto the tape using the solventless system
(solvent-free adhesives are used).

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2.3.1 General information on the coating station

The coating station structure is composed of steel side frames with reinforcing tie-rods between them and is
protected against the oxidation and corrosion.
Fig. 2.3.1A: Configuration of the solventless coating rollers
With reference to Fig. 2.3.1A, the solventless system is made up of four rollers (besides the impression roller
already in the machine).
1 Doctor roller
2. Metering roller.
3. Transfer roller.
4. Coating cylinder.
5. Impression roller (in the machine)

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2.3.1.1 Doctor roller (1)

The doctor blade roller, made of steel with chrome plated surface, is heated inside by water.
The water is heated by a power unit with electric resistors and cooled by a water-to-water heat
exchanger
The doctor roller is fitted on slides and, by activating a pair of pneumatic pistons, can come close to or move away
from the metering roller.
The roller path is controlled by adjustable mechanical stops.

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The rotation of the doctor roller is controlled (during the washing sequence or in the case of particular
working requirements by a specific a.c. motor.
2.3.1.2 Metering roller (2)

the metering roller, made of steel with chrome plated surface, is heated internally by water that comes from the
same source as the doctor blade roller.
The rotation of the metering roller is controlled (through a "Bovex" joint) by the same a.c. motor which controls the
transfer roller.

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2.3.1.3 Transfer roller (3)

The rubber-covered transfer roller is heated through contact with the metering roller and the coating roller.
The rubber of the coating (sleeve) is undercut at its ends so that the adhesive layer transferred from the
transfer roller to the coating cylinder is slightly narrower than the web, thus preserving an adhesive-free
margin along the edges of the web.
This transfer roller (fitted on slides) is moved to the inoperative position (up) / work position (in contact with the
metering roller and the coating roller) by two pneumatic rollers, on the operator side / drive side.
The rotation of the transfer roller is controlled (continuously through the "Inkome" constant velocity joint and
transmission clamp) by the same a.c. motor of the metering roller.

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2.3.1.4 Coating roller (4)

The coating cylinder, made of steel with chrome plated surface, is heated internally by water.
The water used is heated by a power unit having characteristics similar to the power unit used for the
heating of the doctor roller and the metering roller.
The rotation of the coating cylinder is controlled (by means of a toothed belt) by an a.c. motor.

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2.3.1.5 Impression roll (5)

The impression roller, made of steel with rubber coating, is not commanded (rotation is determined by the contact
with the web).
The impression roller is installed on hinged levers (drive side / operator side) and, by operating two pneumatic
cylinders (drive side / operator side), can take two positions with regard to the coating cylinder:
• in contact (at a pressure that is adjustable independently on operator and drive side);
• detached: the web (if present in the machine) is detached from both the coating roller and the impression roller.

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2.3.1.6 Adhesive mixing and dispensing system

The adhesive mixing and dispensing system consists of:
1. An adhesive mixer (for mixing the solventless adhesive) installed near the coating station.
The solventless adhesive is mixed and prepared by BOBST MIX mixers. Please refer to the relevant
documentation for more information.
2. A diffusion device (diffuser) connected to the mixer for dispensing the adhesive between the doctor roller and
metering roller.

NOVA SX 550
3. A diffuser nozzle (where the diffuser is installed) capable of skewing horizontally by means of a pneumatic
piston.
The side stroke of the diffuser is adjustable depending on the position of the side limiters.

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4. Two adjustable sliding dampers (one for operator side / transmission) are installed on the respective support
bars and are located in the area between the doctor blade roller and the metering roller.
The position of the two side dams (installed on specific bars) determines the width of the adhesive band
which will then be applied to the web.
5. A capacitive sensor, connected directly to the mixer, detects the amount of adhesive

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2.3.1.7 Cylinder washing system

The coating station is equipped with a cylinder washing system.
The system consists of:
• A pump to send washing detergent to the trolley.
The pump is installed in the coating station frame.

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• The connection pipes (from drums to pump - from pump to dispensing bar).
• A detergent dispensing bar on the coating station rollers.

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2.3.2.1 Temperature control units
• heating power: 9 kW
• minimum temperature / max. water: 30 - 90 °C.
2.3.2.2 Transfer roller.
• rubber hardness: 85 ±2.5 Shore A
2.3.2.3 Nip roll
• roller diameter: 165 mm

• rubber hardness: 80 ±2.5 Shore A

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2.4 Overhead Connection Crossbeam
The connecting area crossbeam (equipped with idle rollers) connects the coating station to the lamination unit,
thus allowing the passage through the web.

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2.5 Laminator Group
The laminator unit is designed to couple the primary and secondary webs and to pull the coupled web toward the
winding area.

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2.5.1 Laminator composition

The lamination unit is composed by:
• An alignment roller, to correct any transversal misalignments of the lamination inlet web.
• A laminating roller, made of steel with chrome plated surface, whose rotation is driven by an a.c. motor (main
power motor).
The laminating roller has a double wall, and is heated inside using water (temperature controlled by a
dedicated electric heater).

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• An impression roller, with rubber coating, acting on the laminating roller.
• A back pressure roller, made of steel with chrome plated surface activated by two pneumatic cylinders (drive
side / operator side), which acts on the rubber-covered roller.

• laminating roller heater power: 9 kW
• laminating roller heating system working
temperature: from 30 to 90°C

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2.6 Rewinder
The rewinder ends the machine and has the function of rewinding the laminated web. The shaftless single-position
rewinder is capable of winding the laminate in two directions (from underneath or from above) without using
expanding shafts.

NOVA SX 550
2.6.1 Rewinder composition

The rewinder is composed of:
• Two half-arms (operator side and drive side) equipped with 6" aluminium conical chucks for locking the reel
core (locking by penetration).
The rewinder is arranged for the use of an expanding shaft, to be used in place of the conical chucks for
core clamping.
• A piston for the movement of the operator side half-arm for locking / unlocking the reel core.

NOVA SX 550
The half-arms slide on four steel guides (two per drive side / operator side) which are integral with the
unwinder frame.
• An AC motor (installed on the drive side half-arm) for the control (via transmission belt) of the reel core rotation.

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2.6.1.1 Lay-on unit

The lay-on unit (also called the lay-on roller) consists of a contact roller made of aluminium installed on
pneumatically activated levers.
During operation, the lay-on unit presses against the rewinding reel, guaranteeing its compact and
regular winding.
2.6.1.2 Web Guide systems

The rewinder is equipped with an a.c. motor which rotates a worm screw connected to the drive side half-arm.
In this way both halves of the arm (simultaneous movement) can move axially to maintain belt alignment.

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A linear sensor mounted on the drive side half-arm controls the axial movement of the half-arms.
2.6.1.3 Rewind web tension control

Web tension (and possibly its breakage) in this section is controlled by a dancer roller which is loaded
pneumatically according to the set tension.

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2.6.1.4 At inlet to the rewinder

At inlet to the rewinder, the following are present:
• A double wall roller made of aluminium, cooled internally by water; whose rotation is controlled (via
transmission belt) by a dedicated a.c. motor.
• An adjustable roller, to correct any remaining transversal misalignments of the web.

• maximum reel diameter: 1020 mm
• maximum reel weight: 1000 Kg
• inside core diameter: 6” (152 mm)
• material: cardboard / metal / plastic
• lay-on roller diameter: 120 mm

NOVA SX 550
2.7 Notes

3 COMMANDS AND CONTROLS
NOVA SX 550
3.1 Machine
3.1.1 Machine safety systems

Fixed guards are fitted on all the moving power transmission stations and all the impression points.
Every control panel carries an emergency stop command (a red mushroom-head pushbutton with a yellow
background).
The common residual risks on the various sections of the machine are:
• shearing between side (end) surface of the rollers and fixed machine parts.
• dragging and, as a result, crushing relative to the web;
• crushing between the mobile parts of the dancer rollers and the machine structure.
IS STRICTLY FORBIDDEN TO OPERATE THE MACHINE WITH ITS SAFETY DEVICES DEACTIVATED OR
WITH ITS FIXED AND/OR MOBILE GUARDS REMOVED.
OPERATING WITH HANDS OR TOOLS ON ANY MOVING MACHINE PART IS STRICTLY FORBIDDEN.
CAUTION: EVEN WITH SAFETIES ACTIVATED, THE RESIDUAL RISK REMAINS OF SHEARING BETWEEN
THE SIDE SURFACE OF THE ROLLERS AND THE FIXED MACHINE PARTS.
BE PARTICULARLY AWARE OF THE RISK OF CRUSHING BETWEEN MOVING PARTS OF THE DANCER
ROLLERS AND THE MACHINE STRUCTURE.
CAUTION: DON’T TURN OFF THE REEL AXIS AND TENSION NIP UNIT MOTORS DURING PRODUCTION
RISK OF CRUSHING! IN CASE OF MACHINE STOP, THE IDLE ROLLERS CAN REMAIN IN ROTATION FOR
A CERTAIN PERIOD (LONG TIME).
2 Commands and controls Job order 61368 - rev.0

NOVA SX 550
3.1.2 Protection from electric contacts
3.1.2.1 Safety instructions
BREAK THE MAIN ISOLATOR SWITCH OFF BEFORE ACCESSING THE ELECTRICAL SYSTEM
COMPONENTS.
CAUTION: DANGEROUS VOLTAGES MIGHT PERSIST ON CAPACITORS DUE TO THE PRESENCE OF

ACCUMULATED CHARGES, EVEN WITH THE MAIN ISOLATOR SWITCH OPEN.
THE PADLOCK KEYS MUST BE KEPT BY AN EXPERT ELECTRIC ENGINEER APPOINTED BY THE SAFETY
MANAGER OF THE MACHINE USER COMPANY.
THE KEYS TO OPEN THE DOORS OF THE CABINETS AND CONTROL PANELS MUST BE KEPT BY AN
EXPERT ELECTRIC ENGINEER APPOINTED BY THE SAFETY MANAGER OF THE COMPANY.
THE EMERGENCY STOP PUSH BUTTONS NEED TO BE CLEARLY VISIBLE AND ACCESSIBLE: DO NOT
MASK OR REMOVE ELEMENTS INDICATING THEIR PRESENCE. DO NOT OBSTRUCT, EVEN
MOMENTARILY, THE ACCESS AREA TO SUCH PUSH BUTTONS.
Job order 61368 - rev.0 Commands and controls 3

NOVA SX 550
3.1.2.2 Main isolator switch
Power supply to the electric cabinet is through an automatic power switch. This switch incorporates:
• Thermomagnetic breaker;
• Undervoltage breaker coil, which prevents the machine from restarting after a stop caused by a failure of power
supply from mains;
• Control by handle, which can be padlocked.
It also acts as a switch for interrupting the emergency power supply of the machine.
ELECTRIC POWER SUPPLY CUT-OUT CAUSES A MACHINE STOP WHICH IS NOT CONTROLLED BY THE
PLC. USE IT ONLY IN CASE OF REAL NEED. TO EXECUTE MAINTENANCE OPERATIONS ON THE POWER
CIRCUITRY WITH THE MACHINE STOPPED, ACTIVATE (0, OFF) THE MAIN ISOLATOR SWITCH.
Emergency electric cut-out is commanded by the PLC in the following cases: overcurrents, overvoltages, voltage
drops, interruption of a phase.

NOVA SX 550
3.1.2.3 Warnings for protection against direct electric contacts

• Access to the cabinet interior is possible only through the use of a specific key to open the cabinet doors;
• Parts which are live, powered even with the main isolator switch cut-out, are adequately shielded and warning
is given of the hazard;
• Leads which are live, even with the main isolator switch cut-out, are identified by their colour pursuant to the
standards;
• Parts which you may come in contact with during adjustment and calibration operations while the cabinet is
powered have a protection class of at least IP2X.
3.1.2.4 Warnings for protection against indirect electric contacts

The distribution system must be TN-S type
The electric system of the machine is earthed according to standard EN60204-1.
3.1.2.5 Wiring
The machine has been delivered properly wired, according to the following principles:
• Leads are coloured distinctly according to their purpose and to the standards;
• Cables, leads and terminal strips or boxes are numbered;
• Connectors are polarized based on the different operating voltages.
3.1.3 Noise, hearing protection

Silencers and panels have been installed on each compressed air discharge valve to reduce machine noise level.
DO NOT REMOVE THE NOISE REDUCTION GUARDS THAT ARE INSTALLED ON THE MACHINE.

NOVA SX 550
3.1.4 Protection from falling

To prevent falling, you must wear slings and appropriate personal protective equipment when having to reach
areas of the machine located at a considerable height off the floor (for example the air damper positioners or the
ventilation ducts).
3.1.5 Impression rollers safety
CAUTION: IN CASE IT IS NECESSARY TO LOWER THE IMPRESSION ROLLER COVERING RUBBER ENDS
(SLEEVE), IT IS NECESSARY TO CHECK THAT THE SAFETY DISTANCE (INLET POINT) OF 6mm
BETWEEN THE IMPRESSION ROLLER AND THE SAFETY NIP BAR IS NOT EXCEEDED.
CAUTION: IF THE SAFETY DISTANCE OF 6mm BETWEEN IMPRESSION ROLLER AND SAFETY NIP BAR IS
EXCEEDED, A DRAGGING RESIDUAL RISK WITH CONSEQUENT CRUSHING IS GENERATED
3.1.6 Transparent guards
3.1.6.1 Lexan transparent parts

The material of the transparent parts (like the guards) has high scratch resistance and high compatibility with the
solvents usually used in the printing / coating process.
Moreover, belonging to the Lexan category, in case of breakage splinters of material, that could contaminate the
production area, aren’t produced.
3.1.6.2 Polycarbonate transparent parts

The material of the transparent parts with antistatic characteristics doesn’t have high scratch resistance and high
compatibility with the solvents usually used in the printing / coating process.
Moreover, belonging to the polycarbonate category, in case of breakage splinters of material, that could
contaminate the production area, are produced.
3.1.6.3 Antistaticity
The materials used in terms of antistaticity are not subject to mechanical or sliding actions of liquids or air.
The solvents / inks conduction pipes and the ventilation ducts are made of adequate materials.
To further reduce the risk of accumulating the electrostatic energy on the transparent parts, use
appropriate antistatic products (e.g. NEOSTATIC®).

NOVA SX 550
3.1.7 Emergency stop
Red mushroom-head pushbutton
THE EMERGENCY STOP URGES MOVEMENTS TO BE STOPPED FOR THE PROTECTION OF

OPERATORS. IT IS NOT TO BE USED IN REPLACEMENT OF THE "STOP MACHINE" CONTROL.
When pressed, it triggers the emergency stop of the machine. To reset the machine for restart, you need to:
• Remove the cause that caused the interruption of machine operation;
• Rotate the pushbutton;
• Press the blinking EMERGENCY RESET push-button. In the event that the push-button is off, an
emergency condition remains to be resolved. If it displays a steady light, the emergency condition has been
reset.
3.1.8 Compressed air supply

Compressed air supply to the machine is managed via the main valve of the system (see Fig. 3.1.8).
The valve is equipped with a pressure gauge, air pressure regulator, progressive start valve, condensate water
trap and drain.
Upon opening the manually operated valve, all pneumatically controlled parts of the machine are supplied; upon
closing the valve, the compressed air supply is interrupted, with the consequent release of the residual air
contained in the system.
The valve can be padlocked to prevent unexpected activation of the system and be locked in the event of
maintenance.
Fig. 3.1.8: Compressed air supply device

NOVA SX 550
IN ORDER TO LIMIT THE MOVEMENTS DERIVING FROM LACK OR ABSENCE OF PRESSURE IN THE
PNEUMATIC CYLINDERS, THE COMMANDS THAT TRIGGER THE EMERGENCY OR THAT PUT MACHINE
AREAS UNDER SAFETY WILL NOT DETERMINE THE EMPTYING OF THE PNEUMATIC SYSTEM.
FURTHERMORE, IN ORDER TO REDUCE THE MOVEMENT OF PARTS SUBJECT TO GRAVITY OR

DEDICATED TO LOCKING OPERATIONS, CHECK VALVES ARE INSTALLED DIRECTLY ON THE
PNEUMATIC CYLINDERS IN ORDER TO KEEP THEM PRESSURISED EVEN WHEN THE PNEUMATIC
SWITCH IS OFF.
ONLY CARRY OUT MAINTENANCE WORK AFTER CONSULTING THE RELEVANT PNEUMATIC DIAGRAMS
AND BRINGING THE MOVING PARTS TO THEIR REST POSITION OR LOCKING THEM (AS MAY BE
REQUIRED).
3.1.9 Electric supply:

To supply electric voltage to the cabinet and to the machine turn the main isolator switch to 1 (ON).
When – for whatever reason – the main isolator switch is disconnected (mains disconnection because a safety
device has tripped, or there is an electric overload, etc...), you need to:
• Eliminate the cause of main isolator switch opening;
• Reset the switch by turning it firstly to position 0 and then back to position 1 (ON).
The main isolator switch can be padlocked to prevent unexpected activation of the system and can be
locked in case of maintenance.

NOVA SX 550
3.1.10 Machine controls
The master control panel is located on the protective covering of the coating element, on the operator side. it
includes the master console and the supervisor.
The machine sections are equipped with:

• Specific control panels;
• SIMATIC Touch Panel which allows the setting of the parameters for optimum operation of the machine section
it is applied to;
• Machine stop commands.
THE OPERATOR MUST PERFECTLY KNOW THE MEANING OF ALL CONTROLS ON THE MACHINE AND
MUST BE INSTRUCTED / TRAINED ON WHAT TO DO IN CASE OF AN EMERGENCY STOP OR FAILURES
ON THE MACHINE.

NOVA SX 550
3.1.11 Main control panel
The master control panel includes the following controls:
MACHINE START
Once the Start-up sequence has been completed (see paragraph “Start-up sequence”), by pressing this key the
machine will reach its speed setpoint (as set on the supervision system) following a fixed acceleration ramp.
MACHINE STOP
The machine executes a controlled slowdown till it stops. Once the zero speed threshold is reached, the start
sequence is zeroed.
MACHINE ACCELERATION / DECELERATION RAMP HOLD
When pressed during an acceleration or deceleration phase, it stops the increase / decrease of the speed ramp at
the value reached at that instant; the LED lights up and the machine keeps moving at constant speed.
This command is active only if line speed is greater than minimum speed.
MACHINE JOG
Once the Start-up sequence has been completed (see paragraph “Start-up sequence”), this illuminated
pushbutton will start the machine and keep it at minimum speed as long as the pushbutton is pressed; when the
pushbutton is released the machine stops.
EMERGENCY RESET

NOVA SX 550
3.1.12 Supervisor
The supervision system or supervisor is composed of a touch-screen panel.

The touch-screen panel consists of main and calibration display pages.

NOVA SX 550
3.1.12.1 Structure of the main display pages
The supervision system main display pages are divided into three main sections:
• The same dashboard for all main display pages:
The dashboard section contains:

• Date and time
• Display of notifications
• Machine status
• Current job
• Machine speed [m/min]
• Job progress [m]
• Rewound material metre counter [m]

NOVA SX 550
• Diversified content for each display page and contains the control keys or settings that can be made on the
machine.
• The same navigation for all main display pages.
The navigation section contains the control keys that allow access to the various main display pages of the
supervision system.
RECIPES
CONFIGURATION
MONITORING
NOTIFICATIONS
LANGUAGES
SETTINGS

NOVA SX 550
3.1.12.2 RECIPES 1 page (Recipes Management)
This page is used for managing the machine recipes.
Search recipes
This section contains information on

recipes and is divided into three columns:
• Recipe name
• Date
• Details
Collapse/Expand detail column
Sort detail column
Save new recipe
Delete recipe
Load recipe to machine

NOVA SX 550
3.1.12.3 RECIPES 2 page (Modify / Create New Recipes)
This page is used for modifying or creating new recipes.
Recipe name entry field
Recipe detail entry field
Delete recipe
Recipe creation
Recipe Summary

NOVA SX 550
3.1.12.4 CONFIGURATION page
This page is used for configuring the operating mode of the various sections that make up the machine.
• Unwinder 1
On / Off Unwinder
Unwinding direction (from Bottom / Top)
Corona Treater Unit On / Off

NOVA SX 550
• Coating station
Transfer Roller Operation Mode (Manual / Automatic)
Impression Roller Operation Mode (Manual / Automatic)
Open/close doctor roller
Motor On / Off
• Unwinder 2
On / Off Unwinder
Unwinding direction (from Bottom / Top)
Corona treater On / Off (Optional)
• Rewinder
Rewinding direction (from Bottom / Top)
Stop mode
Taper tension Operation Mode (Linear / Hyperbolic)

NOVA SX 550
3.1.12.5 MONITORING page
This page is used to monitor the various sections of the machine during operation.
Unwinder 1:
• Motor On / Off
• Unwinder web tension [N]
• Reel diameter [mm]
Coating station:
• Impression Roller Motor On / Off
• Motor On / Off
• Open / Close impression roller
• Open / Close
• Coating web tension [N]
• Roller Speed [%]
Laminator Unit:
• Motor On / Off

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Unwinder 2:
• Motor On / Off
• Unwinder web tension [N]
Rewinder:
• Motor On / Off
• Rewinder web tension [N]
• Taper [N]
• Start / Stop Tensioning

• Start / Stop Tensioning Release
• Start / Stop Reel Centring

NOVA SX 550
3.1.12.6 NOTIFICATIONS page
This page contains all the notifications (alarms, warnings and information).
Select notification to display

from the notifications list
column.
Reset all notifications.
Notification list
General details of the selected notification

with the possibility of reset.

NOVA SX 550
3.1.12.7 SETTINGS page 1
This page is used for setting the machine.
Access to maintenance pages
Acceleration Ramp (Slow / Fast)
Wash Mode
Start / Stop Lamp Test

NOVA SX 550
3.1.12.8 SETTINGS page 2
This page is used to set the data of the reels in the machine.
Working reel length [m]
Working reel meter counter
Actual reel length [m];
Actual reel meter counter
Previous Reel Length [m]

NOVA SX 550
3.1.12.9 MAINTENANCE page
This page is used for maintenance operations on the various sections of the machine.
ACCESS TO THIS PAGE IS ONLY POSSIBLE BY PASSWORD.
DO NOT DIVULGE THE PASSWORDS THAT GIVE ACCESS TO THE MAINTENANCE DISPLAY PAGES: THE
PASSWORDS ARE TO BE ASSIGNED TO PERSONNEL ACCORDING TO THEIR LEVELS OF COMPETENCY
AND RESPONSIBILITY. SUCH PERSONNEL MUST SAFEGUARD THE PASSWORDS.
Unwinders (1 and 2) and Rewinder:

• Diameter for Unwinder 1 Speed Test [mm]
• Diameter for Unwinder 2 Speed Test [mm]
• Diameter for Rewinder Speed Test [mm]

NOVA SX 550
Web break:
• On / Off Bypass Web Break
• Web Break Length [m]
Test mode:
• Machine Test
• On / Off Motor Speed Test
• LAMP TEST
Calibration:
• Calibration
• Save Recipe Calibration
• Load Recipe Calibration
Settings:
• System Messages
• Screen Cleaning
• System Setting

NOVA SX 550
3.1.12.10 CALIBRATION pages
These pages are used to carry out the various calibrations required for the machine operation.
In the underneath part of each page there are a series of keys allowing access to the different display pages for
calibrating the supervision system:
Regulators + Ramps
Washing
Motors
Half-arms
Web Guide systems
The key allows to leave the calibration pages.

NOVA SX 550
3.1.12.11 REGULATORS + RAMPS page
This page is used for calibrating the unwinders (1 and 2), the coating station, the rewinder and the ramps.
3.1.12.12 WASHING page
This page is used to set the duration of the various coating station washing phases.

NOVA SX 550
3.1.12.13 MOTORS Page
This page is used to monitor the operating temperatures and engine revolutions of the various motors installed in
the machine sections.
3.1.12.14 HALF-ARMS Page
This page is used to set the operating settings for the half-arms of the unwinder (1 and 2) and rewinder.

NOVA SX 550
3.1.12.15 WEB GUIDE page
This page is used to adjust the operating settings for the web guide systems installed in the unwinders (1 and 2).
3.1.12.16 RECIPES CALIBRATION 1 page
This page is used to calibrate the recipes in the machine.

NOVA SX 550
3.1.12.17 RECIPES CALIBRATION 2 page
This page is used to create a new recipe.

NOVA SX 550
3.2.1 Unwinder safety
UNWINDER BLOCKING
This key selector switch is used to put the unwinder in the operative or safe condition.
• Safety condition: dangerous movements are inhibited (motor start), and it is possible to gain access to the
unwinder for reel loading / unloading operations.
• Operative condition: hazardous movements are enabled.
UNWINDER BLOCKING
This light indicates the safety status of the unwinder:

• Steady lit white light: unwinder under safety conditions;
• Light off: unwinder in operative condition.
The rear area of the secondary unwinder is protected by a full guard.
Fig. 3.2.1: Secondary unwinder rear full guard.

NOVA SX 550
3.2.1.1 Safety condition ➔ Operative condition

It is possible to switch from safety condition to operative condition by turning to the left the key selector switch of
the unwinder control panel.
3.2.1.2 Operative condition ➔ Safety condition

Switching from operative condition to safety condition can be achieved manually by turning the key selector switch
to the right.
3.2.1.3 Unloading bars and/or electrostatic assist

The static eliminator bars are used to eliminate any residual charges on the web.
DO NOT REMOVE THE STATIC ELIMINATOR BARS FOR ANY REASON. IN CASE OF MALFUNCTION,
REPLACE THEM BEFORE STARTING THE MACHINE.
3.2.2 Commands on unwinder crossbeam
The control panel on the unwinder crossbeam includes the following controls:
UNWINDER BLOCKING
HALF-ARM OPENING
Pushbutton to open the half-arms on the unwinder to allow the empty reel (core) to be unloaded.

NOVA SX 550
HALF-ARM CLOSURE
Luminous pushbutton to close the unwinder half-arms to allow a new reel to be loaded
When the light is on, it means the reel is perfectly locked (chucks fully penetrated in the core).
HALF-ARMS TOWARDS OPERATOR SIDE / DRIVE SIDE
Selector switch with auto-return to the centre to control simultaneous movement of the half-arms towards the
operator side / drive side, for transverse alignment of the web.
3.2.3 Misaligned roller adjustment
It is possible to adjust the eccentricity of the idle roller at the inlet to the coating area by operating the locking
knobs (one per side).

NOVA SX 550
3.2.4 Unwinder Touch Panel
3.2.4.1 Start page
This display appears when starting the Operator Panel and allows management of the unwinder main operations.
The top of the page shows the production speed.
Under the panel, a set of function keys allows surfing from one display page to another.
F1 - INITIAL DISPLAY
Returns to the start screen.
F2 - MAIN DISPLAY
Returns to the main display.
F3 - AUXILIARY EQUIPMENT PAGE

Returns to the auxiliary equipment page.
F4 - SWITCHING OFF OF THE OPERATOR PANEL

Turns off the operator panel.
The identical controls on both the screens and on the push-button control panels operate parallel (the
last activated control updates the other controls).

NOVA SX 550
3.2.4.2 UNWINDERMAIN page
The keys corresponding to active functions are shown in green ; those related to functions that are presently
inactive but can be activated are light grey ; those of disabled functions are dark grey .
The parameters that can be set are blue; the actual values (measured or calculated) of the same parameters are
green.
MOTOR START
Activates the motor start sequence.
MOTOR OFF.
It commands the motor stop sequence.
UNWINDING FROM THE TOP
It enables the unwinding of the reel from the top (clockwise rotation of the reel).
UNWINDING FROM THE BOTTOM
It enables the unwinding of the reel from the bottom (anticlockwise rotation of the reel).
UNWINDER WEB TENSION [N]
Tension of the unwinding material.
REEL DIAMETER [mm]
Diameter of the unwinding reel.

NOVA SX 550
3.2.4.3 AUXILIARY EQUIPMENT page
This display page allows managing the functions of the web guide system.
MANUAL WEB GUIDE SYSTEM
During production the operator keeps the web aligned. Only use in the event a perfectly square-cut reel is
unwinding.
AUTOMATIC WEB GUIDE SYSTEM
During production, with the sensor already located at the web edge, the web will always flow parallel. If this is not
the case (because of unwinding reel imperfections or otherwise) the system moves the web sideways to correct
the error.
TRANSVERSAL WEB ALIGNMENT CORRECTION VALUE [mm]
Displays the value of web alignment correction presently exerted by the web guide system, in terms of percentage
of the maximum possible correction value.

NOVA SX 550
3.3 Coating Station
3.3.1 Coating station safety

The safety of the coating station is managed by:
• A guard safety nip bar of the inlet point between the impression roller and the coating cylinder.
Fig. 3.3.1A: Impression roll accident prevention bar.
• The front door of the coating station has a sliding mechanism to protect the web outlet area.
Fig. 3.3.1B: Front door (web outlet side) on the coating station.

NOVA SX 550
• A side door protecting the transfer roller drive area.
Fig. 3.3.1C: Side hatch (operator side) coating station
3.3.1.1 E-Stop pull cord
A pull-cord switch is fitted on the coating station: the pull-cord, when activated, causes the emergency stop of the
machine. To reset the switch, press the blue button.

NOVA SX 550
3.3.1.2 Risk of inhaling fumes and vapours

Near the coating element, the concentration of fumes and vapours produced during the coating process may
become too high, posing a health threat to the personnel working there.
The risk is limited by the following devices:
• front door of the station: it captures the fumes and vapours released during coating.
• exhaust system: it captures the air near the station, thus minimising the presence of fumes and vapours in the
air.
Fig. 3.3.1.2: Coating station fumes and vapours inhalation limiting devices
3.3.1.3 Particular risks of solventless coating

Due to the high temperature of the adhesive and the cylinders themselves, the solventless coating contains the
risk of burn residuals.

NOVA SX 550
3.3.2 Controls on the coating station
The coating station’s control panel includes the following controls:
IMPRESSION ROLLER OPEN
Luminous pushbutton for opening the coating station impression roller.
TRANSFER ROLLER CLOSURE
Luminous pushbutton for closing the transfer roller
MACHINE ACCELERATION / DECELERATION RAMP HOLD
When pressed during an acceleration or deceleration phase, it stops the increase / decrease of the speed ramp at
the value reached at that instant; the LED lights up and the machine keeps moving at constant speed.
This command is active only if line speed is greater than minimum speed.

NOVA SX 550
OPENING / CLOSURE OF THE DOCTOR BLADE ROLLER
This selector switch opens or closes the doctor blade roller in respect of the metering roller.
OPENING / CLOSING OF GUARD
Selector switch with auto-return to the centre for opening or closing the front door of the coating station.
DOCTOR ROLLER RUNNING
Selector switch with auto-return to the centre for the clockwise or anticlockwise rotation of the doctor roller.
SLEEVE EXTRACTION
Pressing this pushutton compressed air is sent to the transfer roller shaft in order to expel / insert the sleeve (see
paragraph "Replacing the transfer roller sleeve").
3.3.2.1 Wash pedal
Pedal to manage the machine start during the manual washing sequence.
The pedal has three different conditions:
• Not pressed: machine in standby.
• Pressed as far as half stroke (first click): machine running (washing sequence in progress).
• Pressed until end stroke (second click): machine stopped.

NOVA SX 550
3.3.2.2 Impression Roller pneumatic controls
OPERATOR SIDE PRESSURE
Regulator and pressure gauge for setting and displaying the pneumatic pressure of the impression roller onto the
printing cylinder, operator side.
DRIVE SIDE PRESSURE
printing cylinder, drive side.

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3.3.2.3 Transfer roller pneumatic controls
printing cylinder, operator side.
DRIVE SIDE PRESSURE
printing cylinder, drive side.

NOVA SX 550
3.3.3 Coating Station’s touch panel

The coating station is equipped with a touch panel which allows managing the main functions of the station itself.
F2 - LOGICS PAGE
Returns to the logics page.
F3 - ANALOGUE PAGE
Returns to the analogue page.

With regard to the operating principle of the system, also refer to the description of the unwinder’s touch
panel.

NOVA SX 550
3.3.3.1 COATING STATION LOGICS page
TRANSFER ROLLER MANUAL CLOSURE
It starts the manual closure of the transfer roller.
AUTOMATIC CLOSURE OF TRANSFER ROLLER
Starts the automatic closure of the transfer roller.
MANUAL CLOSURE OF THE IMPRESSION ROLLER
It starts the manual closure of the impression roller.
AUTOMATIC CLOSURE OF THE IMPRESSION ROLLER
Starts the automatic closure of the impression roller.
START OF DIFFUSER NOZZLE MOVEMENT SYSTEM
It starts the continuous transversal movement (back and forth) of the glue diffuser.
STOP OF DIFFUSER NOZZLE MOVEMENT SYSTEM
It stops the transversal movement of the glue diffuser.
START OF AUTOMATIC WASHING
It starts the automatic washing.

NOVA SX 550
STOP OF AUTOMATIC WASHING
It stops the automatic washing.
START OF EXHAUST SYSTEM
It starts the exhaust system.
STOP OF EXHAUST SYSTEM
It stops the exhaust system.
NEXT LOGICS PAGE
PREVIOUS LOGICS PAGE
3.3.3.2 COATING STATION ANALOGICS page
COATING OUTLET WEB TENSION [N]
Web tension downstream of the coating cylinder.
TRANSFER ROLLER SPEED [%]
Transfer roller surface speed, as a percentage of line speed.

NOVA SX 550
3.4 Laminator Group
3.4.1 Laminator unit safety

The laminator unit safety is managed by:
• A protective bar (7) at the inlet point between the back pressure roller and the impression roller.
Fig. 3.4.1A: Impression roll accident prevention bar.
• A complete rear casing equipped with door locked with keys.
Fig. 3.4.1B: Complete rear casing of the laminator unit.

NOVA SX 550
3.4.1.1 Risk of inhaling fumes and vapours

There is the possibility that the concentration of fumes and vapours generated during the lamination process may
become too high near the lamination unit, causing health risks to those working in that area.
The risk is limited by the following device:
• exhaust system: it captures the air in the vicinity of the laminator unit, thus minimising the presence of fumes
and vapours in the air.
Fig. 3.4.1.1: Device limiting the inhalation of fumes and lamination vapours.

NOVA SX 550
3.4.2 Laminator unit controls
The laminator unit control panel includes the following controls:
IMPRESSION ROLLER CLOSE
Luminous pushbutton that closes the laminator unit impression roller.
LAY-ON UNIT MOVEMENT
For further information, refer to paragraph "rewinder side control panel".
MACHINE STOP
By pressing this push button, the machine will stop.

NOVA SX 550
3.4.2.1 Pneumatic controls of the laminator units
Regulator and pressure gauge for setting and displaying the pneumatic pressure of the back pressure roller on the
impression roller (and thus on the laminating roller), operator side
DRIVE SIDE PRESSURE
Regulator and pressure gauge for setting and displaying the pneumatic pressure of the back pressure roller onto
the pressure roller (and thus on the laminating roller), drive side

NOVA SX 550
3.5 Rewinder
3.5.1 Rewinder safety
REWINDER ACCIDENT PREVENTION
This key selector switch is used to put the rewinder in the operative or safe condition.
• Safety condition: dangerous movements are inhibited (motor start), and it is possible to gain access to the
rewinder for reel loading / unloading operations.
• Operative condition: hazardous movements are enabled.
This light indicates the rewinder safety status:

• Steady lit white light: rewinder under safety conditions;
• Light off: rewinder in operative condition.
At the pressure point between the lay-on roller and the rewinding reel, there is a safety protection.
Fig. 3.5.1: Rewinder lay-on unit safety guard.
3.5.1.1 Safety condition ➔ Operative condition

It is possible to switch from safety condition to operative condition by turning to the left the key selector switch on
the rewinder control panel.
3.5.1.2 Operative condition ➔ Safety condition

Switching from operative condition to safety condition can be achieved manually by turning the key selector switch
to the right.

NOVA SX 550
3.5.2 Controls of the rewinder
3.5.2.1 Rewinder side control panel
The side rewinder control panel includes the following controls:
IMPRESSION ROLLER CLOSE
For further information, refer to paragraph "laminator unit control panel".
LAY-ON UNIT MOVEMENT
Selector switch with auto-return to the centre for the lay-on control.
MACHINE STOP
By pressing this push button, the machine will stop.

NOVA SX 550
3.5.2.2 Commands on rewinder crossbeam
The rewinder crossbeam control panel includes the following controls:
HALF-ARM OPENING
Pushbutton to open the rewinder half-arms, to allow the reel to be unloaded.
HALF-ARM CLOSURE
Luminous pushbutton that closes the rewinder half-arms, to allow a new core to be loaded.
When the light is on, it means the reel is perfectly locked (chucks fully penetrated in the core).
HALF-ARMS TOWARDS OPERATOR SIDE / DRIVE SIDE
Selector switch with auto-return to the centre to control simultaneous movement of the half-arms towards the
operator side / drive side, for transverse alignment of the web.

NOVA SX 550
3.5.2.3 Rewinder pneumatic controls
Pressure regulator and gauge for setting and displaying the pneumatic pressure of the lay-on unit on the rewinder,
operator side
DRIVE SIDE PRESSURE
Pressure regulator and gauge for setting and displaying the pneumatic pressure of the lay-on unit on the rewinder,
drive side.

NOVA SX 550
3.5.4 Rewinder Touch Panel

The rewinder is equipped with this touch panel, which allows management of the main functions of this machine
section.
F2 - MAIN DISPLAY
Returns to the main display.
F3 - SUBPAGE
Returns to the subpage.

With regard to the operating principle of the system, also refer to the description of the unwinder’s touch
panel.

NOVA SX 550
3.5.4.1 REWINDER MAIN page
MOTOR START
Activates the motor start sequence.
MOTOR OFF.
It commands the motor stop sequence.
REWINDING FROM THE TOP
It enables the rewinding the reel from the top (clockwise rotation of the reel).
REWINDING FROM THE BOTTOM
It enables the rewinding of the reel from the bottom (clockwise rotation of the reel).
REWINDER WEB TENSION [N]
Tension of the rewinding reel.
TAPER TENSION [%]
Setting of the taper tension factor for the rewinding material; this value can be set in any percentage between 0
and 100%.
The greater the set taper tension value, the greater the web tension reduction will be as reel diameter
increases. For example, by setting a basic tension of 16 daN and a taper tension of 50%, at the end of
the rewinding process (maximum reel diameter) the actual web tension will be of 8 daN. If taper tension is
set to 0, then rewinding will be at constant tension.

NOVA SX 550
3.5.4.2 REWINDER SUB page
METRE STOP
The stop occurs when the length of the rewinding reel has reached the value set in the field (Reel length
per stop).
DIAMETER STOP
The stop occurs when the diameter of the rewinding reel has reached the value set in the field (reel
diameter per stop).
REEL LENGTH PER STOP [m]
If the metre stop has been set, the rewinding stop occurs when the total number of metres wound reaches the
quantity set in this field.
REEL DIAMETER PER STOP [mm]
If the diameter stop has been set, the rewinding stop occurs when the reel reaches the diameter set in this field.

NOVA SX 550
3.6 Notes

NOVA SX 550

4 MACHINE OPERATION
NOVA SX 550
4.1 Using the machine

Production main processes and web materials are indicated in chapter 2.
USING THE MACHINE FOR PROCESSES UNLIKE THOSE MENTIONED IN THIS INSTRUCTION MANUAL,
OR USING UNSUITABLE OR POOR QUALITY MATERIALS MAY RESULT IN DAMAGES TO PRODUCTION
AND/OR THE MACHINE.
4.2 Switching on and off
4.2.1 Switching the machine on
ENSURE THERE IS NOBODY IN THE OPERATING AREA OF THE MACHINE

Proceed to open the compressed air.
Upon turning the main isolator switch on, the machine is in emergency status, i.e.:
• All motors stopped;
• Pressure rollers open;
• Fans off;
• No command is accepted.
When the supervisor is on and operational, execute the alarm reset.
Pushbutton starts blinking; press it to reset the emergency devices.

The machine is now ready.
4.2.2 Switching the machine off

To switch the machine off in a controlled manner, stop the motors (machine stop) and hold the shutdown
pushbutton on the maintenance page of the supervision system down for 4 seconds. The sequence causes:
• Air suction system off;
• Minimum tension on un- and rewinder;
• Tension nip units disabled;
• Machine emergency;
• Mains disconnect.
2 Machine operation Job order 61368 - rev.0

NOVA SX 550
4.3 Starting and Stopping
4.3.1 Start or Run Modes

The available machine run modes are :
• Machine run: the web moves at the set machine speed.
• Machine jog: as long as this pushbutton is pressed, the machine runs at minimum speed; when the pushbutton
is released the machine stops.
It is recommended to use the machine jog mode only for searching possible coating problems and for
partial web threading through the machine.
For information relative to start or run controls, refer to chapter 3.
4.3.2 Start sequence

With the machine stopped (start sequence zeroed) and with emergencies reset, the two start keys and
flashing; pressing one of these keys (with the machine in operative condition) will initiate the start sequence,
which is composed of the following steps:
• The lights of the two aforementioned keys switch go off (extinguished);
• The machine start buzzer rings for about 3 seconds. Then there is a pause of 4 seconds. If one of the two start
keys is pressed during the pause, the sequence is automatically reset and is to be repeated anew.
• The start pushbuttons commence blinking: from this instant on, the operator has 12 seconds available to give a
start command; if he doesn’t, the sequence is reset.
IF A START COMMAND IS ACTIVATED BUT THE BUZZER DOES NOT RING, DO NOT CONTINUE WITH THE
SEQUENCE. REQUEST SERVICING BY THE ELECTRIC MAINTENANCE ENGINEER TO CHECK THE
CONDITION OF THE MACHINE START BUZZER OR TO SEARCH FOR THE CAUSE OF THE MALFUNCTION.
4.3.3 Machine stop
4.3.3.1 Ordinary stop
It is commanded by the key and is executed in a fixed deceleration ramp.

By activating this function, the coating impression roll opens; the coating cylinder rotates at slow speed so that it
keeps getting wet to prevent the adhesive from drying over it. For switching the coating cylinder motor off, key
(Machine Stop) is to be pressed a second time.
Once zero speed is reached (machine stopped), the web tension control systems remain active and web tension is
maintained.
4.3.3.2 Emergency stop

The emergency stop is activated by:
• Pressing one of the red mushroom-head emergency pushbuttons;
• Activating the pull cord switch.
It is always possible to trace the cause that triggered an emergency by identifying the contact that generated it.
Job order 61368 - rev.0 Machine operation 3

NOVA SX 550
4.4.1 Access to the unwinder

Access to the unwinder (for preparation, maintenance, cleaning, etc.) can only take place with the machine
stopped.
BEFORE APPROACHING THE UNWINDER, PUT IT IN A SAFE STATUS, EXTRACT THE KEY WHICH
ENABLES THE ACCIDENT PREVENTION DEVICES AND KEEP IT IN YOUR POCKET DURING THE WHOLE
TIME YOU STAY IN THE UNWINDER AREA.
KEEP AT A SAFE DISTANCE FROM THE UNWINDING REEL, FROM THE UNWINDER ROLLERS AND FROM
THE DANCER ROLLER ARMS WHEN THE MACHINE IS IN OPERA¬TIVE CONDITION.
THE REAR OF THE UNWINDER PARTS SHOULD NOT BE ACCESSED WITH THE SECTION IN OPERATION!
Also with the unwinder stopped, the half-arms can be moved sideways using the specific control panel, for
loading/unloading operations of the reels and web alignment.
PAY PARTICULAR ATTENTION WHEN MOVING THE HALF-ARMS: RESIDUAL RISK OF CRUSHING.

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4.4.2 Preparing the unwinder
4.4.2.1 Unloading the core

The procedure is as follows:
• Cut the web near the exhausted reel.
• Pressing the pushbutton it enables opening / closing the half-arms.
• Press the pushbutton again to open the two half-arms and empty the reel.
IT MAY HAPPEN THAT YOU HAVE TO UNLOAD A REEL WHICH IS STILL NOT COMPLETELY UNWOUND.
IN THIS CASE, BEFORE OPENING THE HALF-ARMS, POSITION A TROLLEY UNDER THE REEL AND
ENSURE IT IS WELL SUPPORTED!
4.4.2.2 Loading a new reel

1. Check the core of the new reel is the same diameter as the previous one; if not, replace the conical chucks
(3" or 6").
2. With the trolley, raise the reel until its core is aligned to the conical chucks (operator side and drive side);
If the half-arms are not open enough, press the (located on the crossbeam of the unwinder) to
open the half-arms to the desired width.
DO NOT ROLL THE REELS.
CHECK THE CORE OF THE REEL IS PERFECTLY ALIGNED WITH THE CONICAL CHUCKS, BEFORE
COMMANDING CLOSURE.
If you try to close the chucks on a core which is not perfectly aligned, then the core might get stuck
causing sudden jerking of the reel and immediate closure of the half-arms (when the chucks re-enter the
core) may cause risks for the operator.

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3. Press the illuminated pushbutton steadily to simultaneously close the half-arms, commanding
complete penetration of the chucks into the core.
DO NOT PUT YOUR HANDS BETWEEN THE CORE AND THE CONICAL CHUCKS WHILE THE HALF-ARMS
ARE CLOSING.
If the trolley holding the reel is not transversally centred compared to the half-arms (i.e. with the reel
nearest the half-arm on the operator side or the half-arm on the drive side), before commanding complete
closure of the half-arms, move them transversally (simultaneously) using the selector , to centre
them compared to the reel.
CLOSING THE HALF-ARMS ON A TRANSVERSALLY OFF CENTRE REEL MEANS THE REEL WILL RUB
AGAINST THE SUPPORT SURFACE OF THE TROLLEY AND COULD GET DAMAGED.

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If the sequence was successful, the light on the illuminated pushbutton , indicating the reel is
correctly fitted. Otherwise, it is necessary to open the half-arms and to execute the closing procedure
again; with the lamp off, production cannot be started.
In case the illuminated pushbutton is released (held down) before the pushbutton light is lit, the
half-arms will start the opening sequence.
5. Remove any packaging residues from the reel and clean the outside surface of the reel carefully.
FRICTION WITH THE SURFACE OF PLASTIC MATERIALS DURING DRY CLEANING MAY GENERATE
ELECTROSTATIC CHARGES.

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6. If production has already begun, start the "automatic reel positioning" function by pressing the illuminated
pushbutton for three seconds to align the new reel transversely with the belt that is already in the
machine.
During the "automatic reel positioning" function, the illuminated pushbutton will flash. The function
will terminate with a steady lit light of the illuminated pushbutton .
7. If production has already begun, paste (attach) the web which is already through the machine to the leading
edge of the new unwinding reel.
8. Free the unwinder area, bringing it to an operational condition and switch on the motor of the reel axis.

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4.5 Coating Station
4.5.1 Access to the coating station

Access to the coating station (for sleeve replacement, maintenance, cleaning, etc.) can only take place when the
machine is stopped.
DO NOT TRY TO ACCESS THE LAMINATOR WITH THE MACHINE RUNNING!
ACCESS TO THE STATION WHEN IT IS RUNNING IS ALLOWED ONLY FOR VISUAL INSPECTION.
DESPITE THE PRESENCE OF THE SAFETY NIP BAR, THE IMPRESSION SIDE BETWEEN THE
IMPRESSION ROLLER AND THE COATING CYLINDER PRESENTS THE RESIDUAL RISK OF DRAGGING
AND CRUSHING. PERIODICALLY CHECK CORRECT POSITIONING OF THE BAR.
With the machine stopped, it is possible to access:

• To the front part of the station (web outlet area) through the front sliding door (after it is opened via the selector
switch) ).

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• To the transfer roller transmission area via the side door.
Both hatches are fitted with safety end strokes that impede opening while the machine is running.
4.5.2 Replacing the transfer roller sleeve

Should it be necessary (due to wear, damage, or inadequacy of width) to replace the transfer roller sleeve, please
proceed as follows:
1. Open the side door to the transmission zone of the transfer roller.

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2. Slacken the support closure know which clamps the transfer roller.
3. Remove the support closure know which clamps the transfer roller.
3. Lift the clamping support in order to release the transfer roller.

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4. Release the clamping ring of the transfer roller movement clamp.
5. Rotate the transfer roller until it is perfectly aligned with the movement clamp.
It will not be possible to remove the transfer roller until it is aligned with the movement clamp.
6. Grip the transfer roller tightly and remove it from its housing until you reach the sleeve extraction position.

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7. Enable the extraction of the transfer roller sleeve by means of the key :the sleeve will be ejected
automatically toward the operator side.
DO NOT STAY WITHIN REACH OF THE SLEEVE WHEN IT IS BEING EJECTED. PAY ATTENTION DURING
THIS PROCEDURE.

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8. Manually position the new sleeve around the shaft and fit it until you encounter resistance; then keep the
pushbutton pressed and fully fit the sleeve on the shaft.

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At this point, it is possible to proceed with bringing the transfer roller to its housing in the machine and, following
the reverse procedure, bring the coating station back to operating condition.
CORRECTLY CLAMP THE MOVEMENT CLAMPING RING AND THE SUPPORT CLOSURE KNOB TO CLAMP
THE TRANSFER ROLLER.
It will be impossible to start the machine until the side safety and protection door to the transmission
zone of the transfer roller is properly closed.

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4.5.3 Preparing for work

1. Install the glue diffuser in its nozzle.
2. Adjust the stroke of the adhesive diffuser repeater by positioning the side limit switches

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3. Based on the previous point, adjust the width of the nip field of the glue in the pan including the doctor and
metering rollers, using the side limiters.
The aforementioned adjustments must comply with the sleeve of the transfer roller in use (lowered at
the ends).
4. Insert the glue level sensor into its housing.

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5. Connect the adhesive mixer for mixing and dispensing the solventless adhesive.
6. Check the distance between the transfer roller and the fixed metering roller and, if necessary, adjust this
distance.
7. Check the distance between the doctor roller and the metering roller; if necessary, adjust this distance using
the knobs on the operator side / drive side.
The gap between doctor roller and metering roller is a contributing factor to the thickness of the
adhesive layer applied to the web.
CHECK THE DISTANCE BETWEEN THE DOCTOR AND METERING ROLLERS ON EACH WORK STOPPAGE.

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KEEP A DUE DISTANCE FROM THE COATING AREA WHEN THE UNIT IS RUNNING: RELEASE OF
ISOCYANATE FUMES.
KEEP AT A SAFE DISTANCE FROM MOVING PARTS, FROM THE LEAD-IN SIDE INTO THE TWO ROTATING
ROLLERS AND FROM THE WEB.
4.5.4 Cleaning the coating zone
DO NOT USE FLAMMABLE LIQUIDS DURING THE CLEANING OPERATIONS.

1. Stop machine production.
2. Release the adhesive found in the coating station.
In order to encourage the release and removal of the adhesive, intervene on the switch , to
detach the doctor roller from the metering roller.
3. Open the side door, on the operator side to the bottom left of the coating station and fill the containers with
cleaning liquid.
We recommend using an ecological cleaner with an inflammability temperature of < 60°C.
If the opening of the doctor roller was triggered, close it by operating the selector switch .
4. Launch the rotation of the doctor roller, setting its rotation in the direction opposite to the inlet point with the
metering roller using the selector , in order to avoid the risk of dragging with consequent crushing.
DO NOT SET THE DOCTOR ROLLER ROTATION IN THE DIRECTION IN ACCORDANCE WITH THE INLET
POINT WITH THE METERING ROLLER: RISK OF DRAGGING AND CONSEQUENT CRUSHING.

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5. Start automatic washing by pressing the key .

The automatic wash consists of various staged with a precise duration that can be set (using a
password) from the supervision system panel.
CLOSE ALL DOORS OF THE COATING STATION BEFORE STARTING THE AUTOMATIC WASH.
DO NOT ATTEMPT TO ACCESS THE ROLLERS FROM BENEATH. IT IS FORBIDDEN TO REMOVE THE PAN
DURING CLEANING OPERATIONS.
Once the automatic washing process has been completed, manually clean the coating station using a rag soaked
in cleaner, pressing the washing pedal until the middle of the stroke (first click) to move the machine.
Grip the cloth and run it along the entire length of the cylinder until all traces of glue have been removed.
GRIP THE CLOTH AS SHOWN IN THE DIAGRAM DO NOT WRAP THE CLOTH AROUND YOUR HAND.
Fig. 4.5.4A: Correct way to hold the cleaning cloth
Fig. 4.5.4B: Manual cleaning stages of the coating cylinder

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When the cleaning is complete. empty the content of the basin, turning the tap, into a specific collection container.

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4.6 Laminator Group
4.6.1 Access to the laminator unit

Access to the laminator unit (for impression roller removal, maintenance, cleaning, etc.) can only take place when
the machine is stopped.
DO NOT TRY TO ACCESS THE LAMINATOR UNIT WITH THE MACHINE RUNNING!
ACCESS TO THE LAMINATOR UNIT WHEN IT IS RUNNING IS ALLOWED ONLY FOR VISUAL INSPECTION.
DESPITE THE PRESENCE OF THE SAFETY NIP BAR, THE IMPRESSION SIDE BETWEEN THE BACK
PRESSURE ROLLER AND THE IMPRESSION ROLLER PRESENTS THE RESIDUAL RISK OF DRAGGING
AND CRUSHING. PERIODICALLY CHECK CORRECT POSITIONING OF THE BAR.
With the machine stopped, it is possible to access:

• At the rear of the laminator unit through the rear door (after opening with the unlock key)
The hatch is fitted with safety end stroke that impedes opening while the machine is running.

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Heating of the laminating roll (if enabled) represents a dangerous heat source for the operator.
RISK OF BURNS: DO NOT TOUCH THE LAMINATING ROLLER AFTER THE MACHINE HAS STOPPED;
BEFORE EXECUTING ANY MAINTENANCE OPERATION ON THE ROLLER, WAIT LONG ENOUGH FOR THE
ROLLER TO COOL DOWN.
4.6.2 Closing the laminating nip

1. Switch on the secondary unwinder and the rewinder (select them ON).
2. Bring it into correspondence with the laminating area to check it is clear.
3. Make sure the laminator access port is closed.
4. Go near the rewinder and check that the laminating area is clear.
DO NOT CLOSE THE LAMINATING NIP, IF THERE ARE PERSONS OR OBJECTS IN THE AREA.
5. Intervene on the illuminated pushbutton to close the impression roller.

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4.6.3 Removing the lamination impression roller

Should it become necessary (due to wear or damage) to replace the impression roller sleeve or to perform a
complete cleaning of this machine section, proceed as follows:
CLEAN THIS MACHINE SECTION REGULARLY, ESPECIALLY THE SURFACES OF THE IMPRESSION
ROLLER AND LAMINATING ROLLER.
To clean the lamination impression roller it is recommended to use:

1. Only Ethyl Alcohol (100%).
2. Mix of Ethyl Alcohol (80%) and Ethyl Acetate (20%).
3. Aliphatic Hydrocarbons (NAPHTHA).
It is not recommended to use:

• Aromatic Hydrocarbons (toluene/toluol type).
• Only Ethyl acetate (100%).
• Other solvents or mixes not mentioned in the recommended products.
Access to the laminating unit in the following procedure takes place on the side of the secondary unwinder.
IF HEATING OF THE LAMINATING ROLLER IS ENABLED, SWITCH IT OFF AND WAIT LONG ENOUGH FOR
THE ROLLER TO COOL DOWN, BEFORE CARRYING OUT THE FOLLOWING PROCEDURE: RISK OF
BURNS!

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1. Open the access door to the laminator using the keys.
2. Remove the impression roller fastening screws on both side in order to release it.
3. Remove the impression roller using a suitable tool and taking care not to bang against the machine.
At this point it is possible to go ahead and fit a new impression roller or the newly cleaned roller that has just been
dismantled, following the reverse procedure, in order to render the laminating group operational.
It will not be possible to start the machine until the access door to the laminator has been shut properly.

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4.7 Rewinder
4.7.1 Access to the rewinder

Access to the rewinder (for preparation, maintenance, cleaning, etc.) can only take place when the machine is
stopped.
BEFORE APPROACHING THE REWINDER, PUT IT IN A SAFE STATUS, EXTRACT THE KEY WHICH
ENABLES THE ACCIDENT PREVENTION DEVICES AND KEEP IT IN YOUR POCKET DURING THE WHOLE
TIME YOU STAY IN THE REWINDER AREA.
KEEP AT A SAFE DISTANCE FROM THE REWINDING REEL, FROM THE REWINDER ROLLERS AND FROM
THE DANCER ROLLER ARMS WHEN THE MACHINE IS IN OPERATIVE CONDITION.
DO NOT ATTEMPT TO ACCESS THE REAR OF THE REWINDER PARTS WHILE THE SECTION IS
OPERATING.
DESPITE THE PRESENCE OF THE PROTECTION, THE PRESSURE POINT BETWEEN THE LAY-ON
ROLLER AND THE REWINDING REEL PRESENTS A RESIDUE RISK OF DRAGGING AND SUBSEQUENT
CRUSHING; PERIODICALLY CHECK CORRECT POSITIONING OF THE BAR.
Also with the rewinder stopped, the half-arms can be moved sideways using the specific control panel, for
loading/unloading operations of the reels and web alignment.
PAY PARTICULAR ATTENTION WHEN MOVING THE HALF-ARMS: RESIDUAL RISK OF CRUSHING.

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4.7.2 Preparing the rewinder
Bring the lay-on roller to the rest position using the selector ; then unload the finished reel and load the new
core on which the web is glued on the machine, following the procedure indicated in the paragraph “Preparing the
unwinder”.
BEFORE OPENING THE HALF-ARMS FOR UNLOADING THE WOUND REEL, YOU SHOULD PUT A
TROLLEY UNDER THE REEL AND MAKE SURE THE REEL ITSELF IS SUPPORTED WELL.
SAFETY DURING REEL UNLOADING OPERATIONS IS DETERMINED BY THE OPERATOR'S SUPERVISION

AND CONTROL, REGARDLESS OF THE UNLOADING DEVICE THAT MAY BE SUPPLIED WITH THE
MACHINE.
WHEN THE HALF-ARMS ARE CLOSING FOR NEW CORE LOCKING, CHECK THE CORE IS PERFECTLY
ALIGNED AND DO NOT PUT HANDS BETWEEN THE CORE AND THE CHUCKS. WHEN THE SEQUENCE IS
COMPLETE, ENSURE THE CHUCKS HAVE PENETRATED THE CORE COMPLETELY AND THE LIGHT ON
THE SELECTOR IS ON.

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4.7.3 Rewinding modes

The pressure exerted by the lay-on roller on the reel can be set to constant mode, or taper pressure mode.
The web tension (which is exerted by the drive torque on the reel) can be set to constant mode, or taper tension.
The work configuration to use mainly depends on the type of web material being rewound. Setting of the
aforementioned factors will determine the compactness and regularity of the rewound reel.
4.7.3.1 Lay-on mode

The pressure exertion mode on the rewinding reel by the lay-on roller can be selected:
• in constant mode, the pressure remains unchanged the entire rewinding process;
• in taper mode, the set pressure decreases proportionally as the reel diameter increases.
The principle of taper pressure is identical to that of taper tension, as illustrated in the next paragraph.
4.7.3.2 Constant tension / Taper tension

Unless taper tension has been set, web tension remains constant throughout the whole rewinding process.
In some cases, in the presence of maximum tension and maximum diameter of the rewinding reel, a
“natural” reduction of web tension may occur, based on the maximum torque supplied by the motor of
the reel (also refer to the technical specifications of the motor).
With the taper tension mode active, web tension decreases as the diameter of the rewinding reel increases.
It is advisable to apply the taper tension mode on extensible web materials or with particularly sensitive
laminates. If constant tension was used with such materials, it could generate telescopic reels or reels
with surface irregularities (creases).

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This web tension decrease can be linear or hyperbolic:

• With linear taper tension, rewinding web tension decreases progressively, inversely proportional to reel
diameter increase;
Fig. 4.7.3.2A: Example of linear web taper tension, in relation to a reel diameter increase.
• With hyperbolic taper tension, rewinding web tension decreases suddenly in the first rewound metres, then the
decrease is more regular and smaller, and continues likewise until the end of the rewinding process.
Fig. 4.7.3.2B: Example of web tension with hyperbolic taper tension.

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4.8 Web threading
BEFORE ACCESSING EACH OF THE SECTIONS ON THE MACHINE, ENSURE THERE ARE NO
UNAUTHORISED PERSONS NOT INOLVED IN THE THREADING OPERATIONS, IN THE AREA.
Before commencing the manual web threading procedure, ensure that all motors of the machine
(whether for the rotation of rollers or of reels) are off, and that all impression rollers are lifted.
Before threading the web, make sure the coating cylinder surface is perfectly clean.
• Load a reel on each unwinder.

• Load one core on the rewinder, and prepare it with self-adhesive tape or glue.
• Thread the webs through all machine sections until reaching the rewinder; then glue them to the rewind core.
Insertion of the web inside the overhead connection crossbeam takes place manually.
• Bring all the sections to operation condition.

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4.9 Putting the web under tension through the machine

For putting the web under tension, proceed as follows:
• Set the desired tension values through the machine, section by section;
Reference should be made to the web tension tables below.
• Make sure all sections are in operative condition;

• On the machine monitoring display page, press the start key to begin the automatic tension sequence.
4.9.1 Web tension tables
4.9.1.1 Paper and cardboard (specific weight 0.8 kg/dm3)
Weight Weight Thickness Thickness Thickness Tension Tension Tension

[g/m²] [lb/rm] [μm] [gauge] [mil] [daN/cml] [pli] [daN/mm2]
16 12.28 20 80 0.79 0.10 0.57 0.50
36 27.63 45 180 1.77 0.18 1.03 0.40
56 42.98 70 280 2.7 0.25 1.43 0.357
76 58.33 95 380 3.7 0.32 1.83 0.337
96 73.68 120 480 4.7 0.37 2.11 0.308
120 92.10 150 600 5.9 0.40 2.29 0.267
140 107.45 175 700 6.9 0.45 2.57 0.257
160 122.8 200 800 7.9 0.50 2.86 0.25
180 138.15 225 900 8.8 0.52 2.97 0.231
200 153.5 250 1000 9.8 0.54 3.09 0.216
1 Ream = 3000 square feet 1 Ream = 3000 square feet

(1 g/m²) = 0.614 lb/rm
(1 lb/rm) = 1.628 g/m²

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4.9.1.2 Cardboard (specific weight 0.8 kg/dm3)

300 184.2 375 1500 14.7 0.58 3.31 0.155
350 214.9 438 1752 17.2 0.62 3.54 0.141
400 245.6 500 2000 19.6 0.70 4.00 0.140
450 276.3 562 2248 22.1 0.78 4.46 0.139
500 307 625 2500 24.6 0.85 4.86 0.136
550 337.7 688 2752 27.0 0.92 5.26 0.134
600 368.4 750 3000 29.5 1.00 5.71 0.133
650 399.1 812 3248 31.9 1.10 6.29 0.131
700 429.8 875 3500 34.4 1.13 6.46 0.129
4.9.1.3 Annealed aluminium foil, for printing and coating in flexible packaging
(specific weight 2.7 kg/dm3)

16.2 9.94 6 24 0.236 0.075 0.43 1.2
24.3 14.92 9 36 0.354 0.108 0.62 1.2
40.5 24.86 15 60 0.59 0.171 0.98 1.2
81 49.73 30 120 1.18 0.3 1.71 1.2
135 82.89 50 200 1.97 0.45 2.57 1.2
202 124.02 75 300 2.95 0.63 3.60 1.2
270 165.78 100 400 3.94 0.7 4.00 1.2
405 248.67 150 600 5.9 0.975 5.57 1.2

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4.9.1.4 Hard tempered aluminium foil for lacquer coating machines (specific weight
2.7 kg/dm3)

40.5 24.86 15 60 0.59 0.21 1.20 1.4
81 49.73 30 120 1.18 0.42 2.40 1.4
135 82.89 50 200 1.97 0.7 4.00 1.4
202 124.02 75 300 2.95 1.05 6.00 1.4
270 165.78 100 400 3.94 1.4 8.00 1.4
405 248.67 150 600 5.9 2.1 12.00 1.4
540 331.56 200 800 7.87 2.8 16.00 1.4
675 414.45 250 1000 9.84 3.5 20.00 1.4
810 497.34 300 1200 11.8 4.2 24.00 1.4
4.9.1.5 Annealed aluminium foil for lacquer coating machines (specific weight 2.7
kg/dm3)

54 33.15 20 80 0.79 0.24 1.37 1.2
81 49.73 30 120 1.18 0.36 2.06 1.2
135 82.89 50 200 1.97 0.6 3.43 1.2
202 124.02 75 300 2.95 0.9 5.14 1.2
270 165.78 100 400 3.94 1.2 6.86 1.2
405 248.67 150 600 5.9 1.8 10.29 1.2
540 331.56 200 800 7.87 2.4 13.71 1.2
675 414.45 250 1000 9.84 3 17.14 1.2
810 497.34 300 1200 11.8 3.6 20.57 1.2

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4.9.1.6 Cellophane (specific weight 1.4 kg/dm3)

28 17.19 20 80 0.79 0.12 0.69 0.60
40 24.56 28.5 114 1.12 0.165 0.94 0.58
52 31.92 37 148 1.45 0.207 1.18 0.56
60 36.84 42.8 171 1.68 0.231 1.32 0.54
4.9.1.7 Polyester (specific weight 1.38kg/dm3)

16.56 10.16 12 48 0.47 0.099 0.57 0.83
27.6 16.94 20 80 0.79 0.16 0.91 0.83
41.4 25.41 30 120 1.18 0.25 1.43 0.83
55.2 33.89 40 160 1.57 0.33 1.89 0.83
4.9.1.8 Cast PP (specific weight 0.9 kg/dm3)

18 11.05 20 80 0.79 0.1 0.57 0.5
27 16.57 30 120 1.18 0.15 0.86 0.5
45 27.63 50 200 1.97 0.25 1.43 0.5
67.5 41.44 75 300 2.95 0.37 2.11 0.5
90 55.26 100 400 3.94 0.50 2.86 0.5

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4.9.1.9 BOPP (specific weight 0.9 kg/dm3)

11.2 6.87 12.5 50 0.49 0.0625 0.36 0.5
18 11.05 20 80 0.79 0.1 0.57 0.5
22.5 13.81 25 100 0.98 0.125 0.71 0.5
31.5 19.34 35 140 1.4 0.17 0.97 0.5
45 27.63 50 200 1.97 0.25 1.43 0.5
54 33.15 60 240 2.36 0.30 1.71 0.5
4.9.1.10 Non-oriented nylon (specific weight 1.13 kg/dm3)

13.5 8.29 12 48 0.47 0.036 0.21 0.3
28.2 17.31 25 100 0.98 0.075 0.43 0.3
56.5 34.69 50 200 1.97 0.15 0.86 0.3
84.7 52.00 75 300 2.95 0.225 1.29 0.3
4.9.1.11 Bi-axially oriented nylon (specific weight 1.13 kg/dm3)

14.1 8.65 12.5 50 0.49 0.0625 0.36 0.5
28.2 17.31 25 100 0.984 0.125 0.71 0.5
56.2 34.69 50 200 1.97 0.25 1.43 0.5
67.8 41.62 60 240 2.36 0.30 1.71 0.5

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4.9.1.12 Soft PVC (specific weight 1.3/dm3)

26 15.96 20 80 0.79 0.04 0.23 0.20
65 39.91 50 200 1.97 0.10 0.57 0.20
97.5 59.86 75 300 2.95 0.15 0.86 0.20
130 79.82 100 400 3.94 0.20 1.14 0.20
162 99.46 125 500 4.92 0.25 1.43 0.20
195 119.73 150 600 5.9 0.30 1.71 0.20
227 139.37 175 700 6.9 0.35 2.00 0.20
260 159.64 200 800 7.87 0.40 2.29 0.20
292 179.28 225 900 8.86 0.45 2.57 0.20
325 199.55 250 1000 9.84 0.50 2.86 0.20
357 219.19 275 1100 10.8 0.55 3.14 0.20
390 239.46 300 1200 11.8 0.60 3.43 0.20
4.9.1.13 Semi-Rigid PVC (specific weight 1.35 kg/dm3)

33.7 20.69 25 100 0.98 0.0625 0.36 0.25
67.5 41.44 50 200 1.97 0.1258 0.72 0.25
101 62.01 75 300 2.95 0.188 1.07 0.25
135 82.89 100 400 3.94 0.25 1.43 0.25
169 103.76 125 500 4.92 0.312 1.78 0.25
202 124.02 150 600 5.9 0.375 2.14 0.25
236 144.90 175 700 6.9 0.438 2.50 0.25
270 165.78 200 800 7.87 0.50 2.86 0.25
337 206.91 250 1000 9.84 0.625 3.57 0.25

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4.9.1.14 Rigid PVC (specific weight 1.4 kg/dm3)

42 25.78 30 120 1.18 0.09 0.51 0.30
70 42.98 50 200 1.97 0.15 0.86 0.30
105 64.47 75 300 2.95 0.225 1.29 0.30
140 85.96 100 400 3.94 0.30 1.71 0.30
210 128.94 150 600 5.9 0.42 2.40 0.28
280 171.92 200 800 7.87 0.52 2.97 0.26
350 214.90 250 1000 9.84 0.60 3.43 0.24
420 257.88 300 1200 11.8 0.66 3.77 0.22
490 300.86 350 1400 13.8 0.70 4.00 0.20
560 343.84 400 1600 15.7 0.72 4.11 0.18
630 386.82 450 1800 17.7 0.74 4.23 0.165
700 429.80 500 2000 19.7 0.76 4.34 0.15
770 472.78 550 2200 21.6 0.77 4.40 0.14
840 515.76 600 2400 23.6 0.78 4.46 0.13
4.9.1.15 LDPE (specific weight 0.92 kg/dm3)

18.4 11.29 20 80 0.79 0.04 0.23 0.20
23 14.12 25 100 0.98 0.05 0.29 0.20
46 28.24 50 200 1.97 0.10 0.57 0.20
69 42.36 75 300 2.95 0.15 0.86 0.20
92 56.48 100 400 3.94 0.20 1.14 0.20
115 70.61 125 500 4.92 0.25 1.43 0.20

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4.9.1.16 LLDPE

- - 20 80 0.79 0.04 0.23 0.20
- - 25 100 0.98 0.05 0.29 0.20
- - 50 200 1.97 0.10 0.57 0.20
- - 60 240 2.36 0.12 0.69 0.20
4.9.1.17 EVA (specific weight 0.95 kg/dm3)

19 11.66 20 80 0.79 0.04 0.23 0.20
23.7 14.55 25 100 0.98 0.05 0.29 0.20
47.5 29.16 50 200 1.97 0.10 0.57 0.20
71.2 43.71 75 300 2.95 0.15 0.86 0.20
95 58.33 100 400 3.94 0.20 1.14 0.20
142 87.18 150 600 5.9 0.30 1.71 0.20

NOVA SX 550
4.10 First job
4.10.1 Setting the machine parameters

By means of the Supervision system, the touch panels and the pushbutton panels of the various machine sections,
enter all the preliminary work settings (as well as set-points already described in the previous paragraphs):
The set-points entered for the first job can then be saved in a production recipe, allowing it to be
retrieved and reused in future for identical or similar processes (where only some values will have to be
changed).
4.10.2 Preparing the machine for coating

1. Start the machine at minimum speed.
2. Turn on the water delivery plant to the temperature controlled rollers.
3. Activate the adhesive supply flow into the coating unit;
4. Position the web guide sensor and start this system in automatic mode.
5. Position and start the air suction system in the coating area.
6. Close the coating station and laminator impression roller.
DO NOT APPROACH THE COATING IMPRESSION ROLLER DURING THE CLOSURE PHASE: RESIDUAL
RISK OF CRUSHING!
4.11 Repeat Job

The machine does not have to be set for a repeat job, as all set-points are already stored in the previous recipe.
The recipe contains all logical and analogue values of the components integrated into the machine.
BEFORE LOADING THE RECIPE, CHECK THAT THE MACHINE IS CONFIGURED IN THE SAME WAY
To prepare the machine for coating, follow the previously described procedure.
4.12 Restarting after an emergency

To restore the machine, proceed as follows:
1. Remove the cause that triggered the emergency;
2. Reset the emergency;
3. In the event of a web break, re-thread the web in the machine;
4. Tension the web again.
It is not necessary to reset the parameters to restart the machine after an emergency.
To prepare the machine for coating, follow the previously described procedure.

NOVA SX 550
4.13 Job Changeover
4.13.1 Routine checks

The fume exhaust openings in the coating area might be clogged; check them at each job changeover and if
necessary, remove any incrustation.
Then clean all the filters (if present) and, if necessary, replace them.
IT IS FORBIDDEN TO USE THE MACHINE WITH THE AIR EVACUATION OPENINGS IN THE COATING UNIT
BLOCKED.
4.13.2 General cleaning

Whenever changing job, it is necessary to clean some parts of the machine, such as the coating rollers, pumps,
tanks and all parts that have been in contact with the adhesive.
For the description of the washing sequence of the coating zone, refer to the specific paragraphs in this chapter.
4.14 Extended periods of machine inactivity
4.14.1 Short-term inactivity (from 3 or 4 weeks to 6 months)

When the machine will be out of use for the aforementioned time, carry out the operations listed below:
• Remove reels and cores from the reel stands;
• Open all impression rollers to prevent the rubber on the rollers flattening due to permanent contact;
• Open the main isolator switch;
• Close the main compressed air intake valve;
• Clean the machine.
4.14.2 Long-term inactivity (over 6 months)

When the machine will be out of use for very long periods of time, carry out the operations listed in the previous
point (short-term inactivity), plus:
• Drain all oil contained in gear reducers and reduction gearboxes;
• Cover the machine units, the control console and panels as well as the electric cabinet with protective material
(for example, plastic sheeting);
• Apply a protective layer of wax or grease to unpainted parts.

NOVA SX 550
4.15 Notes

NOVA SX 550

5 TROUBLE SHOOTING
NOVA SX 550
5.1 Alarms
5.1.1 General re. Alarms

The machine is designed to be “safe” under hazardous conditions. Every time the system detects a dangerous
situation due to a malfunction of one or more parts of the machine system or due to incorrect operations by the
operator, an acoustic and luminous signal goes off to draw the operator’s attention to the main control panel:
• Acoustic signal: the buzzer rings every time an alarm is activated.
• Light signal: the alarm flashes when there is an alarm that has not yet been acknowledged by the operator.
As soon as the alarm is acknowledged, this light stops blinking and becomes steadily lit; once the causes that
triggered the alarm are removed, the light goes out.
• Alarm text on the supervision system: when an alarm condition arises, the supervision system displays the
associated alarm text.
The operator, by pressing a special key on the screen, reaches the display page of alarms in progress. Here, the
operator takes notice of the activated alarms by pressing the Ack key (acknowledgement, reset of alarms): if the
cause of the alarm is no longer present, the system is ready to resume its normal functions; if the cause persists,
the function relating to the current alarm is “frozen” until the cause (the fault that generated the alarm) has been
removed by the operator or by the maintenance staff. For precise details on alarm management, see the Bobst
supervision system manual.
References to PLC address and to the electric diagram:

• For additional fault finding information, the alarm text contains the PLC address and the
number of the electric diagram concerned.
Alarm effects:
• The alarms, depending on the seriousness and impact they may have on personnel safety and on the machine
components, cause a specific machine reaction.
This classification (reaction) is indicated by a number:
Type Effect
2 Ordinary machine stop
Warning only (allows production in progress to

3
be completed)
4 Fast stop of machine
5 Minimum line speed
2 Trouble shooting Job order 61368 - rev.0

NOVA SX 550
5.1.2 Legend of symbols used in the individual alarm sheets:
Symbol Description
Action by the machine operator
Action required by the electric maintenance

engineer.
Action required by the mechanical maintenance

engineer.
Job order 61368 - rev.0 Trouble shooting 3

NOVA SX 550
5.1.3 Summary of alarm description sheets
Compressed air line pressure failure ➔ A-001
Electric cabinet overheating A-002
Reel shaft not chucked ➔ A-003
Drive power supply unit failure A-004
Drive fault A-010
Limit switch failure ➔ A-014
Fan or blower failure A-024
Electric cabinet blower(s) failure A-025
Drive not ready A-031
Web tension timeout (unwinders - rewinder) A-035
Nip roller open A-042
Circuit breaker A-044
Maximum rewinder reel diameter / footage reached ➔ A-046
Please remake process selections on… A-048

NOVA SX 550
Web break detected by … ➔ A-050
Movement prevented by section in safety mode ➔ A-053
Motor overheating A-054
Solventless rollers rotation failure A-057
Cylinders heater failure ➔ A-058
Web material on the core finished A-059
PLC failure A-060
Unwinder-rewinder half-arms auto-centre timeout A-061
Digital output card failure Safe 4F-DO DC24V/2A A-070
Digital input card failure Safe 4/8 F-DI DC24V A-071
Safe PM-E F pp DC24V power supply unit card failure A-072
Telegram Communication failure Safe axis D425-CU320 A-073
Communication Failure of CPU SAFE (FB224 F_RCVDP) A-074

NOVA SX 550
5.1.4 Alarm description sheets
ALARM A-001
COMPRESSED AIR LINE PRESSURE FAILURE

Material required:
1. Multimeter.
2. Electric and pneumatic diagrams (hard copy or electronic format which can be consulted on the "Alarms"
page of the supervision system).
ELECTRICAL MAINTENANCE checks
In the alarm text take note of the corresponding drawing number. Using the above mentioned material, conduct
the following checks:
1. Check that the wiring between the pressure switch and PLC input side is intact.
2. Check the PLC card reading the pressure switch signal is properly power supplied and not faulty.
MECHANICAL MAINTENANCE checks
1. Check the machine connection to the factory compressed air mains is intact.
2. Check the air supply level is consistent with the machine specifications.
3. Check and, if necessary, adjust calibration of the relevant pressure switch.
4. If the pressure switch is properly supplied (both pneumatically and electrically) but doesn’t work, replace it.
IF THE PROBLEM PERSISTS, CONTACT BOBST’S TECHNICAL SERVICE.

NOVA SX 550
ALARM A-002
ELECTRIC CABINET OVERHEATING

Material required:
1. Multimeter.
2. Thermometer.
3. Electric diagrams (hard copy or electronic format which can be consulted on the "Alarms" page of the
supervision system).
1. The PLC input reading the thermostat is not faulty and the connecting wire is not detached.
2. The cabinet door blowers and conditioners (where provided) are operational.
3. The thermostat is calibrated as specified in the corresponding electric diagram.
4. The actual temperature inside the electric cabinet.
5. The thermostat is working properly; read in ohm the contact status and simultaneously operate the
calibration device, verifying the contact condition changes when above and below the calibration threshold.
The operation should be carried out at a temperature lower than the maximum calibration of the thermostat.

NOVA SX 550
ALARM A-003
REEL SHAFT NOT CHUCKED

Material required:
1. Multimeter.
OPERATOR checks
1. Check that the chucks close properly.

2. Check for the correct penetration of the chucks into the core.
3. Close the chucks again, taking care to check whether there are any obstacles that prevent proper closing.
In the alarm text take note of the corresponding drawing number. Using the above mentioned material, conduct the
following checks:
1. Locate the PLC input that reads the pressure switch signal.
2. Check that the pressure switch is power supplied and the connection is intact.
3. Check that the PLC input card that reads the pressure switch is properly power supplied and not damaged.
IMPORTANT: THIS ALARM IS INVOLVED WITH SAFETY OF THE SYSTEM. NEVER USE THE MACHINE IF
THIS SAFETY DEVICE IS BY-PASSED.

NOVA SX 550
ALARM A-004
DRIVE POWER SUPPLY UNIT FAILURE

Material required:
1. Multimeter.
In the alarm text, note the corresponding drawing number and any other drawings referred to in the drawing itself
(references for PLC inputs/outputs). Using the above mentioned material, check that:
1. The power supply unit failure contact is properly power supplied.
2. The PLC input that reads the power supply unit failure signal is not faulty.
3. The connecting wire between the power supply unit contact and PLC input is not detached.
4. The PLC output that controls the power contactor actuation relay is not damaged.
5. The control circuit wiring is intact (from the PLC output to contactor relay).
6. The 24V is present under a delayed emergency condition. See the diagrams relating to the power supplies.

NOVA SX 550
ALARM A-010
DRIVE FAULT
Material required:
1. Drives manual.
2. Programming unit.
1. Find the drive that is faulty, connect the programming unit to it, then read the drive failure code; to solve the
problem, refer to the specific manual.

NOVA SX 550
ALARM A-014
LIMIT SWITCH FAILURE

Material required:
1. Multimeter.
3. Electric and Pneumatic diagrams (hard copy or electronic format which can be consulted on the "Alarms"
page of the supervision system).
In the alarm text take note of the corresponding drawing number. Using the above mentioned material, conduct the
following checks:
1. Read the alarm text to find which program part needs testing in order to display the status of the limit
switches.
2. Use the programming unit to find the limit switch that has signalled a malfunction (it could be more than one).
3. Check that the limit switch is properly power supplied and its supply cable is not interrupted.
4. Check that the PLC card reading the limit switch is properly power supplied and not damaged.
1. If the operation is pneumatically controlled, make sure that the pneumatic circuit is in-tegral and properly
supplied.
2. If the operation is pneumatically controlled, make sure that the pneumatic circuit is intact and properly
supplied.

NOVA SX 550
ALARM A-024
FAN OR BLOWER FAILURE

Material required:
1. Multimeter.
3. Current clamp.
1. Locate the circuit breaker that controls the fan.
2. If the circuit breaker has tripped, check to ensure its adjustment complies with that indicated in the diagrams,
check if there are any short circuits and reset the breaker. With the current clamp, check the fan motor
absorption.
3. If the circuit breaker has not tripped, check that its auxiliary contact is properly power supplied and the power
supply cable is not damaged.
4. Check that the auxiliary contact connection to the PLC input is intact.
5. Check that the card which reads the auxiliary contact is properly power supplied and not faulty.

NOVA SX 550
ALARM A-025
ELECTRIC CABINET BLOWER(S) FAILURE

Material required:
1. Multimeter.
3. Current clamp.
1. Locate the circuit breaker that controls the fan.
2. If the circuit breaker has tripped, check if there are any short circuits, reset the breaker and check the fan
motor absorption with the current clamp.
3. If the circuit breaker has not tripped, check that its auxiliary contact is properly power supplied and the power
supply cable is not damaged.
4. Check that the auxiliary contact connection to the PLC input is intact.
5. Check that the card which reads the auxiliary contact is properly power supplied and not faulty.

NOVA SX 550
ALARM A-031
DRIVE NOT READY

Material required:
3. Multimeter.
1. Put the machine unit involved in safety mode.
2. Before resetting the alarm, take note of the fault code on the inverter display and consult the inverter manual.
After resetting the alarms, the fault code is reset and can no longer be read.
3. Try and reset the alarm.
4. Check that the SAFETY OFF contact on the drive is closed when the unit is operational / open with the unit in
safety mode.

NOVA SX 550
ALARM A-035
WEB TENSION TIMEOUT (UNWINDERS - REWINDER)

This means: the tension/diameter calculation sequence is interrupted during the tensioning process because it is
taking too long.
Material required:
None.
OPERATOR checks
Broken reel
1. Check the (unwinder or rewinder) reels to locate a web break.
2. Re-attach the web and restart.
Too much reel to retrieve

1. Check the (unwinder or rewinder) reels to locate a reel surplus.
2. Rewinding the reel manually.
Dancer roller sensor to be calibrated or not operational

1. Check the operation of the dancer roller position sensor.
2. Calibrate the position of the dancer roller through the SW calibration pages.
OPERATOR checks
The chucks (unwinders - rewinder) rotate empty

1. Check that the chucks are tight on the reel core.
2. Carry out the mechanical checks on the chucks.

NOVA SX 550
ALARM A-042
NIP ROLLER OPEN

Material required:
None.
OPERATOR checks
1. Reset the alarm.

2. Reduce machine speed to a minimum to avoid damage due to sudden contact of the impression roller with
the web material when the machine is running.
3. Close the impression roller.

NOVA SX 550
ALARM A-044
CIRCUIT BREAKER
Meaning: the circuit breaker has tripped (opened), because of a fault in the piece of equipment it protects. Once
the problem with the piece of equipment has been solved, close the breaker.
This alarm would trigger even without any fault, if the maintenance engineer left the circuit breaker open.
Material required:
1. Multimeter.
3. Current clamp.
1. Locate the circuit breaker that caused the alarm.
2. Check that the calibration of the circuit breaker concerned complies with that indicated in the electric
diagrams.
3. Use the multimeter to detect any short circuits between the phases and check all phases are present.
4. Use the multimeter to check the insulation of the output phases to the earth potential. In case of continuity to
the earth potential, check the cable loading or ascertain if it is interrupted due to damage.
5. If the circuit breaker hasn't tripped, check the auxiliary contact is properly power supplied and its wiring is
intact.
6. Check that the cable connecting the auxiliary contact to the PLC is intact.
7. Check that the input card which reads the auxiliary contact is properly power supplied and not damaged.
8. Re-enable (close) the circuit breaker and, using the current clamp, check that absorption of current complies
with the load rating.

NOVA SX 550
ALARM A-046
MAXIMUM REWINDER REEL DIAMETER / FOOTAGE REACHED

Material required:
None
OPERATOR checks
1. Visually check the diameter / footage of the rewinding reel.

2. Begin the change sequence as soon as possible in order to avoid any problems due to mechanical
hindrances.
In the event of an alarm for maximum diameter

1. If the reel change on the rewinder has been performed and the machine has just restarted, bring the lay-on
roller to the work position (in contact with the new reel) to update the rewinding diameter.
2. If point 1 is not satisfied, it means there are problems with diameter calculation; in this case, call Bobst's
technical service.
In the event of an alarm for reaching footage

1. If the reel change sequence has already been carried out and the machine has just re-started, reset the
footage indicator.

NOVA SX 550
ALARM A-048
PLEASE REMAKE PROCESS SELECTIONS ON …

Material required:
None.
A memory reset operation or a loading operation has been performed on one of the machine PLCs, therefore it is
necessary to restore the machine to working conditions.
1. Load the work recipe in the machine.
2. If the work recipe on the machine hasn't been saved yet, load another work recipe and modify the settings
until you obtain correct configuration for the work in progress.

NOVA SX 550
ALARM A-050
WEB BREAK DETECTED BY …

Material required:
1. Multimeter.
OPERATOR checks
1. Ensure that the web on the machine is intact from the unwinder to the rewinder.
2. Ensure web threading has been performed correctly particularly onto the dancer rollers and/or the load cells
that have generated the alarm.
3. If the web is correctly threaded, call the maintenance engineers.
4. If not, and production is necessary, the web break detectors may be by-passed using the corresponding
command. The problem may be solved later.
1. Check if the web break has been detected by a load cell roller or a dancer roller or by motor overspeed when
the unwinders/ rewinder is operating.
In the case of a load cell roller, it is necessary to:

2. Check and, if required, readjust the load cell roller zero.
3. Perform a complete re-calibration of the load cell roller.
4. Replace the load cell roller if it is damaged.
In the case of a dancer roller, it is necessary to:

2. Check the dancer roller position during normal operation. To do so, start and run the machine, and bypass
the web break sensors.
3. Check the reading of the dancer roller position signal by means of the programming unit (move the dancer
roller to its top / bottom stroke ends and check the transducer signal).
4. If necessary, re-position and properly tighten the dancer roller position sensor locks.
If motor overspeed when the unwinders / rewinder is working, you need to:
2. Ensure the web is intact.

NOVA SX 550
ALARM A-053
MOVEMENT PREVENTED BY SECTION IN SAFETY MODE

Material required:
1. Multimeter.
OPERATOR checks
Put the machine section involved to normal operation safety mode by closing its door / turning OFF its key
selector switch.
1. Check the door limit switch wiring is intact / Check the key selector switch is working.
2. Check that the cable connecting the selector switch to the PLC input is intact.
3. Make sure the PLC board is not broken.

NOVA SX 550
ALARM A-054
MOTOR OVERHEATING
Material required:
1. On the machine, locate the motor that has raised the alarm.
2. Check the motor fan is intact and the impeller turns.
3. Check that the cooling air ducts are free.

NOVA SX 550
ALARM A-057
SOLVENTLESS CARTRIDGE ROLLERS ROTATION FAILURE

Meaning: a sensor has detected a failure in rotation of the cylinders during their washing sequence (refer to the
chapter 4 of the manual)
Material required:
1. Multimeter
1. Locate the PLC input which reads the sensor signal.

2. Check that the sensor is power supplied and the connection is intact.
3. Check that the PLC input card which reads the sensor is properly power supplied and not faulty.
It the problem doesn’t concern the sensor, but rather the cylinder drives, Bobst's service staff should be contacted.

NOVA SX 550
ALARM A-058
CYLINDERS HEATER FAILURE

Material required:
1. Multimeter.
4. Heat manual.
1. The heater is on and properly power supplied.
2. The status of the failure contact which, under normal conditions, should be closed.
3. The connection cables to the machine are not cut.
4. Observe the diagnostics provided by the heater and use its manual to solve the problem.
1. Check the water (or oil) piping between the heater and the cylinder is properly connected on both sides.
2. Check the aforementioned tube is intact and not bent.

NOVA SX 550
ALARM A-059
WEB MATERIAL ON THE CORE FINISHED

Material required:
None
OPERATOR checks
Check the outside diameter of the unwinding reel cores was set correctly.

NOVA SX 550
ALARM A-060
PLC FAILURE
Material required:
None
A serious failure occurred on the system.
CONTACT BOBST’S TECHNICAL SERVICE.

NOVA SX 550
ALARM A-061
UNWINDER-REWINDER HALF-ARMS AUTO-CENTRE TIMEOUT

Material required:
1. Multimeter
The transversal position of the half-arms of the unwinders - rewinder was not detected by the relevant limit
switches.
1. Locate the PLC input that reads the limit switch signal.
2. Check that the limit switch is power supplied and the connection is intact.
3. Check that the PLC input card which reads the limit switch is properly power supplied and not faulty.

NOVA SX 550
ALARM A-070
DIGITAL OUTPUT CARD FAILURE SAFE 4F-DO DC24V/2A

Material required:
1. Multimeter.
In the alarm text, note the corresponding drawing number and address of the card. Then check:
1. If the Emergency Reset button quickly blinks, acknowledge the alarm on the supervisor system and reset the
safe alarm by pressing the Emergency Reset button.
2. The SF led (light) status on the card: if the external auxiliary voltage is cut, the SF LED switches on and the
module is passivated. After power is restored, the SF LED switches off again and the module remains
passivated. The SF LED blinks if there are no other errors until the error is acknowledged.
3. Check the diagnostics relating to the card in the S7 hardware configuration.
Table 7-36 Diagnostic functions of EM 4 F-DO DC24V/2° PROFIsafe

Error Diagnostics application
Diagnostic function* LED Configurable
number field
Short circuit 1H SF Channel No
Overload 4H SF Channel No
Overheating 5H SF Module No
Conductor (lead) breakage 6H SF Channel Yes
Error 9H SF Module No
Configuration error 10H SF Module No
Load voltage missing or encoder
11H SF Module No
voltage missing
Communication error 13H SF Module No
* Special for F modules; displayed in STEP 7, see Table 5-1. Diagnostic error types referring to the channel
(except EM 1 F-RO DC24V/AC24..230V/5A) (Page 56).
BEFORE CONFIRMING THE SHORT CIRCUIT DIAGNOSTICS, ELIMINATE THE ERROR AND CONFIRM THE
SAFETY FUNCTION. TO ELIMINATE THE ERROR, COMPLY WITH THE INSTRUCTIONS IN CHAPTER
"ERRORS REACTION” (PAGE 51).
For further details on the diagnostics with reference to all the fail-safe modules, consult chapter
“Diagnostics” and manual "S7 Distributed Safety – configuring and programming or S/ F/FH Systems –
Configuring and Programming".

NOVA SX 550
ALARM A-071
DIGITAL INPUT CARD FAILURE SAFE 4/8 F-DI DC24V

Material required:
1. Multimeter
2. The type of connection of inputs (single or double channel) and the type of power supply (internal or external)
corresponds to the instructions in the electric diagrams.
3. The status of the power supply voltages: in the event of a fault on the power supplies, this is signalled by
LEDs 1Vsf and 2Vsf on module F; this information is also made available on the module (diagnostics record).
In all channels on the module, in the event of channel by channel passivation, only the units involved are
passivated.
• If the external auxiliary voltage is cut, the SF LED switches on and the module is passivated.
• After power is restored, the SF LED switches off again and the module remains passivated. The SF LED
blinks if there are no other errors until the error is confirmed.
• If the power supply of the external encoder is configured and the short circuit test is blocked, the short
circuits towards M on the encoder power supply are recognised and signalled through the corresponding
VsF LED without being recorded in the diagnostics of the module.
• If the power supply of the external encoder is configured and the short circuit test is cyclic, the short circuits
from 1Vs to 2Vs and the short circuits to M and P on the encoder power supply are recognised and signalled
through the corresponding VsF LED without being recorded in the diagnostics of the module.

Error Signalled in Diagnostics Configurabl
Diagnostic function* LED
number application application field e
SF
Short circuit 1H 1VsF 1.2.3 Channel Yes
2VsF
Overheating 5H SF 1.2.3 Module No
Error 9H SF 1.2.3 Module No
Configuration error 10H SF 1.2.3 Module No
Load voltage missing or
11H SF 1.2.3 Module No
encoder voltage missing
Communication error 13H SF 1.2.3 Module No
Detection of some errors (e.g. short circuits or discrepancy errors) depends on the application, on the wiring and
on the test configuration of the short circuit and power supply.

NOVA SX 550
ALARM A-072
PM-E F PP DC24V POWER SUPPLY UNIT CARD FAILURE

Material required:
1. Multimeter.
2. Power supply failure is signalled by the PWR LED on the module: the LED turns its light off. This information
is made available on the module (diagnostics record). The relay output of the module is passivated. If the
external auxiliary voltage is cut, the SF LED switches on and the module is passivated. After power is
restored, the SF LED switches off again and the module remains passivated. The SF LED blinks if there are
no other errors until the error is confirmed.
Table 7-9 Diagnostic functions of PM-E F pp DC24V PROFIsafe
Error Diagnostics application
Diagnostic function* LED Configurable
number field
Short circuit 1H SF Channel No
Overheating 5H SF Module No
Internal error 9H SF Module No
Configuration error 10H SF Module No
Load voltage missing or encoder
11H SF Module No
voltage missing
Communication error 13H SF Module No
Disconnection for safety 19H SF Channel No
*: Special for F modules; displayed in STEP 7, see the “Diagnostics referring to the channel, error types in
fail-safe modules” table.
BEFORE CONFIRMING THE SHORT CIRCUIT DIAGNOSTICS, ELIMINATE THE ERROR AND CONFIRM THE
SAFETY FUNCTION. COMPLY WITH THE INSTRUCTIONS IN CHAPTER “ERROR DIAGNOSTICS (PAGE 53)”.
For further details on the diagnostics with reference to all the fail-safe modules, consult chapter
“Diagnostics” and manual "S7 Distributed Safety – configuring and programming or S/ F/FH Systems –
Configuring and Programming".

NOVA SX 550
ALARM A-073
TELEGRAM COMMUNICATION FAILURE SAFE AXIS D425-CU320

Material required:
In the alarm text, note the corresponding drawing number and address of the telegram; then check:
1. Cabling of the D425-CU320 ethernet cable in which the drive is managed.

NOVA SX 550
ALARM A-074
COMMUNICATION FAILURE OF CPU SAFE (FB224 F_RCVDP)

Material required:
In the alarm text, note the corresponding drawing number; then check:
1. Ethernet cabling of the communicating CPUs.

NOVA SX 550
5.2 Messages
The system informs the operator on the machine status through messages shown on the supervision; such
information is not accompanied by an acoustic or luminous warning.
Some of these status messages are associated to the alarms, in order to provide a broader view to the
operator and/or to maintenance engineers.

NOVA SX 550
5.3 Notes

6 MAINTENANCE
NOVA SX 550
6.1 General safety recommendations
THE SAFETY STANDARDS HEREAFTER ARE TO BE FOLLOWED:

• Machine maintenance engineers are not entitled to make any modification to the software, to mechanical parts
and to systems (whether electric, pneumatic, hydraulic or of any other sort) without the express written approval
by Bobst. In case of infringement of this rule, the machine Buyer/User loses the right to warranty and takes any
and all responsibility on risks and consequences arising from unauthorized modifications.
• Every six months, check operation of the machine emergency commands (pushbuttons and pull cords) and the
limit switches on the doors.
• Refer to chapter 3 and 4 of this manual on the access methods to each of the machine sections.
• For reducer motor maintenance, refer to the manufacturer's documentation.
• When conducting maintenance in high locations with a risk of falling, it is necessary to use and wear
appropriate personal protective equipment and comply with the applicable rules for such activity.
• Comply with the frequency of maintenance interventions.
• Personnel carrying out maintenance operations must correspond, in number and qualification, to the
instructions given in the maintenance sheets.
• Make sure all safety regulations are fully complied with before proceeding with machine maintenance
procedures.
• Mark the area where maintenance is to be conducted with a warning sign such as “Maintenance in progress on
…”.
• During maintenance operations requiring power cut-off, a warning sign must be attached to the power cut-out
devices (switches, circuit breakers, valves, etc.) that strictly forbids reactivation and such devices must be
padlocked.
• If the maintenance engineer manually energises solenoid valves, they must be de-energised once maintenance
work is over.
• Conduct maintenance operations on fans only when the main isolator switch of the machine is open and
padlocked.
• Check the plant grounding system and machine general grounding connection at regular intervals as required
by local regulations.
• Restore machine safety device operation as soon as possible after adjustments in a low-safety situations are
completed.
• Never remove grids, screens, guards or other safety devices from the machine when it is running; they can only
be removed when the machine is switched off.
• If it is necessary to remove safety grids or screens, at the end of the works these must be re-assembled before
re-starting the machine.
2 Maintenance Job order 61368 - rev.0

NOVA SX 550
6.2 Routine maintenance
6.2.1 Structure of maintenance sheets

Scheduled maintenance instructions are divided into sheets, each of which contains:
• a code composed of a first letter identifying the machine section to work on and a progressive number;
• the necessary maintenance frequency;
• one or more symbols defining the type of personnel required.
6.2.1.1 Legend of sheet identification codes
First letter Meaning
AS Unwinders - Rewinder
A Rewinder
C Chill roll
E Coating station
G General (systems or parts common to multiple machine sections)
M Mixer
S Unwinders
6.2.1.2 Legend of symbols used on the sheets
Symbol Description
Action required by the electric maintenance engineer
Action requiring by a mechanical maintenance engineer.
Action by the machine operator
In presence of this symbol, the main isolator switch must be open

(0, OFF) and padlocked.
Job order 61368 - rev.0 Maintenance 3

NOVA SX 550
6.2.2 Summary of maintenance sheets
DAILY INTERVENTIONS
Mixer wash SX M-01
WEEKLY INTERVENTION
Cleaning the hood suction filters SX G-01
General cleaning SX G-02
Visual inspection of cleanness of the mixer containers SX M-02
MONTHLY INTERVENTION
Visual inspection of the cooling roller SX C-01
Cleaning of nozzles SX E-01
Pump pressure check SX E-02
Cleaning of the cylinder washing pump SX E-12
Checking and cleaning the compressed air filter SX G-03
Visual inspection of rubber-covered pressure rollers SX G-04
Visual inspection of the chrome plated rollers SX G-05
Cleaning the cooling fan filters SX G-06
Check the integrity of various system connections SX G-07

NOVA SX 550
Cleaning and/or replacing mixer fan air filters SX M-03
Cleaning the compressed air filter mixer SX M-04
Cleaning the corona treater electrodes unit SX S-01
THREE-MONTHLY INTERVENTION
Checking and cleaning the electric cabinets SX G-08
FOUR-MONTHLY INTERVENTION
Greasing of joints SX G-09
SIX-MONTHLY INTERVENTION
Greasing the half-arms sliding guides SX AS-01
Greasing the half-arms closing worm drive SX AS-02
Greasing the Inkome joint SX E-03
Greasing the doctor roller guides SX E-04
Greasing transfer roller guides SX E-05
Greasing of back / forth guides SX E-06
Greasing of doctor roller and metering roller SX E-07

NOVA SX 550
Water replacement SX G-10
Cleaning the control unit filters SX G-11
Checking the emergency circuit operation SX G-12
Load cell check and adjustment SX G-13
Lubrication of mixer pumps SX M-05
YEARLY INTERVENTION
Checking the rewinder contact roller balance and level SX A-01
Checking the adjustment of dancer rollers SX AS-03
Checking position "0" of half-arms closing sensors SX AS-04
Checking the half-arms closure safety pressure switches SX AS-05
Check the maximum half-arms closing stroke sensors SX AS-06
Check Inkome union clearance SX E-09
Checking booster operation SX E-10
Checking Bovex joint SX E-11
Load cell check and adjustment SX G-13
Checking Idle roller sensitivity (10/15g) SX G-14

NOVA SX 550
Checking the motor torque SX G-15
Belt tensioning SX G-16
Checking the hardness of the rubber-covered roller SX G-17
Checking operation of the drive cooling fans SX G-20
Checking the tightening of cables SX G-21
Checking the rubber-covered roller footage SX G-22
Checking and cleaning the motor cooling fans SX G-23
Checking machine safety devices SX G-24
Checking and calibration of the gap of corona treater

electrodes SX S-02
Checking the corona treater fume suction safety

pressure switch SX S-03
10-YEAR INTERVENTIONS
Replacing lubricated bearings for life SX G-25

NOVA SX 550
6.2.3 Maintenance sheets
MAINTENANCE SX A-01
SECTION: Rewinder FREQUENCY: Annual
CHECKING THE REWINDER CONTACT ROLLER BALANCE AND LEVEL

Rewinder contact roller balance check procedure
1. Checking the balance and levelling of the rewinder contact roller by following the procedure described in the
"idle roller sensitivity control (10gr / 15gr)" tab
Procedure for checking the level of the rewinder contact roller

1. It is possible to control the pressure of the contact roller of the rewinder by setting the pressure ranging from 0
to 6 bars, depending on the type of web and its width.

NOVA SX 550
MAINTENANCE SX AS-01
SECTION: Unwinders and rewinder FREQUENCY: Every six months
GREASING THE HALF-ARMS SLIDING GUIDES

Recommended Products
For the greasing procedure it is recommended to use "Castrol Optileb GR 823-2” grease.
Procedure
1. Grease the upper and lower guides for sliding the half-arms with the grease nipples.

NOVA SX 550
SECTION: Unwinders and rewinder FREQUENCY: Every six months
GREASING THE HALF-ARMS CLOSING WORM DRIVE

Procedure
1. Using the grease nipples, lubricate the worm screw for closing the half-arms.

NOVA SX 550
SECTION: Systems and whole machine FREQUENCY: Annual
CHECKING THE ADJUSTMENT OF DANCER ROLLERS

Dancer roller position verification procedure
1. Access the "CALIBRATION" display page.
2. Manually move the dancer roller, whose position you wish to check, until both ends have reached their
maximum travel.
3. Enter the values in the fields dedicated to that relative dancer roller (example unwinder 1).

NOVA SX 550
Procedure for checking the tension of the dancer roller.

1. Access the "CALIBRATION" display page.
2. The belt should be passed through the dancer roller and the adjacent rollers, whose tension should be
verified.
3. At the end of the belt, position a weight having a known value.
4. In the appropriate field, enter the weight (in Newtons) that has just been applied.

NOVA SX 550
The pressure value shown in the field shown in the figure below remains at 0.
5. Insert in the dedicated field the value under pressure (expressed in bars) that allows the dancer roller to
remain balanced on the weight.

NOVA SX 550
SECTION: Unwinders and rewinder FREQUENCY: Annual
CHECK POSITION "0" HALF-ARM CLOSING SENSORS

Procedure
1. Access the "HALF-ARMS" display page.
2. Manually set the minimum value and the maximum movement value of the half-arm whose position you want
to check. .
Usually the minimum and maximum movement values are 500 mm and 30 mm (as shown in the figure
below).

NOVA SX 550
MOVEMENT VALUES MUST ONLY BE CHANGED IF THERE ARE PROBLEMS WHEN POSITIONING HALF-
ARMS AND REELS.
Check the integrity of the sensors shown in the figure below in case of problems during the positioning of
the half-arms and the reel.
In the event that the above procedure does not resolve the problem or if damaged sensors or
malfunctions are detected, contact Bobst's technical support service.

NOVA SX 550
CHECKING THE SAFETY PRESSURE SWITCHES FOR CLOSING THE HALF-

ARMS
Procedure
1. Open unwinder and rewinder access protective casings.

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2. By acting on the vent points indicated in the figures below, remove air from the reel locking and unlocking
systems (pneumatic pistons).
3. Check that the safety pressure switches work correctly by checking that the half-arms remain closed keeping
the reel / core in the working position.
4. Once the test is complete, restore the air to the system and close the side access protective casings.
If the pressure switches do not work correctly, contact Bobst technical customer service.

NOVA SX 550
CHECK THE MAXIMUM LIMIT SENSORS OF THE HALF-ARMS CLOSING

STROKE
Procedure
1. Position a core with reduced length (e.g. 500 mm).
2. Close the look-outs by means of the illuminated pushbutton in order to lock the core in the working
position.
For the closing procedure of the half-arms, refer to paragraph "Loading a new reel" in Chapter 3.
3. Using the selector switch, move the half-arms towards the drive side until the limit switch is
intercepted. The interception of the limit switch will stop the movement of the half-arms.
If the movement of the half-arms has not been interrupted while the limit switch has been intercepted,
contact Bobst technical customer service.

NOVA SX 550
MAINTENANCE SX C-01
SECTION: Rewinder FREQUENCY: Monthly
VISUAL CHECK THE COOLING ROLLER

The use of Scotch-Brite™ (size 800) abrasive pads is recommended in order to carry out cleaning operations.
Procedure
1. Check the surface of the cooling roller and, if necessary, clean using abrasive sponges or pads as shown in
the image above.
Clean the roller with scouring or abrasive pads; then wash it with soap and water.
DURING CLEANING OPERATIONS, PAY ATTENTION NOT TO RUIN THE SURFACE OF THE ROLLER.
2. Check that there aren’t any noisy and/or faulty bearings.

NOVA SX 550
MAINTENANCE SX E-01
SECTION: Coating station FREQUENCY: Monthly
CLEANING OF NOZZLES
Nozzle Cleaning Procedure
1. Using a spanner, unscrew and remove the dispensing nozzles installed on the detergent dispensing bar.
2. Check the integrity of the nozzles and, using a gun for blowing compressed air, clean the detergent
dispensing holes obtained in the nozzles.
3. Place the clean nozzles in their positions on the detergent dispensing bar, tightening them using the spanner.

NOVA SX 550
MAINTENANCE SX E-02
CHECKING THE PUMP PRESSURE

Procedure
1. Ensure that the pump receives a proper pneumatic pressure in order to operate.
2. Check that the detergent is dispensed correctly from the nozzles of the detergent dispensing bar.
If the detergent is not being dispensed properly, clean the detergent dispensing nozzles and re-check the
operating pressure of the pump according to the instructions provided in the maintenance sheets.
If the above procedure does not solve the problems found, contact Bobst technical customer service.

NOVA SX 550
MAINTENANCE SX E-03
SECTION: Coating station FREQUENCY: Every six months
GREASING OF INKOME JOINT

Procedure
1. Using the oiler, lubricate the "Inkome" constant velocity joint.

NOVA SX 550
The greasing operation of the "Inkome" constant velocity joint removes the operator protective casing.
Once the operation is complete, reassemble the machine.

NOVA SX 550
MAINTENANCE SX E-04
GREASING THE DOCTOR ROLLER GUIDES

Procedure
1. Using the greasing nipples, lubricate the doctor roller sliding guides.

NOVA SX 550
MAINTENANCE SX E-05
GREASING TRANSFER ROLLER GUIDES

Procedure
1. Using the greasing nipples, lubricate the transfer roller sliding guides.

NOVA SX 550
MAINTENANCE SX E-06
GREASING OF BACK / FORTH GUIDES

Procedure
1. Using the greasing nipples, lubricate the horizontal movement system (back / forth) of the diffuser.

NOVA SX 550
The greasing operation of the horizontal translation system (back / forth) involves the removal of the front
protective casing. After completion of the operation, reassemble it.

NOVA SX 550
MAINTENANCE SX E-07
GREASING OF DOCTOR ROLLER AND METERING ROLLER

Procedure
1. Using the greasing nipples, lubricate the rotation bearings of the doctor roller and the metering roller.

NOVA SX 550
In order to grease the doctor roller and metering roller joints, the protective casings on the operator side
and drive side must be removed. After completion of the operation, they must be reassembled.

NOVA SX 550
MAINTENANCE SX E-09
SECTION: Coating station FREQUENCY: Annual
INKOME JOINT CLEARANCE CHECK

Procedure
1. To determine the clearance of the "Inkome" joint, manually rotate the transfer roller to establish how much
latency is required before meeting the resistance generated by the motor.
If the clearance of the joint is greater than a few mm, contact Bobst technical service.

NOVA SX 550
MAINTENANCE SX E-10
BOOSTER OPERATION CHECK

Procedure
1. Open the access door to the area of the sleeve extraction booster
2. Ensure that the pressure indicated on the booster pressure gauges corresponds to the pressure required for
sleeve extraction.

NOVA SX 550
3. Check that the system (tank, pipes, etc.) has no air leaks.
In case of malfunctions or leaks, contact Bobst technical customer service.

NOVA SX 550
MAINTENANCE SX E-11
BOVEX JOINT CHECK

Procedure
1. Check the axial clearance of the "Bovex" joint manually, by moving the joint itself to the right and left.
If the clearance of the joint is greater than 5 mm, contact Bobst technical service.
It is necessary to remove the operator-side protective casing in order to check the "Bovex" joint. After
completion of the operation, reassemble it.

NOVA SX 550
MAINTENANCE SX E-12
CYLINDER CLEANING
Procedure for cleaning the washing pump
1. Open the access door to the washing pump (installed in the operator side coating station frame).
2. Check the integrity of the connections and pipes.

NOVA SX 550
3. Remove the filter, check its integrity and proceed with cleaning.
If the filter is damaged or excessively dirty, replace it.
4. The filter should be reinstalled into its compartment and the access door to the washing pump should be
closed.
In case of malfunctions, contact Bobst technical customer service.

NOVA SX 550
MAINTENANCE SX G-01
SECTION: Systems and whole machine FREQUENCY: Weekly
CLEANING THE HOOD SUCTION FILTERS

Procedure for side filters
1. Remove the side filters from their housings and proceed with cleaning
If the filter is excessively dirty or damaged, replace it.
2. Insert the clean or new filter in its housing.

NOVA SX 550
Procedure for upper filters

1. Using a spanner, remove the nuts and lock washers of the upper filters.
2. Remove the upper filters from their housings and proceed with cleaning

NOVA SX 550
3. Insert the clean or new filter in the housing, and then refit the washers and locking nuts.

NOVA SX 550
MAINTENANCE SX G-02
SECTION: Systems and whole machine FREQUENCY: Weekly
GENERAL CLEANING
Procedure
ALWAYS SWITCH OFF AND DISCONNECT THE MACHINE FROM ITS ELECTRIC AND PNEUMATIC SUPPLY
SOURCES BEFORE STARTING GENERAL CLEANING OPERATIONS; ALLOW PARTS WASHED WITH
SOLVENTS TO DRY, BEFORE CONNECTING THE MACHINE AGAIN.
1. Remove all traces of dirt, paying particular attention to the coating unit, (pan, coating rollers and adhesive
containment tanks). Obviously, the parts in touch with the glue must be washed on each job change or
overnight shut-down.
2. Carry out thorough cleaning of the control panels.
3. Remove all traces of dust and other dirt from the machine control panels using a soft bristle brush.
DO NOT USE ACIDS OR ABRASIVE SUBSTANCES FOR CLEANING. CLEAN THE TOUCH SCREEN WITH
SPECIALISED PRODUCTS ON THE MARKET.
4. Clean the coating impression roller:
• open the nip (impression roller up);
• stop the coating unit;
• remove all traces of dirt from the surface of the impression roller.
DO NOT USE CHEMICAL OR AGGRESSIVE PRODUCTS THAT MAY CAUSE STRUCTURAL DAMAGE TO
THE SURFACE OF THERMOPLASTIC MATERIALS.

NOVA SX 550
MAINTENANCE SX G-03
SECTION: Systems and whole machine FREQUENCY: Monthly
CHECKING AND CLEANING THE COMPRESSED AIR FILTER

Procedure
1. Close the tap on the main pneumatic system.
2. Check the compressed air couplings are efficient and airtight.
3. Unhook the filter cup using the blue release pushbutton
4. Remove the filter cup

NOVA SX 550
5. Unscrew until the locking screw of the filtering cartridge is removed
6. Remove the filtering cartridge.

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6. Clean the filtering cartridge with a compressed air jet (if necessary replace it).
If the cartridge is excessively dirty or damaged, replace it.
Clean the filter cup only with aromatic-free petrol or with soapy water.
DO NOT USE ALCOHOL TO CLEAN THE FILTER CUP.

7. Refit the filtering cartridge.
8. Tighten the filter cartridge locking screw completely.
9. Refit the filter cup by connecting it again using the blue pushbutton.

NOVA SX 550
MAINTENANCE SX G-04
SECTION: Coating station and laminator unit FREQUENCY: Monthly
VISUAL INSPECTION OF RUBBER-COVERED PRESSURE ROLLERS

Procedure
1 Conduct a visual inspection of the rubber-covered pressure rollers installed in the coating station and in the
lamination unit, taking particular care to ensure that the surface is free of defects or damage.
2. Check that there aren’t any noisy and/or faulty bearings.
In case of damaged rubber pressure rollers or with bearings showing malfunctions, contact Bobst
technical customer service.

NOVA SX 550
MAINTENANCE SX G-05
SECTION: Coating station and laminator unit FREQUENCY: Monthly
VISUAL INSPECTION OF THE CHROME PLATED ROLLERS

Laminator unit procedure
1 Visually check the two chrome plated rollers (back pressure roller and laminator unit), in particular checking that
the surfaces are clean and free from defects or damage and that there are no noisy and/or malfunctioning
bearings.
In case of damaged chrome plated rollers and/or defective bearings, contact Bobst technical customer
service.
Coating station procedure

1 Visually check the two chrome plated rollers (doctor, metering, and coating rollers), in particular checking that
the surfaces are clean and free from defects or damage and that there are no noisy and/or malfunctioning
bearings.
If the coating cylinder is damaged and/or defective bearings, contact Bobst technical customer service.
In case the doctor blade roller and/or metering roller are damaged and/or with bearings showing
malfunctions, refer to the extraordinary maintenance section "Removing the chrome plated coating
station cylinders".

NOVA SX 550
MAINTENANCE SX G-06
CLEANING THE COOLING FAN FILTERS

Procedure
1. In order to separate the filter closing cover from the filter housing, insert the screwdriver into the slots (located
on the filter closing cover).

NOVA SX 550
2. Remove the filter closing cover.
3. Remove the filter from the housing and proceed with cleaning.
4. Replace the clean or new filter in the housing.

5. Refit the filter closing cover by pressing on the sides until it comes into contact with the filter housing.

NOVA SX 550
MAINTENANCE SX G-07
CHECKING THE INTEGRITY OF VARIOUS SYSTEM CONNECTIONS

Procedure
1. By accessing the various protective casings, check (both visually and by hand) the integrity of all the
connections (electrical, hydraulic and pneumatic).

NOVA SX 550
MAINTENANCE SX G-08
SECTION: Systems and whole machine FREQUENCY: Three-monthly
CHECKING AND CLEANING THE ELECTRIC CABINETS

Procedure
AFTER DEACTIVATING (OFF) THE MAIN CUT-OUT SWITCH, WAIT FOR ANY RESIDUAL CHARGES ON
CAPACITORS TO BE EXHAUSTED.
ATTENTION IS TO BE PAID TO ORANGE LEADS: THEY ARE LIVE EVEN WITH THE MAIN CUT-OUT
SWITCH IS DEACTIVATED.
1. Open the electric cabinets and clean all internal parts thoroughly.
2. Check that terminal strips, controls and indicators are intact and check the mechanical robustness of the
connections.
3. Check proper operation of the heat exchanger on the electric cabinet conditioning system (where planned).
4. When completed, close the electric cabinet protective casings.

NOVA SX 550
MAINTENANCE SX G-09
SECTION: The whole machine FREQUENCY: Four-monthly
JOINT GREASING

NOVA SX 550
Procedure
1. Using the greasing nipples, lubricate the following:
• The joints of the coating station rollers.
Greasing the joints between the metering roller and the coating cylinder requires the removal of the
operator and drive side protective covers. After completion of the operation, they must be reassembled.

NOVA SX 550
• The laminator unit roller joints.
In order to grease the joints of the laminating roller, it is necessary to remove the protective casings on the
operator and drive sides. After completion of the operation, they must be reassembled.

NOVA SX 550
• Cooling roller joints.
The greasing operation of the cooling roller joints involves the removal the operator side protective casing.
After completion of the operation, reassemble it.

NOVA SX 550
MAINTENANCE SX G-10
SECTION: Systems and whole machine FREQUENCY: Every six months
WATER REPLACEMENT
Procedure
EVERY SIX MONTHS IT IS NECESSARY TO CHANGE ALL THE WATER IN THE COOLING SYSTEM (ALSO
REFER TO THE PARAGRAPH “COOLING WATER SYSTEM”, IN CHAPTER 8).
1. Close the water return valves to the control units.
2. In order to remove water from the utility systems, open the drain valves.

NOVA SX 550
3. When the water has been emptied out, close the drain valves of the utility systems.
4. Open the water return valves to the control units.
When new water is placed in the system, stabilizing germicide products must be added, so that the water
remains free of algae and bacteria which would otherwise quickly grow and reproduce and ultimately clog
the system) and corrosion proofing products (these are essential to prevent corrosion of the aluminium
rollers and scale in the system).
5. Using an Allen wrench, loosen the purge screws (located on each side of the chill rolls) until some water leaks
out, then tighten the purge screws again until they are completely locked.
THE PURGE operation described above is necessary in order to completely remove any air left inside the
cooling system.

NOVA SX 550
MAINTENANCE SX G-11
CLEANING THE CONTROL UNIT FILTERS

Procedure
1. As shown in the maintenance data sheet relating to "REPLACEMENT OF WATER", empty the control units of
the water.
2. Using a spanner, unscrew and remove the cap of the upper filter compartment.

NOVA SX 550
3. Remove the upper filter, checking its integrity and proceeding with cleaning.
If the filter is damaged or excessively dirty, replace it.
4. Refit the filter into its compartment.

5. Replace the cap of the filter compartment and proceed with its tightening using the spanner.
6. Clean the lower filter in the same way as the upper one.
7. After cleaning, referring to what is shown in the maintenance sheet relating to "WATER REPLACEMENT",
proceed to fill the water cooling system.

NOVA SX 550
MAINTENANCE SX G-12
EMERGENCY CIRCUIT OPERATION CHECK

Procedure for electrical board 110A14
Emergency signals are only connected in series and arrive directly at the inputs of the PLC.
1. To access the electric board 110A14 of the PLC, open the electric cabinet.
2. Check on the electric board 110A14 that leds 0 and 4 are on when all of the following safety devices or
emergency mushroom-head pushbuttons are on:
• Laser device (if provided).
• Emergency mushroom-head pushbutton on the main control panel.

NOVA SX 550
• Emergency mushroom-head pushbutton on the coating station control panel.
• E-Stop pull cord.
• Emergency mushroom-head pushbutton on the control panel crossbeam of the main unwinder.
3. After completed operations, close the protective cases of the electric cabinet.
If malfunctions are detected, contact Bobst technical customer service.

NOVA SX 550
Procedure for electrical board 150A11
Emergency signals are only connected in series and arrive directly at the inputs of the PLC.
1. To access the electric board 150A11 of the PLC, open the electric cabinet.
2. Check on the electric board 150A11 that leds 0 and 4 are on when all of the following safety devices or
emergency mushroom-head pushbuttons are on:
• Emergency mushroom-head pushbutton on the laminator unit control panel.
• Emergency mushroom-head pushbutton on the rewinder crossbeam control panel.

NOVA SX 550
• Emergency mushroom-head pushbutton on the secondary unwinder crossbeam control panel.
3. After completed operations, close the protective cases of the electric cabinet.
If malfunctions are detected, contact Bobst technical customer service.

NOVA SX 550
MAINTENANCE SX G-13
SECTION: Systems and whole machine FREQUENCY: Every six months / Yearly
LOAD CELL CHECK AND ADJUSTMENT

Description
The load cell is applied to the web tension: it indicates the force exercised by the web on a steel roller connected
to it and transmits a signal to the PLC; this signal is processed to display the web tension on that roller.
Procedure
Refer to the PIXYS supplier manual attached to this manual

NOVA SX 550
MAINTENANCE SX G-14
IDLE ROLLER SENSITIVITY CONTROL (10gr / 15gr)

Procedure
1. Using the adhesive weighing 10g / 15g, check the sensitivity / balance of the idle rollers as follows:
• Place the adhesive weight in the upper part of the roller (as in the photo).
• Check that the roller rotates until the weighing bottom part is down (as in the photo).
If the roller does not rotate correctly, contact Bobst technical customer service.

NOVA SX 550
MAINTENANCE SX G-15
SECTION: The whole machine FREQUENCY: Annual
CHECKING THE MOTOR TORQUE

Engine performance display procedure
1. Access the "MOTORS" display page to view the performance of the machine motors.

NOVA SX 550
Engine performance monitoring procedure

1. Access the "MAINTENANCE" display page.
2. Press the engine speed test start key.

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3. Set machine speed to 30 m/min.
4. Set the unwinder and rewinder diameters to 80 mm.

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5. Start the motor by pressing the pushbutton .

6. Access the "MOTORS" display page to view the performance of the machine motors.
When high temperatures or too much torque is detected, check all the components on the machine and, if
the problem persists, contact Bobst's technical support.

NOVA SX 550
MAINTENANCE SX G-16
TENSIONING THE BELTS

Belt tensioning control procedure
1. Proceed to check the tension of the belts by referring to what is shown in the paragraph "Extraordinary
Maintenance - Belt Tensioning". If the voltage is incorrect, tighten it according to the following methods
indicated in the paragraphs below.

NOVA SX 550
Coating cylinder belt tensioning procedure
The tensioning operation involves the removal of the drive side protective casing. After completion of the
operation, reassemble it.
1. Using a spanner, loosen the four screws that secure the coating cylinder control motor.

NOVA SX 550
2. Using a spanner, adjust the screw until the desired belt tension is achieved.
3. Tighten the four screws that secure the coating cylinder control motor.
Tensioning of the metering roller gear reducers belt.

The tensioning operation removes the operator side protective casing. After completion of the operation,
reassemble it.

NOVA SX 550
1. Using an Allen wrench, loosen the Allen screw which secures the belt tensioner.
2. Act on the tensioner until the desired belt tension is obtained.

To facilitate the positioning procedure of the tensioner, loosen the tension exerted by the belt by
pressurising the two pulleys of the gearboxes.
3. Using an Allen wrench, tighten the Allen screw which secures the belt tensioner.

NOVA SX 550
Laminator belt tensioning procedure

The tensioning operation involves the removal of the drive side protective casing. After completion of the
1. Using a wrench, loosen the four screws which secure the laminating roller control motor.

NOVA SX 550
3. Tighten the four screws that secure the laminating roller control motor.
Cooling roller belt tensioning procedure

The tensioning operation involves removing the belt closing protective casing. After completion of the

NOVA SX 550
1. Using a spanner, loosen the four screws that secure the cooling roller rotation control motor
3. Tighten the four screws that secure the cooling roller rotation control motor.

NOVA SX 550
Rewinder belt tensioning procedure

The tensioning operation involves removing the belt closing protective casing. After completion of the
1. Using a spanner, loosen the four screws that secure the rewinder shaft rotation control motor.
3. Tighten the four screws that secure the rewinder shaft rotation control motor.

NOVA SX 550
MAINTENANCE SX G-17
SECTION: Coating station, laminator unit FREQUENCY: Annual
CHECK THE HARDNESS OF THE RUBBER-COVERED PRESSURE ROLLERS

Procedure
1. Using a hardness tester, check the rubber hardness of the impression rollers of the coating station, of the
laminator unit.
If the hardness value does not fall within the established parameters, contact Bobst technical customer
service.

NOVA SX 550
MAINTENANCE SX G-20
CHECKING OPERATION OF THE DRIVE COOLING FANS

Procedure
1. Proceed to check the operation of the drive cooling fans by feeding them, and check that the extracted air flow
is sufficient.
If a fault is found in the cooling fans, contact Bobst technical customer service.

NOVA SX 550
MAINTENANCE SX G-21
CABLE TIGHTENING CONTROL

Procedure
1. By accessing the various protective casings, check (both visually and by hand) the integrity of the electrical
connections in the machine.

NOVA SX 550
MAINTENANCE SX G-22
SECTION: Coating station and laminator units FREQUENCY: Annual
CHECK OF RUBBER-COVERED ROLLER FOOTAGE

Coating station pressure roller procedure
1. Open the side protective casings for access to the side area of the coating station.
2. Place two web stripes (as shown in the figure below) under the pressure roller of the coating station.
3. Using a screwdriver, manually close the coating station impression roller.

NOVA SX 550
CAUTION: THIS OPERATION INVOLVES MOVEMENT OF THE IMPRESSION ROLLER FROM THE
INOPERATIVE POSITION TO THE WORK POSITION (IN CONTACT WITH THE COATING CYLINDER).
4. With the impression roller in work position (in contact with the coating cylinder), check that both web stripes
are pressed equally by the impression roller against the coating cylinder.
In the event that both web stripes are not evenly pressed against the coating cylinder by the impression
roller, it is necessary to adjust the pressure of the two pistons of the impression roller until the desired
result is achieved.
5. Once the test has been completed, control the opening of the impression roller to its inoperative position,
remove the web stripes and close the side ptotective casing for access to the side area of the coating station.

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Laminator unit impression roller procedure

1. Open the side protective casing to access the side area of the laminator unit.
2. Place two web stripes (as shown in the figure below) under the pressure roller of the laminator unit.
6. Using a screwdriver, manually close the back pressure roller on the impression roller.

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CAUTION: THIS OPERATION INVOLVES MOVEMENT OF THE CONTACTED ROLLER FROM THE
INOPERATIVE POSITION TO THE WORKING POSITION (IN CONTACT WITH THE IMPRESSION ROLLER).
7. With the back pressure roller in work position (in contact with the impression roller), check that both web
stripes are also pressed by the back pressure roller against the impression roller.
If both web stripes are not pressed by the back pressure roller against the impression roller, it is necessary
to adjust the pressure of the two back pressure roll actuation pistons until the desired result is obtained.
8. Once the test has been completed, control the opening of the back pressure roller to its inoperative position,
remove the web stripes and close the side protective casing for accessing the side area of the laminator unit.

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MAINTENANCE SX G-23
CHECKING AND CLEANING THE ENGINE COOLING FANS

Procedure
1. Using an Allen wrench, loosen and remove the four Allen screws which secure the motor cooling fan support.
2. Remove the cooling fan support.

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3. Proceed to check the fan (in particular, check that the blades are not damaged and that the fan rotates on its
shaft without making any noise or jamming) and, if dust or accumulated dirt is found, clean the fan housing.
4. When finished, reassemble the fan support in its housing on the motor case.

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5. Using an Allen wrench, tighten and lock the four Allen screws which secure the motor cooling fan support.

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MAINTENANCE SX G-24
CHECKING MACHINE SAFETY DEVICES

Procedure
Periodically check the safety components (electromechanical parts with safety function) such as, for example,
mushroom-head emergency push-buttons, turret indexing limit switches, and key selector switches.
This operation must be carried out following the dedicated check list supplied as an annex to this manual.
Procedure
1. Replace safety components if 10 years have elapsed since the machine was delivered or since their last
replacement.
2. Check the correct functioning of the safety components, making sure that the behaviour of the machine is
that described in the check list.

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MAINTENANCE SX G-25
SECTION: Systems and whole machine FREQUENCY: 10 years
REPLACING LUBRICATED BEARINGS FOR LIFE

Procedure
1. In order to replace the bearings on the roller, remove it from its compartment on the machine.
2. Remove the bearings to be replaced from the roller shaft.
3. Place the bearing near its new compartment (previously clean).
4. The bearing must be inserted into its compartment on the shaft of the roller by means of a special punch with
a teflon tip and a hammer.
5. Perform the same operation for the bearing located at the other end of the roller shaft.
6. Refit the roller with the new bearings in its machine compartment.

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MAINTENANCE SX M-01
SECTION: Mixer FREQUENCY: Daily
MIXER WASHING
Procedure
Refer to BOBST MIX manual attached to this manual.

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MAINTENANCE SX M-02
SECTION: Mixer FREQUENCY: Weekly
VISUAL INSPECTION OF CLEANNESS OF THE MIXER DRUMS

Procedure
Refer to BOBST MIX manual attached to this manual

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MAINTENANCE SX M-03
SECTION: Mixer FREQUENCY: Monthly
CLEANING AND/OR REPLACING MIXER FAN AIR FILTERS

Procedure

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MAINTENANCE SX M-04
SECTION: Mixer FREQUENCY: Monthly
CLEANING THE COMPRESSED AIR FILTER MIXER

Procedure

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MAINTENANCE SX M-05
SECTION: Mixer FREQUENCY: Every six months
LUBRICATION OF MIXER PUMPS

Procedure

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MAINTENANCE SX S-01
SECTION: Unwinders FREQUENCY: Monthly
CLEANING THE CORONA TREATER ELECTRODES UNIT

Procedure
Refer to the "VETAPHONE" documentation attached to this manual.

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MAINTENANCE SX S-02
SECTION: Unwinders FREQUENCY: Annual
CHECK AND CALIBRATION OF CORONA TRACTOR ELECTRODE GAP.

Procedure

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MAINTENANCE SX S-03
SECTION: Unwinders FREQUENCY: Annual
CHECKING THE CORONA TREATER FUME SUCTION SAFETY PRESSURE

SWITCH
Procedure

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6.3 Extraordinary maintenance

For any complex servicing not described in this manual, you should request assistance from Bobst’s
technical service.
6.3.1 Checking the tension of drive belts
THE FOLLOWING PROCEDURE SHOULD BE PERFORMED WITH THE MAIN ISOLATOR SWITCH OPEN
AND PADLOCKED (NO POWER SUPPLY TO THE MACHINE).
It is very important that the belt is fitted with the correct tension and that the pulleys are properly aligned, in order
to optimize belt efficiency and durability.
A lower tension than recommended leads to excessive belt oscillations and to faulty functioning, with possible loss
of synchronism. Higher tensions cause premature belt wear and increased noise.
Belt mounting should be manual, without using tools (for example levers) which may indent the belt or the pulley.
For finding the correct tension to be set for the belt, measure the F camber (produced by exerting a Q force at the
centre of the free span of the belt and perpendicularly to the belt itself); camber F must be 1.5% of the free span of
the belt.
To determine the correct value of force Q (knowing the belt model and pitch), refer to the belt
manufacturer’s documentation.
Fig. 6.3.1: Tensioning the belt.
As an alternative to this method, it is possible to check belt tension by using electronic tension measuring devices
(these instruments are available on the market from belt dealers.

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6.3.2 Removing the coating station chrome plated cylinders
6.3.2.1 Removing the doctor blade roller

If it becomes necessary to remove the doctor blade roller, proceed as follows:
A. Remove the web outlet guard door sliding area of the coating station as follows:

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• Disconnect the two door opening pistons (Fig. 6.3.2.1A) removing the nuts and washers (Fig. 6.3.2.1B)
located at the top of the door in correspondence with the fixing plates (Fig. 6.3.2.1C).
Fig. 6.3.2.1A: Sliding door opening pistons.
Fig. 6.3.2.1B: Nuts and lock washers of the pistons

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Fig. 6.3.2.1C: Sliding door piston fixing plates

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• Remove the sliding door sliding pads (Fig. 6.3.2.1D) unscrewing the fixing front screws (Fig. 6.3.2.1E).
Fig. 6.3.2.1D: Sliding pads of the sliding door
Fig. 6.3.2.1E: Front screws securing sliding pads of the sliding door

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• Remove the sliding door.
DANGER OF FALLING! THE SLIDING DOOR MUST BE REMOVED FROM TWO OPERATORS.
B. Using an Allen screw, loosen the Allen screws which lock the two locking latches of the bushings with doctor
blade roller bearings.

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C. Remove the pan
DANGER OF FALLING! THE PAN MUST BE REMOVED BY TWO OPERATORS.
D. Unscrew the locking screw of the gear reducer to the doctor blade roller shaft.

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E. Disconnect the motor with gear reducer from the doctor blade roller shaft.
F. Disconnect the cylinder temperature control pipes.

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G. Using a spanner loosen the rotating joint.
H. Remove the rotating joint from the doctor blade roller shaft.

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I. Using a couple of clamps, remove the bearing locking seeger.
J. Tighten two Allen screws to the outside of the bearing and proceed with its removal.

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K. Using two screwdrivers, remove the inside of the bearing

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L. Deposit the internal part of the bearing on the external part of the bearing.
M. Using a spanner, remove the Allen screws connecting the pneumatic pistons to the doctor blade roller.

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N. Using a spanner, remove the screws that secure the doctor blade roller supports to the sliding guides.
O. Using a forklift, lift the doctor blade roller from its compartment and take it out of the machine.
DANGER OF FALLING! PAY ATTENTION WHEN HANDLING THE DOCTOR BLADE ROLLER.
COVER THE FORKS WITH RUBBER-COATED MATERIAL IN ORDER TO AVOID DAMAGING THE SURFACE
OF THE DOCTOR BLADE ROLLER.
PLACE THE CYLINDER ON A STABLE SURFACE BY PLACING THE RUBBER-COATED MATERIAL UNDER
THE CYLINDER ITSELF.

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P. With the cylinder out of machine, remove the supports from the doctor blade roller shaft.
6.3.2.2 Removing metering roller

If it becomes necessary to replace the metering roller, proceed as follows:
BECAUSE OF THE SPACE LIMITS, BEFORE REMOVING THE METERING ROLLER IT IS NECESSARY TO
REMOVE THE DOCTOR BLADE ROLLER (REFER TO PARAGRAPH "REMOVING DOCTOR BLADE
ROLLER").
A. Using a spanner, remove the screws that secure the motor and the gearboxes to the machine structure.

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B. Remove the motor and the gearboxes.
C. Remove the "Bovex" joint from the metering roller shaft.

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D. Disconnect the cylinder temperature control pipes.
E. Then remove the rotating joint and the bearing as described in paragraph "Removing the doctor blade roller"
F. Using a spanner, remove the locking screws of the metering roller bushings from the machine structure.

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G. With the assistance of a forklift, remove the metering roller from the compartment within the machine.
H. Using a forklift, take the metering roller out of the machine.
DANGER OF FALLING! PAY ATTENTION WHEN HANDLING THE METERING ROLLER.
COVER THE FORKS WITH RUBBER-COATED MATERIAL IN ORDER TO AVOID DAMAGING THE SURFACE
OF THE METERING ROLLER.
PLACE THE CYLINDER ON A STABLE SURFACE BY PLACING THE RUBBER-COATED MATERIAL UNDER
THE CYLINDER ITSELF.

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6.3.3 Repairs and actions on the pipe fittings of the cooling water system
In cooling water systems where the pipes and their fittings are made of PVC, in case maintenance is required at the
connection between fittings and pipes, the following basic procedures should be followed.
6.3.3.1 Glued connections

If – once pipes and fittings are connected – there are leaks, dry the connection points properly (possibly also on the
inner contact faces), and smear glue over the existing one in order to seal any possible micro-cracks.
6.3.3.2 Threaded joints

Three-way joints:
In this case, sealing is obtained by means of an O-ring placed in a specific compartment on one side of the
connection.
For assembly, proceed as follows:

1. Make sure the O-ring is in its own compartment;
2. Lubricate the O-ring sealing with grease;
3. Tighten the rotating ring of the connection with the strength of your hand only.
A TUBE SPANNER SHOULD NOT BE USED, AS IT COULD COMPROMISE THE INTACTNESS OF THE PIECE.
If however tightening is accomplished with a tube spanner, then great care must be taken, bearing in mind
that a maximum force up to ⅛ (one eighth) of the circumference of the piece is allowed. Rotating the nut
by as much as ¼ (one quarter) of a turn would damage the fitting, which initially would show as a crack
only, but it will tend to expand over time.
Sleeve couplings
Screwing of sleeve couplings on the thread of pipes to be joined is normally performed by first screwing the sleeve
coupling on one of the two pipes, then by screwing the other pipe into the sleeve coupling. In this case sealing of
the two threads is ensured by means of hemp with paste for PVC threads, or by Teflon tape.
Also in this case the force applied must be minimal, as sealing is guaranteed by the filling between the
threads. If a tube spanner is used to tighten, bear in mind that already a ¼ of the circumference may
damage the pieces (depending on the length of the threads and on the free space in the internal thread of
the sleeve coupling).

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6.3.4 Rollers rubber covering (Rossini)

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6.3.4.1 Print and lamination pressure rollers rubber sleeves

Take care that steel cylinders are always clean and dry, otherwise sleeves mounting properties will be affected:
• Clean the cylinder using ethyl acetate.
• No oil or grease must be in touch of cylinder surface.
In solventless coating mode, refer to following paragraph about operation on POLYCOAT covering (transfer roller).
Air pressure needed for insertion / extraction of sleeves is 16 bar and in any case never below than 13 bar; air flow
rate of 700 litres per minute with an inlet pipe section diameter no less than 8 mm.
Handle the sleeves with care, for antistatic sleeves particularly take care to the carbon fiber ring edge (carbon fiber
is very hard and stiff than so easy to be damaged).
Regarding the sleeves storage it’s recommended to keep them in standing position inside a room with temperature
between 10°C and 40°C (a climatised room is preferred).
When pressure sleeve looks damaged on surface a regrinding is recommended.

the best procedure is to use a wheel grain BR54/55, remove 0.2 mm per pass, than in finishing remove 0.05 mm
and finally 3 passes with no increment.
Usually it is enough to remove 2 mm on diameter to get a smooth surface.
Minimum rubber thickness reachable is 5 mm (8 mm for ESA-sleeves).
Rossini do not recommend any re-rubberising of sleeves
6.3.4.2 POLYCOAT coverings (transfer roller)

Rossini recommends to treat the roller surface with a softener (for example LIOFOL ECOCLEAN (Henkel) or
NOVACOTE SP 900 (Coim) before using the transfer roller for the first time in the machine, after having ground the
roller surface and during regular cleaning intervals.
Normal cleaning agents (i.e. pure Ethylacetate or cleaning mixtures) are not sufficient on their own for cleaning, as
they don’t stop the chemical hardening process of the solventless glue, and therefore the rubber surface becomes
damaged.
The softener stops the quick chemical reaction of the solventless glue and prevents the rubber surface from
hardening (crusting).
The above suggestions are requested to prevent generation of pin holes bubbles on rubber surface.
The softener should dampen the rubber surface evenly and remain there for approx. 10 minutes. Afterwards, the
roller can be cleaned with pure ethylacetate. Afterwards, the roller can be cleaned with pure ethylacetate.
It is absolutely necessary to apply this cleaning procedure without fail, whenever the machine stops or also when the
roller is still on the machine, for example during a job change.

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6.4 Lubricants
Correct lubrication of the various machine components is essential to ensure their good operation and expected
lifetime.
Lubricants, in addition to reducing friction and preventing direct contact between sliding parts, decreases
wear, corrosion and protects from intrusion of dust, dirt and other polluting agents, whether liquid or solid
(possible cause of seizure); moreover, depending on their application, they can facilitate heat transfer,
reduce noise and provide (or complete) tightness.
Lubricants can be liquid (oil), creamy or pasty (greases) and solid (graphite, molybdenum bi-sulphide, mild metals).
The choice of suitable lubricant depends on the following conditions:

• Load;
• Temperature range;
• Speed;
Speed refers to the sort of movement of the part involved; for example, in the case of a shaft, it is
understood as its rotation speed.
• External environment conditions;
• Other operating conditions.
PLEASE READ CAREFULLY THE SPECIFICATIONS (DATA SHEETS) AND THE RISK SHEETS OF THE
LUBRICANTS USED.

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6.4.1 Grease lubrication

As a lubricant, grease has a series of advantages over oil: it makes installation simpler, less costly, it offers better
adherence and protects from humidity and impurities.
6.4.1.1 Mechanical parts lubricated by grease
Bearings
Most bearings are grease lubricated.
In general, bearings are lubricated after they have been assembled, for various reasons (mainly cleanliness).
Bearings must be lubricated before installation only in the cases when it is impossible to ensure a uniform
distribution of grease at a later time.
Bearings must not be filled completely with grease: the internal free space of the bearing must be filled by about 30
/ 50%. In applications free of vibrations, the free internal space may be filled even up to 90% without occurrence of
excessive overheating problems: this effectively prevents the penetration of dirt, and therefore re-lubrication may be
less frequent.
If bearings are to operate at extremely high speeds and a low temperature is to be maintained, they must be
lubricated with a smaller quantity of grease (25 - 35% of the free internal space of the bearing), therefore re-
lubrication must be more frequent.
Bearings which are screened / lubricated for life do not need any greasing interventions.
These bearings, in fact, are fitted with seals or screens; 30 / 40 % of their internal free space is filled with grease,
and it is distributed evenly in the bearing during the first operating hours.
Sliding blocks with recirculation of balls / rollers

Grease lubrication is recommended also in this case, specially for preserving the sliding blocks and the linear
guides from failures due to wear or seizing caused by deposits of dust and dirt.
Bronze bushings or sliding parts

For these components, it is necessary to identify all metal-to-metal sliding parts where the application of lubricant
on installation is determining to avoid possible seizure of the parts during machine start-up.
Gears
Greasing must be done only on gears having a medium / low rotation speed, and whose operating temperature is
not high.

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6.4.1.2 Greasing principles

The grease application method must be perfectly suitable to the item to be lubricated; the simplest way is through
grease nipples, by using manual or semi-automatic pumps.
All grease nipples must be mounted with care, cleaned and tried before use; moreover, the part to be
greased must be clean before grease is applied.
The grease to be used on the Bobst machines is suitable for machinery in foodstuff environments, and it complies
with international USDA H1 certification.
Bobst suggests using the Castrol lubricant, type MOLUB-ALLOY 823-2 FM (grease for the foodstuff industry -
Edition 1/2006).
Alternatively, it is possible to use the following compatible greases:

• MOBIL GREASE FM 222
• KLUBER POLYLUB GA 352 P
• BRUGAROLAS G.B. CAPLEX M-2 ATOX
CAUTION! DON’T USE GREASES WHOSE BASE IS UNLIKE COMPLEX ALUMINIUM, IN THAT THEY COULD
CAUSE IRREPARABLE DAMAGES TO THE PARTS INVOLVED. YOU MUST USE ONLY GREASES THAT ARE
BASED ON COMPLEX ALUMINIUM OF CLASS 2, AND SUCH GREASES ARE TO BE USDA H1 CERTIFIED.
Frequency of bearings lubrication:

• Twice a year, if the machine works on two shifts (16 hours a day).
• Three times a year, if the machine works on three shifts (24 hours a day).
Planned life of bearings:

• Screened / lubricated for life bearings:
• starting from the sixth year, check every 2 years (by a specialist technician), using tools to measure
intactness and wear.
• replace them after ten years
• Bearings not lubricated for life: starting from the tenth year, have checks performed every 2 years (by a
specialist technician), using tools to measure intactness and wear. This condition is only valid through periodic
lubrication as per the previous point.

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6.5 Internet sites of auxiliary equipment and sensor

manufacturers
Siemens (CPU, Drives, Safety relays)

http://support.automation.siemens.com/WW/llisapi.dll?query
Schneider Electric
http://www.schneider-electric.com/sites/corporate/en/home.page
Load Cells
http://www.asa-rt.com/
http://www.fms-technology.com/en/index.php
http://www.gefran.com/
Position Transducers
http://www.mtssensor.de/Products.211.0.html
http://www.stegmann.com/
http://www.heidenhain.de/en_UK/products_and_applications/
http://www.kuebler.com/english2/index.html
HW Components
http://www.findernet.com/index.php
http://www.pilz.com/support/index.en.jsp

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6.6 Notes

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7 TRANSPORT
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7.1 Safety precautions
FOR LIFTING, TRANSPORTING AND HANDLING THE MACHINE OR PARTS OF IT, COMPLY WITH THE
PRECAUTIONS GIVEN IN THIS PARAGRAPH.
DO NOT TRANSIT OR STAY WITHIN THE ACTION RANGE OF CRANES OR BRIDGE CRANES WITH
SUSPENDED LOADS.
USE ROPES OR CHAINS SUITABLE FOR THE WEIGHT OF THE HEAVIEST PART, WHILE MAINTAINING A
REASONABLE SAFETY MARGIN.
7.1.1 Preliminary operations

The following preliminary operations need to be completed before transporting the machine:
• Before handling / hoisting, lock the mobile parts of every group.
• Close the unwinder and rewinder half-arms until they are completely closed.
• Remove the coating cylinder motor, the laminator unit and the cooling roller.
• Remove the exhaust fan motors.
• Remove the conditioning heater.
• Remove the protective casings from the various units.
2 Transport Job order 61368 - rev.0

NOVA SX 550
7.1.2 Lifting the machine
MAKE SURE THE PART IS WELL BALANCED DURING THE LIFTING PHASE.
Ropes or chains must be used with the hooks provided to lift the machine, as shown in the relevant transport
drawings.
The figure below shows the theoretical centre of gravity.
The parts of the machine which have been previously removed (e.g. motors) should be lifted using
appropriate tools, according to the weights and indications on the transport crates.
Job order 61368 - rev.0 Transport 3

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7.1.2.1 Eyebolts
THE EYEBOLTS MUST BE ADEQUATE TO THE WEIGHT INDICATED ON EACH MACHINE UNIT.
In case of oblique pulling, make sure the angle between the horizontal level and the ropes or chains used is
greater than 45° (as shown in figure 7.1.2.1B).
For exerting their full (nominal) strength, the eyebolts must be screwed thoroughly.
Fig. 7.1.2.1A: Eyebolts
I. Straight pull
II. 45° pull
Fig. 7.1.2.1B: Load position
7.1.3 Machine Transport & Shipping

The machine and its parts are transported and shipped by containers or special lorries / articulated lorries.
If the machine was shipped by sea, silica gel packets were put in the containers and cabinets. This
material has the purpose of absorbing humidity.
7.1.4 Storage
Store the machine and its parts, in a sheltered area, suitably protected against environmental and atmospheric
agents.

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7.2 Notes
Job order 61368 - rev.0 Transport 5

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8 INSTALLATION
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8.1 Foundations
Before the machine arrives at the customer's plant, some checks and measurements must be carried out in
accordance with the assembly and foundation drawings.
INSTALL THE MACHINE AS AGREED IN THE PURCHASE/SALES ORDER, OR AS SHOWN IN THE BOBST
DRAWINGS ACCEPTED BY THE BUYER.
IF THE MACHINE USES FLAMMABLE LIQUIDS WITH A FLAMMABLE POINT OF LESS THAN 55 °C, THE
FLOOR MUST BE CONDUCTIVE 1 METER ABOVE THE POTENTIALLY EXPLOSIVE AREA.
8.1.1 Tolerances of foundation building works

The civil engineering foundation works shall have their top level with an accuracy that will facilitate machine
installation and future use of the machine (smooth movement of parts, easy cleaning).
The bearing platform made of reinforced concrete must be levelled with a max. tolerance of ±10 mm.
The machine bearing and anchor beams should be able to support the loads indicated in the machine foundation
drawing and should have a maximum admissible levelling tolerance of ± 5 mm.
8.1.1.1 Foundation works. Instructions for the customer

Consult a qualified engineer to check the foundation bed strength complies with the machine weights. Ensure that
no settling of the foundation occurs over time so as not to jeopardise the operation of the machine.
8.1.1.2 Settling on the foundation plinth, beams and plates

Maximum foundation settling tolerance (lowering) over time after the machine has been positioned:
• Transversal: 0.1 mm per metre;
• Longitudinal: 0.1 mm per metre same settling between operator side and drive side i.e. homogeneous settling).
Settling tolerance for the coating machine (i.e. horizontal movement of the machine):
• Transversal: 0.1 mm per metre;
• Longitudinal: 0.1 mm per metre;
2 Installation Job order 61368 - rev.0

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8.2 Preparations for machine installation
8.2.1 Preliminary activities for machine assembly

Check that the foundation is within the level accuracies shown in the assembly and foundation drawing; verify that
all the other directions given in the same drawing have been complied with.
Should any errors be found, correct them before the coating machine arrives at its installation site.
Finally, after you are sure the foundation base where the machine will be positioned complies with the tolerances
required in Bobst’s foundation drawings, remove all rubble and vacuum the foundation base itself.
Removing the dust will prevent it from deposit¬ing on the mechanical parts and cause possible seizures.
O PREVENT DAMAGE OF THE MACHINE UNITS, PLACE ALL PACKAGES IN THE ULTIMATE PLANT OR
SHEDS, PROTECTED FROM BAD WHEATHER. IT SHOULD ALSO BE AVOIDED AS MUCH AS POSSIBLE TO
STACK THEM.
ELECTRIC AND ELECTRONIC PARTS ARE TO BE KEPT IN ENVIRONMENTS WHERE THE RELATIVE
HUMIDITY COMPLIES WITH THE MANUFACTURER’S REQUIREMENTS.
8.2.2 Preparing the erection yard

Since the assembly operations will take place inside the customer’s plant, the latter will have to decide with the
Bobst engineers on the building site dimensions.
The customer will prohibit access to all unauthorised personnel.
The structure shall be equipped with an electric system designed and made in accordance with the regulations in
force and be state of the art. A copy of the certificate of conformity for the works, issued by the company that
carried them out, must be available.
The premises where the works are carried out shall be equipped with a heating system which ensures a
comfortable ambient air temperature, namely 18°C +2°C.
Job order 61368 - rev.0 Installation 3

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8.2.3 General handling instructions

In order to lift the different components, we recommend using chains that are suitable for the weight of the
heaviest component, while maintaining a reasonable safety margin.
To lift the loads safely, see the assembly and foundation drawing (for the weights and the final installed layout of
the parts) as well as the transport chapter in this manual.
When you get to the point indicated in the foundations, lower the component.
Put some oil (or grease) on the grub screws to let them work properly and obtain reduced friction. Then adjust the
level screws and raise the component up to about 100 mm between the foundation and the upper level of the
component base plate.
If the components have narrow bearing bases (e.g. vertical beams) make sure they are stable on their level plates;
good stability can be achieved by raising the component evenly and adjusting the level screws.
Carry out the aforementioned operations for all machine components to be inserted in the foundations.
8.2.4 Preliminary checks

First of all, prepare all the equipment to operate properly (square and linear spirit level, comparator, comparator
rods, alignment shafts, crossbeam bearing uprights, push rods, …) and find on the machine adequate areas where
the spirit levels can be positioned to achieve an accurate reading.
Also check that all machine contact and/or con-nection surfaces have been processed and cleaned properly.

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8.3 Machine erection and alignment

When the machine is being installed, everything that was removed during transport needs to be re-fitted.
Furthermore, once the machine has been installed and aligned, the lower tie-rods installed at the
transport stage can be removed.
8.3.1 Analysis of hazards related to machine installation

All the personnel involved in installation operations are specially trained and informed, with regard to:
• Use of personal protective equipment;
• Risks in the operations to be carried out;
• Correct working method / operating procedures.
In the preliminary analysis of the risks inherent in the assembly operations of the machine, the following hazards
and the corresponding protective measures were identified:
MECHANICAL HAZARDS
The operators are equipped with the PPE (Personal Protective Equipment) required to work in safe conditions,
namely:
• Safety footwear (against mechanical injury);
• Safety gloves (against mechanical injury);
• Protective goggles (for use if handling compressed air and during grinding, piercing and welding operations);
• Safety belt;
• Safety helmet;
• Welding PPE, if and when welding is required.
Moreover, during both machine installation and subsequent operation, personnel must not wear long hair down or
loose clothing, necklaces, bracelets or other objects which could get caught in moving machine parts.
The operators have been informed and trained about the correct use of the aforementioned personal protective
equipment and its compulsory use; all personnel involved in mechanical installation of the machine have been
trained and informed for the work to be carried out.
ELECTRICAL HAZARDS
During the assembly phase, all metal parts of the machine will be connected to the electric protective lead of the
Buyer’s plant. All persons involved in electric installation have been informed and trained; moreover, personnel
who have access to the electric cabinets area are considered “skilled persons”, “informed persons” and “trained
persons” in compliance with laws and standards.
With regard to mechanical installation engineers working on the machine, it is unlikely that they are subject to
electrical hazards due to stray currents etc., as the machine is connected to the equipotential loop of the plant and
all electric cabinets have an IP 44 or higher protection rating.

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FALL OF MATERIAL FROM HEIGHTS - FALL OF OPERATORS
The hazard of materials falling from heights is due to the fact that some persons work in elevated positions and
that, during machine assembly, hoisting means are used.
All engineers are equipped with tool bags and suitable personal protective equipment. All the personnel involved
have also been informed and trained on the safe use of hoisting and lifting means. These must exhibit the
technical and safety characteristics as outlined by the applicable legislation in force.
Operators can prevent falling by means of safety belts.
RISK OF COLLISION WITH FORKLIFT TRUCKS
The area dedicated to machine assembly shall be protected and equipped with warning signs to be agreed upon
with the customer. The installation crew shall also be informed and trained on the safe use of handling equipment.
Such handling equipment shall comply with the applicable legal requirements.
USE OF PORTABLE ELECTRICAL EQUIPMENT
All portable electrical equipment brought to the installation site by the Bobst personnel complies with Italian and
European Union requirements.
PRESENCE OF PERSONNEL UNAUTHORISED FOR INSTALLATION
Only personnel authorised by the Customer shall have access to the installation site. Should any unauthorised
person be found on the site, he/she will be escorted away immediately. Should a specialist company be required
for handling particularly heavy or bulky components, the applicable legal provisions and standards on the matter
must be followed.
NOISE PRODUCED BY ELECTRICAL TOOLS DURING MACHINE INSTALLATION
The noise caused by machine installation operations shall not influence (increase considerably) the overall noise
in the Customer’s factory. The only source of noise that might cause disturbance are electrical tools.
Their average sound pressure of electric tools is 85 dB(A); such tools shall be used for a maximum of one hour a
day discontinuously.
THERMAL HAZARDS
The thermal hazard is due to the presence of hot pipes conveying diathermic oil, steam or hot water (it depends on
what systems the machine is equipped with), hot air ducts and the possible use of hot melts or mixtures. When the
machine is being installed, such parts might not yet be heat insulated or equipped with safety guards, or they
might hold hot fluids from the Customer’s general lines to be connected to the Bobst machine. The machine itself
is labelled with warning signs noting the danger due to contact with hot surfaces. Bobst personnel are equipped
with adequate personal protective equipment.
Also see the general safety warnings in Chapter 1 of this manual.

NOVA SX 550
8.4 Auxiliary systems

The utility system drawings delivered with the machine provide all technical information for adequate sizing and
connection of the power supply systems to the coating machine.
8.4.1 Pneumatic system

The machine will be delivered with its on-board pneumatic system fully pre-installed.
The connection point between the 6 bar compressed air line (of the factory) and the machine is on one side of the
machine. For higher pressure utilities (such as sleeves extraction), the machine is provided with a dedicated
compressor.
8.4.1.1 Technical recommendations for the compressed air line and its connection to
users
The compressed air must enter into the on-machine connections from above, so that the air is taken as dry as
possible.
A supplementary tank must be installed in proximity of the machine, when the distance between machine and air
compressor exceeds 50 metres.
8.4.1.2 Technical recommendations about the installation of a compressed air

generation unit
The compressor must be located in a fresh place, and the air it sucks must be clean and dry.
Should this not be possible, it is recommended to take the air outdoors.
Downstream the compressor, the usual air treatment equipment is to be installed.

NOVA SX 550
8.4.2 Cooling water system

The cooling water system for the chill rolls must comply with given requirements. The water must be treated in
order to avoid forming of limestone sediments and/or impurities that may obstruct the water flow, thus
compromising the performance of the chill rolls.
Bobst provide all technical data for a correct interconnection to the general waterways and water chiller of your
plant, or to a specific water chiller for the machine. Such technical data are:
• Cooling water flow rate;
• Water pressure to the user apparatuses on the machine;
• Water temperature to the user apparatuses on the machine;
• Cooling power required;
• Quantity of water contained in the system supplied by Bobst;
• Location and diameter of couplings (connection points).
and the required physical and chemical characteristics the water must have to avoid:
• Corrosion phenomena;
• Circuit clogging;
• Heat exchange reduction (thermal drop).
Temperatures 18 - 22°C
Supply pressure Min. 2 bar / Max. 2,5 bar
Total hardness [French degrees] Min. 7 / Max. 15
Water consumption (flow rate) by each cooled roller 1500 Ndm3/h
It is recommended to strictly respect the data in the table, contacting specialized companies for the
treatment and filtration of water.
Please note that:

• Temperatures are to be considered as a function of relative humidity to avoid formation of condensate on
cooled components.
• No condensate should be present on the brakes. This would cause rust on the internal parts, which would then
hinder their smooth operation of the brakes.
• Rolls being supplied with water under pressure are equipped with a rotary union.
• Rolls designed for liquid flow through them should not rotate when the fluid is not being conveyed. When
rotating dry, their gaskets will get damaged, resulting in fluid leaks.
• For preventing breakage of a rotary union, the rod which secures the rotary union must not hinder the
movement of the rotary union itself.

NOVA SX 550
8.4.2.1 Recommended products to treat the water circulating through chill rolls
GERMICIDES
• DETRAL SAN 360 (Rhochem Italy)
• GARDO CIDE 250 (Chemetall Italy)
• BERKECID-HYDREX 7310 (Veolia Water)
• ZEP BIOCONTROL 5 (Zep – Industries)
CORROSION PROOFING CHEMICALS

• DETRAL BST 88 (Rhochem Italy)
• GARDO TOWER 453 (Chemetall Italy)
• BERKESAL KHD 32 M (Veolia Water)
• ZEP LOOP SOFT METAL FG (Zep – Industries)
BIODISPERSIVE CHEMICALS
• GARDO TREAT 429 (Chemetall Italy)
• ZEP BIOCONTROL 5 (Zep Industries)
WHEREAS GERMICIDES AND CORROSION PROOFING CHEMICALS ARE TO BE USED NORMALLY IN THE
PROCESS (FOR TREATING THE WATER), BIODISPERSIVE CHEMICALS MUST ONLY BE USED FOR
WASHING THE SYSTEM.

NOVA SX 550
8.4.3 Installation of the machine’s electrical hardware

The first phase of the installation procedure consists of:
• Checking the availability of the necessary materials for the electric cabinet / machine / control console
interconnection (cables, etc.).
• Checking the readiness of the machine and systems to start cable laying: control panel and cabinets in place,
cable channels installed, accessories assembled, etc.
Then, to install the whole interconnection system correctly, we recommend to :

• Clean the cable channels before laying the cables;
• Number the destination cabinet panels in order to help the installation crew;
• Disassemble the cabinet bases for access;
• Check the position of the cable locking bars inside the cabinets.
Proceed with preparation of the cables (cutting them, if in roll, and numbering them), then with laying and
connecting the cables.
Start with the power cables and continue with the machine lighting supply cables (the lighting system is necessary
to increase visibility on the machine when the plant is poorly lit).
Throughout the interconnection cabling operation, the Bobst electric diagrams and cable lists are to be
followed.
Prepare, lay and secure the auxiliary cables (control voltages) and then, in order, those of serial links, fibre optics
and any Ethernet links – (in respective order) for electric cabinet/machine/control panel connection for the various
machine sections and their auxiliary systems.
Finally:
• Close the cable channels;
• Connect the cable channels to the earth.
• Clean the whole installation site.
Notes:
• Any modifications made should be recorded on drawings/lists. A copy of such revisions should be forwarded to
Bobst, who will return to the Customer clean updated copies of the literature.
• During installation, the electric or electronic engineers from Bobst and from the Customer should work together
so that the latter can learn as much as possible on machine start-up and functioning.
See the paragraph “Identifying hazards in machine installation” in this chapter for the risks and hazards during the
installation phase.

NOVA SX 550
8.5 Machine systems position
8.5.1 Front View

NOVA SX 550
8.5.2 Top view

NOVA SX 550
8.5.3 Side View

NOVA SX 550
8.6 Machine systems connection points

NOVA SX 550
8.6.1.1 Connection point A (laminator unit 1 exhaust fan)
Connection flange Example of connection
8.6.1.2 Connection point B (coating station 2 exhaust fan)

NOVA SX 550
8.6.1.3 Connection point A (corona treater exhaust – if supplied)

NOVA SX 550
8.6.1.4 Connection point D (machine compressed air supply)
Connection point Example of connection
8.6.1.5 Connection point E (machine temperature control water supply)

NOVA SX 550
8.6.1.6 Connection point F (machine power supply)
Connection point
8.6.1.7 Attachment point G (electric supply of BOBST MIX adhesives)
Connection point
For further information, refer to BOBST MIX manual annexed to this manual.

NOVA SX 550
8.6.1.8 Attachment point H (BOBST MIX adhesive mixer compressed air supply)
For further information, refer to BOBST MIX manual annexed to this manual.
8.6.1.9 Attachment point I (electric supply of corona treater primary and secondary
unwinders - if supplied)
Connection point

NOVA SX 550
8.7 Start-up
8.7.1 Installation / configuration of the machine software

Once electric hardware installation is completed, there is to install the software and to check certain functions. In
particular: In particular:
• Switch on the power supply systems of the machine (equipment/sections with their own switches);
• Check for the efficiency of the various electric power supplies;
• Load the software supplied into the machine's PLC (updated after the testing performed at Bobst’s premises);
• Configure the drives, they are interlinked via Profinet;
• Check that the Profinet network is working properly;
• Check the emergency stop devices (mushroom-head pushbuttons, pull cords, other devices...);
• Test the logical sequences of the various machine sections and auxiliary systems;
• Thread the web into the machine; calibrate the load cells and dancer rollers;
• Test the negative pressure, pressure and temperature controls;
• Define the clean signal for the machine in production (impression rollers low, machine speed above minimum).
8.7.2 Adjustments and final web handling tests

Once the pneumatic and electric calibration is complete, thread the web, test tension control to (verify the stability
of the set web tensions).
If the aforementioned operations are performed properly, the machine is ready for its production trials and
acceptance.
Prepare the machine for the tests; install all the splash guards supplied with the machine; then conduct the tests
as shown in the contract specifications or however as necessary for assessing that, under working conditions, the
machine complies with said specifications.
In order to comply with the applicable safety regulations, there is to check, with a supervisor by the Customer, that
all hazards are indicated by means of specific signs affixed to the machine and that all required safety guards are
in place (see the accident prevention layout, showing the location of warning signs and labels).
This operation is particularly dangerous because the machine might work with some safety devices disabled, to
allow carrying out any required calibrations. The whole perimeter around the machine shall remain circumscribed
and no unauthorized person shall be allowed in.
Also see the general safety warnings in Chapter 1 of this manual.
During the preliminary risk assessment relating to operations in first machine start-up, the hazards and
corresponding safety measures were determined, as in the following paragraph:

NOVA SX 550
8.7.3 Hazard Analysis in machine testing
MECHANICAL AND ELECTRICAL HAZARDS
All mechanical and electrical hazards will be under control since the whole area surrounding the machine is duly
fenced off and entry into the area is only allowed to the delegated Bobst engineers, as well as other authorised
persons to perform operations such as:
• Reel loading/unloading;
• Various adjustments.
We hereby state that Bobst personnel have been informed and trained pursuant to legislation.
As a precautionary measure, people with a pacemaker should not enter the protected area.
CHEMICAL RISKS, FIRE AND EXPLOSION HAZARDS
The chemical hazard is due to the presence of solvents and adhesives used by the machine. These products must
be properly segregated and stored; smoking is forbidden and no open flames are allowed in the perimeter where
these operations are performed.
Workers are to be duly informed and trained on safe handling of the chemical products used during their work.
Furthermore, the operators who handle chemical substances are to be provided with suitable PPE.
During the first start-up phase, and then in routine production, flammable materials are used; therefore all suitable
measures to prevent and protect from fire and/or explosion should be taken. Bobst personnel have been informed
and trained on these hazards pursuant to legislation. However, considering the operations as a whole and the
involvement of other people and factory means and vehicles, the Customer must coordinate and manage all
prevention and protection activities, checking the operations in progress comply with the accident prevention
certificate issued by the qualified authority. The Customer must also inform Bobst personnel of emergency
procedures, fire fighting systems, escape routes and personnel assembly points, etc.
Bobst personnel will strictly comply with the instructions received.
DURING THE FIRST START-UP PHASE AND ALSO IN ALL SUBSEQUENT ORDINARY PRODUCTION, THE
USE OF MOBILE PHONES IS FORBIDDEN AS THEY CONTAIN FLAMMABLE MATERIALS WHICH ARE
FORBIDDEN IN THE PROTECTED PERIMETER. MOREOVER THE CLOTHING WORN BY OPERATORS
WORKING ON THE MACHINE MUST BE MADE OF MATERIAL THAT DOES NOT CREATE ELECTROSTATIC
SPARKS AND SAFETY SHOES SHOULD BE SUITABLE FOR THE PURPOSE.

NOVA SX 550
NOISE
During machine testing, the sound level may exceed 85 dB(A) because some guards might have been removed.
All operators will be provided with suitable hearing protection equipment.
DURING NORMAL PRODUCTION, DO NOT REMOVE OR MOVE THE SOUND-PROOFING PANELS:

OTHERWISE NOISE WOULD INCREASE IN THE AREA AROUND THE MACHINE.
THERMAL HAZARD DUE TO CONTACT WITH HOT PARTS
The thermal hazard is due to the presence of hot pipes conveying diathermic oil, steam or hot water (depending on
what systems the machine is equipped with), hot air ducts and the possible use of hot melts or mixtures. When the
machine is first started up and trials are performed, such parts might not be heat insulated or equipped with all
safety shields yet. The machine itself is labelled with warning signs noting the danger due to contact with hot
surfaces. Bobst personnel are equipped with adequate personal protective equipment.
When all operations are complete, the Customer’s manager, having checked all danger warning signs are in place
and all machine safety devices are in working order, will sign a document certifying the safety equipment has been
checked and is working properly.
ENVIRONMENTAL HAZARD WHEN DISPOSING OF WASTE
All rubble, waste and any other material that is still on site should be removed and/or disposed of by the Customer
pursuant to applicable legislation.
HAZARDS DUE TO SIMULTANEOUS, DIFFERENT OPERATIONS
In case of several companies working simultaneously, the site foreman, i.e. the Customer, will implement the
coordination procedures pursuant to the applicable safety legislation or standard.

NOVA SX 550
8.8 Notes

NOVA SX 550

9 DISMANTLING
NOVA SX 550
9.1 General Rules
IN CASE OF SCRAPPING OR DISPOSAL OF MATERIALS, THE REGULATIONS IN FORCE IN THE USER

COUNTRY SHOULD BE COMPLIED WITH.
9.2 Dismantling electric systems
SPECIAL ATTENTION SHOULD BE PAID WHEN DISCONNECTING THE FEEDING CABLES (UTILITIES)
THAT ARE STILL LIVE EVEN AFTER MAINS POWER CUT-OUT. REMOVE ANY AND ALL POWER SUPPLY
TO THE ELECTRIC CABINET AND TO ANY DEVICE ON THE MACHINE WHICH MAY BE POWER
SUP¬PLIED SEPARATELY.
9.3 Dismantling the pneumatic system and the utility

systems of the machine
Dismantle the pneumatic systems by referring to the associated diagrams.
Dismantle the auxiliary systems serving the machine by referring to the corresponding drawings provided by
Bobst.
9.4 Mechanical dismantling

Wash all machine parts that were in contact with the web or with the adhesives, and clean the machine structure
thoroughly before starting the dismantling operations.
To remove the machine from the plant, you should comply with the safety instructions in the “installation” and
“transport chapters of this manual.
9.5 Packing
Use packaging suitable for the weight and characteristics of the parts.
Secure a data label to the packing indicating weight, contents and other information necessary for transport.
2 Machine dismantling Job order 61368 - rev.0

NOVA SX 550
9.6 Notes
Job order 61368 - rev.0 Machine dismantling 3

NOVA SX 550
4 Machine dismantling Job order 61368 - rev.0

10 SPARE PARTS
NOVA SX 550
10.1 Spare parts list
10.1.1 Overview
This technical manual of use and maintenance is accompanied by a list of the spare parts included in the basic
supply of the Coating / Laminating machine NOVA SX 550.
USE ORIGINAL SPARE PARTS ONLY, OR SPARE PARTS COMPLETELY COMPATIBLE WITH THOSE
ALREADY FITTED ON THE MACHINE.
10.1.2 Spare parts

Spare Part Code (ITEM) Description Quantity
KI6001 CAPACITIVE SENSOR 1
1200.8M.30.SD. TEXROPE SYNCHRONIZED BELT HTD SUPRADIVE 1
880.8M.50.SD.TEXROPE SYNCHRONIZED BELT SUPRADRIVE HTD TEXROPE 1
424.8M.20 BELT GATES 424.8M.20 1
1080.8M.30 BELT GATES 1080.8M.30 1
AKA-120 LOAD CELL 1
3RF20301AA04 RELAY 380V 20A 1
DIAPHRAGM PRESSURE TRANSDUCER - RANGE 0/100BAR
FPT100.0A 1
4/20ma, 1/2" JOINT
ME1032 STATOMIX ME10-32 10
2 Spare parts Job order 61368 - rev.0

NOVA SX 550
10.2 Notes
Job order 61368 - rev.0 Spare parts 3

NOVA SX 550
4 Spare parts Job order 61368 - rev.0

11 ATTACHMENTS
11.1 Acceptance of the technical manual
11.2 Statement of Conformity
11.3 Accident prevention diagram

MB-61368 NOVASX550InstructionBook EN Rev00

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Technical Manual

Job Order: 61368

Translation of the original instructions

0.1 Identification document of the “Technical Manual” .................... 2

Job order 61368 - rev.0 Contents III

IV Contents Job order 61368 - rev.0

2 MACHINE SECTIONS .................................................................. 1

2.1 Machine .......................................................................................... 2

2.2 Main & Secondary Unwinders ....................................................... 7

2.4 Overhead Connection Crossbeam.............................................. 26

Job order 61368 - rev.0 Contents V

VI Contents Job order 61368 - rev.0

3 COMMANDS AND CONTROLS ................................................... 1

3.1 Machine .......................................................................................... 2

3.2 Main & Secondary Unwinders ..................................................... 30

Job order 61368 - rev.0 Contents VII

3.2.1.2 Operative condition ➔ Safety condition ............................................................31

3.3 Coating Station ............................................................................ 36

3.4 Laminator Group .......................................................................... 46

VIII Contents Job order 61368 - rev.0

4 MACHINE OPERATION ............................................................... 1

4.1 Using the machine ......................................................................... 2

4.4 Main & Secondary Unwinders ....................................................... 4

4.5 Coating Station .............................................................................. 9

4.8 Web threading .............................................................................. 30

Job order 61368 - rev.0 Contents IX

4.10 First job......................................................................................... 39

X Contents Job order 61368 - rev.0

5 TROUBLE SHOOTING ................................................................. 1

Job order 61368 - rev.0 Contents XI

6.1 General safety recommendations ................................................. 2

6.4 Lubricants .................................................................................. 115

6.5 Internet sites of auxiliary equipment and sensor manufacturers

XII Contents Job order 61368 - rev.0

7.1 Safety precautions ......................................................................... 2

Job order 61368 - rev.0 Contents XIII

8.1 Foundations ................................................................................... 2

8.2 Preparations for machine installation .......................................... 3

8.7 Start-up ......................................................................................... 20

XIV Contents Job order 61368 - rev.0

8.8 Notes ............................................................................................. 23

Job order 61368 - rev.0 Contents XV

9.1 General Rules ................................................................................. 2

XVI Contents Job order 61368 - rev.0

10 SPARE PARTS ............................................................................. 1

10.1 Spare parts list ............................................................................... 2

Job order 61368 - rev.0 Contents XVII

XVIII Contents Job order 61368 - rev.0

0.1 Identification document of the “Technical Manual”

JOB ORDER 61368

Q.ty of copies Given to

Rev. Description Date Chapter Checked

2 Introduction Job order 61368 - rev.0

0.2 Customer obligation re. the technical manual

0.4 How to consult and use the Technical Manual

0.4.1 Technical Manual Composition

0.4.2 Care of the Technical Manual

Job order 61368 - rev.0 Introduction 3

0.4.3 Standard safety texts and symbols

0.5 Technical manual revision in the event of machine

The revision implemented can be of the following type:

4 Introduction Job order 61368 - rev.0

Job order 61368 - rev.0 Introduction 5